Foldable Insulated Container Using Pre-Consumer Cotton Waste
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Solution Overview
Problem
Existing insulated containers for temperature-sensitive products are expensive, heavy, environmentally harmful, prone to contamination, and require additional non-biodegradable materials, and often manufactured separately from packaging facilities, leading to inefficient transportation.
Innovation Solution
Utilizing post-industrial, pre-consumer cotton waste as the insulating layer, eliminating plastic wrapping, and incorporating a biodegradable natural fiber lamination for a lightweight, efficient, and environmentally friendly insulated shipping container that maintains temperature consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If post-consumer waste materials are used for insulation, then environmental friendliness is improved, but contamination risk and reliability deteriorate
Solution Approach 1:
The patent extracts and removes contaminants from post-consumer waste materials through a multi-step process including shredding, screening, and washing to eliminate yarn dies, chemicals, and other contaminants before the material is used for insulation
Solution Approach 2:
The patent changes the physical and chemical parameters of the waste material through processing - transforming it from a contaminated state to a purified state with controlled moisture content, density, and composition suitable for reliable insulation application
2Reliability
If plastic wrapping is used to protect recycled insulation, then reliability is improved, but environmental harm and manufacturing cost worsen
Solution Approach 1:
The patent removes the harmful plastic wrapping layer from the insulation structure, eliminating the environmental harm associated with non-biodegradable materials while maintaining protection through properly processed and dried recycled insulation material
Solution Approach 2:
The patent converts potentially harmful contaminants in recycled material into beneficial properties by thoroughly processing and drying the material, transforming it into a reliable, protective insulation layer that eliminates the need for additional plastic barriers
3Temperature
If traditional insulation materials are used, then temperature maintenance is improved, but weight and cost worsen
Solution Approach 1:
The patent optimizes the physical parameters of the recycled insulation material including density, thickness, and compression properties to achieve effective temperature maintenance with reduced weight compared to traditional insulation materials
Solution Approach 2:
The patent creates a composite insulation structure using processed recycled materials combined with natural fiber lamination, achieving effective thermal insulation with lighter weight than conventional single-material insulation systems
4Ease of manufacture
If insulated containers are manufactured separately from packaging facilities, then manufacturing specialization is improved, but transportation efficiency and time worsen
Solution Approach 1:
The patent combines the insulation manufacturing process with the packaging facility operations, integrating insulation production directly at the packaging location to eliminate separate manufacturing and transportation steps while maintaining manufacturing quality
Solution Approach 2:
The patent prepares insulation materials in advance at the packaging facility, performing preliminary processing and positioning of insulation components before actual packaging operations to streamline the overall process and reduce time losses
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 a cost-effective, lightweight, and eco-friendly container that maintains internal temperature for 48 hours, minimizing environmental impact and facilitating efficient manufacturing and transportation.
Implementation Method 1
The insulated container may include an insulation layer formed from a post-industrial, pre-consumer natural fiber
Data Source
AI summary
An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer or may be housed in a biodegradable plastic. The insulated layer may be manufactured in a capital âTâ shape such that it may be folded for compact transportation prior to end use. The folded insulation layer may bound by a separable band. The separable band may be removed when folded insulation layer is placed in the rigid container. The insulation layer and the band may be biodegradable in an anaerobic environment.