U.S. patent application number 12/260711 was filed with the patent office on 2010-04-29 for reusable container.
This patent application is currently assigned to GATE GOURMET, INC.. Invention is credited to Don Easterbrook, James Long, John Marenic.
Application Number | 20100102057 12/260711 |
Document ID | / |
Family ID | 42116491 |
Filed Date | 2010-04-29 |
United States Patent
Application |
20100102057 |
Kind Code |
A1 |
Long; James ; et
al. |
April 29, 2010 |
REUSABLE CONTAINER
Abstract
A reusable container for storing or transporting a product to be
refrigerated or frozen such as a food product is provided,
comprising an inner wall, an outer wall, and a wall space provided
between the inner wall and the outer wall. The wall space is
substantially separated from the environment outside of the
reusable container and a slurry is provided in the wall space. In
some embodiments, the container can be generally rectangular or
generally cylindrical. A method of shipping a product to be
refrigerated or frozen in a reusable container and a method of
producing a reusable container are also provided.
Inventors: |
Long; James; (Lantana,
TX) ; Marenic; John; (Coral Springs, FL) ;
Easterbrook; Don; (Surrey, CA) |
Correspondence
Address: |
FISH & RICHARDSON P.C.
P.O BOX 1022
Minneapolis
MN
55440-1022
US
|
Assignee: |
GATE GOURMET, INC.
Reston
VA
Marenic Food Service Consulting, Inc.
Coral Springs
FL
Thermal & Protective Packaging, Inc.
Caledon
|
Family ID: |
42116491 |
Appl. No.: |
12/260711 |
Filed: |
October 29, 2008 |
Current U.S.
Class: |
220/62.15 ;
206/503 |
Current CPC
Class: |
F25D 3/08 20130101; B65D
21/0223 20130101; A45C 11/20 20130101; B65D 81/382 20130101; Y02W
30/80 20150501; F25D 2331/804 20130101; F25D 2303/0831 20130101;
A01N 1/0263 20130101; Y02W 30/807 20150501; A45C 5/02 20130101;
F25D 2303/085 20130101 |
Class at
Publication: |
220/62.15 ;
206/503 |
International
Class: |
B65D 1/40 20060101
B65D001/40; B65D 21/02 20060101 B65D021/02 |
Claims
1. A reusable container for storing or transporting a product to be
refrigerated or frozen, comprising: an inner wall; an outer wall; a
wall space provided between said inner wall and said outer wall,
said space being substantially separated from the environment
outside of the reusable container; a slurry provided in the wall
space that is allowed to move freely within the wall space.
2. The container of claim 1, wherein the container is generally
rectangular, the inner wall is a first inner wall, and the outer
wall is a first outer wall, and the container further comprises:
second, third and fourth inner walls; second, third and fourth
outer walls; a bottom; and a top.
3. The container of claim 1, wherein the container is generally
cylindrical and further comprises a bottom and a top.
4. The container of claim 1, wherein the bottom comprises an inner
bottom wall and an outer bottom wall with a bottom space
therebetween, and the bottom space includes said slurry.
5. The container of claim 1, wherein the top comprises an inner top
wall and an outer top wall with a top space therebetween, and the
top space includes said slurry.
6. The container of claim 1, wherein at least one of the inner wall
and the outer wall is formed of steel.
7. The container of claim 1, wherein at least one of the inner wall
and the outer wall is formed of an insulating plastic material.
8. The container of claim 1, wherein the slurry comprises at least
one of a salt of 2-propenoic acid or a glycol material.
9. The container of claim 8, wherein the glycol material includes
polyethylene glycol or methoxypolyethylene glycol.
10. The container of claim 1, wherein the inner wall and the outer
wall are connected together such that the wall space is fully
contained.
11. The container of claim 1, wherein 50-99% of the wall space
comprises the slurry.
12. The container of claim 1, wherein 75-95% of the wall space
comprises the slurry.
13. The container of claim 1, wherein the container is
stackable.
14. The container of claim 13, wherein the container includes
protrusions on a top end of the container and corresponding
indentions on a bottom end of the container.
15. The container of claim 1, further comprising a hinged lid, said
lid including a lid space therein and comprising a slurry within
the lid space.
