U.S. patent application number 12/625027 was filed with the patent office on 2010-03-25 for reusable shipping container and method for using the same.
This patent application is currently assigned to Eggs Overnight, Inc.. Invention is credited to Kent H. Dickinson, Nissim Ozer, Robert C. Smallman.
Application Number | 20100072211 12/625027 |
Document ID | / |
Family ID | 42036584 |
Filed Date | 2010-03-25 |
United States Patent
Application |
20100072211 |
Kind Code |
A1 |
Dickinson; Kent H. ; et
al. |
March 25, 2010 |
REUSABLE SHIPPING CONTAINER AND METHOD FOR USING THE SAME
Abstract
Embodiments disclose a reusable shipping container. The
container may comprise six multi-layered walls of a plastic
material. Further, the container may comprise a rail fastened to a
top edge of the container with a plurality of first fasteners,
wherein the fasteners penetrate on the rail, a first layer and a
second layer of the container. Moreover, the container may comprise
an insulation layer of vacuum insulation material and an inner
layer corresponding to each wall of the container. Methods are also
described for packing a parcel for shipment. The insulation layer
and the inner layer are inserted into the container, wherein the
inner layer encloses the parcel. Thereafter, an insulation layer
corresponding to a top wall is inserted and the top wall is
closed.
Inventors: |
Dickinson; Kent H.;
(Covington, GA) ; Ozer; Nissim; (Las Vegas,
NV) ; Smallman; Robert C.; (Snellville, GA) |
Correspondence
Address: |
HOLLAND & HART, LLP
P.O BOX 8749
DENVER
CO
80201
US
|
Assignee: |
Eggs Overnight, Inc.
Stone Mountain
GA
|
Family ID: |
42036584 |
Appl. No.: |
12/625027 |
Filed: |
November 24, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12041459 |
Mar 3, 2008 |
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12625027 |
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11665762 |
Mar 28, 2008 |
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PCT/US2005/009400 |
Mar 18, 2005 |
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12041459 |
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12115057 |
May 5, 2008 |
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11665762 |
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60554559 |
Mar 18, 2004 |
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61047234 |
Apr 23, 2008 |
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Current U.S.
Class: |
220/592.27 ;
220/324; 220/62.15; 220/62.22; 220/643; 220/692; 220/810;
53/452 |
Current CPC
Class: |
B65D 43/16 20130101;
B65D 81/051 20130101; B65D 81/3823 20130101; B65D 43/22 20130101;
B65D 81/052 20130101; Y02W 30/80 20150501; Y02W 30/807 20150501;
B65D 81/1275 20130101 |
Class at
Publication: |
220/592.27 ;
220/810; 220/324; 220/62.15; 220/62.22; 220/643; 220/692;
53/452 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 43/16 20060101 B65D043/16; B65D 43/22 20060101
B65D043/22; B65D 1/40 20060101 B65D001/40; B65D 6/10 20060101
B65D006/10; B65D 6/28 20060101 B65D006/28 |
Claims
1. A reusable shipping container comprising: (A) a bottom, two
opposite side walls, and two opposite end walls, wherein the side
walls and the end walls include upper edges defining a top edge of
the container, and wherein each of the bottom wall, the side walls
and the end walls includes (i) a first layer of a plastic material
forming an external side of the container, the first layer having a
thickness of about 5 mm to 7 mm; and (ii) a second layer of the
plastic material substantially coextensive with the first layer,
the second layer being secured to the first layer, the second layer
having a thickness of about 5 mm to 7 mm; (B) a rail extending
around the top edge of the container, the rail being secured to the
container by a plurality of first fasteners, wherein the first
fasteners penetrate only the rail and first layer of the side walls
and the end walls; and (C) a top wall forming a lid of the
container and hingeably connected to a hinge end of the top edge,
including (i) the first layer; (ii) the second layer; (iii) a third
layer of the plastic material substantially coextensive with the
second layer, the third layer being secured to the second layer,
the third layer having a thickness of about 5 mm to 7 mm; and (iv)
a plurality of second fasteners adapted to secure the top wall to
the hinge end, wherein the second fasteners penetrate only the
first layer and the second layer of the top wall.
2. The container according to claim 1 further comprising: (A) an
insulation layer corresponding to each of the bottom wall, the side
walls, the end walls and the top wall, wherein the insulation layer
includes a vacuum insulation material and is placed substantially
coextensive with the second layer; and (B) an inner layer
corresponding to each of the bottom wall, the side walls, the end
walls and the top wall, the inner layer forming an internal side of
the container, wherein the inner layer is placed substantially
coextensive with the insulation layer.
3. The container according to claim 2, wherein each insulation
layer is pressure fitted in the container.
4. The container according to claim 2, wherein each inner layer
includes the plastic material.
5. The container according to claim 2, wherein each inner layer
includes a corrugated paper material.
6. The container according to claim 2, wherein each inner layer
includes a temperature holding material.
7. The container according to claim 2, wherein the inner layer
includes three first interlocking sides conjoined with three second
interlocking sides to form six sides.
8. The container according to claim 1, wherein the plastic material
is corrugated polypropylene.
9. The container according to claim 1, wherein the plastic material
of the first layer of the side walls and the end walls comprises a
plurality of flutes perpendicular to the bottom wall.
