U.S. patent application number 11/401183 was filed with the patent office on 2006-08-10 for insulated shipping container and method.
Invention is credited to Gary Lantz.
Application Number | 20060174648 11/401183 |
Document ID | / |
Family ID | 36778543 |
Filed Date | 2006-08-10 |
United States Patent
Application |
20060174648 |
Kind Code |
A1 |
Lantz; Gary |
August 10, 2006 |
Insulated shipping container and method
Abstract
An improved shock-absorbing, disposable, insulated shipping
container including an insulated body having a cavity for holding
contents to be shipped in the container. The container also
includes an especially configured dual-function structure, which is
shock-absorbing and provides for air circulation about the contents
of the container. A fan package provides for fan-forced circulation
of air within the container over the contents and a temperature
control mass, so that the contents are maintained at a desired
uniform temperature during shipment.
Inventors: |
Lantz; Gary; (Lake Forest,
CA) |
Correspondence
Address: |
Law Office of Terry L. Miller
24832 Via San Fernando
Mission Viejo
CA
92692
US
|
Family ID: |
36778543 |
Appl. No.: |
11/401183 |
Filed: |
April 10, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11044392 |
Jan 26, 2005 |
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11401183 |
Apr 10, 2006 |
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Current U.S.
Class: |
62/371 ;
62/407 |
Current CPC
Class: |
F25D 17/06 20130101;
F25D 2317/0665 20130101; B65D 81/3816 20130101; F25D 2317/0661
20130101; F25D 2331/804 20130101; F25D 3/08 20130101; F25D 3/14
20130101; F25D 2303/0844 20130101; F25B 27/00 20130101 |
Class at
Publication: |
062/371 ;
062/407 |
International
Class: |
F25D 3/08 20060101
F25D003/08; F25D 17/04 20060101 F25D017/04 |
Claims
1. An improved shock absorbing insulated shipping container, said
container comprising: a chambered insulating body, said body
including a base portion defining a chamber therein and an opening
from said chamber, and a lid portion spanning and closing said
opening; said container also including dual-function structure
disposed within said chamber for receiving contents to be shipped
in said container, and a temperature-control mass, said
dual-function structure on the one hand providing a shock-absorbing
structure spacing the contents away from inside surfaces of said
chamber so as to maintain a surrounding cushion space of controlled
crushability, and on the other hand, also providing an air
circulation space surrounding the contents, whereby air currents
are allowed to circulate about said contents and said
temperature-control mass.
2. The shipping container of claim 1, wherein said insulating body
includes foamed polymer.
3. The shipping container of claim 1, further including an air
circulation fan package communicating with said chamber.
4. The shipping container of claim 3 wherein said air circulation
fan package is disposed within said chamber.
5. The shipping container of claim 3, wherein said air circulation
fan package includes a battery, a motor, and a fan driven by said
motor.
6. The shipping container of claim 3, further including a
temperature responsive control device for effecting controlled
fan-forced circulation of air within said chamber by operation of
said fan in response to temperature within said chamber.
7. The shipping container of claim 6, wherein said temperature
responsive control device includes a temperature responsive
switch.
8. The shipping container of claim 3, further including a voltage
control circuit element interposed in circuit with said battery and
said motor and operating said motor at less than full battery
voltage while said battery is fresh, while also extending the
operating time for said motor, whereby, said voltage control
element extends the operating interval for said motor.
9. The shipping container of claim 8, wherein said voltage control
circuit element includes a zener diode.
10. The shipping container of claim 8, wherein said voltage control
circuit element includes a transistor.
11. The shipping container of claim 1, wherein said dual-function
structure disposed within said chamber for receiving contents to be
shipped in said container, and a temperature-control mass, includes
plural crushable channel members, each of said plural crushable
channel members being respectively interposed between an inside
surface of said chamber and said contents.
12. The shipping container of claim 11, wherein said crushable
channel members include a pair of spaced apart legs extending from
an inside surface of said chamber to a portion spanning between
said pair of spaced apart legs, and said pair of spaced apart legs
having a determined crushability.
13. The shipping container of claim 12, wherein said pair of spaced
apart channel legs include features for modifying the crushability
of said pair of spaced apart legs.
14. The shipping container of claim 13, wherein said features for
modifying the crushability of said pair of legs are selected from
the group consisting of: openings, holes, slots, and slits formed
in said pair of spaced apart legs.
15. The shipping container of claim 11, wherein said base portion
includes plural pairs of spaced apart grooves extending along an
inside surface of said chamber, and said channel members each
include a pair of spaced apart legs respectively received
retainingly in said pairs of spaced apart grooves.
16. The shipping container of claim 15, wherein said base portion
includes at least one pair of spaced apart grooves extending from
adjacent said opening of said chamber along a side wall surface to
a floor of said chamber, and along said floor to an opposite side
wall, and along said opposite side wall to terminate adjacent said
opening of said chamber, and said one pair of spaced apart grooves
receiving a channel member which is U-shaped to extend along said
one and said opposite side wall as well as across said floor of
said chamber.
17. The shipping container of claim 15, wherein said base portion
includes at least one pair of spaced apart grooves extending from
adjacent said opening of said chamber along a side wall surface to
terminate adjacent to a floor of said chamber, and said one pair of
spaced apart grooves receiving a channel member which is
substantially straight to extend along said side wall between said
opening of said chamber and said floor.
18. The shipping container of claim 1, wherein a tray member is
further received in said chamber and carries said thermal mass,
said tray member defining air circulation openings communicating
with said dual-function structure so as to allow air circulation
about said thermal mass and about the contents to be shipped in
said container.
19. The shipping container of claim 18, wherein said tray member
carries said fan package, said fan package receiving air from said
air circulation space of said dual-function structure to circulate
this air over said thermal mass, and delivering fan-forced air
circulation into said air circulation space.
20. The shipping container of claim 4, wherein said base portion
defines a floor wall, and said floor wall defines a recess
communicating with said chamber, said fan package being disposed in
said recess to receive air from said air circulation space of said
dual-function structure, and delivering fan-forced air into said
air circulation space.
21. The shipping container of claim 1, wherein said dual-function
structure includes plural interlocking wall members, said plural
interlocking wall members defining at least one well for receiving
the contents to be shipped in said container, and said plural
interlocking wall members further including protruding crushable
end portions extending outwardly of said at least one well and
engaging inside surfaces of said chamber to both provide said
cushion space and to also provide at least a part of said air
circulation space.
22. The shipping container of claim 21, wherein said plural
interlocking wall members cooperatively define plural wells for
receiving the contents to be shipped in said container, and said
plural interlocking wall members also defining a chimney passage
among said wells and defining a portion of said air circulation
space, whereby said air circulation space includes said cushion
space surrounding the contents to be shipped in said container as
well as said central chimney passage among the contents to be
shipped in said container, so that the contents have air
circulation space about these contents as well as among these
contents.
23. The shipping container of claim 22, wherein said plural
interlocking wall members define a chimney passage of cruciform
configuration, so that a part of said cruciform passage is
interposed between adjacent wells for receiving contents to be
shipped in said container.
24. The shipping container of claim 22, wherein said chimney
passage communicates directly with said fan of said fan
package.
