EVA Foam Cooler With Alternating Walls And Columns
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Solution Overview
Problem
Conventional coolers face issues with durability, water absorption, and material complexity, leading to high costs, weight, and environmental impact, as well as inefficiencies in insulation and ease of use.
Innovation Solution
A flexible, unitary cooler structure made from ethylene-vinyl acetate (EVA) foam that provides insulation, durability, and ease of manufacturing, featuring a single molded piece with alternating walls and columns for enhanced structural integrity and recyclability, while being lightweight and dishwasher-safe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional coolers use multiple materials (plastic, foam, fabric) for construction, then insulation performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (insulation, structure, durability, flexibility) into a single EVA foam material. The cooler body is molded as one piece from EVA foam, eliminating the need for separate plastic shells, fabric covers, and foam insulation layers used in conventional coolers. This single-material approach maintains effective insulation while dramatically simplifying the device structure and manufacturing process.
Solution Approach 2:
The patent utilizes EVA foam as a composite material that inherently provides both structural integrity and thermal insulation properties. This closed-cell foam material combines the insulating characteristics of traditional foam with the durability and flexibility needed for a complete cooler construction, replacing multiple different materials with one optimized composite material.
2Strength
If conventional coolers use hard plastic and metal components for durability, then strength is improved, but weight increases
Solution Approach 1:
The patent changes the material parameters by using EVA foam with optimized density and cellular structure. This material provides sufficient structural strength and impact resistance for cooler applications while maintaining a much lower density than hard plastics or metals. The foam's closed-cell structure provides both durability and light weight simultaneously.
3Adaptability or versatility
If conventional coolers use fabric and plastic components, then flexibility is improved, but water absorption and durability worsen
Solution Approach 1:
The patent utilizes the closed-cell porous structure of EVA foam to achieve water resistance. The closed cells prevent water penetration while the foam material itself remains flexible and adaptable. This porous structure naturally repels water without requiring additional waterproof coatings or laminates, solving both flexibility and water resistance requirements simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The EVA foam cooler maintains temperature stability, is resistant to impacts and chemicals, and is easier to clean and recycle, offering improved durability and reduced weight, making it more convenient and environmentally friendly.
Implementation Method 1
The center section and the bottom section are a unitary structure formed of a flexible insulating material
Data Source
AI summary
A container (100), such as a cooler, has a center section (108), a bottom section, and a cover or lid. The center section has a plurality of outer walls (202) and a plurality of partial columns (210). Each outer wall has an inner surface (206), an outer surface (202), a top surface, a thickness, and a plane (204, 208) defined by the outer surface. Each partial column has an inner surface (214), an outer surface (212), a top surface (218), and a thickness, and defines a corner angle (216), such as approximately 90 degrees. The partial columns alternate with the outer walls, and the outer surface of a partial column extends beyond the plane of an adjacent outer wall. The center section and the bottom section are a unitary structure formed of a flexible insulating material, such as an EVA foam.