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I just noticed that all the coolers I have owned were well insulated on sides and bottom but the top remains to be fairly hollow.
I recently installed an igloo marine cooler and noticed that the top was extremely cold on the outside and I have to say I was somewhat disappointed at how thin the covering on this cooler seemed to be, they just aren't up to the old standards.
So I ask this, Is there any reason why you can't use a soft expanding foam in the lid for extra insulation?
I in no way question theory but I will always question industry cutting corners to save a buck.
So is there a reason the top is not insulated?
I have taken one of my older hollow top coolers and filled it with a soft expansion foam just for a torture test to see if this is an industry corner cutting method, has anyone else tried this?
I guessing the first thought is, will the top simply just 'balloon' up but I'm guessing with it still being vented or not being cometely sealed, it will maintain shape. We'll see!

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While not a expert in thermodynamics, I would proffer one thought.

Since cold air sinks, there is less need to insulate the lid. I would think it is a cost cutting move. If there is a good seal and insulation in the sidewalls and bottom, it should be good.

If you want a hard core cooler, consider the Yetti brand. Pricey. "In style" in some parts.

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Yetis are great but you can buy a lot of ice for the amount of premium you pay for one.

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While I agree with your theory, I don't agree with your conclusion.

As noted by Turpin.

Please keep us informed your results, procedures and pictures would be nice.

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Perhaps you could add a seat cushion to the top, ala Montauk or Outrage style. This would add both insulation and extra seating comfort.

Dennis

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Yes, I think there is a reason. I do not know for sure, I do not design coolers, but I would venture to guess that the people that do design coolers to compete with other manufacturers test their designs very thoroughly before they release them on the market to insure they actually work to hold ice to standards they are required to meet by their employers.

I think you could very well find with your test that the cooler does not hold ice for as long, or that it holds ice exactly the same amount of time, as your foam-filled top.

I would venture that the air space inside the lid of the cooler could act as an intermediate temperature barrier that reduces the speed of change in temperature inside the cooler when the sun beats down on the top of the cooler during normal use. Just a guess :)

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I wished I had thought this earlier in the season as it is getting colder now.
Though I don't know that insulation in the top will make a significant difference, I can't help but think it will help. I would think anything you can do to aid in keeping the outside heat from transferring to the inside even being the top, can only help the cooler.

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My OEM 1989 igloo coolers are still in service today. I've added a few new parts over the year but....

Maybe my technique is different, but I tend to drink what's in the cooler before it gets warm!

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That's my point exactly, your 1989 igloo cooler may have or use the same hardware as the latest coolers "but" the material that makes up the liner, outer shell and lid are much thinner than the older coolers i.e. Corner cutting to save money thus producing a cheaper (in quality) product. So this launched my question about the lid.
The industry now provides these high end coolers at obscene prices when 30 years ago though it would probably be considered a nice cooler, it's ability to keep ice and quality of construction was more or less the factory standard then and we get sub standard coolers now.

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http://s355.photobucket.com/user/stie...oler%20mod
So this is how it turned out and what I did to insulate the lid of the cooler.
Judgement is is still in limbo as to how it will perform, I'm not not overly satisfied with this cooler's performance out of the box as it falls way short of the older cooler it replaced which was a fairly standard Picnic style cooler.

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I spoke with an Igloo rep a few years back when I was looking at a replacement cooler for my 17 Montauk. Listening between the lines, coolers have evolved from a lifetime product (the old metal-sided, clumsy to carry but worked great) to a throwaway product (what you see on the shelves at Walmart). Replacement parts are provided for those of us that actually care for their coolers or opt for the higher grade products (Marine series being the low end, Yeti/Orca/Engel being the higher). Igloo realizes your basic cooler customer is going to treat it terribly and at some point put it on the curb. Then someone like me picks it up, spends $10 to fix the hinges, a little pressure washing, bleach, and paint and I make it last 10+ years. You just decide your price point and go with it, because a cooler ONLY works well if you keep the lid closed. This goes across the board. A cheaper cooler will have thinner walls and lids, less insulation, but will work fine to keep your drinks cold for a day on the water. You just won't keep the ice very long. If I was having a kidney or liver shipped cross-country, I would pay for the Yeti/Orca/Engel because the lid will stay closed and they are manufactured to keep ice/cold longer, but ONLY if the lid stays closed.

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If you want your ice to last longer try cutting a piece or two of that silver / bubble duct insulation to fit inside your cooler to cover your ice, it really helps.