16. The container of claim 1, further comprising an assembly that
allows the container to be locked.
17. The container of claim 1, comprising a single chamber for
storing a product to be refrigerated within said inner wall.
18. The container of claim 1, comprising two chambers for storing
products within said inner wall and two lids, wherein each lid
corresponds to a particular chamber.
19. The container of claim 1, wherein the inner wall and the outer
wall have substantially the same thickness.
20. The container of claim 1, further comprising an secondary
insulating material that surrounds the container.
21. The container of claim 1, wherein a chamber defined by an
interior surface of the inner wall of the container is capable of
maintaining a refrigerating temperature of greater than 32 to
41.degree. F. for 8 or more hours in a room temperature
environment.
22. The container of claim 1, wherein a chamber defined by an
interior surface of the inner wall of the container is capable of
maintaining a freezing temperature of -10 to less than 32.degree.
F. for 8 or more hours in a room temperature environment.
23. The container of claim 1, wherein the product to be
refrigerated is a food product.
24. A method of shipping a product to be refrigerated or frozen in
a reusable container, comprising: refrigerating a reusable
container comprising an inner wall, an outer wall, a wall space
provided between said inner wall and said outer wall, said wall
space being substantially separated from the environment outside of
the reusable container, and a slurry provided in the wall space
wherein said slurry is allowed to move freely within the wall
space; inserting a product to be refrigerated or frozen in the
reusable container; and storing the product to be refrigerated or
frozen in the reusable container until the product can be used or
consumed.
25. The method of claim 24, wherein said storing step comprises
storing the product to be refrigerated in the reusable container in
a refrigerated environment for more than 8 hours.
26. The method of claim 24, wherein said storing step comprises
storing the product at a temperature of greater than 32 to
41.degree. F.
27. The method of claim 24, wherein said storing step comprises
storing the product at a temperature of -10 to less than 32.degree.
F.
28. The method of claim 24, wherein said refrigerating step
comprises refrigerating the container at a temperature of -30 to
41.degree. F.
29. A generally rectangular, reusable container for storing or
transporting a product to be refrigerated, comprising: first,
second, third and fourth inner walls; corresponding first, second,
third and fourth outer walls; a bottom; a top; one or more chambers
for storing a product to be refrigerated defined by said inner
walls, said bottom and said top; a wall space provided between at
least two of said inner walls and said corresponding outer walls,
said space being substantially separated from the environment
outside of the reusable container; and a slurry provided in the
wall space and allowed to move freely within the wall space.
30. A method of producing a reusable container for storing or
transporting a product to be refrigerated or frozen, comprises:
forming a container comprises a side inner wall, a side outer wall,
a side wall space provided between said inner wall and said outer
wall, a bottom inner wall, a bottom outer wall, a bottom wall space
provided between said bottom inner wall and said bottom outer wall,
and an aperture in communication with said bottom wall space,
wherein said bottom wall space is in fluid communication with said
side wall space; inverting the container; providing a slurry to
said aperture to allow the slurry to flow into the bottom wall
space and the side wall space such that the total bottom wall space
and the side wall space is at least 50% filled with said slurry;
and sealing said aperture.
Description
TECHNICAL FIELD
[0001] This disclosure relates to reusable containers for
refrigerating products such as food products.
BACKGROUND
[0002] The importance of keeping products refrigerated or frozen is
well understood. For example, food products must be refrigerated to
prevent spoilage or growth of undesirable organisms. Products such
as organs for transplant must be kept refrigerated so they can
maintain their viability for transplant. Some pharmaceutical
products must be kept refrigerated to maintain their efficacy.
Typically, these products are refrigerated at refrigerating
temperatures just above freezing, e.g., greater than 32.degree. F.
to 41.degree. F. (greater than 0.degree. C. to 5.degree. C.). In
addition, products such as food products may be stored and
transported frozen to maintain long term freshness, e.g., from
-10.degree. F. to less than 32.degree. F. (-23.degree. C. to less
than 0.degree. C.). There is a need for reusable containers that
not only keep products refrigerated or frozen but that are also
able to keep products refrigerated or frozen for 4 hours or
more.
SUMMARY
[0003] A reusable container for storing or transporting a product
to be refrigerated or frozen such as a food product is provided,
comprising an inner wall, an outer wall, and a wall space provided
between the inner wall and the outer wall that comprises a slurry.
