Fiber-Based Single-Walled Cooler to Replace Non-Biodegradable Foam
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Solution Overview
Problem
Conventional disposable coolers made of expanded polystyrene foam are non-biodegradable and environmentally harmful, leading to significant environmental issues due to their persistence in the environment and resistance to chemical breakdown, necessitating a sustainable and cost-effective alternative for storage and transportation of temperature-sensitive items.
Innovation Solution
A single-walled disposable cooler made from pulp-based or fiber-based materials, which are compostable, recyclable, and biodegradable, featuring a body and lid designed to maintain temperature and include features like a handle and cup holders, manufactured using a process involving a slurry composition, die form, vacuum mechanism, and pressure mechanism to create a molded layer that is self-supporting and water-resistant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If disposable coolers are made from expanded polystyrene foam, then they are less expensive and provide effective thermal insulation, but they cause significant environmental harm due to non-biodegradability and persistence in the environment
Solution Approach 1:
The patent changes the material parameter from polystyrene foam to molded fiber material, transforming the cooler from non-biodegradable to compostable while maintaining the disposable nature and thermal insulation functionality
Solution Approach 2:
The patent maintains the disposable concept with molded fiber coolers that are inexpensive to manufacture and intended for single use, but resolves the environmental issue by making them compostable and biodegradable rather than persistent in the environment
2Temperature
If disposable coolers are made from expanded polystyrene foam, then they provide effective thermal insulation, but they resist chemical breakdown and persist in the environment for centuries
Solution Approach 1:
The patent changes the material composition parameter from polystyrene to molded fiber, altering the degradation parameter from centuries-long persistence to weeks-long composting while preserving the thermal insulation function through the molded fiber structure
Solution Approach 2:
The patent converts the previously harmful characteristic of material persistence into a beneficial composting process, where the cooler naturally degrades and returns to the environment without toxic residue, transforming an environmental problem into a sustainable solution
3Strength
If conventional plastic coolers are used, then they are durable and reusable, but they are expensive and bulky
Solution Approach 1:
The patent adopts the disposable approach with molded fiber coolers that are lightweight and compact, sacrificing long-term durability for reduced weight and cost, while maintaining sufficient strength for single-use applications
Solution Approach 2:
The patent changes the material parameter from heavy conventional plastic to lightweight molded fiber, reducing the weight and bulk of the cooler while providing adequate strength for disposable use through optimized fiber molding and wall thickness design
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 pulp-based cooler provides an eco-friendly solution that can be disposed of without toxic residue, meets regulatory requirements, and maintains temperature effectively for several hours, offering a cost-effective and sustainable alternative to traditional coolers.
Implementation Method 1
inserting the die form into the slurry and applying vacuum through the die form to draw slurry and fibers against the die form
Implementation Method 2
delivering a pressurized charge of gaseous fluid through the die form, whereupon the molded layer has a second shape
Data Source
AI summary
A single-walled disposable cooler is provided and generally includes a body and a lid. The body is generally made from a pulp-based material or fiber-based material and includes a base and a plurality of support walls coupled to the base. At least one of the plurality of support walls includes a substantially planar surface. The plurality of support walls and the base define an interior cavity of the body, while the plurality of support walls extend upwardly from the base to form an opening at an upper terminus of the body in fluid communication with the interior cavity. The lid is also made from the pulp-based material or fiber-based material and corresponds with the body. The lid is shaped to cover the opening of the body.