U.S. patent application number 10/395227 was filed with the patent office on 2003-12-25 for insulated shipping container.
This patent application is currently assigned to Tuscarora Incorporated. Invention is credited to Hagopian, Eric M., Pringle, Thomas Craig.
Application Number | 20030234255 10/395227 |
Document ID | / |
Family ID | 28675337 |
Filed Date | 2003-12-25 |
United States Patent
Application |
20030234255 |
Kind Code |
A1 |
Hagopian, Eric M. ; et
al. |
December 25, 2003 |
Insulated shipping container
Abstract
An insulated shipping container includes an exterior housing; an
interior sleeve; and an intermediate insulating portion, wherein
the intermediate insulating portion includes an open cell core
material having at least about 95% open cell and a metalized
barrier material sealed about the core material in an airtight
manner, with a reduced pressure atmosphere in the intermediate
portion.
Inventors: |
Hagopian, Eric M.; (Fresno,
CA) ; Pringle, Thomas Craig; (Scottsdale,
AZ) |
Correspondence
Address: |
BURNS DOANE SWECKER & MATHIS L L P
POST OFFICE BOX 1404
ALEXANDRIA
VA
22313-1404
US
|
Assignee: |
Tuscarora Incorporated
|
Family ID: |
28675337 |
Appl. No.: |
10/395227 |
Filed: |
March 25, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60367226 |
Mar 25, 2002 |
|
|
|
Current U.S.
Class: |
220/592.25 ;
220/62.2; 220/62.22 |
Current CPC
Class: |
B32B 5/18 20130101; B32B
3/22 20130101; B32B 27/40 20130101; B65D 81/3886 20130101; B32B
3/02 20130101; B65D 81/3823 20130101 |
Class at
Publication: |
220/592.25 ;
220/62.2; 220/62.22 |
International
Class: |
B65D 003/22 |
Claims
What is claimed is:
1. An insulated shipping container comprising: an exterior housing;
an interior sleeve; and an intermediate insulating portion, wherein
the intermediate insulating portion has an R value of about 20 or
greater.
2. The insulated shipping container of claim 1, wherein the
exterior housing is made of a rigid material.
3. The insulated shipping container of claim 1, wherein the
exterior housing is made of cardboard.
4. The insulated shipping container of claim 1, wherein the
exterior housing is made of one of fiberboard, metal and
plastic.
5. The insulated shipping container of claim 1, wherein the
exterior housing includes a cap with threads or clasps for opening
and reclosing.
6. The insulated shipping container of claim 1, wherein the
intermediate insulating portion has an R value of at least 20.
7. The insulated shipping container of claim 1, wherein the
intermediate insulating portion has an R value between 25 to 30 per
inch.
8. The insulated shipping container of claim 1, wherein the
intermediate insulating portion includes a core material and a
barrier material sealed about the core material in an airtight
manner.
9. The insulated shipping container of claim 8, wherein the barrier
material is a metal foil or a metalized film laminate.
10. The insulated shipping container of claim 8, wherein the core
material is an open cell material.
11. The insulated shipping container of claim 10, wherein the core
material is an open-cell polystyrene or polyurethane foam.
12. The insulated shipping container of claim 1, wherein the
intermediate insulating portion includes a reduced pressure therein
to enhance insulating properties thereof.
13. The insulated shipping container of claim 12, further
comprising a vacuum detection indicia to indicate when there is a
reduced pressure within the intermediate insulating portion.
14. The insulated shipping container of claim 1, wherein a largest
exterior dimension of the container is 20 inches.
15. The insulated shipping container of claim 8, wherein the
interior sleeve is made of a rigid plastic material.
16. An insulated shipping container comprising: an exterior
housing; an interior sleeve; and an intermediate insulating
portion, wherein the intermediate insulating portion includes a
core material and a barrier material sealed about the core material
in an airtight manner.
17. The insulated shipping container of claim 16, wherein the
exterior housing is made of a rigid material.
18. The insulated shipping container of claim 16, wherein the
exterior housing is made of cardboard.
19. The insulated shipping container of claim 16, wherein the
exterior housing is made of one of fiberboard, metal and
plastic.
20. The insulated shipping container of claim 16, wherein the
exterior housing includes a cap with threads or clasps for opening
and reclosing.
21. The insulated shipping container of claim 16, wherein the
intermediate insulating portion has an R value of at least 20.
