Foldable Insulated Transport Box with Integrated Hinges
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Solution Overview
Problem
Thermally insulating transport boxes are bulky when not in use due to their integral one-piece production, which increases transport volume, and existing folding mechanisms compromise load-bearing capacity and insulation effectiveness.
Innovation Solution
A thermally insulating transport box design featuring pivotally mounted longitudinal and transverse side parts with integrally formed hinge elements, allowing for compact folding and high stability when open, without the need for additional materials or assembly steps, using a base part with corner projections and ball-shaped hinge elements for secure articulation and latching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermally insulating transport boxes are made integrally from molded particle foam, then good thermal insulation and inexpensive production are achieved, but the boxes become very bulky when not in use requiring high transport volumes
Solution Approach 1:
The transport box is divided into multiple separable components: a base part, two longitudinal side parts, two transverse side parts, and at least one lid part. Each part is separately molded from particle foam and can be independently handled. This segmentation enables the box to be folded into a compact configuration when not in use, dramatically reducing storage and transport volume while maintaining the insulating properties of the foam material.
2Volume of stationary object
If folding mechanisms with hinge axes and bearings are used, then foldability and space-saving storage are achieved, but the mechanisms cannot be attached or formed in foamed EPP or EPS parts
Solution Approach 1:
The hinge elements are integrally molded directly into the foamed plastic parts themselves, merging the hinge function with the structural components. The base part has hinge elements molded into its corner regions, and the side parts have corresponding hinge elements that receive them. This integration eliminates the need for separate bearings, hinge axes, or attachment fasteners, simplifying manufacturing while enabling reliable folding articulation.
Solution Approach 2:
The hinge elements act as intermediary structures that are formed as integral parts of both the base and side walls. These molded-in features serve as the articulation interface, allowing rotational movement between components without requiring external mechanical hardware. The hinge elements are specifically designed with geometric features that enable pivotable connection while maintaining structural integrity.
3Ease of operation
If thin panels are used to enable folding, then foldability is achieved, but load-bearing capacity and stability as well as insulating effect are limited
Solution Approach 1:
The box employs different wall thicknesses in different locations to optimize both foldability and structural strength. The side parts have reduced thickness in regions requiring articulation to enable folding, while maintaining sufficient thickness in load-bearing areas. The hinge elements themselves are molded with appropriate thickness and geometric reinforcement to provide the necessary strength for pivotable connection without requiring the entire panel to be thick.
Solution Approach 2:
The invention uses particle foam material (EPP or EPS) with specific density ranges (30-80 kg/m³ for EPP, 10-30 kg/m³ for EPS) that provide an optimal balance between flexibility for folding and structural strength for load-bearing. The foam's cellular structure provides both insulation and mechanical properties, allowing thin-walled construction that can fold while maintaining adequate strength and thermal performance.
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 design achieves a compact storage form while maintaining high load capacity and thermal insulation, with all parts formed integrally from particle foam for cost-effective and recyclable production, ensuring stability and ease of use.
Implementation Method 1
a thermally insulating transport box (100), which consists of a base part (1), two longitudinal side parts (2), two transverse side parts (4) and at least one lid part (6), which delimit a transport space and are made of a thermally insulating material
Data Source
Figure 1a~1b
Figure 2~4
Figure 3a~3b
AI summary
The invention relates to a thermally insulating transportation box, comprising a base part (1), two longitudinal side parts (2), two transverse side parts (4) and at least one top part (6a, 6b), which parts bound a transportation space and are produced from a thermally insulating material, with the longitudinal side parts (2) and the transverse side parts (4) being pivotably mounted on the base part about pivot axes which each run parallel to the base part, so that they can be folded open from a folded-together arrangement, which extends parallel to the base part, into an arrangement which is perpendicular to this and in which they bound the transportation space, and the transportation space can subsequently be closed by means of the at least one cover part (6a, 6b).