10. The container according to claim 1, wherein the plastic
material of the second layer of the side walls and the end walls
comprises a plurality of flutes arranged at an angle of 0 degrees
with respect to the bottom wall.
11. The container according to claim 1, wherein the top wall
includes a first thickness equivalent to a combined thickness of
the first layer, the second layer and the third layer
12. The container according to claim 11, wherein the first
thickness of the top wall is equivalent to a depth of the rail.
13. The container according to claim 1 further comprising one or
more hardware accessories adapted to handle the container, wherein
the one or more hardware accessories are secured with a plurality
of third fasteners.
14. The container according to claim 13, wherein the third
fasteners are fastened to one or more backers and penetrate only
the first layer of the container.
15. The container according to claim 13, wherein the third
fasteners comprise rivets.
16. The container according to claim 1 further comprising one or
more locking mechanisms adapted to secure a second end of the top
wall to the container.
17. The container according to claim 16, wherein the one or more
locking mechanisms comprises a latch and a receiver.
18. The container according to claim 17, wherein the latch is
secured to an end wall through a third plurality of fasteners, and
wherein the third plurality fasteners penetrate only the first
layer of the end wall.
19. The container according to claim 17, wherein the receiver is
secured to an end wall through the third fasteners, and wherein the
third fasteners penetrate only the first layer and the second layer
of the top wall.
20. The container according to claim 1, wherein the rail engages
the end walls and the side walls together.
21. The container according to claim 1, wherein the first fasteners
and the second fasteners comprise rivets.
22. A reusable shipping container for housing one or more vacuum
insulation panels, comprising: (A) a bottom, two opposite side
walls, and two opposite end walls, wherein the side walls and the
end walls include upper edges defining a top edge of the container,
and wherein each of the bottom wall, the side walls and the end
walls includes (i) a first layer of a plastic material forming an
external side of the container, the first layer having a thickness
of about 5 mm to 7 mm; and (ii) a second layer of the plastic
material substantially coextensive with the first layer, the second
layer being secured to the first layer, the second layer having a
thickness of about 5 mm to 7 mm; (B) a rail extending around the
top edge of the container, the rail being secured to the container
by a first plurality of fasteners, wherein the first plurality of
fasteners penetrate the rail and only the first layer of the side
walls and the end walls; (C) a top wall forming a lid of the
container and hingeably connected to a hinge end of the top edge;
(D) an insulation layer corresponding to each of the bottom wall,
the side walls, the end walls and the top wall, wherein the
insulation layer includes the one or more vacuum insulation panels
placed substantially coextensive with the second layer; and (E) an
inner layer corresponding to each of the bottom wall, the side
walls, the end walls and the top wall, wherein the inner layer is
placed substantially coextensive with the insulation layer, and
wherein the inner layer forms an internal side of the
container.
23. The container according to claim 22, wherein the top wall
comprises: (i) the first layer; (ii) the second layer; (iii) a
third layer of the plastic material substantially coextensive with
the second layer, the third layer being secured to the second
layer, the third layer having a thickness of about 5 mm to 7 mm;
and (iv) a plurality of second fasteners adapted to secure the top
wall to the hinge end, wherein the second fasteners penetrate only
the first layer and the second layer of the top wall.
24. The container according to claim 22, wherein each inner layer
includes a temperature holding material.
25. The container according to claim 22 further comprising one or
more hardware accessories adapted to handle the container, wherein
the one or more hardware accessories are secured with a plurality
of third fasteners.
26. The container according to claim 25, wherein the third
fasteners are fastened to one or more backers and penetrate only
the first layer of the container.
27. The container according to claim 22, wherein each insulation
layer includes vacuum insulation panels having an R-value of about
30 to 52.
28. The container according to claim 22, wherein the thickness of
each inner layer is about 3 mm to 4 mm.
29. A method for packing a parcel for shipment to an intended
recipient, comprising: providing a reusable shipping container,
wherein the container includes a bottom wall, two opposite side
walls, and two opposite end walls, and wherein each of the bottom
wall, the side walls and the end walls include a first layer
forming an external side of the container, and a second layer
substantially coextensive with said first layer; inserting an
insulation layer corresponding to each of the bottom wall, the side
walls, and the end walls into the container, wherein the insulation
layer includes the one or more vacuum insulation panels placed
substantially coextensive with the second layer; inserting an inner
layer corresponding to each of the bottom wall, the side walls, the
end walls and the top wall, wherein the inner layer is placed
substantially coextensive with the insulation layer, and wherein
each inner layer provides a temperature controlled environment to
the parcel located therein; inserting the insulation layer
corresponding to the top wall, wherein the insulation layer is
placed substantially coextensive with the inner layer of the top
wall; and closing the top wall of the container.
30. The method according to claim 29 including the step of closing
the top wall of the container, wherein the top wall is closed by
using one or more locking mechanisms.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 12/041,459, filed Mar. 3, 2008, titled
SHIPPING CONTAINER, SYSTEM AND PACKING METHOD, ALONG WITH REUSABLE
PACKING ACCESSORY FOR USE THEREWITH, which is a
continuation-in-part of U.S. patent application Ser. No.
11/665,762, filed Apr. 16, 2007, titled SHIPPING CONTAINER, which
is a National Stage entry from PCT Application No.