25. The shipping container of claim 2, wherein said dual-function
structure includes plural integral spaced apart features protruding
from an inside surface of said chamber; said protruding features
being selected from the group including: columns, fins, ribs, and
blocks, each formed integrally of the foamed polymer material of
said container and having a determined crushability; and said
spaced apart features providing a portion of said air circulation
space therebetween.
26. The shipping container of claim 25, wherein said plural
integral spaced apart features protruding from an inside surface of
said chamber are selected to include pair of closely spaced apart
ribs, and said pairs of closely spaced apart ribs extending along
opposite side walls of said chamber, said pairs of closely spaced
apart ribs receiving therebetween a partition member dividing said
chamber into a first and a second portion, and an additional part
of said dual-function structure as well as said contents to be
shipped in said container being received into only one of said
first and said second chamber portions, whereby said container has
a variable-volume capacity within said chamber for receiving said
additional part of said dual-function structure and said contents
to be shipped in said container.
27. A method of isolating contents to be shipped in a container
both from shock and from ambient temperatures, said method
including steps of: providing a chambered insulating body;
configuring said body to include a base portion defining a chamber
therein and an opening from said chamber; providing a lid portion
spanning and closing said opening; included in the chamber of the
body a dual-function structure for receiving contents to be shipped
in said container along with a temperature-control mass;
configuring said dual-function structure to on the one hand provide
a shock-absorbing structure spacing the contents away from inside
surfaces of said chamber so as to maintain a surrounding cushion
space of controlled crushability, and to on the other hand to also
provide an air circulation space surrounding the contents; whereby
air currents are allowed to circulate about said contents and said
temperature-control mass.
28. The method of claim 27 further including the steps of:
providing a fan communicating with said chamber, and utilizing said
fan to effect fan-forced air circulation in said air circulation
space surrounding the contents.
29. The method of claim 28 including steps of: providing said fan
by providing a fan package including a battery providing electrical
power, a motor receiving electrical power from said battery, and a
fan driven by said motor.
30. The method of claim 29 further including the step of: effecting
controlled fan-forced circulation of air within said chamber by
operation of said fan in response to temperature within said
chamber.
31. The method of claim 30 including the step of providing a
temperature responsive control device in said fan package.
32. The method of claim 31 including the step of including a
temperature responsive switch in said control device.
33. The method of claim 30 including the steps of including a
voltage control circuit element interposed in circuit with said
battery and said motor and operating said motor at less than full
battery voltage while said battery is fresh, and utilizing said
voltage control circuit element to extend the operating time for
said motor, whereby, said voltage control element extends the
operating interval for said motor before said battery is
exhausted.
34. The method of claim 27 including step of disposing as a part of
said dual-function structure within said chamber for receiving
contents to be shipped in said container plural crushable channel
members, and interposing each of said plural crushable channel
members between an inside surface of said chamber and said
contents.
35. The method of claim 34 including steps of providing for each of
said crushable channel members a pair of spaced apart legs
extending from an inside surface of said chamber to a portion
spanning between said pair of spaced apart legs, and providing said
pair of spaced apart legs with a determined crushability.
36. The method of claim 35 wherein said pair of spaced apart
channel legs of said channel members are provided with a determined
crushability by including features weakening the pair of spaced
apart legs.
37. The method of claim 36 wherein the step of including features
for weakening said pair of spaced apart legs includes forming
features selected from the group consisting of: openings, holes,
slots, and slits formed in said pair of spaced apart legs.
38. The method of claim 34 wherein said base portion is formed to
include plural pairs of spaced apart grooves extending along an
inside surface of said chamber, and said channel members each
include a pair of spaced apart legs respectively received
retainingly in said pairs of spaced apart grooves.
39. The method of claim 27 further including in said chamber of
said container a tray member, and carrying said thermal mass on
said tray member; and defining air circulation openings in said
tray member communicating with said dual-function structure so as
to allow air circulation about said thermal mass and about the
contents to be shipped in said container.
40. The method of claim 39 further including the steps of carrying
said fan package on said tray member, and providing for said fan
package to receive air from said air circulation space of said
dual-function structure and to circulate this air over said thermal
mass and to deliver fan-forced air currents into said air
circulation space.
41. The method of claim 29 further including steps of: configuring
said base portion to defines a floor wall, and in said floor wall
providing a recess communicating with said chamber; disposing said
fan package in said recess to receive air from said air circulation
space of said dual-function structure; and delivering fan-forced
air into said air circulation space by operation of said fan
package.
42. The method of claim 27 further including steps of: including in
said dual-function structure plural interlocking wall members;
configuring said plural interlocking wall members to define at
least one well for receiving the contents to be shipped in said
container; and providing for said plural interlocking wall members
to further include protruding crushable end portions extending
outwardly of said at least one well to engage respective inside
surfaces of said chamber; whereby said protruding crushable end
portions both provide said cushion space and provide at least a
part of said air circulation space.
43. The method of claim 42 further including steps of: providing
for said plural interlocking wall members to cooperatively define
plural wells for receiving the contents to be shipped in said
container; utilizing said plural interlocking wall members to also
define a chimney passage among said wells; and utilizing said
chimney passage to define a portion of said air circulation space;
whereby said air circulation space includes said cushion space
surrounding the contents to be shipped in said container as well as
said chimney passage among the contents to be shipped in said
container, so that the contents have air circulation space about
these contents as well as among these contents.
44. The method of claim 43 including the steps of: utilizing said
plural interlocking wall members to define said chimney passage;
and providing for said chimney passage to be part of a passage of
cruciform configuration defined by said plural interlocking walls
and separating said plural wells for receiving contents to be
shipped in said container.
45. The method of claim 27 further including steps of: forming said
insulating body to include foamed polymer; providing for said
dual-function structure to include plural integral spaced apart
features of foamed polymer protruding from an inside surface of
said chamber; providing for said protruding features to be selected
from the group including: columns, fins, ribs, and blocks; forming
said protruding features each integrally from the foamed polymer
material of said container and having a determined crushability
according to the strength of said polymer material; and further
providing for said protruding features to be sufficiently spaced
apart such that they cooperatively define spaces therebetween which
define at least a part of said air circulation space.
46. The method of claim 45 including steps of: selecting said
plural integral spaced apart features to include a pair of closely
spaced apart ribs, and extending one pair of closely spaced apart
ribs along opposite side walls of said chamber; providing for said
pairs of closely spaced apart ribs to receiving therebetween a
partition member dividing said chamber into a first and a second
portion; whereby said container has a variable-volume capacity
within said chamber for receiving said dual-function structure and
said contents to be shipped in said container.
47. An improved disposable, shock-absorbing insulated shipping
container, said container comprising: a chambered foam polymer
insulating body; said body including a base portion including a
floor wall and at least one side wall cooperatively bounding a
chamber therein and an opening from said chamber; said body
including also a lid portion spanning and closing said opening;
disposed within said chamber, said container also including a
dual-function structure for receiving contents to be shipped in
said container, and a temperature-control mass; said dual-function
structure on the one hand providing a shock-absorbing structure
spacing the contents away from inside surfaces of said chamber
walls so as to maintain a surrounding cushion space of controlled
crushability, and on the other hand, also providing an air
circulation space surrounding the contents so that air currents are
allowed to circulate about said contents and said
temperature-control mass; and an air circulation fan package
disposed within said chamber.
48. The shipping container of claim 47, wherein said disposable air
circulation fan package includes a battery, a motor, and a fan
driven by said motor.
