Foldable Insulated Container with Recyclable Blank for Compact Storage
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Solution Overview
Problem
Packaging perishable or temperature-sensitive items poses challenges due to spoilage, destabilization, freezing, melting, or evaporation when temperature is not maintained, and existing insulated packages are often bulky, difficult to store, and non-recyclable, leading to environmental issues.
Innovation Solution
A method of assembling an insulated container using a foldable insulated blank with a piece of insulation material encapsulated between sheets, forming a slot between bottom flaps to create an insulated cavity, which can be easily assembled and disassembled, and made from recyclable materials to reduce environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional insulated packages are used to maintain temperature for sensitive items, then temperature maintenance is effective, but the packages are bulky and difficult to store
Solution Approach 1:
The insulated package is divided into separate components: an insulated blank with encapsulated insulation material and a separate closure mechanism. This segmentation allows the insulation layer to be flattened and stored compactly while maintaining its insulating properties when assembled.
Solution Approach 2:
The insulation material is nested within the sheet structure, with the reflective layer and insulating layer positioned between outer sheets. This nested configuration allows the insulation to be compacted to a thin profile for storage while expanding to provide full insulation when the package is assembled.
2Temperature
If traditional insulated packages are used to maintain temperature for sensitive items, then temperature maintenance is effective, but the packages cannot be recycled and are disposed of in landfills
Solution Approach 1:
The package is constructed from homogeneous, recyclable materials including paper or cardboard sheets and recyclable insulation materials. This uniform material composition throughout the structure enables the entire package to be recycled together through standard recycling processes, eliminating the environmental harm of landfill disposal.
Solution Approach 2:
The design enables the package to be easily disassembled and the materials recovered for recycling. The separate layers and components can be separated and sent to recycling facilities, transforming the package from a disposable item into a recoverable resource that reduces environmental impact.
3Ease of operation
If foldable insulated blank with slot is used, then assembly is easy and storage is compact, but the slot extending through insulation material may compromise thermal performance
Solution Approach 1:
The slot is positioned and designed to minimize direct thermal pathways. The closure mechanism that attaches to the slot area uses materials and construction methods that restore thermal performance, acting as an intermediary that compensates for the thermal disruption caused by the slot while maintaining the benefits of easy assembly.
Solution Approach 2:
The insulation structure is designed with varying local properties: the slot area has reduced insulation to allow assembly, while surrounding areas maintain full insulation thickness. This localized differentiation allows the slot to exist without significantly compromising overall thermal performance, as the majority of the package surface retains full insulating capability.
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 solution provides effective temperature maintenance for sensitive items, reduces storage and disposal issues, and promotes recyclability, enhancing the sustainability of insulated packaging solutions.
Implementation Method 1
the insulated blank comprises a piece of insulation material at least partially encapsulated by at least one sheet
Data Source
AI summary
A method of assembling an insulated container can include folding a body portion of an insulated blank including folding a first panel of the body portion relative to a second panel of the body portion, the first panel defining a first end of the insulated blank; folding the second panel relative to a third panel of the body portion; folding the third panel relative to a fourth panel of the body portion, the fourth panel defining a second end of the insulated blank; attaching the first end of the insulated blank to the second end of the insulated blank to at least partially enclose an insulated cavity; folding a first bottom flap of the insulated blank relative to the first panel to further enclose the insulated cavity; and folding a second bottom flap of the insulated blank relative to the second panel to further enclose the insulated cavity.