22. The insulated shipping container of claim 16, wherein the
intermediate insulating portion has an R value between 25 to 30 per
inch.
23. The insulated shipping container of claim 16, wherein the
barrier material is a metal foil or a metalized film laminate.
24. The insulated shipping container of claim 16, wherein the core
material is an open cell material.
25. The insulated shipping container of claim 16, wherein the core
material is an open-cell polystyrene or polyurethane foam.
26. The insulated shipping container of claim 16, wherein the
intermediate insulating portion includes a reduced pressure therein
to enhance insulating properties thereof.
27. The insulated shipping container of claim 26, further
comprising a vacuum detection indicia to indicate when there is a
reduced pressure within the intermediate insulating portion.
28. The insulated shipping container of claim 16, wherein a largest
exterior dimension of the container is 20 inches.
29. The insulated shipping container of claim 16, wherein the
interior sleeve is made of a rigid plastic material.
30. An insulated shipping container comprising: an exterior
housing; an interior sleeve; and an intermediate insulating
portion, wherein the intermediate insulating portion includes an
open cell core material comprising at least about 95% open cell and
a metalized barrier material sealed about the core material in an
airtight manner, with a reduced pressure atmosphere in the
intermediate portion.
31. The insulated shipping container of claim 30, wherein the
exterior housing is made of a rigid material.
32. The insulated shipping container of claim 30, wherein the
exterior housing is made of cardboard.
33. The insulated shipping container of claim 30, wherein the
exterior housing is made of one of fiberboard, metal and
plastic.
34. The insulated shipping container of claim 30, wherein the
exterior housing includes a cap with threads or clasps for opening
and reclosing.
35. The insulated shipping container of claim 30, wherein the
intermediate insulating portion has an R value of at least 20.
36. The insulated shipping container of claim 30, wherein the
intermediate insulating portion has an R value between 25 to 30 per
inch.
37. The insulated shipping container of claim 30, wherein the core
material is an open-cell polystyrene or polyurethane foam.
38. The insulated shipping container of claim 30, wherein the
intermediate insulating portion includes a reduced pressure therein
to enhance insulating properties thereof.
39. The insulated shipping container of claim 38, further
comprising a vacuum detection indicia to indicate when there is a
reduced pressure within the intermediate insulating portion.
40. The insulated shipping container of claim 30, wherein a largest
exterior dimension of the container is 20 inches.
41. The insulated shipping container of claim 30, wherein the
interior sleeve is made of a rigid plastic material.
42. An insulated shipping container comprising: an exterior
housing; an interior sleeve; and an intermediate insulating
portion, wherein the intermediate insulating portion has an R value
of about 20 or greater; wherein outside dimensions of the exterior
housing are equal to or less than twelve inches by six inches by
six inches.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application No. 60/367,226, filed in the United States
on Mar. 25, 2002, the entire contents of which are hereby
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates, generally, to shipping
containers, and more particularly, to insulated shipping
containers, as may be used for the shipping of various
temperature-sensitive products by regular mail or other like
delivery services.
[0004] 2. Description of Related Art
[0005] With the rapid worldwide growth in the demand for the
shipment and handling of temperature sensitive products, such as
blood, gourmet food products, pharmaceuticals, vaccines,
bioengineered products and the like, the need for more thermally
efficient shipping containers continues to increase dramatically.
Particularly with the increase of e-commerce, many companies need
thermally efficient shipping containers for shipping such products
through inexpensive modes of transportation, such as regular U.S.
Mail, directly to the end user.
[0006] In designing and manufacturing insulated shipping
containers, various factors must be considered, including weight,
size and durability. Since many of the products must be shipped at
great distances by rail, truck or air travel, the designers of
these containers must strive to keep the weight of these containers
at a minimum and yet still provide sufficient protection of the
goods at the desired temperature for extended periods, e.g., by
providing containers with a sufficiently thick layer of insulation,
such as polyurethane and the like. In addition, due to the volume
of the goods to be shipped, as well as limitations in available
cargo space, the size and configuration of the shipping container
must be optimized to maintain the desired temperature and yet
minimize the area required for storage.
[0007] As a result of these factors, many of today's shipping
containers utilize combinations of inexpensive paperboard boxes and
more costly foam insulating materials, such as, for example,
polyurethane, polystyrene or the like. Although these materials
combine to provide a low-cost insulating container, because these
materials typically attempt to trap gases to reduce heat transfer,
these materials typically provide a low insulation value, such as
R-7 or lower. Furthermore, these characteristics of prior art
materials require thicker materials to be utilized, thus resulting
in bigger and bulkier containers in an attempt to compensate for
these thermal inefficiencies. Accordingly, streamlined shipping
containers which provide both effective thermal protection and
smaller outer dimensions are not currently available for mail-order
applications.