49. The shipping container of claim 47, further including a
temperature responsive control device for effecting controlled
fan-forced circulation of air within said chamber by operation of
said fan in response to temperature within said chamber.
50. The shipping container of claim 47, further including a voltage
control circuit element interposed in circuit with said battery and
said motor and operating said motor at less than full battery
voltage while said battery is fresh, while also extending the
operating time for said motor, whereby, said voltage control
element extends the operating interval for said motor before said
battery is exhausted.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a Continuation-in-Part application of U.S. patent
application Ser. No. 11/044,392, filed 26 Jan. 2005, now U.S. Pat.
No. ______.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to shipping
containers, and more particularly relates to an improved insulated
shipping container and method. The improved insulated shipping
container has particular utility for shipping fragile or high value
contents, which may be destroyed or damaged either because fragile
bottles of the contents can be broken by dropping or jarring the
container during shipping, or which may be rendered unusable by
temperature variations (either too high or too low a temperature)
experienced during shipping. The improved insulated shipping
container is configured and constructed to provide both shock
absorption, and to provide temperature regulation for the contents
of the container by promoting natural or fan-forced convection
currents within the container in order to maintain a temperature
controlled condition which may be neither freezing or too warm, and
which is maintained for an extended period of time without
significant temperature stratification during transport by common
carrier. Most preferably, the insulated shipping container
according to this invention is disposable, and is used for only one
shipping of a high-value contents, although the invention is not so
limited.
[0004] 2. Related Technology
[0005] Traditionally, disposable containers for shipping
temperature sensitive products have generally included conventional
cardboard shipping containers having an insulating material
therein. The insulating material may be simple loose-fill Styrofoam
"peanuts," for example, in which a chunk of dry ice is placed along
with the material to be shipped. Another variety of conventional
insulated shipping container utilized panels or containers made of
an insulating material, such as expanded polystyrene (EPS). EPS is
a relatively inexpensive insulating material, and it may be easily
formed into a desired shape, has acceptable thermal insulating
properties for many shipping needs, and may be encapsulated or
faced with protective materials, such as plastic film or metal
foil, or plastic film/metal foil laminates.
[0006] Containers including EPS are often provided in a modular
form. That is, individual panels of EPS insulation, possibly
wrapped in foil or the like, are preformed using conventional
methods, typically with beveled or rabbeted edges. The panels are
then inserted into a conventional cardboard box type of shipping
container, one panel against each wall, to create an insulated
cavity within the container. In this arrangement, the beveled or
rabbeted edges of adjacent panels form seams at the corners of the
container. A product is placed in the cavity and a plug, such as a
thick polyether or polyester foam pad, is placed into the top of
the cavity and over the top of the product before the container is
closed and prepared for shipping. In many cases, a coolant, such as
packaged ice, gel packs, or loose dry ice, is placed around the
product in the cavity to refrigerate the product during
shipping.
[0007] Alternatively, an insulated body may be injection molded
from expanded polystyrene, forming a cavity therein and having an
open top to access the cavity. A product is placed in the cavity,
typically along with coolant, and a cover is placed over the open
end, such as the foam plug described above or a cover also formed
from EPS.
[0008] For shipping particularly sensitive products, such as
certain medical or pharmaceutical products, expanded rigid
polyurethane containers are often used, as expanded polyurethane
has thermal properties generally superior to EPS. Typically, a
cardboard container is provided having a box liner therein,
defining a desired insulation space between the liner and the
container. Polyurethane foam is injected into the insulation space,
substantially filling the space and generally adhering to the
container and the liner. The interior of the box liner provides a
cavity into which a product and coolant may be placed. A foam plug
may be placed over the product, or a lid may be formed from
expanded polyurethane, typically having a flat or possibly an
inverted top-hat shape.
[0009] For large size durable (i.e., expensive and not disposable)
shipping containers, it is known to provide a dedicated
refrigeration device (i.e., a mechanical refrigeration set using a
refrigerant such as Freon, with a power supply, and a compressor,
with heat exchangers, fans, and controls). However, such durable
powered refrigerated containers are both large and expensive. They
also require that the empty containers be shipped back (usually
empty) to the place of origin for reuse. This return shipping adds
significantly to the cost of using such large durable refrigerated
containers. Such containers are also expensive initially, and
require skilled service after every use to prepare them for their
next use. They are subject to damage during shipping, and sometimes
are stolen simply because of their intrinsic value. Thus, such
larger durable refrigerated shipping containers have a very large
initial cost, require service of the refrigeration package and its
power supply after every use, have a high first cost, and a
significant cost of use, incur large shipping costs (in part
because of the empty return shipping), and are suitable only for
shipments of large size. That is, such powered refrigerated
containers are not suitable for shipments of smaller size (i.e., up
to about 100 pounds).
[0010] For shipments of smaller size, containers using dry ice or
frozen gel packs are commonly employed. With such conventional
shipping containers, the fact that the product and coolant are
typically placed together within a cavity in the container, may
have several adverse effects. When shipping certain products, it
may be desired to refrigerate but not freeze the product. Placing a
coolant, such as loose blocks of dry ice, into the cavity against
the product may inadvertently freeze and damage all or a portion of
the product. Even if held away from the product, the coolant may
shift in the cavity during shipping, especially as it melts and
shrinks in size, inadvertently contacting the product. In addition,
with gel packs, if they become perforated then melted coolant may
leak from the pack, possibly creating a mess within the cavity or
even contaminating the product being shipped.
[0011] Finally, polyurethane containers of the type using two
cardboard boxes nested together with polyurethane injected into the
space between these boxes (i.e., a composite container) may also
create a disposal problem. When polyurethane is injected into such
a container, it generally adheres substantially and strongly to the
walls of both the inner and the outer cardboard box. Thus, the
cardboard and insulation components of the container cannot be
easily separated, and may have to be disposed of together, usually
into a land fill, preventing recycling of the container. Some
countries, states, and other jurisdictions have prohibited local
disposal of such composite containers, requiring that the
containers be shipped back to their place of origin for disposal or
re-use.
[0012] Further, when temperature sensitive materials are shipped in
winter time, there is a need to prevent low ambient temperatures
from freezing the product being shipped.
[0013] Accordingly, there is a need for an improved shipping
container to both cushion contents and prevent shocks and jarring
from damaging the shipped contents, and to maintain temperature
sensitive materials in a temperature controlled condition which is
not freezing or too warm during transport and over an extended
period of time.
SUMMARY OF THE INVENTION
[0014] The present invention is directed generally to an improved
insulated shipping container and method. Particularly, the improved
insulated shipping container provides for controlled energy
absorption, so that shocks and jarring experienced during shipping
(such as aboard a truck operated by a common carrier) do not damage
fragile contents of the container. Further, the improved insulated
shipping container provides for a temperature regulated condition,
which is not frozen or too warm, for an extended period of time.
That is, the improved container may be used to ship refrigerated
contents during all seasons. Alternatively, the container may also
be used in cold weather conditions to prevent an item being shipped
from being frozen by low ambient temperatures. In the latter
situation, gel packs with are warmed prior to shipping of the
container are used, and the features of the container are employed
to maintain a temperature controlled environment within the
shipping container during shipment.