The wall space is substantially separated from the environment
outside of the reusable container. For example, the inner wall and
the outer wall can be connected together such that the wall space
is fully contained. In some embodiments, the slurry is loose within
the wall space and allowed to move freely within the wall space. In
some embodiments, 50-99% or 75-95% of the wall space comprises the
slurry. The slurry can include, for example, a salt of 2-propenoic
acid and/or a glycol material.
[0004] In some embodiments, the container is generally rectangular,
the inner wall is a first inner wall and the outer wall is a first
outer wall; and the container further comprises second, third and
fourth inner walls and second, third and fourth outer walls; a
bottom; and a top. In some embodiments, the container is generally
cylindrical and further comprises a bottom and a top. In some
embodiments, the container can include a bottom and the bottom can
include an inner bottom wall and an outer bottom wall with a bottom
space therebetween, wherein the bottom space includes the slurry.
In some embodiments, the container can include a top and the top
can include an inner top wall and an outer top wall with a top
space therebetween, wherein the top space includes the slurry. In
some embodiments, at least one of the inner wall and the outer wall
is formed from steel or an insulating plastic material.
[0005] In some embodiments, the container is stackable. For
example, the container can include protrusions on a top end of the
container and corresponding indentions on a bottom end of the
container. The container can, in some embodiments, include a hinged
lid, the lid including a lid space therein and comprising a slurry
within the lid space. In some embodiments, a chamber is formed by
the interior surface of the inner wall and an interior surface of a
bottom. In some embodiments, the container includes an assembly
that allows the container to be locked. In some embodiments, the
container can include a single chamber for storing products to be
refrigerated within said inner wall. In some embodiments, the
container can include two chambers for storing products within said
inner wall and two lids, wherein each lid corresponds to a
particular chamber. The container can include a chamber defined by
an interior surface of the inner wall of the container that is
capable of maintaining a refrigerating temperature of greater than
32 to 41.degree. F. for 4 or more, or even 8 or more hours in a
room temperature environment. Alternatively, the chamber is capable
of maintaining a freezing temperature of -10 to less than
32.degree. F. for 4 or more, or even 8 or more hours in a room
temperature environment. In some embodiments, the inner wall and
the outer wall have substantially the same thickness. A secondary
insulating material such as a secondary container can be used to
surround the reusable container.
[0006] A method of shipping a product to be refrigerated in a
reusable container is also provided. The method comprises
refrigerating a reusable container comprising an inner wall, an
outer wall, a wall space provided between the inner wall and the
outer wall, the wall space being substantially separated from the
environment outside of the reusable container, and a slurry
provided in the wall space. A product to be refrigerated can be
inserted into the reusable container and then stored in the
reusable container until it can be used or consumed. In some
embodiments, the product to be refrigerated in the reusable
container can be stored at a refrigerating temperature (e.g. at a
temperature of greater than 32 to 41.degree. F.) or a freezing
temperature (e.g. at a temperature of -10 to less than 32.degree.
F.) for 4 or more or 8 or more hours.
[0007] A method of producing a reusable container for storing or
transporting a product to be refrigerated or frozen is also
provided. The method comprises first forming a container comprises
a side inner wall, a side outer wall, a side wall space provided
between the inner wall and the outer wall, a bottom inner wall, a
bottom outer wall, a bottom wall space provided between the bottom
inner wall and the bottom outer wall, and an aperture in
communication with the bottom wall space, wherein the bottom wall
space is in fluid communication with the side wall space. The
container can then be inverted and a slurry provided through the
aperture to allow the slurry to flow into the bottom wall space and
the side wall space such that the total bottom wall space and the
side wall space is at least 50% filled with the slurry. The
aperture can then be sealed such as through sonic welding to
prevent the slurry from leaking out of the container.
[0008] The details of one or more embodiments are set forth in the
accompanying drawings and the description below. Other features,
objects, and advantages will be apparent from the description and
drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a reusable container that is
generally rectangular.
[0010] FIG. 2 is a view drawn along line 2-2 of FIG. 1 that
illustrates a wall space between inner and outer walls.
[0011] FIG. 3 is a perspective view of a reusable container that is
generally rectangular and includes a lid or top portion.