PCT/US2005/009400, filed Mar. 18, 2005, titled SHIPPING CONTAINER,
which claims the benefit of U.S. Provisional Patent Application
Ser. No. 60/554,559, filed Mar. 18, 2004, titled SHIPPING
CONTAINER. This application is also a continuation-in-part of U.S.
patent application Ser. No. 12/115,057, filed May 5, 2008, titled
REUSABLE SHIPPING CONTAINER AND SYSTEMS THEREOF, which claims the
benefit of U.S. Provisional Patent Application Ser. No. 61/047,234,
filed Apr. 23, 2008, titled CONTAINER SYSTEM WITH SWELL LATCH. The
entire contents and substance of the above applications are
incorporated herein by reference.
FIELD
[0002] The present invention is broadly directed to containers.
More specifically, the present invention is directed to reusable
shipping containers suitable for shipping good(s) that are
sensitive to temperature.
BACKGROUND
[0003] Various types of containers are available for holding and
transporting products. Examples of such containers include
corrugated cartons, tote containers, and other boxes. The
containers may be designed according to the need of transportation
and the properties of goods. For example, there are goods that must
be held at a consistent temperature because of high risk of
spoilage, such as blood, tissues, and so forth. Further, the
duration of transportation may be crucial for the goods.
[0004] There are a wide variety of containers that use different
temperature control techniques to keep the goods safe during the
time of holding or transportation. One known technique uses wet
pads or dry ice to control or maintain the temperature of the
goods. For example, U.S. Pat. No. 4,294,079, assigned to Better
Agricultural Goals Corporation, discloses an insulated shipping
container for perishable goods, which uses dry ice as a refrigerant
for controlling temperature. However, dry ice in amounts greater
than 5.5 lbs are generally considered a hazard. Therefore, this
technique can be limited for a small quantity of goods. Another
known technique is the use of Vacuum Insulation Panels (VIP) in the
containers. The VIP are high cost, high-value performance
insulation manufactured by various companies such as American
Aerogel, AcuTemp, and Nanopore. The VIP materials are sealed with a
strong vacuum to effectively remove air from the VIP. As a result,
a very effective material for maintaining temperature is generated.
For example, the thermal resistance value (R-value) of VIP is about
50, as compared to an igloo cooler having a typical R-value of
about 5 or 6. Moreover, temperature control material required in
case of the VIP is drastically less as compared to other insulation
techniques. Therefore, the weight and size of the shipment
containing the goods may be reduced. Furthermore, there is an
option, for example, to delay transport of the shipment from
overnight to a second day or even ground transfer. As a result,
these can be huge savings in the supply chain of
transportation.
[0005] There are several limitations associated with the use of the
VIP. First, the VIP are expensive. For example, depending on the
size of other packaging material, the VIP may cost 15 to 30 times
the cost of packaging material. Second, the VIP is very susceptible
to puncture. As a result, in case of a puncture, the insulation
value of the VIP is completely lost. Third, the VIP is intended to
be reused; however it is occasionally the case that the VIP is
generally destroyed during transportation. Generally, VIP are
pressure fit into a cardboard box. However, sharp objects, such as
sorting belts and equipment or other packages easily penetrate the
box during transit. Cardboard is not rigid, therefore, any harsh
handling of the box shifts the VIP insulation. As a result, air
gaps are created in the seams. Therefore, the purpose of the VIP to
eliminate air penetration is defeated. Moreover, the lack of
rigidity of the cardboard box allows air to penetrate, resulting in
a premature cooling. Furthermore, when the VIP is not reused, a lot
of waste is generated, which is both a high cost and burden for
recipients of temperature sensitive goods. For example, an existing
technique as disclosed in U.S. Patent Application Publication No.
2007/0051734 assigned to VA-Q-TEC AG, uses vacuum insulation
material in shipping containers. However, the technique does not
identify means to prevent the vacuum insulation material from
puncture. Moreover, the container and vacuum insulation of this
technique are not designed for reuse.
[0006] Another existing solution uses the VIP in a thermoformed
container. However, the molding of an outer shell of the
thermoformed container requires expensive tools. Therefore, the
cost to change the design is high and as a result, size and shape
of the container are limited. Further, the molded case design may
include structural ridges, tapered edges, and rounded corners. As a
result, the VIP having a square design profile may be difficult to
fit in the container. Therefore, modifications and adjustments in
the container are required to house the VIP, which leads to
over-sizing of the container dimensions. Furthermore, the container
may be designed with an onboard battery and sensor system to
promote and maintain temperature control. For example, U.S. Pat.
No. 6,771,183, assigned to Kodak Technologies Inc., discloses a
thermal container with battery and other electronic circuitry to
monitor temperature of goods. Yet another existing solution,
disclosed in U.S. Pat. No. 5,943,876 assigned to Vacupanel Inc.,
uses a portable refrigerated container for housing vacuum
insulation panel. However, there is an inherent risk if the battery
system fails, which can result in failure of the cooling. As a
result, the goods can be damaged.