[0008] With reference to FIG. 1, a prior art shipping container for
transporting temperature sensitive materials is shown. Typically,
such prior art containers include a exterior protective surface and
end cap or lid comprised of cardboard materials and the like. The
exterior surface is typically configured with an interior lining
for containing the temperature sensitive products. In addition, an
insulation material is encapsulated between the exterior protective
housing and the interior lining.
[0009] This insulating material is typically bonded to the exterior
housing and comprises low efficiency types of insulating material.
For example, the insulating material generally includes expanded
polystyrene or polyurethane and the like which provide a thermal
efficiency value, or R-Value, of between 4.0 and 7.2 per inch. As a
result, the shipping constraints for prior art shipping containers
require the temperature-sensitive products contained within to be
shipped within 24 to 48 hours, thus limiting the free use of
regular U.S. Mail for transportation, which can take four or five
days for delivery. Instead, prior art shipping containers typically
require more expensive modes of transportation to be utilized, such
as Federal Express Next or Second Day service or UPS Red or Blue
services, among others.
[0010] Moreover, due to the inefficiencies of prior art containers,
temperature sensitive products frequently require refrigerated or
heated trucks or vehicles for transport. Furthermore, as regulatory
agencies continue to enact more stringent regulations for the
temperature control of perishable and other temperature-sensitive
goods, the need for more reliable and efficient insulating
materials continues to grow.
[0011] Accordingly, a need exists for a shipping container for
temperature sensitive products which provides more efficient
thermal protection, such as a high R-value, for example, of 20 or
more, and which can permit lower cost methods of transportation to
be utilized, such as regular U.S. Mail or other four- to five-day
delivery services. Furthermore, a need exists for an insulated
shipping container that is streamlined and less bulky than prior
art containers to provide for the effective use of cargo space
during transporting of the temperature-sensitive goods.
SUMMARY
[0012] A vacuum insulation panel according to the present invention
addresses many of the shortcomings of the prior art. In accordance
with the present invention, an insulated shipping container is
provided that may be utilized for mail-order applications, such as
the shipment of drugs and specialty food products.
[0013] An exemplary container may comprise an exterior protective
housing that provides protection for an insulated portion from the
environment, e.g., from shipping and handling damages. Although the
insulated portion comprises various forms of insulated materials,
preferably a vacuum-insulated panel (VIP) configuration is
utilized. The insulated portion includes an insulated cap or lid.
In addition, the exemplary container may also include an interior
protective sleeve or tube for encasing the temperature sensitive
products, e.g., pharmaceuticals or vaccines. Further, a
refrigerant, a heat source, or other temperature stabilizing
material may be placed within or between the interior sleeve and
the insulated portion, with the refrigerant, heat source, or
temperature stabilizing material and the sleeve being sealed within
the insulated portion by the cap. Thereafter, the insulated portion
and the sleeve may be placed within the exterior housing and
enclosed with the housing end cap.
[0014] In accordance with one embodiment of the present invention,
an insulated shipping container comprises an exterior housing; an
interior sleeve; and an intermediate insulating portion, wherein
the intermediate insulating portion has an R value of about 20 or
greater.
[0015] In accordance with one embodiment of the present invention,
an insulated shipping container comprises an exterior housing; an
interior sleeve; and an intermediate insulating portion, wherein
the intermediate insulating portion includes a core material and a
barrier material sealed about the core material in an airtight
manner.
[0016] In accordance with one embodiment of the present invention,
an insulated shipping container comprises an exterior housing; an
interior sleeve; and an intermediate insulating portion, wherein
the intermediate insulating portion includes an open cell core
material comprising at least about 95% open cell and a metalized
barrier material sealed about the core material in an airtight
manner, with a reduced pressure atmosphere in the intermediate
portion.
[0017] In accordance with another aspect of the present invention,
particularly for the VIP application, the insulated portion may
comprise a vacuum detection indicator. The vacuum detection
indicator is configured to facilitate the evaluation of the
integrity of the vacuum within the vacuum insulation panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention will be hereinafter described in
conjunction with the appended drawing figures, wherein like
designations denote like elements, and:
[0019] FIG. 1 is a view of a conventional art shipping
container;
[0020] FIG. 2 is a view of an exemplary insulated shipping
container in accordance with the present invention; and
[0021] FIG. 3 is a view of various exemplary embodiments of the
container in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The embodiments of the present invention may be described
herein in terms of various types of materials and processing steps.