[0012] FIG. 4 is a perspective view of the reusable container of
FIG. 3 with a portion cutaway.
[0013] FIG. 5 is a perspective view of only the lid or top portion
of a reusable container.
[0014] FIG. 6 is a perspective view of only the lid or top portion
of a reusable container further illustrating a plug.
[0015] FIG. 7 is a perspective view of a bottom portion of a
reusable container further illustrating a plug.
[0016] FIG. 8 is an alternative perspective view of the reusable
container of FIG. 7.
[0017] FIG. 9 is a front view of a reusable container that is
generally cylindrical.
[0018] FIG. 10 is a front view of the reusable container of FIG. 9
with portions cut away and the lid opened.
[0019] FIG. 11 is a side view of two generally rectangular
containers stacked upon each other.
[0020] FIG. 12 is a side partial cutout view of the containers in
FIG. 11 stacked upon each other.
[0021] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0022] The term "comprising" and variations thereof as used herein
are used synonymously with the term "including" and variations
thereof and are open, non-limiting terms.
[0023] A reusable container for storing or transporting a product
to be refrigerated or frozen is provided. Any product to be
refrigerated or frozen can be used with the reusable container. For
example, a food product or a beverage can be provided in the
container. Alternatively, a pharmaceutical product, a
transplantable organ, or other products to be refrigerated or
frozen can be stored and transported in the container.
[0024] The reusable container comprises an inner wall, an outer
wall, a wall space provided between the inner wall and the outer
wall, the space being substantially separated from the environment
outside of the reusable container, and a slurry provided in the
wall space. In some embodiments such as the embodiment in FIG. 1,
the reusable container 10 can be generally rectangular in shape and
can include rounded corners. The reusable container in FIG. 1
includes inner walls 12, 22, 32 and 42 and corresponding outer
walls 14, 24, 34, and 44, respectively. The inner walls 12, 22, 32
and 42 and respective outer walls 14, 24, 34 and 44 can include a
wall space therebetween. For example, as shown in FIG. 2, the inner
wall 12 and outer wall 14 can include a wall space 16 and the wall
space can further include a slurry 18. Although not shown in FIG.
1, wall spaces can also exist between inner wall 22 and outer wall
24, inner wall 32 and outer wall 34, and/or inner wall 42 and outer
wall 44, and can further include the slurry. For example, FIG. 4
illustrates a wall space 26 in phantom between inner wall 22 and
outer wall 24, a wall space 36 between inner wall 32 and outer wall
34 and a wall space 46 between inner wall 42 and outer wall 44. In
some embodiments, at least two, at least three, or all four of the
respective inner and outer walls include a wall space and can
further include a slurry in the wall space.
[0025] The wall space 16 is substantially separated from the
environment outside of the reusable container 10. For example, the
wall space 16 can be separated from the outside environment during
normal use so the slurry 18 is not exposed to the environment as it
could affect the performance of the slurry. However, the wall space
16 may be accessible to the outside environment if the slurry 18 in
the wall space 16 needs to be replaced or replenished. In some
embodiments, the wall space 16 can be separated from the outside
environment and can be fully contained by connecting the inner wall
12 and outer wall 14 together, for example, at locations 50 and 52
shown in FIG. 2.
[0026] In some embodiments, the reusable container 10 includes a
top portion. For example, as shown in FIG. 3, the top portion 58
can include two lids 60 and 62. The lid (e.g. lid 60) can include
an inner lid wall or inner top wall 64 and an outer lid wall or
outer top wall 66 with a inner lid space or inner top space 68
between the inner lid wall 64 and the outer lid wall 66 as shown in
FIG. 4. The inner top space 68 can further include a slurry.
Although not shown in FIG. 3 or 4, the lid 62 can have the same
configuration as the lid 60. Furthermore, although the top portion
58 of the reusable container in FIG. 3 includes two lids 60 and 62,
one lid can alternatively be used or more than two lids can be
used. In some embodiments, the lids 60 and 62 have the ability to
be locked to the container 10 using holes 70 and 72 and by using a
lock or a metal or plastic security seal (not shown). This allows
the reusable container 10 to be tamper proof
[0027] FIGS. 5 and 6 further illustrate the lids 60 and 62. As
shown these figures, the lids 60 and 62 can be hinged and rotate
along axis 74. The lids 60 and 62 can also include a plug 76 that
substantially separates the lid space 68 from the environment
outside of the reusable container. This plug 76 is provided at a
location where a hole is provided in the lid 60 so the slurry can
be provided in the lid space 68. Once the slurry is provided, the
plug 76 can be sonic welded so the slurry is contained within the
lid space 68. This prevents leakage of the slurry outside of the
lid space 68.
