Ethan Clarke
Plastic coolers are used to keep food and beverages cool. They are made from a variety of materials, including different types of polymers such as PU foams, polyethylene, and elastomer. The outer shell of these coolers is typically made from moulded high-density polyethylene, while the inner layer is usually white and smooth. Basic coolers are often made from polystyrene or spray-foam walls with a thin blow-moulded polypropylene plastic exterior. More expensive coolers tend to have a thick roto-moulded polyethylene shell that is injected with polyurethane foam, which is a superior insulator. Polyurethane foam is denser than styrofoam, which is typically used in cheaper coolers, and contains smaller air bubbles.
| Characteristics | Values |
|---|---|
| Major Material | Plastic or polymer |
| Types of Polymer | Polyurethane foam (PU foam), Polyethylene, Elastomer |
| Polyurethane Foam Production | Three phases: production of bulk polymer, further processing, transformation of PU foam into a finished product |
| Polyethylene | Most produced plastic in the world, composed of carbon and hydrogen, three types with different densities (HDPE, LLDPE, LDPE) |
| Polyethylene Advantages | Excellent electrical insulation and chemical resistance, low price, toughness |
| Elastomer | Natural resource from rubber trees |
| Insulation | Foam insulation, styrofoam, polyurethane foam |
| Rotational Molding | Process where heated and softened material is applied to inner wall of slowly rotating mold |
| Roto-molded Coolers | YETI, ORCA, Grizzly, and Coleman |
| Polyurethane Foam | Superior thermal performance and durability, exceptional thermal efficiency |
| Thermal Conductivity | Measured in watts per square meter of surface area for a temperature gradient of one Kelvin per meter of thickness |
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What You'll Learn
Plastic coolers are made of polymers
Plastic coolers, also known as picnic coolers, are made of polymers. The different components of the plastic cooler are made with different types of polymers to maximise its ability. The durability shared among all the polymers makes it hard to degrade, which contributes to environmental damage.
Polyurethane foam or PU foam is one of the polymers that make up the picnic cooler. PU foam is a secondary material produced from the chemical reaction between an isocyanate and a polyol. These two products are derived from crude oil. The production of PU foams can be broken down into three phases: the production of the bulk polymer, further processing, and the transformation of PU foam into a finished product. During the first phase, the reacting raw materials pass through a heat exchanger, causing polymerization reactions—a chemical reaction of monomers joined together to form polymers. At the processing phase, the PU foam is layered with baking paper and cut into its desired length. Lastly, the PU foam is packaged and shipped.
Another polymer that makes up the picnic cooler is polyethylene. Polyethylene is the most produced plastic in the world, with more than 80 million tons manufactured annually. It has the simplest basic structure among polymers and is composed of only carbon and hydrogen. There are three types of polyethylene, each with a different density: high-density polyethylene (HDPEs), linear low-density polyethylene (LLDPEs), and low-density polyethylene (LDPEs). HDPE is used to produce the plastic picnic cooler, and its raw material is petroleum.
In addition to PU foams and polyethylene, elastomer is another polymer that is used in plastic coolers. Elastomer is a natural polymer derived from natural rubber trees. However, the endless consumption of these trees for elastomer production can lead to instability and potential depletion of this natural resource. Furthermore, processing elastomer requires a large amount of fossil fuels, contributing to higher carbon dioxide emissions during transportation.
Plastic polymers have significantly contributed to our quality of life, and many products we rely on daily would not be possible without them. For example, strong, lightweight plastics have reduced the weight of cars and airplanes, lowering the energy needed to operate them and, in turn, reducing emissions.
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Polyurethane foam is a common polymer
Plastic coolers are made up of different types of polymers, including PU foams, polyethylene, and elastomers. Polyurethane foam, or PU foam, is a common polymer found in plastic coolers. It is a synthetic material with a highly diverse range of applications. Polyurethane foams are primarily used for thermal insulation and as cushioning material in mattresses, upholstered furniture, or vehicle seating. Its low density and thermal conductivity, along with its mechanical properties, make it an excellent thermal and sound insulator.
Polyurethane foam is a solid polymeric foam based on polyurethane chemistry. It is produced by reacting di- and tri-isocyanates with polyols, often in the presence of a catalyst or ultraviolet radiation. The most common catalysts include tertiary amines such as DABCO and DMDEE or metallic soaps like dibutyltin dilaurate. The polymer typically has a highly cross-linked molecular structure, resulting in a thermosetting material that does not melt upon heating. However, some thermoplastic polyurethanes are also produced.
The production of PU foams can be divided into three phases: the production of the bulk polymer, further processing, and the transformation of PU foam into a finished product. During the first phase, the reacting raw materials pass through a heat exchanger, initiating polymerization reactions where monomers join to form polymers. The two components, the polyol stream and the isocyanate, are referred to as a polyurethane system.
Polyurethane foam has two main types: flexible (soft) and rigid (hard) foams. Flexible polyurethane foams have an open-cell structure with interconnected pores, while rigid foams have closed-cell structures with non-interconnected pores. The choice between these two types depends on the specific application and desired properties.