[0015] One aspect of the present invention provides a shock
absorbing insulated shipping container for transporting a fragile
product or contents comprising: an insulated body having a cavity
defining an opening; the insulated body providing both thermal
insulation to the contents of the container, isolating the contents
form ambient conditions outside the container, a energy absorbing
structure defining a controlled-crush structure extending about the
contents and isolating the contents from shocks and jarring
experienced by the container during shipping, and an air
circulation space or channels extending about the contents of the
cavity. More particularly, the present invention provides an
improved shock absorbing insulated shipping container, said
container comprising: a chambered foam polymer insulating body,
said body including a base portion defining a chamber therein and
an opening from said chamber, and a lid portion spanning and
closing said opening; said container also including dual-function
structure disposed within said chamber for receiving contents to be
shipped in said container, and a temperature-control mass, said
dual-function structure on the one hand providing a shock-absorbing
structure spacing the contents away from inside surfaces of said
chamber so as to maintain a surrounding cushion space of controlled
crushability, and on the other hand, also providing an air
circulation space surrounding the contents, whereby air currents
are allowed to circulate about said contents and said
temperature-control mass.
[0016] According to another aspect, the present invention provides
a method of isolating contents to be shipped both from shock and
from ambient temperatures. This method includes steps of providing
a chambered foam polymer insulating body, and configuring said body
to include a base portion defining a chamber therein and an opening
from said chamber, and a lid portion spanning and closing said
opening. Included in the chamber of the body is a dual-function
structure for receiving contents to be shipped in said container,
and a temperature-control mass. Configuring said dual-function
structure to on the one hand provide a shock-absorbing structure
spacing the contents away from inside surfaces of said chamber so
as to maintain a surrounding cushion space of controlled
crushability, and to on the other hand also provide an air
circulation space surrounding the contents, whereby air currents
are allowed to circulate about said contents and said
temperature-control mass.
[0017] Other objects and features of the present invention will
become apparent from consideration of the following description
taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0018] FIG. 1 provides an external perspective view of an insulated
shipping container embodying the present invention;
[0019] FIG. 2 is a side elevation view of the container seen in
FIG. 1, taken at the line 2-2, and looking in the direction of the
arrows, and shows contents within a cavity of the shipping
container;
[0020] FIG. 2A is a side elevation view like FIG. 2, showing the
insulated shipping container with no contents in the cavity for
clarity of illustration of certain features and structures of the
insulated shipping container;
[0021] FIG. 2B provides a plan view of the container seen in FIG.
2A, and is taken at the line 2B-2B of that Figure;
[0022] FIG. 3 is a fragmentary perspective view of the lower
portion of the container seen in FIGS. 1-2B, partially in cross
section, with some elements of the container omitted, and with the
two walls and a portion of the container closest to the viewer
broken away for clarity of illustration;
[0023] FIG. 4 provides a fragmentary elevation view, partially in
cross section, of a portion of the insulated container seen in
FIGS. 1-3, and is taken at line 4-4 of FIG. 2B;
[0024] FIG. 5 is a side elevation view of an alternative embodiment
of insulated shipping container, and is similar to the view seen in
FIG. 2, except that the embodiment of this Figure includes a
power-driven forced-convection fan device;
[0025] FIG. 5A provides a side elevation view of the alternative
embodiment of insulated shipping container seen in FIG. 5, but is
shown without contents in the cavity of the container for clarity
of illustration;
[0026] FIG. 6 provides an enlarged fragmentary view, partly in
cross section, of the alternative embodiment of insulated shipping
container seen in FIGS. 5 and 5A;
[0027] FIG. 7 is a fragmentary side elevation view, similar to
FIGS. 5 and 5A, but showing yet another alternative embodiment of a
shipping container according to this invention including a
power-driven, forced-convection fan device;
[0028] FIG. 8 provides a generalized diagrammatic or schematic
illustration of a power and control circuit for a forced-convection
fan device such as is included in the embodiments of FIGS. 5-7;
[0029] FIGS. 9, 10, and 11 each provide an illustration of a
respective control element which may be included in the control
circuit of FIG. 8, in order to effect controlled fan-forced
convection for an insulated shipping container according to this
invention;
[0030] FIGS. 12 and 13 each provide side elevation views, partially
in cross section, of yet another alternative embodiment of
insulated shipping container, including fan-forced convection, with
FIG. 12 illustrating contents in the cavity of the container, while
FIG. 13 illustrates the container with its cavity empty of contents
for shipping;
[0031] FIG. 14 provides a plan view of the container seen in FIG.
12, with the container lid removed to provide a view into the
cavity of the container;
[0032] FIG. 15 provides a fragmentary elevational perspective view
of the container seen in FIGS. 12-14;
[0033] FIG. 16 is an exploded perspective view of components of the
insulated container seen in FIGS. 14-15;
[0034] FIG. 17 provides an elevation view of an insulated shipping
container embodying the present invention;
[0035] FIG. 18 is an elevation view of the container seen in FIG.
17, but is shown without contents in the cavity of the container
for clarity of illustration;
[0036] FIG. 19 provides a fragmentary perspective view of the lower
portion of the container seen in FIGS. 17 and 18, partially in
cross section, with some elements of the container omitted, and
with the two walls and a portion of the container closest to the
viewer broken away for clarity of illustration;
[0037] FIG. 20 is a plan view of the container seen in FIGS.
17-19;
[0038] FIG. 21 provides an elevation view of an insulated shipping
container with its lid removed (similar to FIG. 14), and
illustrates another alternative embodiment of insulated shipping
container embodying this present invention; and
[0039] FIG. 22 is an elevation view of the container seen in FIG.
21, and includes additional elements of the container.
[0040] FIGS. 23 and 24 provide respective plan views in perspective
of still another alternative embodiment of an insulated shipping
container according to this invention; and
[0041] FIG. 25 is a fragmentary elevation view of the container
seen in FIGS. 23 and 24, but with contents illustrated within the
container.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Turning now to the drawings, considering FIGS. 1-4 in
conjunction, and giving attention first of all to FIG. 1, this
Figure shows a shock absorbing, insulated shipping container 10 in
accordance with the present invention. The container 10 generally
includes a rectangular prismatic body 12, which is formed
principally of insulative and shape-retaining, but somewhat
yieldable, foamed polymer. Preferably, the body 12 is formed of
foamed polyurethane polymer, although the invention is not so
limited. That is, the insulated and chambered container may be
formed of other materials and may employ other insulation methods
or structures. The body 12 includes a base or main portion 14, and
a lid portion 16. The base portion 14 in this embodiment includes
planar wall portions 14a/b/c/d, and a planar floor portion 14e As
is best seen in FIGS. 2, 2A, and 3, the body 12 is chambered, and
defines an interior chamber or cavity 18. The base portion 14
defines an opening 20 to the cavity 18, and a lip 22 surrounding
this opening 20. Outwardly of the lip 22, the base portion 14
defines a circumferential rabbet 24. Considering FIGS. 2 and 2A, it
is seen that the lid portion 16 includes a wall portion 26 spanning
the opening 20, and a circumferential flange 28 received into
rabbet 24 and about the lip 22.
[0043] Disposed within the cavity 18 are the contents (generally
referenced with the numeral 30) to be shipped in the container 10.
In this case, the contents 30 includes plural relatively small
boxes 32 (individually labeled 32a/32b/32c, etc.), each of which
may contain, for example, a liquid material carried in a glass
bottle or vial, although the invention is not so limited. By way of
example only, the liquid contents of the boxes 32 may include human
growth hormone, or a vaccine. Thus, it is to be understood that the
contents of shipping container 10 may have a high value.