[0007] Alternate designs use phase change material that can be
frozen multiple times. However, the performance of these materials
is decreased over time of usage. Moreover, phase change materials
are expensive as compared to materials, such as gel pack, wet ice,
and dry ice. In the case of the thermoformed container, the outer
shell is sensitive to extreme shocks. Therefore, if the outer shell
is damaged, generally the entire container is scrapped because of
air penetration. Moreover, the repairing of the container may not
be cost-effective. Further, the container is heavy due to the
material, construction and design. For example, the material of the
container is generally twice as heavy as compared to a cardboard
box. Therefore, the weight of the empty container may exceed, for
example, 50 lbs. The use of this solution may therefore, cause
additional shipping and handling costs during transportation.
Moreover, the wastage may be detrimental to the environment.
[0008] Yet another existing solution, as disclosed for example, in
WO Publication No. 2009/067007 to Colratech B. V., explains the use
of multiple layers of VIP as the material of contraction for the
container. However, the VIP materials are vulnerable to puncture,
which can result in damage to the goods. Further, a technique
disclosed in WO Publication No. 2009/019251 to F. Hoffmann-La Roche
A G uses multiple layers of foam material to form the walls of a
container. The VIP are then arranged in the walls. However, the
container may be susceptible to damage due to the material of the
walls. Moreover, the shipping in this container may be limited only
to a couple of days.
[0009] Generally, a secure and airtight locking is desirable for
containers including VIP. An existing technique disclosed, for
example in U.S. Pat. No. 6,244,458 assigned to Thermo Solutions
Inc., explains the use of handles or latches that are secured by
fasteners with one end in contact with VIP. However, the ends of
the fasteners may damage the VIP during shipping or handling of the
container. Another existing solution that houses the VIP uses
hardware accessories that secured the lid of the container from the
inside. For example, the hardware accessories include a flush
mounted swell latch and one-fourth turn latch to close the lid from
inside the container. One such container is disclosed in U.S.
Patent Application Publication No. 2008/0203090 assigned to the
assignee of the present invention and incorporated herein by
reference. However, this design requires additional space inside
the container. Moreover, additional foam is required to protect the
VIP from the internal hardware accessories such as rivets, bolts or
plates of handles, latches and the like. Furthermore, the foam
tends to allow the VIP to shift during transportation, and hence
create air gaps. Air gaps allow outside air to penetrate the
container and the performance of the VIP is reduced. Moreover, the
use of internal hardware accessories and foam adds to the size and
weight of the container. This impacts overall shipping costs.
[0010] There has long been a need for a container that is rigid,
lightweight, flexibly designed and extremely resistant to shock and
vibration that are typically experienced when transporting
high-value, prone-to-damage, and temperature sensitive goods.
Accordingly, there is a need for a container to effectively house,
protect, and repeatedly ship the high performance, yet fragile and
tear-prone VIP. Further, there is a need for a reusable container
that maximizes the interior space, while minimizing necessary
coolant. Moreover, there is a need for a container that can be
designed and manufactured for a wide variety of transportation
requirements. The container should use hardware accessories and
fasteners such that they do not puncture the VIP and can be reused.
One or more of these needs is addressed by the present
disclosure.
SUMMARY
[0011] One aspect of the exemplary embodiments disclosed herein is
to a reusable shipping container.
[0012] Another aspect of the exemplary embodiments disclosed herein
is to provide a container to effectively house vacuum insulation
material.
[0013] According to one or more of the exemplary embodiments, a
reusable shipping container is provided. The container generally
includes a bottom, two opposite side walls (i.e., left and right),
two opposite end walls (i.e., front and back), and a top wall. The
side walls and the end walls include upper edges that define a top
edge of the container.
[0014] Each of the bottom wall, the side walls and the end walls
include a first layer of a plastic material forming an external
side of the container, and a second layer of the plastic material
substantially coextensive with the first layer, the second layer
being secured to said first layer. The first layer and the second
layer may have a thickness of about 5 mm to 7 mm.
[0015] The container further includes a rail extending around the
top edge of the container. The rail may be secured to the container
by a plurality of first fasteners. The first fasteners may
penetrate only the rail and first layer of the side walls and the
end walls. Moreover, the container may include a locking mechanism
or hardware accessories. The locking mechanism or hardware
accessories may be secured to the container by fasteners that
penetrate only the first layer of the container.
[0016] The top wall of the container may form a lid of the
container and may be hingeably connected to a hinge end of the top
edge. The top wall may include the first layer, the second layer,
and a third layer substantially coextensive with the second layer.
The third layer may be formed of the plastic material and may have
a thickness of about 5 mm to 7 mm. Further, the top wall may
comprise a plurality of second fasteners adapted to secure the top
wall to the hinge end of the rail. The second fasteners may
penetrate only the first layer and the second layer of the top
wall.
[0017] The container may further include an insulation layer
corresponding to each of the bottom wall, the side walls, the end
walls and the top wall. The insulation layer may include vacuum
insulation material and may be placed substantially coextensive
with the second layer. Furthermore, the container may include an
inner layer corresponding to each of the bottom wall, the side
walls, the end walls and the top wall. The inner layer may form an
internal side of the container and may be placed substantially
coextensive with the insulation layer.
