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Manufacturing

The manufacturing process will be a combination of injection molding and secondary operations.  There will be four parts to injection mold and assemble.  Part 1 is the outer shell of the cooler body.  Part 2 is the inner shell of the cooler body.  Part 3 is the top cover.  Part 4 is the bottom of the cover. A sonic welder will be used to attach parts 1 & 2 as well as 3 & 4.  Hinges, latches, and gaskets will be attached to cooler in the final assemble process.

Assembly Process:

Injection Molding:

  1. Injection mold Parts 1,2,3 & 4
  2. Trim Parts
  3. Visually inspect
  4. Stack in separate piles

 

Sonic Welding:

  1. Place parts 1 & 2 and 3 & 4 together
  2. Sonic weld pieces in designated areas
  3. Visually inspect weld

 

Foam Injection:

  1. Place injection nozzle into hole
  2. Inject closed cell polyurethane foam into cooler cover and shell

 

Assembly:

  1. Mount adhesive gasket into designated channel
  2. Attach hinges onto cover in designated holes and then attach cover to cooler shell in designated holes
  3. Attach top latch piece onto cover in designated holes and then attach bottom latch onto cooler shell in designated holes