Insulating device
An insulating device may include a body comprising an outer shell, an insulating layer and aerogel structure adjacent to the outer shell, and an inner liner secured to the outer shell. The aerogel structure may comprise skiving features that extend from a surface of the aerogel structure to a mid-point width of the aerogel structure and may be configured to facilitate folding of the aerogel structure.
1 . A method comprising:
forming a body assembly by forming a lower outer shell, placing a lower insulating layer and an aerogel structure into the lower outer shell, and securing a lower inner liner portion to the lower outer shell, wherein the aerogel structure comprises skiving features that extend from a surface of the aerogel structure to a mid-point width of the aerogel structure and are configured to facilitate folding of the aerogel structure, wherein the aerogel structure is surrounded by an external shell within the lower outer shell, and wherein the aerogel structure is not attached to the external shell;
forming a lid assembly of an upper outer shell, an upper inner liner portion and an upper insulating layer and an aerogel structure therebetween; and
joining the lid assembly to the body assembly by securing a closure between the lid assembly and the body assembly and by securing a binding material to the body assembly and the lid assembly.
2 . The method of claim 1 wherein the lower insulating layer and the aerogel structure float between the lower outer shell and the lower inner liner portion.
3 . The method of claim 1 wherein the binding material is nylon.
4 . The method of claim 1 wherein the binding material is stitched to the body assembly and the lid assembly.
5 . The method of claim 1 wherein the lid assembly is also welded to the body assembly.
6 . The method of claim 1 wherein the lower inner liner portion is formed by injection molding.
7 . The method of claim 1 wherein the lower inner liner portion is secured to the lower outer shell by a weld.
8 . The method of claim 1 wherein the external shell is deformable.
9 . The method of claim 1 wherein a thermal conductivity of the aerogel structure is 0.01 W/m·K or less.