[0018] A method for packing a parcel for shipment to an intended
recipient is also contemplated. According to this method,
insulation layers and the inner layers corresponding to a bottom
wall, two opposite side walls, and two opposite end walls may be
inserted into the container. The inner layer may enclose the
parcel. Thereafter, an insulation layer corresponding to a top wall
is inserted and the top wall is closed. Further, the method may
include a step of closing the top wall by using one or more locking
mechanisms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Having thus described aspects of the invention in general
terms, reference will now be made to the accompanying drawings,
which are not necessarily drawn to scale, and wherein:
[0020] FIG. 1 is a perspective view of a shipping container
according to an exemplary embodiment;
[0021] FIG. 2a is a perspective view of the shipping container
shown in FIG. 1 (with the lid open), in an unpacked, or
pre-shipment state;
[0022] FIG. 2b is a perspective view of the shipping container
shown in FIG. 1 (with the lid removed) displaying insulation layers
and inner layers inside the container;
[0023] FIG. 3a is a representative cross sectional view depicting
the layered construction for the side walls, end walls, or a bottom
wall of the container shown in FIG. 1;
[0024] FIG. 3b is a cross sectional view as shown in FIG. 3a, along
with insulation layers and inner layers of the container shown in
FIG. 1;
[0025] FIG. 3c is a cross sectional view as shown in FIG. 3b,
illustrating the penetration of multiple fasteners;
[0026] FIG. 3d is a cross sectional view, illustrating the
penetration of a rail by the fasteners at a top edge of the
container shown in FIG. 1;
[0027] FIG. 3e is a cross sectional view of a top wall of the
container shown in FIG. 1, along with the insulation layer and the
inner layer; and
[0028] FIG. 4 illustrates a cross sectional view of a lower corner
region of the container shown in FIG. 1 with a parcel located
therein.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0029] Illustrative embodiments now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments are shown. Indeed, the invention may
be embodied in many different forms and should not be construed as
limited to the embodiments set forth herein; rather, these
embodiments are provided so that this disclosure will satisfy
applicable legal requirements. Like numbers refer to like elements
throughout.
[0030] With initial reference to FIG. 1, a reusable shipping
container 10 is shown closed, locked and ready for shipment to an
intended recipient. Container 10 is a rigid, lightweight container,
flexibly designed and extremely resistant to shock and vibration
typically experienced when transporting high-value, prone-to-damage
goods. Moreover, container 10 is adapted to hold, store and
transport goods that are sensitive to temperature. Container 10 is
generally rectangular or box-like in shape to maximize the internal
size. Various components of container 10 are described with
reference to FIGS. 1, 2a, and 2b. As shown with reference to FIGS.
2a and 2b, container 10 is adapted to receive a parcel 32. The
various components of container 10 may generally include, as shown
with reference to FIGS. 1, 2a-b, 3a-e and 4, a bottom wall 12, two
opposite side walls 14(1)-14(2), two opposite end walls
16(1)-16(2), a top wall 18, insulation layers 28(1)-28(6), and
inner layers 30(1)-30(6).
[0031] Other container constructions which can be adapted to
benefit from the insulative characteristics and other features
described herein include those described in the various
applications referred to in the "Cross Reference to Related
Applications" section above, each of which is specifically
incorporated herein by reference in its entirety.
[0032] With reference again to container 10, taking each of the
components in turn, bottom wall 12 forms the base, and top wall 18
forms the lid of container 10. Side walls 14(1)-14(2) and end walls
16(1)-16(2) form the sides of container 10. As shown with reference
to FIG. 1 and FIG. 2, side walls 14(1)-14(2) and end walls
16(1)-16(2) define a top edge 36 of container 10. Preferably, top
wall 18 is hingeably connected to a hinge end 38 of the top edge 36
of container 10 by using multiple second fasteners 42, as available
from Fastenel of Minnesota as part No. CM-AAA612. Therefore, top
wall 18 can move about an open and a closed position on container
10. Each of bottom wall 12, side walls 14(1)-14(2), end walls
16(1)-16(2), and top wall 18 may have multiple layers and may be
formed of a plastic material. The plastic material can be, for
example, polypropylene. The arrangement of the various layers of
side walls 14(1)-14(2), end walls 16(1)-16(2), or bottom wall 12 is
shown with reference to FIGS. 3a-3d, and the arrangement of the
layers of top wall 18 is shown with reference to FIG. 3e. Container
10 includes a rail 34 which extends along the top edge 36. Rail 34
may generally be of a plastic material, for example, but not
limited to, Polyvinyl Chloride (PVC). Further, rail 34 may have an
`h` shape as generally known in the art. As shown with reference to
FIG. 3d, rail 34 is secured to side walls 14(1)-14(2) and end walls
16(1)-16(2) through first fasteners 20, as available from Fastenel
of Minnesota as part No. AB6-4A. Rail 34 engages side walls
14(1)-14(2) and end walls 16(1)-16(2) together. Further, rail 34
provides additional rigidity to container 10. Moreover, rail 34 may
be easily placed or removed from container 10. Therefore, container
10 can be easily repaired in case of any damage.