The versatility of polyurethane foam arises from its ability to exhibit different characteristics through small modifications in formulation. Adjusting the type and content of polyols, isocyanates, catalysts, surfactants, blowing agents, and additives allows for control over the properties of the resulting foam. Surfactants, for example, are used to modify the characteristics of both foam and non-foam polyurethane polymers. They help emulsify liquid components, regulate cell size, and stabilize the cell structure to prevent collapse and sub-surface voids.
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Polyethylene is another polymer used
There are three types of polyethylene, each with a different density: high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), and low-density polyethylene (LDPE). The density of polyethylene depends on the molecular weight, crosslinking, and presence of comonomers. LDPE has a lower melting point than HDPE, at around 110-115 °C, while HDPE's melting point is typically in the range of 120-130 °C. LDPE is softer and more flexible than HDPE, due to the presence of both long and short branches in its molecular structure.
HDPE is the type of polyethylene used to produce plastic coolers. It was first synthesized in 1933 by Eric Fawcett and Reginald Gibson, who reacted ethylene and benzaldehyde under high pressure. However, the process was difficult to reproduce until 1935, when Michael Perrin developed a reproducible high-pressure synthesis. The breakthrough in commercial production came in the 1950s with the development of catalysts that promoted polymerization at milder temperatures and pressures, such as the Phillips catalyst and the Ziegler catalyst.
The versatility of polyethylene, especially HDPE, makes it a popular choice for manufacturing various products, including water bottles, plastic bags, agricultural mulch, wire and cable insulation, toys, and housewares. However, its chemical resilience also makes it a long-lasting pollutant when disposed of improperly, contributing to environmental damage.
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Rotational moulding is a manufacturing process
Plastic coolers are made of different types of polymers, such as PU foams, polyethylene, and elastomers. The most common type of polyethylene used in plastic coolers is high-density polyethylene (HDPE). Polyethylene is composed of carbon and hydrogen, and it offers advantages like excellent electrical insulation, chemical resistance, toughness, and a low price.
Rotational moulding, also known as rotomolding, is a manufacturing process used to create plastic coolers. This process involves placing plastic powder or resin into a heated hollow mold, which is then rotated slowly in two perpendicular axes, distributing the melted plastic evenly across the interior surfaces of the mold. The rotation continues during the heating and cooling phases, and once the plastic is stable, the rotation stops, and the final product is removed from the mold. This process results in thick, even walls, especially in the corners, providing excellent strength and durability.
The benefits of rotational moulding include the ability to create seamless parts with uniform wall thickness, eliminating high fabrication costs, and supporting a wide variety of surface textures and colours. Rotational moulding is also cost-effective, as it can be performed at low pressure, reducing the cost of materials. However, it is a slower process than injection moulding, which can increase production costs.
The rotational moulding process allows for the creation of strong, hollow plastic parts that can be filled with polyurethane foam insulation. This foam insulation provides additional rigidity and thermal insulation, making the coolers ideal for keeping food and beverages cold. The coolers may also feature additional components such as wheels, cup holders, bottle openers, handles, and tie-down slots.
Overall, rotational moulding is a valuable manufacturing process that creates durable, stress-free, and seamless plastic products, such as coolers, with strong outside corners and consistent wall thickness.
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Coolers are insulated to keep heat out
Plastic coolers are made from a variety of polymers, including polyethylene, elastomer, and polyurethane foam. The latter is a secondary material derived from the chemical reaction between an isocyanate and a polyol, which are themselves derived from crude oil. The density of the foam depends on the type of isocyanate used, with TDI and MDI being cheaper and more reactive. The hardness of the foam, on the other hand, is determined by the molecular weight of the polyol.
Polyethylene is the most commonly produced plastic globally, with over 80 million tons manufactured annually. It has a simple structure, composed of only carbon and hydrogen, and offers excellent electrical insulation, chemical resistance, toughness, and a low price. High-density polyethylene (HDPE) is used to produce plastic picnic coolers.
Some coolers, like the Esky Auto Box, use cork sheeting for insulation. Rotationally molded (roto-molded) coolers, such as YETI, ORCA, and Grizzly, have become popular in recent years. Roto-molded coolers are manufactured using a heated and softened material applied to the inner wall of a slowly rotating mold. This process creates a thick and uniform final product with no seals or imperfections, enhancing durability. Roto-molded coolers typically feature a thick layer of insulation beneath the plastic exterior.
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Frequently asked questions
Plastic coolers are made of polymers, which are durable and hard to degrade. The different components of the cooler are made with different types of polymers, including polyurethane foam (PU foam), polyethylene, and elastomer. The outer shell of the cooler is almost always moulded high-density polyethylene.
Coolers primarily use different types of foam insulation. Cheaper coolers use styrofoam, while premium coolers like Grizzly or Kenai use polyurethane foam, which is denser and contains smaller air bubbles. Polyurethane sets hard, adding extra strength to the cooler.
Polyurethane foam is considered one of the best materials for insulation in plastic coolers. The denser the polyurethane foam, the better it insulates, but also the heavier it becomes. Polyurethane foam from EcoMate is used in Grizzly Coolers for its superior thermal performance and durability.