[0044] Considering the contents and arrangement of the cavity 18,
it is seen that a cushion space or substantially void volume,
generally referenced with the numeral 34 surrounds the contents 30.
Below the contents 30 (as well as on the vertical side of the
contents "toward" and away from the viewer of FIG. 2), the void
volume 34 is maintained by a pair of channel shaped members 36.
These channel members 36 are both channel shaped in cross section,
as well as being U-shaped overall. Toward the left and right sides
of the contents 30 (as viewed in FIG. 2) the void space or cushion
34 is maintained by channel members 36a. The channel members 36a
are channel shaped in cross section, but are straight overall. Each
of the channel members 36, 36a is a "dual function" structure (as
will be further explained), and each is preferably formed of
corrugated paper board (i.e., corrugated cardboard), although the
invention is not so limited. As is seen in the various drawing
Figures, the corrugations of the corrugated cardboard channel
members 36, 36a preferably run parallel to the length dimension of
these channel members. So, at the exposed ends 36b of these channel
members 36, 36a (best seen in FIGS. 2 and 2B), the serpentine
corrugations are visible. Moreover, it is noted that also toward
both the left-hand and right-hand sides of the contents 30 (as seen
in FIG. 2), the respective channel members 36a are carried by the
respective walls of the base portion 14 and that each may define
plural spaced apart holes or openings 36c along the sides there.
These channel members 36a maintain the cushion space 34
respectively to the right and left side of the contents as seen in
FIG. 2. Similarly, above the contents 30 (as is also best seen in
FIG. 2), the cushion space 34 is maintained by a layer of packing
material 38, which is preferably cellular foam polymer, and which
further preferably may define plural vertically extending holes or
passages 38a.
[0045] Above the top end edges 36b of the channel members 36, and
supported thereby, is a partition member or tray member 40, which
similarly may define plural vertically extending holes or passages
40a therein, which preferably align with or communicate with the
passages 38a. Finally, it is to be noted that disposed upon the
tray member 40, is a temperature control or refrigerant mass 42.
This temperature control or refrigerant mass 42 may include a block
of dry ice, for example. Or, the temperature-control, or
refrigerant mass 42 may include a refrigerated (or warmed) gel
pack, for example. Alternatively, the mass 42 may include a
quantity of chunked or cubed dry ice. Water ice may also be
employed as temperature control mass 42, and is preferably
contained within a plastic bag.
[0046] Considering now FIGS. 2A, 2B, and 3 in conjunction, it is
seen that the base portion 14 of body 12 in order to carry or
receive the channel members 36, 36a, and tray 40 defines a shallow
ledge 44 circumscribing the cavity 18, and plural vertically
extending and laterally spaced apart grooves 46 and 48 each
extending from this ledge downwardly to the floor 18a (i.e., the
top surface of wall 14e within cavity 18). The grooves 46 are
defined in walls 14a and 14c (only wall 14c being seen in FIG. 3),
while the grooves 48 are defined in walls 14b and 14d (only the
wall 14b being seen in FIG. 3). It is seen best in FIG. 3 that the
grooves 46 extend not only vertically along the walls 14a and 14c,
but also continue across the floor 18a (wall 14e) to communicate
with the respective grooves 46 in the opposite wall. Into these
grooves 46 and 48, respective end portions of the two opposite
walls of the channel members 36/36a are slidably and retainingly
received. That is, the width dimensions of the grooves 46, 48 is
selected to provide a snug sliding and retaining fit therein of the
corrugated cardboard from which the channels 36, 36a are
formed.
[0047] As is best seen in FIGS. 2A, 2B, and 3, the channel members
36 are continuous vertically along opposite walls 14a and 14c (and
across the floor 18a) while the channel members 36a extend only
along the vertical walls 14b and 14d. As is seen in FIGS. 2 and 2A,
these channels 36/36a may preferably define a plurality of spaced
apart lateral perforations or holes 36b, which communicate through
the opposite sides of the channel members adjacent to the
respective walls. In this way, the channel members 36/36a provide
for substantially unimpeded air circulation about the contents 30.
As is seen best in FIG. 4, the channel members 36 are preferably
continuous vertically along the side walls 14c and 14a (only wall
14c being seen in FIG. 4), and define a "living" hinge feature or
section 50. Accordingly, when the channel members 36 are disposed
as seen in the drawing Figures, they also form an open corner
passage 52, also providing for additional air flow area between the
inside and outside of each channel member 36.
[0048] Further viewing FIGS. 2, 2A, and 2B, it is seen that each
channel member 36, 36a includes a central portion 54 upon which the
contents 30 may make contact, and a pair of laterally spaced apart
leg portions (each indicated with the numeral 56). The legs 56 are
sufficiently longer than the depth of the grooves 46 and 48, that
the central portion 54 is spaced from the respective walls 14,
leaving an air passage 58. Considering now the drawing FIGS. 2-4 in
conjunction with one another, it will be apparent that entirely
about the contents 30, the insulated shipping container 10
maintains a void space or cushion volume 34 in which substantially
unimpeded convection currents may circulate in order to maintain
thermal equilibrium between the contents 30 and the refrigerated
(or warmed) mass 42. In this way, the contents 30 are maintained at
a substantially uniform temperature throughout, so that hot or cold
spots are avoided because of ambient warmth (or cold) conducting
through the walls 14 or lid 16. This is especially the case because
colder air from the refrigerated mass 42 will settle toward the
bottom of cavity 18, while warmer air will tend to circulate by
natural convection toward the top of cavity 18, where it will come
into contact with the mass 42 and be cooled. So to, warmth
conducting through the walls 14 toward the contents 30 will be
intercepted by convection currents before reaching the contents 30
because the void volume about these contents prevents contact of
the contents 30 directly with the walls 14.
[0049] Further to the above, it is to be appreciated that in
addition to providing air circulation space and channels about the
contents 30, the channels 36, 36a provide a spacing structure of
controlled crushability (energy absorption), spacing the contents
30 from the walls 14. That is, each channel 36, 36a includes a pair
of spaced apart legs 56 providing the air passage 58. In the event
that the container 10 is subjected to a shock or jarring of
sufficient force and violence, some of the energy of the shock will
be absorbed by the expanded foam polymer material from which the
walls 14 or lid 16 is made. However, for fragile contents 30, the
polymer foam from which the container 10 (i.e., body 12 and lid 16)
is formed may nevertheless allow too much energy to be transmitted
to the contents. So, the crushability of the channel members 36,
36a can be selected by variation of a combination of factors,
including: the thickness of the cardboard from which these channel
members 36, 36a are made, the weight of paper used for the face
sheets of that cardboard, the weight of paper used for the
corrugations of the cardboard, the length of the legs 56, and the
width of the central portion 54. Also, the number and size of the
perforations 36c can be varied. These perforations may be omitted,
or may be large or small, as is needed to accomplish a desired
degree of crushability for the channel members 36 and 36a.
Similarly, the channel members 36 and 36a may be individually
tailored to the requirements necessary to safeguard the contents
30, as the contents 30 may have a differing weight in a particular
direction, as well as possibly having a greater or lesser strength
in a particular direction. The result is that a structure defining
an air circulation space (i.e., for convection currents), with this
structure also providing a controlled crush space and energy
absorption, is provided about the contents 30 within the cavity
18.