[0033] With reference to FIG. 3a, a partial cross sectional view is
shown which may correspond to an exterior portion of either bottom
wall 12, one of side walls 14(1)-14(2), or one of end walls
16(1)-16(2). FIG. 3a, thus, illustrates an exemplary arrangement of
the various layers for these walls. As shown, the layers include a
first (or outermost) layer 44 and a second layer 46 generally
formed of the plastic material. The plastic material may be, for
example, corrugated polypropylene. Second layer 46 is placed
parallel and substantially coextensive with first layer 44. Second
layer 46 may be secured to first layer 44 by using adhesives or
glues. In an embodiment of the invention, end walls 16(1)-16(2) may
have flaps that fold in to create a double-layer of corrugated
plastic. Therefore, the flaps may form second layer 46 of end walls
16(1)-16(2).
[0034] First layer 44 forms the exterior of container 10 and may
generally include flutes of corrugated plastic, which are arranged
perpendicular to bottom wall 12. Further, second layer 46 may also
include flutes of corrugated plastic, which are arranged parallel
to bottom wall 12. The thickness of each of first layer 44 and
second layer 46 may be about 5 mm to 7 mm. This arrangement of
flutes provides extra strength and rigidity to container 10 and
further increases resistance to puncture. Moreover, this
arrangement of flutes helps in absorbing and distributing shocks on
container 10 during transportation.
[0035] FIG. 3b is a cross sectional view as shown in FIG. 3a, along
with insulation layers 28(1)-28(6) and inner layers 30(1)-30(6) of
the container 10. As shown, only one layer of insulation layers
28(1)-28(6) and inner layers 30(1)-30(6) is visible in FIG. 3b. A
person skilled in the art will appreciate that the cross section as
shown in FIG. 3b is similar for each of bottom wall 12, side walls
14(1)-14(2), or end walls 16(1)-16(2). Therefore, a specific
mention of a particular insulation layer is not required.
Insulation layers 28(1)-28(6) may be formed of vacuum insulation
material. The vacuum insulation material may be, for example,
Vacuum Insulation Panels (VIP) manufactured by various companies
such as American Aerogel, AcuTemp, and Nanopore. The VIP are high
cost, high-value performance thermal insulation material with a
thermal resistance value (R-value) of about 30 to 52. Generally,
the VIP is placed in container 10 as six insulation layers
28(1)-28(6), as supplied by the manufacturers. A typical VIP is
disclosed in U.S. Pat. No. 7,005,181 assigned to American Aerogel
Corporation. However, the VIP are also very susceptible to
puncture. For example, sharp objects, such as sorting belts and
equipment or other packages can easily penetrate container 10
during transit. Moreover, any mechanical fasteners with edges can
penetrate the VIP. Any puncture in the VIP can lead to loss of
insulation and deterioration of temperature sensitive goods in
container 10. However, the design and construction of container 10
prevents damage to insulation layers 28(1)-28(6). Moreover, the
fasteners used in container 10 are designed and used so as not to
touch insulation layers 28(1)-28(6) and hence prevent any
damage.
[0036] With reference to FIG. 3c, multiple third fasteners 48 are
illustrated that secure hardware accessories, such as handle 22 or
latch 24, to the layers of side walls 14(1)-14(2) and end walls
16(1)-16(2). Handle 22 may be as available from Penn Elcom Inc. of
California as part No. H1078. Here, third fasteners 48 include
rivets that are designed to penetrate only first layer 44. Of
course, a person skilled in the art will appreciate that third
fasteners 48 can include other means of mechanical securing, such
as bolts, nuts, and screws of various sizes or configurations.
Further, third fasteners 48 are affixed to a tail or a backer (not
shown) to provide holding strength to the hardware accessories. The
ends of third fasteners 48 are covered by second layer 46, and
therefore, are prevented from contacting insulation layers
28(1)-28(6). Third fasteners 48 may be as available from Fastenel
of Minnesota as part No. 48 AB6-6A.
[0037] Referring again to FIG. 1, an exemplary locking mechanism
containing latch 24 and a receiver 26, as available from Penn Elcom
Inc., California as part Nos. L0737/46 and L0926-90Z, is used from
outside to close top wall 18 of container 10. Therefore, there is
no contact of the locking mechanism with insulation layers
31(1)-31(6). This design is a preferred replacement to flush
mounted swell latch and 1/4 turn latch described in U.S. Patent
Application Publication No. 2008/203090, assigned to the assignee
of the present invention. The earlier design required crucial space
and used additional foam on the inside of the container to prevent
insulation layers 28(1)-28(6) from touching the locking mechanism.
Further, these modifications added to the size and weight of the
container, while also risking the stability of insulation layers
28(1)-28(6).
[0038] With reference to FIG. 3d, a cross sectional view of side
walls 14(1)-14(2) or end walls 16(1)-16(2) near the top edge 36 of
container 10 is illustrated. Further, FIG. 3d illustrates a portion
of rail 34 and first fasteners 20. First fasteners 20 secure rail
34 to the top edge 36 of container 10. As shown, first fasteners 20
penetrate only rail 34 and first layer 44. Therefore, as also
discussed in conjunction with FIG. 3c, insulation layers
28(1)-28(6) are prevented from touching first fasteners 20.
Therefore, the chances of puncture to insulation layers 28(1)-28(6)
are reduced.
[0039] With reference to FIG. 3e, a cross sectional view of top
wall 18 near hinge end 38 is illustrated. During transport,
container 10 may come under weight or pressure of other parcels,
boxes or containers. The weight or pressure of other containers may
damage insulation layers 28(1)-28(6) and parcel 32. Therefore, top
wall 18 of container 10 needs to be strong to prevent the damage.
