Patent ID: 8028394

Claim:
A manufacturing method of a thermally insulated housing including an outer shell comprising an outer case and an inner case that is housed at a spaced interval within the outer case, and formed by charging foam insulation between the outer case and the inner case when the outer shell is set in a foaming jig, the method including the steps of: overlapping edges of adjacent panels for at least one surface of the outer case and/or the inner case, wherein at least one adjacent panel has an overlapping edge formed in advance by bending the overlapping edge toward an opposing overlapping edge of an other adjacent panel; placing the inner case within the outer case; mounting a plurality of spacers between the inner case and the outer case, two or more of the plurality of spacers are positioned at substantially regular intervals along a length proximate to the overlapping edges; placing the outer shell within a foaming jig; and charging foam insulation between the inner case and the outer case such that the pressure of the foam deforms the bent overlapping edge to a substantially flat condition.