Thermoplastic Rubber Cooler Latch Assembly
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Solution Overview
Problem
Conventional cooler latches made of single plastic components are prone to cracking and breaking due to stress and fatigue, leading to premature failure and the need for replacement, resulting in unnecessary disposal or purchase of new coolers.
Innovation Solution
The development of a latch assembly using thermoplastic rubber materials for the intermediate component, which is fabricated in three components, including an upper, lower, and intermediate portion, with the intermediate portion being flexible and featuring an auto-stop design to prevent over-stretching and extend the latch's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single plastic component latch is used, then the device complexity is reduced, but the reliability deteriorates due to cracking and breaking from stress and fatigue
Solution Approach 1:
The latch is divided into three separate components: upper portion, lower portion, and intermediate portion. This segmentation allows each component to be optimized independently, with the intermediate portion made of flexible thermoplastic rubber to withstand stress and fatigue without cracking, while the upper and lower portions provide structural support. This resolves the contradiction by improving reliability through specialized components while maintaining reasonable complexity.
Solution Approach 2:
The intermediate portion is made of thermoplastic rubber material, which combines flexibility and durability. This composite material approach allows the latch to endure repeated opening and closing cycles without failing, directly addressing the reliability issue while maintaining a relatively simple overall structure.
2Manufacturing precision
If the intermediate portion is made of rigid plastic, then the manufacturing precision is improved, but the reliability deteriorates due to stress and fatigue cracking
Solution Approach 1:
The material parameter of the intermediate portion is changed from rigid plastic to flexible thermoplastic rubber. This parameter change allows the component to withstand stress and fatigue without cracking, significantly improving reliability and lifespan while maintaining manufacturability through standard injection molding processes.
Solution Approach 2:
Using thermoplastic rubber as a composite material provides both flexibility for stress absorption and durability for long-term use. This material selection resolves the contradiction by prioritizing reliability over rigid manufacturing precision requirements.
3Device complexity
If the latch is designed with limited flex, then the device complexity is reduced, but the duration of action deteriorates as the latch breaks after a certain number of uses
Solution Approach 1:
The flexibility parameter of the intermediate portion is increased by using thermoplastic rubber material. This allows the latch to undergo many more opening and closing cycles before failing, directly extending the duration of action while maintaining a simple three-component design structure.
Solution Approach 2:
The intermediate portion is designed to be flexible and dynamic, allowing it to bend and flex with each opening and closing motion. This dynamic design enables the latch to absorb stress and fatigue, significantly extending its operational life compared to rigid designs.
4Ease of operation
If the intermediate portion is made thinner to allow movement, then the ease of operation is improved, but the reliability deteriorates due to increased stress and fatigue
Solution Approach 1:
The material parameter of the intermediate portion is changed to thermoplastic rubber, which provides high flexibility and stress resistance. This allows the portion to be made thin enough for easy lid movement while maintaining sufficient thickness and strength to withstand repeated stress and fatigue without cracking or breaking.
Solution Approach 2:
The thermoplastic rubber material provides a combination of flexibility and durability that allows the intermediate portion to be optimally thin for operation while remaining robust enough to withstand the stresses of repeated use, resolving the contradiction between ease of operation and reliability.
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 thermoplastic rubber latch assembly provides increased flexibility and durability, allowing for multiple open and close cycles without breaking, thereby extending the life of the cooler and reducing the need for frequent replacements.
Implementation Method 1
The intermediate component is more easily seen with respect to FIGS. 3A and 3B, which is described more detail below. The intermediate component 190 is fabricated using a thermoplastic rubber material, or TPR material.
Implementation Method 2
The intermediate component 190 is fabricated using a thermoplastic rubber material, or TPR material. In certain exemplary embodiments, the thermoplastic rubber material includes certain ultraviolet and/or chemical resistant additives
Data Source
AI summary
The insulated cooler includes a body, a lid, and at least one latch assembly. The body includes an outer shell, an inner liner disposed therein creating a gap therebetween, and an insulating layer disposed within the gap. The body defines a cavity therein with an opening formed at its upper end. The lid is removably coupled to the body and covers the body's opening. The latch assembly includes an upper component having at least one aperture formed therein, a lower component having at least one opening formed therein, and an intermediate component having a first portion coupled to the upper component and a second portion coupled to the lower component. The intermediate component is fabricated using a thermoplastic rubber. The upper component is coupled to the lid using at least one aperture. The lower component is coupled to a top portion of the outer shell using at least one opening.