U.S. patent application number 13/111129 was filed with the patent office on 2011-11-24 for insulated shipping container.
This patent application is currently assigned to PLYMOUTH FOAM, INC.. Invention is credited to Randon M. Armstrong, Jeffrey D. Pahl, George M. Palmer, David P. Waite.
Application Number | 20110284556 13/111129 |
Document ID | / |
Family ID | 44971639 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110284556 |
Kind Code |
A1 |
Palmer; George M. ; et
al. |
November 24, 2011 |
Insulated Shipping Container
Abstract
An insulating container is disclosed. The insulating shipping
container includes an outer container and pieces of laminated foam,
which are cut or scored to create hinges that permit the laminated
foam pieces to be configured into an insulating enclosure.
Alternatively, the laminated foam pieces may be formed without
hinges and friction fit into the outer container.
Inventors: |
Palmer; George M.; (Kohler,
WI) ; Armstrong; Randon M.; (Massillon, OH) ;
Pahl; Jeffrey D.; (Newton, WI) ; Waite; David P.;
(Grafton, WI) |
Assignee: |
PLYMOUTH FOAM, INC.
Plymouth
WI
|
Family ID: |
44971639 |
Appl. No.: |
13/111129 |
Filed: |
May 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61346231 |
May 19, 2010 |
|
|
|
Current U.S.
Class: |
220/592.25 ;
53/410 |
Current CPC
Class: |
B65D 81/3862
20130101 |
Class at
Publication: |
220/592.25 ;
53/410 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65B 17/00 20060101 B65B017/00; B65D 25/02 20060101
B65D025/02 |
Claims
1. An insulated container comprising: an outer container; and a
plurality of laminated foam pieces, the laminated foam pieces each
having a foam core with a first laminated face covering a side
thereof; the laminated foam pieces having at least one hinge
created by a score in the foam core that does not extend through
the first laminated face; and wherein the laminated foam pieces are
folded at the at least one hinge so as to create an insulating
enclosure, the insulating enclosure positioned within the outer
container.
2. The insulated container of claim 1 further comprising a second
laminated face covering a side of the foam core opposite of that
covered by the first laminated face.
3. The insulated container of claim 1 wherein the foam core is a
graphite impregnated expanded polystyrene.
4. The insulated container of claim 2 wherein the first laminated
face and the second laminated face are made from different
materials.
5. The insulated container of claim 4 wherein the first laminated
face is made from a material with a melting point higher than that
of the second laminated face.
6. The insulated container of claim 4 wherein the first laminated
face is made from polypropylene and the second laminated face is
made from polyester.
7. A method of assembling an insulated container comprising the
steps: selecting an outer container; selecting a first laminated
foam piece and a second laminated foam piece; folding the first
laminated foam piece along a hinge; placing the partially folded
first laminated foam piece into the outer container; folding the
second laminated foam piece along two hinges; placing the folded
second laminated foam piece into the outer container; and folding
the first laminated foam piece along a hinge.
8. A method of manufacturing an insulating enclosure comprising the
steps: preparing a foam core by shaping it to a desired thickness;
joining two laminate facers to the outer panels of the foam core to
form laminated foam pieces, wherein each of the laminate facers are
comprised of different materials; stacking the laminated foam
pieces so that the laminate facers are not touching the same type
of laminate facer material; cutting the laminated foam pieces to
the desired length and width; and cutting hinges into the laminated
foam pieces at appropriate locations in order for the laminated
foam pieces to be configured into an insulating enclosure wherein
edges of the foam core adjacent to the hinge are flush with the
surface of the outer container.
Description
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
[0001] This application is based on and claims priority to U.S.
Provisional Application No. 61/346,231 filed on May 19, 2010, which
is incorporated herein in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
insulated shipping containers.
BACKGROUND
[0003] The prior art contains numerous examples of coolers and
shipping containers with a variety of configurations. Nevertheless,
a need exists for a shipping container that has improved thermal
properties and that is efficient to manufacture.
[0004] Both expanded polystyrene foam ("EPS") and extruded
polystyrene foam ("XPS") are known for their thermal insulating
properties and are widely used as insulating materials. It is also
known that combining or impregnating foam polymers with other
materials can improve the thermal properties of foam. For example,
impregnating styrene polymers with graphite is now known to enhance
the insulating properties of foam. See, e.g., U.S. Pat. Nos.
6,130,265; 6,340,713; 6,384,094; 6,414,041, 5,977,197, 5,582,781,
and U.S. Publication No. 2006/0189703 which are incorporated herein
by reference for all purposes. An example of one commercially
available graphite impregnated foam is NEOPOR.RTM. by the chemical
company, BASF. NEOPOR is a graphite impregnated expanded
polystyrene foam. The graphite flakes in NEOPOR foam reflect heat
radiation, and therefore improve the thermal insulation properties
of the foam. Graphite impregnated foam has greater thermal
insulating ability than regular foam and helps to keep frozen items
frozen during shipping or to keep warm items warm. The ability to
maintain the temperature of the contents of the container without
the use of ice or other agents is advantageous because such
containers are lighter weight, and cost less to ship.
