Heat Insulation Box Recess Forming Without Vacuum-Formed Trays
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Solution Overview
Problem
The existing methods for manufacturing heat insulation boxes using vacuum-formed trays require new dies for shape changes, lead to gaps between components, and are prone to cracking, which lowers productivity and heat insulation performance due to urethane foam leakage and condensation.
Innovation Solution
A method involving an inner and outer box with a foamed material filling the space between them, using an elastic sheet to form a recessed portion without a tray, where the elastic sheet is pushed into the space by a jig and foamed to create a tight seal, eliminating the need for a tray and preventing foam deterioration from condensation.
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 vacuum molding die is required and productivity is lowered
Solution Approach 1:
The invention extracts and eliminates the tray component from the heat insulation box structure. Instead of forming a recessed portion using a separate vacuum-formed tray, the patent directly forms the recessed portion in the heat insulation box body itself, removing the need for vacuum molding dies and tray assembly steps, thereby improving productivity
Solution Approach 2:
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 separate tray component and its manufacturing process, combining multiple functions into a single structure to improve manufacturing efficiency
2Ease of manufacture
If a tray processed by vacuum forming is used, then the recessed portion can be formed, but the tray is not flexible and gaps are generated between the tray and outer box
Solution Approach 1:
The invention replaces the rigid vacuum-formed tray with a flexible sheet material that is stretched and fixed to the inner box. This flexible sheet can adapt to dimensional changes and thermal expansion/contraction, preventing gap formation between components while maintaining the recessed portion structure
Solution Approach 2:
The invention introduces dynamic adaptability by using a flexible sheet that can move and deform with thermal expansion and contraction. This dynamic response prevents gap formation that occurs with rigid trays, improving manufacturing precision and maintaining sealing under varying conditions
3Reliability
If sealing material is disposed on the side of the tray to prevent urethane foam leakage, then foam leakage is prevented, but productivity is lowered
Solution Approach 1:
The invention extracts and eliminates the separate sealing material component by using the flexible sheet itself as the sealing element. The flexible sheet is stretched and fixed to create a tight seal between the inner box and outer box, preventing urethane foam leakage without requiring additional sealing materials or assembly steps
Solution Approach 2:
The flexible sheet serves multiple functions simultaneously: it forms the recessed portion structure, provides sealing to prevent foam leakage, and accommodates thermal expansion/contraction. This multi-functionality eliminates the need for separate sealing materials, improving productivity while maintaining reliability
4Ease of manufacture
If a vacuum-formed tray is used, then the recessed portion can be formed, but the tray may crack due to shrinkage from heat change
Solution Approach 1:
The invention replaces the rigid vacuum-formed tray with a flexible sheet material that can withstand thermal expansion and contraction without cracking. The flexibility of the sheet allows it to deform elastically with temperature changes, maintaining structural integrity and preventing cracks that would compromise reliability
Solution Approach 2:
The invention changes the material parameter from rigid (vacuum-formed tray) to flexible (elastic sheet), enabling the structure to accommodate thermal parameter changes (expansion/contraction) without failure. This parameter change ensures reliability under varying temperature conditions
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 trays and maintains heat insulation performance by preventing urethane foam degradation and condensation, ensuring a tight seal and flexible deformation to accommodate shape changes.
Implementation Method 1
a foamed material that fills a space between the inner box and the outer box by foaming
Implementation Method 2
covering the opening from outside of the outer box with an elastic sheet; pushing the elastic sheet into the space between the inner box and the outer box with the projected portion
Data Source
AI summary
A method for manufacturing a heat insulation box, wherein said method involves disposing an outer box over the outside of an inner box such that there is space therebetween, covering an opening with an elastic sheet from the outside of the outer box, inserting a jig into the opening from the outside of the outer box to force the elastic sheet into the space between the inner box and the outer box, and injecting the urethane foam heat insulating material into the space between the inner box and the outer box so as to foam therein to form a recess with the elastic sheet tightly adhering to the surface thereof.