EPS Cooler Slide-Locking Lid for Secure Foam Retention
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Solution Overview
Problem
Expanded polystyrene foam coolers have a loose-fitting lid due to their brittle nature, causing the lid to fall off when the cooler is turned upside down or subjected to movement, and conventional metal or hard plastic hinges are not practical for securing the lid without damaging the foam.
Innovation Solution
A transversely-extending ridge with opposed flanges on the lid and horizontal channels on the cooler body allow the lid to slide into a locked position, where the flanges fit tightly into the channels, securing the lid without applying excessive pressure that could break the foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tight friction fit is used for the lid, then the lid would be securely held in place, but the brittle foam material would likely break at the contact points between the lid and cooler body
Solution Approach 1:
The lid retention system is segmented into multiple independent locking points distributed around the perimeter. Instead of relying on a single tight friction fit, the lid is secured at multiple discrete locations through the locking mechanism, distributing the stress and preventing localized breakage while maintaining overall retention reliability
Solution Approach 2:
An intermediary locking mechanism is introduced between the lid and cooler body. This mechanism acts as a mediator that provides secure retention without requiring direct high-stress contact between the foam lid and cooler body, thereby preventing breakage while maintaining lid security
2Reliability
If conventional metal or hard plastic hinges or locking mechanisms are used, then the lid can be securely locked, but the brittle foam cannot take and/or keep screws or rivets in place in normal use
Solution Approach 1:
The locking mechanism parameters are changed to accommodate foam material properties. Instead of using rigid metal hinges or locking mechanisms that require high fastener tolerance, the system uses a molded-in locking mechanism with flexible tolerances that work specifically with foam material, achieving reliable lid locking without compromising the foam structure
Solution Approach 2:
The locking mechanism is created as a composite structure where the lid and cooler body are molded together with integrated locking features. This composite approach combines the foam material with the locking geometry in a single piece, eliminating the need for separate fasteners like screws or rivets that would compromise the foam
3Weight of moving object
If the lid is made lightweight to maintain the cooler's portability, then the cooler remains easy to transport, but even a breeze or quick movement can cause the lid to dislodge or come flying off
Solution Approach 1:
The locking mechanism is designed with dynamic characteristics that adapt to movement conditions. The sliding and locking action allows the mechanism to respond to vibrations and movements during transport, maintaining lid retention reliability without requiring additional weight or rigid structural support
Data Source
AI summary
Disclosed is an expanded polystyrene cooler having a body, a lid and a lid locking mechanism, said lid locking mechanism including a transversely-extending ridge near the perimeter of the underside surface of the lid, with the ridge surrounding the majority of said underside surface. There are at least two opposed flanges on the underside surface having extended portions extending towards the edge of the lid, as well as at least two horizontal channels on the inner surface of the body, each channel including an opening at one end facing the flanges and configured to receive one of the flanges and including a section having an extension towards the inside of the body, said section configured to rest upon the flange extended portion and lock the lid with the body, when the flange is positioned below the extension, whereby the lid is in place atop the cooler body.