Moreover, top wall 18 may not have any component that may be caught
between sorting belts and equipment during the transport of
container 10. As shown with reference to FIG. 3e, top wall 18
includes first layer 42 and second layer 46, as discussed with
reference to previous figures. Further, top wall 18 includes a
third layer 50 of a plastic material. Third layer 50 may have a
thickness of about 5 mm to 7 mm and is substantially coextensive
with second layer 46. The plastic material of third layer 50 may be
corrugated polypropylene. As shown, top wall 18 is connected to
container 10 at hinge end 38 with second fasteners 42. Further,
second fasteners 42 penetrate first layer 44 and second layer 46 of
top wall 18 to provide strength to hinge 52. Hinge 52 may be as
available from ONO Inc. of Pennsylvania as part no. FFH2/4050
Flex-Fold 2 Bk. Moreover, second fasteners 42 may be affixed to a
tail or a backer (not shown) to provide holding strength to the
hinge. Thereafter, third layer 50 is secured over second layer 46.
Third layer 50 may be secured by gluing it to second layer 46 to
provide a smooth, penetration-free surface to top wall 18. A person
skilled in the art will appreciate that other means of securing
third layer 50 to second layer 46 can be used. The total thickness
of top wall 18 may include the thickness of first layer 44, second
layer 46, and third layer 50. This total thickness of top wall 18
may be equivalent to a depth of rail 34 to provide a smooth surface
on top of container 10 when closed. Therefore, the chances of
damage to container 10 from sorting belts, other packages or
hardware during transportation are reduced.
[0040] With reference to FIGS. 1, 2a-b, 3b, 3c, 3d, 3e, and 4,
inner layers 30(1)-30(6) are placed substantially coextensive with
insulation layers 28(1)-28(6). A person skilled in the art will
appreciate that the cross section as shown in FIGS. 3b, 3c, 3d, or
3e is similar for each of bottom wall 12, side walls 14(1)-14(2),
or end walls 16(1)-16(2). Therefore, a specific mention of a
particular inner layer is not required. Inner layers 30(1)-30(6)
may be made of corrugated plastic, generally 3 mm to 4 mm in
thickness. Further, inner layers 30(1)-30(6) may be made of single
wall corrugated paper, or a standard commercial grade Polyethylene
(PE) or Polyurethane (PU) foam supplied as Foam-Tech.TM. of
Vermont. Additionally, inner layers 30(1)-30(6) may be a
temperature holding material as supplied by RNC Industries of
Atlanta, Ga.
[0041] Inner layers 30(1)-30(6) may have a pad-set design, where
three interlocking sides are conjoined with another three
interlocking sides to form six sides for fitting into container 10.
Of course, the top side would be free to pivot about its hinge and
otherwise not interconnected to the other sides. In an embodiment
of the invention, inner layers 30(1)-30(6) may have a one-piece
design to form six sides of container 10. Inner layers 30(1)-30(6)
may be designed to fit snugly inside the six insulation layers
28(1)-28(6) and, together, form the interior of container 10.
[0042] Inner layers 30(1)-30(6) enclose parcel 32 and may have
cushioning, air-restriction, and temperature holding properties.
Parcel 32 being shipped in container 10 may be required to be free
from disease-causing contaminants, or in other words require a
sterile enclosure. For example, parcel 32 can include blood sample,
or organic tissues. Therefore, inner layers 30(1)-30(6) may be
changed after transportation of such parcel 32. As a result,
insulation layers 28(1)-28(6) may not be required to be changed and
may be reused. The reuse of insulation layers 28(1)-28(6) reduces
the wastage after every shipment and reduces adverse environmental
impact. Furthermore, various colors may be used for inner layers
30(1)-30(6) to either hide or show its soiling. Therefore, an
intended usage or sterility requirements of inner layers
30(1)-30(6) may be displayed. Moreover, inner layers 30(1)-30(6)
may provide protection to insulation layers 28(1)-28(6) from
coolants during shipment. Further, inner layers 30(1)-30(6) may
enhance temperature holding performance beyond just insulation
layers 28(1)-28(6).
[0043] With reference to FIG. 4, a cross sectional view reveals the
arrangement of various layers near bottom wall 12, side walls
14(1)-14(2) or end walls 16(1)-16(2) of container 10. As shown in
FIG. 4, parcel 32 is enclosed by inner layers 30(1), 30(4) and
30(5), which are in turn enclosed by insulation layers 28(1),
28(4), and 28(5). Of course a person skilled in the art will
appreciate that parcel 32 will also be enclosed by inner layers
30(2), 30(3) and 30(6) and insulation layers 28(2), 28(3), and
28(6), which are not shown in FIG. 4 for the sake of simplicity of
the drawing and description.
[0044] As a result of the encapsulation, the insulation and
temperature of parcel 32 is maintained. Further, first layer 44,
second layer 46 and third layer 50 provide strength and rigidity to
container 10, and smooth and penetration-free surfaces for
insulation layers 28(1)-28(6).