[0050] Turning now to FIGS. 5, 5A, and 6, a second embodiment of an
insulated shipping container 110 in accordance with the present
invention is shown. Because this second embodiment shares many
features and structures in common with the first embodiment
described above, these features are indicated on FIGS. 5, 5A, and 6
with the same numeral used above, and increased by one-hundred
(100). Viewing FIGS. 5, 5A, and 6 in conjunction, it is seen that a
shock absorbing, insulated shipping container 110 in accordance
with a second embodiment of the present invention is substantially
the same as the first embodiment described above, with important
differences to be described immediately below. An important
difference of the container 110 is that the floor wall 114e is
preferably thicker than was the case with container 10. This added
thickness of floor wall 114e is needed to accommodate or provide
space for a power-driven, forced-circulation fan package, generally
referenced with the numeral 60. While the present embodiment
includes the fan package 60 within cavity 118, the invention is not
so limited. In other words, an insulated container according to
this invention could employ a fan outside of but communicating with
the cavity 118. This fan package 60 is received into a stepped
recess 62 defined in the floor wall 114e of the insulated shipping
container 110. Importantly, the stepped recess 62 includes a
smaller diameter portion 62a, and a larger diameter portion 62b
opening to the cavity 118. Thus, it is to be appreciated that the
stepped recess 62 is most preferably circular or round in plan
view, although the invention is not so limited.
[0051] Snugly received into the portion 62a of the recess 62 is a
base portion 64 of the fan package 60. This base portion 64 may
house batteries and controls (not detailed in FIGS. 5, 5A, and 6)
for the fan package 60. Above the base portion 64, the fan package
60 may include a motor 66, and this motor 66 preferably drives a
fan 68, which is illustrated in the Figures as being a shrouded fan
so that the individual fan blades are not visible in these figures.
Importantly, the fan 68 is disposed most preferably in the larger
portion 62b of recess 62, so that an air flow space 70 (arrowed
with flow arrows on FIG. 6) is provided about the fan 68. As a
result, the fan 68 when operating is able to provide a discharge
flow of air (arrows 72 on FIG. 6) discharging into the cavity 118.
As is seen most clearly in FIG. 6, the fan 68 most preferably
receives inflow from within the channels 136, and discharges air
flow between these channels 136. When contents 130 are disposed in
the cavity 118, the discharge air flow will flow about these
contents in the air flow and cushion space 134 thereabout, and at
least some of this fan-forced circulation air flow will pass to and
over the refrigerated mass 142.
[0052] In view of the above, it is seen that the insulated shipping
container 110 will experience a vigorous fan-forced circulation air
flow within the cavity 118 while the fan 68 is operating during
shipping of the container 110. This fan-forced circulation air flow
is especially important in the event that the container 110 is
placed on its side or inverted. As will be easily understood from a
consideration of the convection air flow within the first
embodiment of insulated shipping container 10 described above, in
the event that the refrigerated mass 42 (or 142) is not at the top
of the cavity 18/118 (i.e., because the container is on its side or
is inverted), then some of the contents may become unduly warm
because the cold air from the mass 42/142 circulates downwardly by
natural convection. Also, experience has shown that even when an
insulated container is in the desired orientation, temperature
stratification can occur within the cavity of the container. That
is, natural convection currents are not sufficient to prevent some
of the contents of the container from experiencing a higher than
desired temperature (i.e., in the case of contents that require
cooling), while other of the contents may experience a temperature
that is too low. However, with the insulated shipping container 110
including fan package 60, so long as this fan package is running,
the cool air from refrigerated mass 42 will be circulated about the
contents 130 regardless of the orientation of the container 110.
The container 110 provides the same advantages of providing a
dual-function structure both spacing the contents of the package
110 away from the inside surfaces of the walls 114 with a
controlled crushability (i.e., so as to isolate the contents
against shock), and also providing a surrounding air flow space, as
was the case with the first embodiment described above.
[0053] Turning now to FIGS. 7-11 alternative embodiments of a fan
package are illustrated. Because this fan package includes many
features in common with the embodiment illustrated in FIGS. 5-6,
the same reference numerals utilized above are used in FIGS. 7-11,
with an added one-hundred, etc., added to distinguish between
alternative embodiments. Viewing first FIG. 7, it is seen that a
fan package 160 may include an extended discharge tube 74 extending
upwardly between the channel members 136 so that air discharged
from the fan is forced to flow upwardly within the cavity 118.
Similarly, the size of the air flow passages 170 may be enlarged so
as to provide an abundant air flow space for circulation of air
within the cavity 118. FIG. 8 diagrammatically illustrates that the
fan package 160 includes not only a battery 76 (of one or more
cells), a motor 166, and a fan 168, but also includes a control
element 78. FIGS. 9 and 9A illustrate that the control element 78
may include a temperature-responsive thermal-switch 78a (also
indicated with the characters "TS" on FIG. 9). FIG. 9A indicates
that the thermal-switch 78 exhibits an hystorisis loop a-b-c-d, in
which the switch closes at temperature a, so that the motor 166
drives fan 168 circulating air and dropping the local temperature
to point b, at which the switch 78a opens (point c). With the
switch open, the fan 168 will not be running, and with the passage
of time, heat inflow from ambient will raise the local temperature
to point d, at which temperature the switch 78a will again close
(point a) to repeat the temperature control cycle. With a
temperature-responsive switch type of control element 78, the
temperature within cavity 118 will generally be maintained between
the temperatures indicated by "a" as the upper temperature and "c"
as the lower temperature. Thus, items within cavity 118 are neither
frozen nor allowed to become too warm so long as the thermal mass
142 has sufficient capacity, and the batteries 76 have sufficient
power.
[0054] Alternatively, FIGS. 10 and 11 illustrate that an effective
temperature control may be effected by the use of a semi-conductor
element (i.e., a zener diode 80, or a transistor 82) connected in
series with the motor 166 as a control element 78. In each case,
the element 80 or 82 acts as a voltage control for the motor 166,
such that the motor 166 runs more slowly than it would if provided
with full battery voltage when both the thermal mass and batteries
are fresh (i.e., at a time when a lesser degree of air circulation
is sufficient to maintain a desired temperature in the cavity 118),
but also, so that power for the fan 160 lasts longer. A result is
that the fan 160 will operate longer and will still be operating
later in the use of the container 110 when the thermal mass is no
longer fresh, is no longer so cold (or warm), and when a desired
level of air circulation is desired within the cavity 118 in order
to maintain the desired temperature uniformity in this cavity.
[0055] Turning now to FIGS. 12-16, still another alternative
embodiment of a temperature controlled insulated and shock
absorbing shipping container according to this invention is
illustrated. Because the embodiment of FIGS. 12-16 has many
features in common with the embodiments illustrated and described
above, the same reference numerals (increased by two-hundred (200))
are utilized in FIGS. 12-16. Viewing FIGS. 12 and 13 an insulated,
shock absorbing and temperature controlled shipping container 210
generally includes a rectangular prismatic body 212, which is
formed principally of foamed polymer. The body 212 includes a base
or main portion 214, and a lid portion 216. The base portion 214 in
this embodiment includes wall portions 214a/b/c/d (best seen in
drawing FIG. 14), and a floor portion 214e. The body 212 is
chambered, and defines an interior chamber or cavity 218.