[0028] As shown in FIGS. 3 and 4, the reusable container 10 can
further include a bottom portion 80 such as bottom 82. The bottom
82 can include a bottom inner wall 84 and a bottom outer wall 86. A
bottom space 88 can be provided between the bottom inner wall 84
and the bottom outer wall 86, and can further include a slurry.
FIG. 7 provides an additional view of the reusable container 10
that illustrates the bottom portion 80 and bottom 82. As shown in
FIG. 7, the bottom 82 can include a plug 90 that provides a hole 92
where the slurry can be provided to the bottom space 88 and the
wall spaces (16, 26, 36 and 46), which can communicate with the
bottom space 88. The container 10 can be inverted, the slurry
provided through the hole 92 and then the plug 90 can be sonic
welded to contain the slurry within the bottom space 88 and the
wall spaces (16, 26, 36 and 46) to prevent leakage of the slurry
and to separate the bottom space 88 and the wall spaces (16, 26, 36
and 46) from the outside environment. A drainage hole (not shown)
can optionally also be included to facilitate cleaning or to
otherwise remove liquids from the container 10 by providing access
to the outside environment.
[0029] As shown in the figures, a chamber 100 is defined by the
respective interior surfaces of the inner walls 12, 22, 32, and 42,
the interior surface of the top 58 and the interior surface of the
bottom 82. As shown in FIG. 8, the bottom of the chamber 100 (or
the inner bottom wall 84) can be sloped along directions 94 to
allow liquids to collect in one location in the container 10,
particularly when a drainage hole is used. Alternatively, the
bottom of the chamber 100 can be substantially flat. Although the
container 10 is drawn with a single chamber, multiple chambers can
be included. For example, a chamber could correspond to each of the
lids 60 and 62 and an additional interior wall (not shown) provided
to separate the chambers. The interior wall could further include a
space and a slurry in some embodiments. Although not shown, the
container can also include one or more integral handles to
facilitate transportation of the container.
[0030] The inner walls 12, 22, 32 and 42 and the outer walls 14,
24, 34 and 44 can have thicknesses of between about 1/4 and about
3/4 inch (e.g. 1/2 inch). In some embodiments, the inner walls 12,
22, 32 and 42 all have approximately the same thickness (e.g.
within about 10%) and the outer walls 14, 24, 34 and 44 all have
approximately the same thickness. In some embodiments, the inner
walls 12, 22, 32 and 42 and the outer walls 14, 24, 34 and 44 all
have approximately the same thickness. The wall spaces 16, 26, 36
and 46 can have widths of about 1/2 and about 11/4 inches (e.g. 7/8
inch). The lid inner wall 64 and the lid outer wall 66 can have
thicknesses of about 1/4 and about 3/4 inch (e.g. 1/2 inch) with
the space 68 therebetween having a width of about 1/2 and about
11/4 inches (e.g. 7/8 inch). The bottom inner wall 84 and the
bottom outer wall 86 can have thicknesses of about 1/4 and about
3/4 inch (e.g. 1/2 inch) and the bottom wall space 88 can have a
width of about 1/2 and about 11/4 inches (e.g. 7/8 inch).
