Tapered Foam Container Structure for Vertical Cool Pack Alignment
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Solution Overview
Problem
Existing thermally insulated containers for transporting temperature-sensitive products require multiple types of cool packs and additional fixings, which increases complexity and cost, and may not maintain uniform temperature due to misalignment and convection issues during transportation.
Innovation Solution
A thermally insulated container with a main body and lid moulded from expanded foam, featuring tapered inner surfaces to align and secure rectangular cool packs vertically, eliminating the need for additional fixings and allowing for standardized cool packs, and a method to incorporate insulation panels for enhanced thermal efficiency by varying the mould tool dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple types of cool packs and additional fixings are used, then the temperature uniformity and security of cool packs may be improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The container structure itself provides the alignment and securing function through its tapered inner surfaces, eliminating the need for separate fixings. The walls guide the cool packs into correct vertical positioning automatically when the lid is closed, making the system self-aligning and self-securing.
Solution Approach 2:
The tapered inner surfaces of the container walls serve multiple functions: they align the cool packs vertically, secure them in position, and guide their placement. This multi-functional design replaces what would otherwise require separate alignment mechanisms and fixings.
2Reliability
If multiple types of cool packs and additional fixings are used, then the temperature uniformity and security of cool packs may be improved, but the manufacturing cost increases
Solution Approach 1:
The container structure itself provides the alignment and securing function through its tapered inner surfaces, eliminating the need for separate fixings. The walls guide the cool packs into correct vertical positioning automatically when the lid is closed, making the system self-aligning and self-securing.
Solution Approach 2:
The tapered inner surfaces of the container walls serve multiple functions: they align the cool packs vertically, secure them in position, and guide their placement. This multi-functional design replaces what would otherwise require separate alignment mechanisms and fixings.
3Device complexity
If cool packs are allowed to move during transportation, then the container structure is simpler, but the temperature uniformity deteriorates due to misalignment and convection
Solution Approach 1:
The container structure itself provides the alignment and securing function through its tapered inner surfaces, eliminating the need for separate fixings. The walls guide the cool packs into correct vertical positioning automatically when the lid is closed, making the system self-aligning and self-securing.
Solution Approach 2:
The tapered inner surfaces of the container walls serve multiple functions: they align the cool packs vertically, secure them in position, and guide their placement. This multi-functional design replaces what would otherwise require separate alignment mechanisms and fixings.
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, efficient, and secure means to maintain uniform temperature during transportation by aligning cool packs and enhancing thermal insulation, reducing the risk of product damage and extending shelf life.
Implementation Method 1
a main body moulded from a single piece of expanded foam
Implementation Method 2
the inner surfaces of the walls of the main body taper from the mouth of the main body to the base of main body
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A thermally insulated container (1) comprising a lid (3) and a main body (2) moulded from a single piece of expanded foam with outwardly tapering inner walls, necessitated by the moulding process. The container (1) is arranged to be closed by the lid (3) so that cool packs (6) to (9) in the container (1) extend from a base inside the main body (2) to inside the lid (3), wherein the inner surface of the walls of the lid (3) are tapered such that positioning the lid (3) on the main body (2), with the cool packs arranged around the inner surfaces of the walls, causes the cool packs (6) to (9) to be aligned so that they extend vertically, perpendicular to an inner surface of the base of the main body (3). A method of moulding such a container is also provided.