It should be appreciated that such materials and steps may be
realized by any number of components configured to perform the
specified functions. For example, the embodiments of the present
invention may employ various insulating materials, wrapping
materials, labels, end cap connectors and the like, which may carry
out a variety of functions. In addition, those skilled in the art
will appreciate that the embodiments of the present invention may
be practiced in any number of shipping contexts and that the
embodiments relating to an insulated shipping container for
mail-order applications, as described herein, is merely one
exemplary application of the invention. For example, the
principles, features and methods discussed may be applied to any
shipping application wherein temperature-sensitive products are to
be transported. Further, such general techniques that may be known
to those skilled in the art are not described in detail herein.
[0023] As discussed above, many temperature-sensitive products,
such as drugs and vaccines, currently have to be kept refrigerated
and thus are transported on large refrigerator trucks to pharmacies
and hospitals. Furthermore, current containers for drugs do not
lend themselves to being shipped directly from the drug
manufacturer to the patient via regular U.S. Mail or other four or
five day delivery services.
[0024] However, in accordance with the present invention, an
improved shipping container can be provided for facilitating the
shipment of temperature sensitive products directly from the
supplier to the end user by use of low-cost transportation
services.
[0025] With reference to FIG. 2, an exemplary insulated shipping
container 200 comprises an exterior housing 202, an insulated
portion 208 and an interior sleeve 214. Exterior housing 202
includes an open end 204 and an end cap or lid 203, and is
configured for providing protection for the insulated portion 208
from the environment, e.g., from shipping and handling damages.
Exterior housing 202 and end cap 203 may comprise various
materials, such as, for example, fiberboard, cardboard, metals or
plastics and the like, which are suitably configured for protection
of the insulated portion 208. Further, exterior housing 202 and end
cap 203 suitably include a means for connecting together, such as
threaded engagement portions 205 and 206, or by any other suitable
means now known or hereinafter devised, such as press-fitting,
clasping, fastening or other similar arrangements. In addition, it
is preferable for cap 203 and housing 202 to be connected in a
tamper-proof manner to prevent easy or unintentional opening of
housing 202.
[0026] Insulated portion 208 suitably comprises various forms of
insulated materials, such as polyurethane, polystyrene, and other
similar materials. Preferably, insulated portion 208 comprises a
vacuum-insulated-panel (VIP) configuration. Insulated portion 208
may also be comprised of a single component, i.e., one insulating
material or one vacuum insulating panel, or of a plurality of
components, configured in the desired shape to suitably contain
interior sleeve 214. In addition, insulated portion 208 suitably
includes an insulated end cap 212. Further, insulated portion 208
suitably includes an opening 210 configured for the interior sleeve
214. In accordance with this aspect, insulated portion 208 may also
be configured to contain a refrigerant, such as ice, dry ice or
other refrigerants, or to contain a heat source or other
temperature stabilizing material, with or without packaging around
the refrigerants or heat source, to provide additional insulated
cooling or heating to the temperature sensitive products.
[0027] In addition, the exemplary container may also include an
interior protective sleeve 214 having an opening 216 for encasing
the temperature sensitive products. Interior sleeve 214 comprises a
tube, container or liner and the like suitably configured to
contain dry, solid or liquid materials, e.g., pills or liquids. The
interior sleeve 214 may be made from plastic, cardboard, or any
other suitable material. Further, in addition to, or instead of,
the placement of a refrigerant, heat source, or other temperature
stabilizing material within opening 210 of insulated portion 208,
the refrigerant or heat source may be placed within interior sleeve
214 and sealed within interior sleeve 214 by an associated end cap
(not shown). Moreover, interior sleeve 214 is suitably provided
with an exterior surface which serves as a liner to protects the
inner area of insulated portion 208 from being punctured or
damaged.
[0028] Upon enclosing of the temperature sensitive products within
interior sleeve 214 and its associated end cap, interior sleeve 214
may be suitably placed within insulated portion 208. Upon closure
by insulated end cap 212, both sleeve 214 and insulated portion 208
may be suitably placed within exterior housing 202 and enclosed
with end cap 203. In addition, although shown as separate
components, i.e., each component being capable of removal, re-use
or replacement, exterior housing 202, insulated portion 208 and
interior sleeve 214 could be configured together, such as by
bonding, adhesion or other like manners.