[0031] In some embodiments such as the embodiment in FIGS. 9 and
10, the container 110 can be generally cylindrical. The cylindrical
container can include an inner wall 112 and an outer wall 114, with
a wall space 116 therebetween. The wall space 116 can include a
slurry 118. As with the embodiments illustrated in FIGS. 1-8, the
wall space 116 can be substantially separated from the environment
outside of the reusable container 110. The container 110 further
includes a top portion 120 such as top 121 and a bottom portion 122
such as bottom 123. The top 121 can include a lid 124 and the lid
can be hinged. The lid can include an outer lid wall 126 and an
inner lid wall 128 and a space 130 therebetween that can further
include a slurry. A chamber 132 can be formed by the interior
surface of the inner wall 112, the interior surface of the top 121
and the interior surface of the bottom 123 for the product to be
refrigerated. The bottom 123 can include a bottom inner wall 136, a
bottom outer wall 138, and a bottom space 140 therebetween that can
further include a slurry. Although not shown in FIGS. 9 and 10, a
hole can be provided in the bottom outer wall 138 to access the
bottom space 140 and the wall space 116 and the container 110
inverted and the slurry fed through the hole. The hole can then be
sealed as described herein. A hole can also be provided in the lid
inner wall 128 that accesses the lid space 130 for providing the
slurry and the hole can be sealed as described herein. The
thicknesses of the walls and the widths of the spaces between the
walls can be in the same ranges described for the generally
rectangular container 10. Although the container is illustrated in
the figures to be either generally rectangular or generally
cylindrical, it can be provided with different shapes if
desired.
[0032] In some embodiments such as the embodiment illustrated in
FIGS. 11 and 12, the reusable container can be stackable. FIGS. 11
and 12 illustrate two containers 150 and 152 stacked upon one
another. The reusable containers 150 and 152 can include any
features that allow the containers to be stacked. For example, as
illustrated by top container 150 in FIGS. 11 and 12, a top end 154
of the container 150 can include protrusions 156 and 158. The top
container 150 can also include indentions 160 and 162 on a bottom
end 164 of the container. The bottom container 152 can include
protrusions 166 and 168 at the top end 170 that correspond to the
indentions 160 and 162 of the top container 150.
[0033] The reusable container 10 can be formed of any suitable
material. Exemplary materials include steel and insulating plastic
material and the entire container can be made of the same material
or different materials can be used for different portions of the
container. In some embodiments, all or a portion of the container
can be formed of a polycarbonate, a polyethylene polymer or
copolymer, or a hexene copolymer material. An exemplary hexene
copolymer is a linear low density hexene copolymer sold by
ExxonMobil as a LL 8555 series LLDPE. The insulating plastic
material can be formed of a food grade chemical and can have
inherent fire retardance or UV stability or can further include
additives such as a fire retardants, mold inhibitors and UV
stabilizers. The plastic material can also include a filler
material such as fibers or filler particles. In some embodiments,
the use of an insulating plastic material results in a container
that is dishwasher safe and/or that has low warpage. In some
embodiments, the material used for the container can have a shelf
life of 5 or more years and can be suitable for approval by the
National Sanitation Foundation (NSF).
[0034] As discussed above, a slurry can be provided in a wall space
(e.g. slurry 18 in wall space 16). The slurry can include a polymer
latex and/or a glycol material. For example, a latex such as
LUQUASORB FP 800 latex (BASF Corporation) comprising a 2-propenoic
acid homopolymer, sodium salt (93.6%), water (5%) and propylene
glycol (1%) can be used as the latex material in the slurry. An
exemplary glycol material includes a CARBOWAX polyethylene glycol
or methoxypolyethylene glycol material (Dow/Union Carbide). Other
glycols can also be used including ethylene glycol, diethylene
glycol, propylene glycol, and polymers or copolymers of these
glycols, and the like. In some embodiments, the slurry can be
modified by adding liquid nitrogen to the above components. For
example, the liquid nitrogen can be injected into the slurry
composition, e.g., in an amount of 1-10%, 2-8% or 5% by weight of
the slurry composition. Once provided in the composition to form
the slurry, the liquid nitrogen can become a dissolved gas within
the slurry. The chemicals used in the slurry can be food grade
chemicals such as the LUQUASORB FP 800 latex discussed above so
possible leakage of the slurry does not cause health issues. The
chemicals used in the slurry can also, in some embodiments, also
provide fire retardance to the container. In some embodiments, the
slurry can be provided in more concentrated form to increase the
ability of the slurry to maintain the refrigerating or freezing
temperature.