[0056] Disposed within the cavity 218 are the contents, generally
referenced with numeral 230, and individually as boxes 232 (seen in
FIG. 12 but not in FIGS. 13, 15, or 16) to be shipped in the
container 210. Along with the contents, the container 210 includes
a shock-absorbing and air-channeling interlocking wall structure
(best seen in FIGS. 15 and 16) indicated generally with the numeral
84.
[0057] Considering the contents and arrangement of structure within
the cavity 218, it is seen that a cushion space or substantially
void volume, generally referenced with the numeral 234 surrounds
the contents 230. Below the contents 230, the void volume 234 is
maintained by a plurality of protrusions 86, which may be
configured, for example, as blocks, or ribs, or fins of the foam
material of floor 214e, which protrusions 86 protrude upwardly into
the cavity 218 all to substantially the same height, and so
cooperatively provide an aggregate surface 86a (or aggregate
support plane) upon which the wall structure 84 and the contents
230 rest. These blocks, ribs, or fins 86 provide an air channel
space, and also have a selected cushion effect. That is, the number
and size (i.e., in cross section) of the blocks or fins 86 of foam
material is selected in view of the strength of the foam material
in compression, so that these blocks or fins 86 have a determined
crush or buckling strength. Toward the left, right, front and back
sides of the contents 30 (again, as best viewed in FIG. 14) the
void space or cushion 234 is maintained by protruding end portions
84a (best seen in FIG. 16) of the wall structure 84. Because this
wall structure 84 is preferably formed of interlocking panels or
pieces 84e of fiberboard or paper board (i.e., corrugated
cardboard) it is well understood in view of the disclosure above
how the crush or buckle strength of these protruding portions 84a
can be selected to safeguard the contents 230 from shock.
[0058] Further to the above, the void space 234 also provides air
circulation space surrounding the contents 230. Importantly, the
wall structure 84 is arranged in such a way as to provide on the
one hand, vertically extending wells 84b for receiving the contents
230, and on the other hand to provide in addition to the
surrounding void space 234, a centrally located (i.e., among the
contents 230, but not necessarily central of the cavity 218)
"chimney" 84c, which provides for very open or effective air
circulation in the cavity 218. In this case, the chimney 84c is of
cruciform configuration, with a central passage indicated by the
arrowed numeral in FIG. 15, as well as four side passages (or
slots) 84d, also seen in FIG. 15. A result of the cruciform chimney
configuration is that the contents 230 of the cavity 218 are
surrounded by cooling air flow circulation, substantially
preventing warmth from the ambient from reaching any part of the
contents 230. Thus, in the event that the contents 230 is a
high-value and very temperature sensitive product (such as a
vaccine, or human growth hormone, for example), the temperature
isolation and protection from ambient warmth provided by the
container 210 to these contents is far better than conventional
insulated shipping containers can provide.
[0059] Turning now to FIG. 16 in greater detail for an illustration
of how the wall structure 84 is constructed of interlocking pieces
84e, it is also seen that a top panel 88 defines plural air
circulation perforations 88a, and a centrally located larger
perforation or hole 88b. Received into the hole 88b is a fan
package 90 carrying a fan 262. The fan package is shown larger in
size in FIG. 16 in order to make its details better visible to the
viewer. In fact, the fan 262 of fan package 90 will only be about
one inch or slightly larger in diameter, and the fan package itself
will be about 3 inches in diameter. This fan package 90 fits into
and is snuggly retained in the hole 88b, and is disposed directly
above the chimney 84c. Thus, as is best illustrated in FIGS. 12 and
13, the fan package 90 causes air within cavity 218 to be
vigorously circulated (as is depicted by the air flow arrows on
FIGS. 12 and 13). Atop of the panel or tray 88 and around the fan
package 90 is disposed thermal masses 242 (or gel packs) so as to
provide cooling or warming to the contents 230 in cavity 218.
[0060] Considering now to FIGS. 17-20, and recalling the
description above about the protruding features 86 (i.e., blocks,
ribs, or fins, for example), yet another embodiment of the present
invention is depicted. Because this embodiment has many features
which are the same or analogous in structure or function to those
of earlier embodiments, these features are indicated on FIGS. 17-20
with the same numeral used above, and increased by one-hundred
(100). As FIG. 17 illustrates, a shock absorbing, insulated
shipping container 310 in accordance with the present invention
includes a generally rectangular prismatic body 312. This body 312
is preferably formed principally of foamed polymer (i.e.,
preferably of foamed polyurethane polymer). The body 312 includes a
base or main portion 314, and a lid portion 316. The base portion
314 in this embodiment includes planar side wall portions
314a/b/c/d, and a planar floor wall portion 314e As is best seen in
FIGS. 18-20, the body 312 is chambered, and defines an interior
chamber or cavity 318. The base portion 314 defines an opening 320
to the cavity 318, and a lip 322 surrounding this opening 320.
Outwardly of the lip 322, the base portion 314 defines a
circumferential rabbet 324. The lid portion 316 includes a wall
portion 326 spanning the opening 320, and a circumferential flange
328 received into rabbet 324 and about the lip 322.
[0061] However, inspection of FIGS. 17-20 will show that in this
embodiment the contents 330 (i.e., boxes 332, for example) rest
upon and are spaced away from the interior wall surfaces of the
container 310 almost entirely by cushioning structures (to be
further described) which are integral with the container 310
itself. Turning to FIGS. 19 and 20, it is seen that the base
portion 314 defines plural inwardly protruding features 186, which
may be configured, for example, as a plurality of spaced apart
ribs, as is shown in these Figures. Alternatively, the features 186
may be configured as a plurality of blocks, fins, or even as pins
or individual columns of foam material protruding from the inside
surfaces of the walls 314a-e and into the cavity 318. These
protrusions 386, regardless of their configuration (i.e., blocks,
ribs, fins, etc.) are sized and spaced apart so as to on the one
hand provide an air channel and cushion space 334, and on the other
hand to also have a selected cushion effect. That is, the number
and size (i.e., in cross section) of the blocks, ribs, fins, etc.,
386 of foam material are selected in view of the strength of the
foam material in compression, so that these protrusions 386 have a
determined crush or buckling strength.
[0062] Above and resting upon a circumferential ledge 344 defined
about cavity 318 is a top panel 388 (best seen in FIG. 17). This
panel defines plural air circulation perforations 388a. On this
panel or tray 388 is disposed a thermal mass 342 (or gel pack) so
as to provide cooling or warming to the contents 330 in cavity 318.
A panel 338 of foam packing material is interposed between the
contents 330 and the tray 388, and defines plural air circulation
holes 338a.
[0063] Attention now to FIGS. 21 and 22 in conjunction, and
recalling the description above of FIGS. 17-20, still another
embodiment of the present invention is depicted. Because this
embodiment also has many features which are the same or analogous
in structure or function to those of earlier embodiments, these
features are indicated on FIGS. 21 and 22 with the same numeral
used above, and increased by one-hundred (100). As FIG. 22
illustrates, a shock absorbing, insulated shipping container 410 in
accordance with the present invention includes a generally
rectangular prismatic body 412. This body 412 is preferably formed
principally of foamed shape-retaining but somewhat resilient
polymer. The body 412 includes a base or main portion 414, and a
lid portion 416. The base portion 414 in this embodiment includes
planar side wall portions 414a/b/c/d, and a planar floor wall
portion 414e As is best seen in FIG. 21, the body 412 is chambered,
and defines an interior chamber or cavity 418. The base portion 414
defines an opening 420 to the cavity 418, and a lip 422 surrounding
this opening 420. Outwardly of the lip 422, the base portion 414
defines a circumferential rabbet 424. The lid portion 416 includes
a wall portion 426 spanning the opening 420, and a circumferential
flange 428 received into rabbet 424 and about the lip 422.