[0029] Although insulated portion 208 may comprise various
materials, in accordance with an exemplary embodiment of the
present invention, insulated portion 208 preferably comprises a
vacuum insulation panel configuration. In accordance with this
embodiment, insulated portion 208 comprises a barrier material and
a core material configured to provide an R-value of 20 or more, for
example, 25 to 30 per inch. The barrier material preferably
comprises a thin, flexible, film-like material, such as, for
example, a metal foil or metalized film laminate, e.g., a metalized
polymer or polymeric structure, or a non-metallic structure.
Moreover, the barrier material is preferably configured to suitably
encapsulate the core material and facilitate the maintaining of a
vacuum within.
[0030] According to one embodiment, the walls of the insulated
portion are between 1/2 to 1 1/2 inches thick, preferably about 1
inch thick.
[0031] Preferably, the core material comprises an open-cell core
material, such as, for example, an open-cell polystyrene or
polyurethane foam and the like, or silica or aerogel, suitably
configured to facilitate the drawing of a vacuum area between the
barrier material and the core material. In accordance with this
aspect, the core material is preferably configured to provide
greater than 95% open-cell, and most preferably approximating 99%
or greater open-cell material. Preferably, the core material
comprises a substantially rigid material, but may also include more
flexible compositions.
[0032] Although an exemplary embodiment for an insulated portion
comprising a vacuum insulating panel is described, the insulated
panel can also comprise any other means now known or hereinafter
devised for providing a thermal protection factor, i.e., an
R-Value, of 20 or more. Furthermore, any known method for providing
a vacuum insulating panel or material may be utilized in accordance
with the present invention, and the exemplary embodiment described
above is merely for illustration purposes.
[0033] Although the vacuum insulation panels are durable, often
lasting two years or more, the barrier film can be susceptible to
deterioration, puncture, tear and other wear that can cause
insulated portion 208 to lose the vacuum within the barrier film
and thus become inefficient for critical temperature applications.
Although a detailed visual inspection may lead an evaluator of the
panels to a determination as to the integrity of the vacuum within
the panel, generally only the largely visible punctures or tears
may be visible. Further, because various of the defects are not
readily detectable, damaged vacuum insulation panels currently have
the potential to be reused, and thus the potential exposure to the
environment for the temperature-sensitive goods is increased.
Accordingly, by providing a determination of whether the vacuum is
maintained within the vacuum insulation panel, the integrity and
thermal efficiency of the vacuum insulation panel can be evaluated.
Thus, in accordance with another embodiment of insulated portion
208, the core material may be configured with a vacuum detection
indicia visually apparent when a vacuum is drawn within the vacuum
insulation panel, such as disclosed in U.S. patent application Ser.
No. 10/241,867, assigned to Applicant, and filed Sep. 12, 2002.
[0034] In accordance with another embodiment of the present
invention, exemplary shipping container 200 may comprise various
shapes. For example, with reference to FIG. 3, shipping container
200 may comprise a cylindrical shape 306, a semi-circular shape
302, or a rectangular shape 304. Accordingly, any shape configured
for containing insulated portion 208 and interior sleeve 214 may be
utilized. Further, insulated portion 208 and interior sleeve 214
may comprise any suitable shapes. Moreover, exterior housing 202,
insulated portion 208 and interior sleeve 214 may comprise the same
or different shapes, depending on different design criteria.
[0035] An objective of one embodiment of the present invention is
to provide a package that can be easily shipped through the U.S.
mail. Accordingly, it is preferred that no dimensions of the outer
container exceed twenty inches. And, preferably, a maximum
dimension of the container shall be smaller than twelve inches.
According to one embodiment, the container shall fit in an
enclosure of twelve inches by six inches by six inches.
[0036] The present invention has been described above with
reference to various preferred embodiments. However, those skilled
in the art will recognize that changes and modifications may be
made to the various preferred embodiments without departing from
the scope of the present invention. For example, rather than
providing a threaded-like arrangement for the various end caps, any
means for securely engaging an end cap may be utilized. Further,
each of the end caps or lids may use similar or different means for
enclosing onto their respective container portions. Accordingly,
these and other changes or modifications are intended to be
included within the scope of the present invention.
* * * * *