[0035] In some embodiments, the slurry is allowed to move freely
within the wall space (and also the top space and bottom space
where included in the container). For example, the slurry can be
provided loose within the wall space and contained only by the
inner and outer walls. Thus, the slurry is not confined by other
means such as by being provided in a gel pack. The slurry can
occupy 50-99%, 75-95% or 80-90% of the total space (i.e., the total
wall space, top space and bottom space). The amount of slurry used
can depend on the level of refrigeration desired for the container
(e.g. refrigerating temperatures or freezing temperatures) and the
products to be provided therein. In some embodiments, the chamber
100 is capable of maintaining a refrigerating temperature of
greater than 32 to 41.degree. F. for 2 or more, 4 or more, 6 or
more, 8 or more, or even 10 or more or 12 or more hours in a room
temperature environment (outside of the container). In some
embodiments, the chamber 100 is capable of maintaining a freezing
temperature of -10 to less than 32.degree. F. for 2 or more, 4 or
more, 6 or more, 8 or more, or even 10 or more or 12 or more hours
in a room temperature environment. In some embodiments, the
temperature in the container increases less than 0.5.degree., less
than 0.75.degree., or less than 1.degree. F. per hour. In some
embodiments, the container can include a temperature gauge to
provide the temperature of the chamber 100. Although not shown, a
cooling blanket can further be used within the container to further
increase the refrigeration of the container.
[0036] In some embodiments, a secondary insulating material (not
shown) can surround the container to further increase the ability
of the container to maintain refrigerating temperatures for longer
periods of time and can limit condensation on the exterior of the
container. The secondary insulating material can, for example, be
in the form of a secondary container such as a MYLAR bag, cardboard
or an insulated, optionally foamed, plastic container that
surrounds the reusable container. For example, ROXUL mineral wool
insulation available from Roxul, Inc., which comprises 94-99%
mineral fiber bound using a cured urea extended phenolic
formaldehyde binder (1-6%) can be used as the secondary insulating
material. The mineral wool insulation can be provided as an
insulated blanket that is customized to cover all the side of the
container 10 and then the covered container can be placed in
corrugated cardboard case for storage or transport. Although able
to maintain a refrigerating or freezing temperature, the reusable
container can, in some embodiments, still be heated to temperatures
exceeding 100.degree. F. without damage to the container or
slurry.
[0037] The reusable container can be produced by various methods.
In some embodiments, particularly where a plastic material is used
to form the container, the container can be formed in a mold such
as a rotational mold (rotomold) by providing the plastic material
as a powder, heating the powder to allow it to flow within the
mold, and casting the mold. Holes provided in the container to
provide the slurry composition can be sealed using a sonic spin
weld.
[0038] A method of shipping a product to be refrigerated in a
reusable container is also provided. The method comprises
refrigerating a reusable container as described above. For example,
the reusable container can be provided in a standing refrigerator
or freezer to provide the desired initial temperature. In some
embodiments, the container can be refrigerated at a temperature of
-30 to 41.degree. F., with temperatures greater than 32.degree. F.
typically used for products to be stored at refrigerating
temperatures and less than 32.degree. F. used for products to be
stored at freezing temperatures. A product to be refrigerated or
frozen can be inserted in the reusable container and then stored in
the reusable container until it can be used or consumed. As
mentioned above, the product can be kept in the container in a
refrigerating or freezing environment for the periods of time
discussed above.
[0039] Depending on the particular level of refrigeration desired
for the reusable container, certain parameters in the container can
be modified. For example, the number of wall, top or bottom spaces
and how many of these spaces include slurry can affect the level of
refrigeration for the container (at a refrigerating or freezing
temperature). The percentage of the total space occupied by the
slurry can also affect the level of refrigeration. The container
materials selected, the inner wall thicknesses, the outer wall
thicknesses, the wall space widths, the slurry composition and the
slurry viscosity can all be selected or modified to provide a
particular level of refrigeration. For example, the wall
thicknesses and/or the space widths can be increased to increase
the ability of the container chamber to maintain the desired
temperature.
[0040] A number of embodiments have been described. Nevertheless,
it will be understood to one skilled in the art that various
modifications may be made. Further, while only certain
representative combinations of the formulations, methods, or
products are disclosed herein are specifically described, other
combinations of the method steps or combinations of elements of a
composition or product are intended to fall within the scope of the
appended claims. Thus a combination of steps, elements, or
components may be explicitly mentioned herein; however, all other
combinations of steps, elements, and components are included, even
though not explicitly stated.
* * * * *