[0045] The design, material and construction of container 10 as
described above allow the dimensions of container 10 to be easily
and rapidly adapted based on the dimensions of parcel 32 or
requirement of transportation. Further, container 10 can be easily
repaired in case of damage. Furthermore, the plastic material of
container 10 can be reused various times, which increases the usage
life of container 10. Moreover, the weight and wastage of material
is reduced.
[0046] Now that the components of container 10 have been described,
the assembly thereof can be more readily understood. As may be
appreciated, any suitable hardware accessories such as latch 24 of
the locking mechanism or handle 22 may be secured to first layer 44
of container 10. Moreover, rail 34 is secured to the top edge 36 of
container 10 by using first fasteners 20. Rail 34 engages side
walls 14(1)-14(2) and end walls 16(1)-16(2) together to form four
sides of container 10. The hardware accessories and rail 34 may be
secured with fasteners such as rivets. The rivets may be designed
according to the thickness of first layer 44. Further, first
fasteners 20 may be designed to penetrate only rail 34 and first
layer 44. The rivets may be reusable. Therefore, the rivets can be
replaced or reused with container 10. The ends of the fasteners are
affixed to first layer 44 by using backers or tails. Thereafter,
second layer 46 is secured substantially coextensive with first
layer 44 to cover the ends of the fasteners and provide a smooth
penetration free surface to the interior of container 10. Second
layer 46 is designed to match the thickness of rail 34. As a
result, foam or shim may not be required to fill any gap between
rail 34 and second layer 46.
[0047] Top wall 18 may be connected to the top edge 36 of container
10 at the hinge end 38 by using second fasteners 42. Second
fasteners 42 penetrate first layer 44 and second layer 46 of top
wall 18. Further, the ends of second fasteners 42 are affixed to
second layer 46 by using backers or tails to provide more strength
to container 10. Thereafter, third layer 50 is secured
substantially coextensive with second layer 46 of top wall 18 to
cover the ends of second fasteners and provide a smooth
penetration-free surface to the interior of top wall 18.
[0048] Thereafter, insulation layers 28(1)-28(5) corresponding to
bottom wall 12, side walls 14(1)-14(2), and end walls 16(1)-16(2)
are disposed inside container 10. Insulation layers 28(1)-28(5) are
substantially coextensive with second layer 46 of bottom wall 12,
side walls 14(1)-14(2), and end walls 16(1)-16(2). Insulation
layers 28(1)-28(5) may be pressure fitted into container 10 to
remove any air between the layers. Inner layers 30(1)-30(5) are
then provided to cover inside surfaces of insulation layers
28(1)-28(5). Thereafter, parcel 32 for shipment is disposed in
container 10 and is covered on top by inner layer 30(6). As a
result, parcel 32 is enclosed completely by inner layers
30(1)-30(6). Insulation layer 28(6) corresponding to top wall 18 is
then placed on top of inner layer 30(6).
[0049] Top wall 18 may then be closed by moving it about hinge end
38. Further, top wall 18 may provide pressure on insulation layer
28(6) to remove any air or air gap for better insulation. Top wall
18 may be secured from outside container 10 by using the locking
mechanism. If desired, a locking structure could be provided to
retain latch 24 and receiver 26 at their closed position. Other
appropriate locking structures are also contemplated that would
retain locking mechanisms in the closed position so as to safely
retain parcel 32 in container 10.
[0050] With the above components and assembly thereof in mind, it
should be appreciated that alternative components, constructions
and materials can be used to accomplish the benefits derived from
container 10. For example, container 10 may include multiple
locking mechanisms of different types. Further, the locking
mechanisms can be placed on different walls of container 10. Also,
the arrangement of the flutes of the various layers can be modified
so that the same strength or rigidity is provided to container
10.
[0051] Having discussed the exemplary embodiments and contemplated
modifications to the container, it should be appreciated that a
method of packing a parcel to be shipped in the container is also
contemplated. According to this method, a reusable shipping
container is provided. The container includes a bottom wall, two
opposite side walls, two opposite end walls, and a top wall, each
having at least a first layer and a second layer. The first layer
forms an external side of the container, and the second layer is
substantially coextensive with said first layer. An insulation
layer of vacuum insulation material is inserted in the container
corresponding to each of the bottom wall, the side walls, the end
walls into the container. Thereafter, an inner layer corresponding
to each of the bottom wall, the side walls, the end walls and the
top wall is inserted substantially coextensive with the insulation
layer. The parcel is then disposed in the container, and each inner
layer provides a temperature-controlled environment to the enclosed
parcel. Thereafter, an insulation layer corresponding to the top
wall is inserted substantially coextensive with the inner layer of
the top wall, and the top wall is closed to retain the parcel. The
method further comprises the step of securing the top wall with a
locking mechanism to retain the parcel securely in the
container.
[0052] While the invention has been described in connection with
what is presently considered to be the most practical and various
embodiments, it is to be understood that the invention is not to be
limited to the disclosed embodiments, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the scope of the appended claims.
[0053] This written description uses examples to disclose
embodiments of the invention, including the best mode, and also to
enable any person skilled in the art to practice the invention,
including making and using any devices or systems and performing
any incorporated methods. The patentable scope of embodiments of
the invention is defined in the claims, and may include other
examples that occur to those skilled in the art. Such other
examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal
language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages
of the claims.
* * * * *