Heat insulation box manufacturing method and heat insulation box
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Solution Overview
Problem
The existing methods for manufacturing heat insulation boxes require a tray processed by vacuum forming, which necessitates a new die for each shape change, leading to productivity issues and potential gaps between components, and the trays can crack due to heat changes, compromising insulation performance.
Innovation Solution
A method for manufacturing a heat insulation box without using a tray, utilizing an elastic sheet made of polyurethane elastomer to form a recessed portion around the cascade capacitor, which is flexible and prevents liquid permeation, eliminating the need for a tray and enhancing insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tray processed by vacuum forming is used to form the recessed portion, then the recessed portion can be formed, but a new die is required for each shape change, lowering productivity
Solution Approach 1:
The invention extracts and eliminates the tray component from the heat insulation box structure. Instead of using a separate tray to form the recessed portion, the recessed portion is directly formed in the heat insulation box body itself, removing the need for vacuum forming dies and improving manufacturing flexibility and productivity
Solution Approach 2:
The invention merges the function of the tray with the heat insulation box body. The recessed portion is integrated directly into the box body structure, combining what were previously separate components (tray and box body) into a single unified structure, thereby eliminating the need for separate tray manufacturing
2Ease of manufacture
If a tray processed by vacuum forming is used, then the recessed portion can be formed, but gaps are generated between the tray and outer box, requiring sealing materials and lowering productivity
Solution Approach 1:
The invention merges the tray function with the heat insulation box body by directly forming the recessed portion in the box body. This integration eliminates the interface between tray and outer box, removing the need for sealing materials and preventing urethane foam leakage, thereby improving productivity
3Ease of manufacture
If a tray processed by vacuum forming is used, then the recessed portion can be formed, but the tray may crack due to shrinkage from heat change, allowing condensation to adhere to urethane foam and lowering heat insulation performance
Solution Approach 1:
The invention extracts and eliminates the tray component that is prone to cracking from the structure. By directly forming the recessed portion in the heat insulation box body, the design removes the vulnerable tray element that cracks under thermal stress, preventing condensation pathways and maintaining reliable heat insulation performance
Solution Approach 2:
The invention uses a heat insulation box body made of heat-resistant material that can withstand thermal changes without cracking. By forming the recessed portion directly in this robust box body rather than using a separate tray, the structure gains inherent resistance to thermal stress and maintains integrity under temperature variations
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
This approach improves productivity by eliminating the need for a tray and prevents condensation from compromising the heat insulation performance, maintaining effective insulation even at low temperatures.
Implementation Method 1
an elastic sheet made of polyurethane elastomer to form a recessed portion around the cascade capacitor, which is flexible and prevents liquid permeation
Implementation Method 2
urethane foam is injected into a space between an inner box and the outer box to fill the space by foaming
Data Source
Figure 1
Figure 2~3B
Figure 4
AI summary
A method for manufacturing a heat insulation box that comprises an inner box (31) in which articles are housed, an outer box (32) which has an opening (32b), and a urethane foam heat insulating material (33) which is foam-filled in a space between the inner box (31) and outer box (32) and has a recess (34) at the opening (32b) of the outer box (32), wherein said method involves disposing the outer box (32) over the outside of the inner box (31) such that there is space therebetween, covering the opening (32b) with an elastic sheet (9) from the outside of the outer box (32), inserting a jig (10) into the opening (32b) from the outside of the outer box (32) to force the elastic sheet (9) into the space between the inner box (31) and the outer box (32), and injecting the urethane foam heat insulating material (33) into the space between the inner box (31) and the outer box (32) so as to foam therein to form the recess (34) with the elastic sheet (9) tightly adhering to the surface thereof.