[0064] However, inspection of FIGS. 21 and 22 will show that
similarly to the embodiment of FIGS. 17-20, this embodiment defines
plural inwardly protruding features 286, which in this embodiment
are configured as a plurality of spaced apart blocks 286a on the
floor wall 414e, and connecting vertically extending ribs 286b
extending generally upwardly from the blocks 286a along the corners
of the cavity 418. Within these ribs 286b and resting on the blocks
286a is an interlocking wall structure 184 similar to wall
structure 84 (recalling FIG. 16), but not requiring or including
the protruding end portions 84a of wall structure 84. In this case,
the ribs 286b serve to space the wall structure 184 away from the
inside surface of the side walls 414a-d, and provide a
circumferential cushion space 434. This cushion space 434 is also
maintained below the contents by the blocks 286a, upon which the
wall structure 184 and contents 430 rest.
[0065] Above and resting upon a circumferential ledge 344 defined
about cavity 418 by the ribs 286b is a top panel 488 (best seen in
FIG. 22). This panel defines plural air circulation perforations
488a. On this panel or tray 488 is disposed a thermal mass 442 (or
gel pack) so as to provide cooling or warming to the contents 430
in cavity 418. A panel of foam packing material (not seen in FIG.
21 or 22) may be interposed between the contents 430 and the tray
488, and define plural air circulation holes, if additional
cushioning space is desired in the upward direction (i.e., relative
to the contents 430). It is also seen in FIG. 22 that the tray or
panel 488 defines a centrally located larger perforation or hole
488b. Received into the hole 488b is a fan package 490 carrying a
fan 462. This fan package 490 is disposed directly above a chimney
184c defined by the wall structure 184. Thus, as is best
illustrated in FIG. 22, the fan package 490 causes air within
cavity 418 to be vigorously circulated (as is depicted by the air
flow arrows on FIG. 22).
[0066] Finally, attention now to FIGS. 23-25 in conjunction will
illustrate another embodiment of the present invention. Because
this embodiment also has many features which are the same or
analogous in structure or function to those of earlier embodiments,
these features are indicated on FIGS. 23-25 with the same numeral
used above, and increased by one-hundred (100) over their prior
usage. In general this embodiment of the invention provides an
insulated shipping container which has both structure providing a
surrounding cushion space, as well as air circulation channels or
spaces, as well as providing a variable-volume feature. This
variable-volume feature allows a container of a given size to be
used to safely transport shipments of contents of a much smaller
volume. As a result, a reduced number of different sizes and shapes
of insulated shipping containers will suffice to ship many
differing sizes and volumes of contents.
[0067] Turning first to FIG. 23, a shock absorbing, insulated
shipping container 510 in accordance with the present invention
includes a generally rectangular prismatic body 512. This body 512
is preferably formed principally of foamed shape-retaining but
somewhat resilient polymer. The body 512 includes a base or main
portion 514, and a lid portion 516 (seen in FIG. 25). The base
portion 514 in this embodiment includes planar side wall portions
514a/b/c/d, and a planar floor wall portion 514e As is best seen in
FIGS. 23 and 24, the body 512 is chambered, and defines an interior
chamber or cavity 518. The base portion 514 defines an opening 520
to the cavity 518, and a lip 522 surrounding this opening 520.
Outwardly of the lip 522, the base portion 514 defines a
circumferential rabbet 524.
[0068] Moreover, inspection of FIGS. 23 and 24 will show that
similarly to the embodiment of FIGS. 17-22, this embodiment defines
plural inwardly protruding features 486, which in this embodiment
are configured as a plurality of spaced apart ribs 486a on the
floor wall 514e, and connecting vertically extending ribs 486b
extending generally upwardly along the side walls 514a-d. Attention
to FIG. 23 will show that the ribs 486b are spaced apart in
alternating pairs, with a closely spaced pair of ribs being more
widely spaced from the next adjacent pair of closely spaced ribs.
Also, in one direction across the floor wall 514e, the ribs 486a
are aligned with the space between a closely spaced pair of the
ribs 486b. In fact, as FIG. 24 illustrates, the closely spaced
pairs of ribs 486b are spaced such as to receive and retain a
partition wall 90. The partition wall rests upon one of the ribs
486a extending across floor wall 414e, and effectively divides the
cavity 518 into two portions 518a and 518b.
[0069] Thus, within one of the cavity portions 518a or 518b,
dependent upon the size and number of contents items to be shipped
in the container 510, an interlocking wall structure 584 similar to
wall structure 84 (recalling FIG. 16, and FIGS. 17-20), and also
not requiring or including the protruding end portions 84a of wall
structure 84 (seen in FIG. 16), is received into one of the cavity
portions. In this case also, the ribs 486b serve to space the wall
structure 584 away from the inside surface of the side walls
514a-d, and provide a circumferential cushion space 534. This
cushion space 534 is maintained below the contents of the cavity
518 by the ribs 486a, upon which the wall structure 584 and
contents 530 rest (viewing FIG. 25).
[0070] Above and resting upon a circumferential ledge 544 defined
about cavity 518 by the ribs 586b is a top panel 588 (seen in FIG.
25). This panel defines plural air circulation perforations 588a.
On this panel or tray 588 is disposed a thermal mass 542 (or gel
pack) so as to provide cooling or warming to the contents 530 in
cavity 518. A panel of foam packing material (not seen in FIG. 25)
may be interposed between the contents 530 and the tray 588, and
defines plural air circulation holes, if additional cushioning
space is desired in the upward direction (i.e., relative to the
contents 530). It is also seen in FIG. 25 that the tray or panel
588 defines a larger perforation or hole 588b. In this case, the
hole 588b is disposed over the one of the cavity portions 518a or
518b, receiving the contents 530. Received into the hole 588b is a
fan package 590 carrying a fan 562. This fan package 590 is
disposed directly above a chimney 584c defined by the wall
structure 584. Thus, as is best illustrated in FIG. 25, the fan
package 590 causes air within cavity 518 to be vigorously
circulated (as is depicted by the air flow arrows on FIG. 25).
[0071] In view of the above, it is seen that the container 510 is
able to receive, transport, cushion, and circulate temperature
controlling air about contents that would not completely fill the
cavity 518. By utilizing only a controlled and partitioned portion
of the cavity 518, the contents 530 are maintained in a compact
mass (best seen in FIG. 25), for which it is easier to control the
temperature of this mass, and to cushion the contents 530 against
shocks during transport.
[0072] While the invention is susceptible to various modifications,
and alternative forms, specific examples thereof have been shown in
the drawings and are herein described in detail. It should be
understood, however, that the invention is not to be limited to the
particular forms disclosed, but to the contrary, the invention is
to cover all modifications, equivalents and alternatives falling
within the spirit and scope of the appended claims.
* * * * *