Modular Ice Barrel Design to Reduce Shipping Volume and Weight
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Solution Overview
Problem
Fully assembled ice barrels often exceed the volume capacity of standard shipping containers, leading to wasted space and increased shipping costs, and their weight can pose safety risks when emptying.
Innovation Solution
A modular ice barrel design featuring an expandable bladder and semi-rigid exterior wall that can be assembled at the destination, reducing shipping volume and weight, and incorporating an insulative material for thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ice barrel is shipped fully assembled, then the structural integrity and functionality are ensured, but the shipping volume increases and empty space is wasted
Solution Approach 1:
The ice barrel is divided into multiple components including an exterior barrel wall, interior barrel wall, insulative layer, lid, and base that can be shipped separately in a collapsed or disassembled state. These segments are then assembled at the destination to form the complete ice barrel, reducing shipping volume while maintaining structural integrity when assembled
Solution Approach 2:
The interior barrel wall and insulative layer are designed to nest within the exterior barrel wall when disassembled. The lid and base can also be positioned within the barrel cavity or attached to the barrel walls, allowing all components to be compacted into a minimal shipping volume similar to nested dolls
2Manufacturing precision
If injection molded components are used, then the manufacturing precision and durability are improved, but the weight increases and shipping cost increases
Solution Approach 1:
Different components of the ice barrel utilize different manufacturing methods appropriate to their specific requirements. The exterior barrel wall may use injection molding for precision where needed, while other components use alternative methods that reduce weight. This localized application of manufacturing techniques optimizes the balance between precision and weight rather than applying a single method to all parts
Solution Approach 2:
The ice barrel employs composite construction with an exterior barrel wall, interior barrel wall, and insulative layer made from different materials optimized for their specific functions. This composite approach allows selection of lighter materials where full injection molding is not necessary, reducing overall weight while maintaining structural precision through material properties
3Strength
If the barrel is made heavier for structural strength, then the durability and insulation performance are improved, but the safety risk during emptying increases
Solution Approach 1:
The barrel is segmented into multiple components that can be assembled and disassembled. The interior barrel wall can be detached from the exterior barrel wall, allowing the heavy insulative layer and structural components to remain in place while only the lighter interior wall and contents need to be emptied, reducing the weight handled during emptying operations
Solution Approach 2:
The interior barrel wall acts as an intermediary between the contents and the heavy exterior structure. During emptying, users can detach and remove only the interior wall containing the lighter contents, while the heavy exterior barrel wall with insulative layer remains stationary, eliminating the safety hazard of lifting and turning heavy barrels
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 modular design minimizes shipping costs and weight, allowing for more barrels to be transported in a single shipment while reducing the risk of injury from heavy barrels during emptying.
Implementation Method 1
an insulative layer (160) formed between the exterior barrel wall and the interior barrel wall
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A portable ice barrel system composed of collapsible components that are configured to form a cylindrical insulation layer (160) that also forms an opening at the top of the barrel (1). The base includes a grid (139), a disc (138), a rim (122), and a series of wheels (137). An inner liner (202) extends into the opening of the cylindrical insulation layer (160) to form an interior barrel cavity (110) and an exterior barrel wall (103). The portable ice barrel (1) may include a plurality of clips (146) for holding the inner liner (202) onto the cylindrical insulation layer (160). The portable ice barrel (1) can include an expandable bladder (3) or an insulative material that is injected into a gap (32) between an inside surface (12) of the exterior wall and an exterior surface (17) of the expandable bladder to form an insulative layer. The portable ice barrel (1) can include a plurality of sections that form an inner cylindrical insulation layer (160). The portable ice barrel (1) may also include a hinged top and a hinged base that can be collapsed when deconfigured with the other components and shipped in a flat configuration.