Ozone Adhesion Process for Insulating Container Manufacture

• US 20160279840A1
• Filed: 03/23/2015
• Published: 09/29/2016
• Est. Priority Date: 03/23/2015
• Status: Active Grant

• Current Assignee: YETI Coolers LLC (YETI Holdings, Inc.)
• Original Assignee: YETI Coolers LLC (YETI Holdings, Inc.)
• Inventors: French, John, Nugent, Paul, Laxamana, Francis, Adarlo, Argel
• Granted Patent: US 9,694,521 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 41/042 by rotating a mould around its axis of symmetry for concrete B28B21/30
• CPC Class Codes: B29C 44/08 using several expanding or moulding steps
• CPC Class Codes: B29C 44/129 Enhancing adhesion to the preformed part using an interlayer
• CPC Class Codes: B29C 44/18 Filling preformed cavities B29C44/1204 takes precedence
• CPC Class Codes: B29C 44/186 Filling multiple cavities B29C44/181, B29C44/182 and B29C44/188 takes precedence
• CPC Class Codes: B29C 44/188 Sealing off parts of the cavities
• CPC Class Codes: B29C 44/3403 Foaming under special conditions, e.g. in sub-atmospheric pressure, in or on a liquid
• CPC Class Codes: B29C 59/103 of profiled articles, e.g. hollow or tubular articles
• CPC Class Codes: B29C 59/142 of profiled articles, e.g. hollow or tubular articles
• CPC Class Codes: B29C 71/009 using gases without chemical reaction C08J7/12 takes precedence; in combination with blow-moulding B29C49/46; surface treatment using plasma B29C59/14, ionised gas B29C59/16
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2025/06 PS, i.e. polystyrene
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2067/003 PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2995/0015 Insulating
• CPC Class Codes: B29K 2995/0092 hydrophilic
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/712 : Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: B29L 2031/7622 : Refrigerators
• CPC Class Codes: B65D 81/3816 : formed of foam material
• CPC Class Codes: B65D 81/3823 : formed of different materials, e.g. laminated or foam filling between walls

Abstract

Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

Claims

1. A method of manufacturing an insulating container, comprising:

molding an external structure of the insulating container from a polymer, the external structure comprising;

an inner trough;

an outer shell coupled to the inner trough by a top edge surface;

an internal cavity spaced between the inner trough and the outer shell and extending around four sides and a base of the external structure;

a first opening extending into the internal cavity at a first corner of a base surface of the outer shell;

a second opening extending into the internal cavity at a second corner, opposite the first corner, of the base surface of the outer shell;

positioning the external structure such that the second opening is above the first opening;

injecting an ozone gas containing 5-7.5% ozone into the first opening;

filling at least 80% of the cavity with the ozone gas to displace a mass of air out through the second opening;

flushing the cavity with air to remove ozone gas from the cavity; and

filling the cavity with an insulating foam.

2. The method of claim 1, wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at least 4 minutes.

3. The method of claim 1, wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at most 10 minutes.

4. The method of claim 1, wherein the flushing the cavity with air further comprises flushing for at least 2 minutes.

5. The method of claim 1, wherein the flushing the cavity with air to remove ozone gas comprises removing at least 95% of the ozone gas from the cavity.

6. The method of claim 1, wherein the flushing the cavity with air to remove ozone gas comprises removing at least 97% of the ozone gas from the cavity.

7. The method of claim 1, wherein the flushing the cavity with air to remove ozone gas comprises removing at least 99% of the ozone gas from the cavity.

8. The method of claim 1, wherein the molding of the external structure utilizes a rotational molding process.

9. The method of claim 1, wherein the polymer is polyethylene.

10. The method of claim 1, wherein the insulating foam is polyurethane.

11. The method of claim 1, wherein the ozone gas is injected at room temperature.

12. The method of claim 1, wherein the outer shell has a substantially cuboidal shape.

13. A method for producing an insulating structure, comprising:

(a) molding an outer shell of the insulating structure from a polymer, the outer shell comprising;

an internal cavity;

a first opening extending into the internal cavity;

a second opening extending into the internal cavity;

(b) positioning the outer shell such that the second opening is above the first opening;

(c) injecting an ozone gas containing 5-7.5% ozone into the first opening;

(d) filling the cavity with the ozone gas to displace a mass of air out through the second opening;

(e) at a time after step (d), filling the cavity with a gas to remove at least 97% of the ozone gas from the cavity; and

(f) injecting an insulating foam into the cavity.

14. The method of claim 13, wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in at least 4 minutes.

15. The method of claim 13, wherein a volume flow rate of the ozone gas into the first opening is such that a volume of the cavity is filled in approximately 4-10 minutes.

16. The method of claim 13, wherein step (e) begins approximately 4 to 10 minutes after step (c) began.

17. The method of claim 13, wherein step (e) is completed within no more than two minutes after step (e) began.

18. The method of claim 13, wherein step (d) of filling the cavity with the ozone gas to displace a mass of air out through the second opening comprises filling at least 90% of the cavity with ozone gas.

19. The method of claim 13, wherein step (d) of filling the cavity with the ozone gas to displace a mass of air out through the second opening comprises filling at least 95% of the cavity with ozone gas.

20. The method of claim 13, wherein the molding of the outer shell utilizes a rotational molding process.

21. The method of claim 13, wherein the polymer is polyethylene.

22. The method of claim 13, wherein the gas is air.

23. The method of claim 13, wherein the first opening is adjacent a bottom portion of the internal cavity and the second opening is adjacent a top portion of the internal cavity.

24. A method for manufacturing a cooler, comprising:

(a) molding an external structure of the cooler from polyethylene, the external structure comprising;

an inner trough;

an outer shell coupled to the inner trough by a top edge surface;

an internal cavity spaced between the inner trough and the outer shell and extending around four sides and a base of the external structure;

a first opening extending into the internal cavity at a first corner of a base surface of the outer shell;

a second opening extending into the internal cavity at a second corner, opposite the first corner, of the base surface of the outer shell;

(b) positioning the external structure such that the second opening is above the first opening;

(c) injecting an ozone gas containing 5-7.5% ozone into the first opening;

(d) filling at least 90% of the cavity with the ozone gas in at least four minutes to displace a mass of air out through the second opening;

(e) flushing the cavity with air for at least two minutes to remove ozone gas from the cavity; and

(f) filling the cavity with polyurethane insulating foam.

25. The method of claim 24, wherein the outer shell has a substantially cuboidal shape.