[0005] It is also known in the prior art to use foam panels or foam
as the insulation material for shipping containers. See, e.g., U.S.
Pat. Nos. 3,890,762; 4,497,859; 4,682,708; 6,325,281. Some of these
prior designs use mitred, hinged, or scored panels as an insulation
material. See, e.g., U.S. Pat. Nos. 5,441,170, and 3,980,005. It is
also known in the prior art to use U-shaped padding or insulation
panels. See, e.g., U.S. Pat. Nos. 4,033,806; 4,928,847; 5,111,957;
and 5,201,868. However, these hinge and panel shape designs are
generally complicated and inefficient to manufacture, or time
consuming to disassemble and assemble. The existing shipping
containers and insulating methods, therefore, have significant
shortcomings, and there is a need for a shipping container that has
improved thermal properties, which is simple to assemble or
disassemble, is reusable, and is efficient to manufacture.
[0006] It will be understood by those skilled in the art that one
or more aspects of this invention can meet certain objectives,
while one or more other aspects can lead to certain other
objectives. Other objects, features, benefits and advantages of the
present invention will be apparent in this summary and descriptions
of the disclosed embodiment, and will be readily apparent to those
skilled in the art. Such objects, features, benefits and advantages
will be apparent from the above as taken in conjunction with the
accompanying figures and all reasonable inferences to be drawn
therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of the outer container and the
two laminated foam pieces of one embodiment of an insulated
container in accordance with the present invention.
[0008] FIG. 2 is a perspective view showing the inner surfaces of
the two laminated foam pieces of the container shown in FIG. 1.
[0009] FIG. 3 is a perspective view of the two laminated foam
pieces of the container shown in FIG. 1, showing the hinges of the
laminated foam pieces.
[0010] FIG. 4 is a perspective view of one of the laminated foam
pieces from the container shown in FIG. 1, showing the piece in a
folded position.
[0011] FIG. 5 is a perspective view of the laminated foam piece
shown in FIG. 4, with the ends of the outer panels flush with the
surface on which the piece is resting so as to complete the
corner.
[0012] FIG. 6 is a perspective view of one of the laminated foam
piece shown in FIGS. 4 and 5, in the outer container.
[0013] FIG. 7 is a perspective view of the two laminated foam
pieces of the container shown in FIG. 1, demonstrating how the two
pieces can be positioned to provide an insulating enclosure within
the outer container.
[0014] FIG. 8 is a perspective view of the two laminated foam
pieces of the container shown in FIG. 1, showing how the two
laminated pieces provide the insulating enclosure when the pieces
are in the outer container.
[0015] FIG. 9 is a perspective view of the top of a laminated foam
piece inside the container shown in FIG. 1, shown positioned to
provide an insulating enclosure with a lid, and positioned inside
the outer container.
[0016] FIG. 10 is a flow chart drawing showing one way to fold the
laminated foam pieces to assemble the container shown in FIG.
1.
[0017] FIGS. 11a and 11b are perspective views of an alternative
assembly configuration for the two laminated foam pieces of the
container shown in FIG. 1.
[0018] FIGS. 12a and 12b are perspective views of an alternative
embodiment of laminated pieces cut to fit within an outer container
(not shown).
DETAILED DESCRIPTION
[0019] In one embodiment of the invention, shown in FIGS. 1-9, an
insulated shipping container comprises an outer container 1, and
two laminated foam pieces 2, 3. The laminated foam pieces are
scored to provide hinges 4 that enable the laminated foam pieces 2,
3 to be configured into an insulating enclosure 5. In one
embodiment of the invention, the insulating enclosure 5 is a square
or rectangular shape. Thus, one of the laminated foam pieces 2 has
a slightly smaller dimension than the other laminated foam piece 3,
so that the two can be configured into the cuboid insulating
enclosure, as shown in FIGS. 7 and 8. Although the embodiment shown
in FIGS. 1-9 employs two laminated foam pieces and a box for an
outer container, it is understood that other numbers of laminated
foam pieces may also be used (for example, the alternative
embodiment shown in FIGS. 12a and 12b, as well as other shapes of
outer containers.
[0020] The outer container 1 can be any type of container, such as
a box, bag, compartment, or any other item or enclosure that can
contain matter. As best seen in FIGS. 4 and 5, the laminated foam
pieces 2, 3 comprise a foam core 6 at least partially disposed
between laminate facers 7. The foam core 6 may be manufactured from
any suitable variety of expanded polystyrene ("EPS"), which may be
modified, unmodified, colored, or impregnated with other materials
such as graphite (e.g., NEOPOR), and of any density; extruded
polystyrene ("XPS") of any density, compressive strength, or color;
Urethane (polyisocyanurate); or any other suitable foam material.
The laminate facers 7 may be manufactured from polypropylene PP,
polyethylene PE, polyethylene terephthalate PET (polyester), high
density polyethylene HDPE, linear low density polyethylene LLDPE,
or polyamide (nylon), or materials such as aluminum foil with a
paper or polymer backing, or any other suitable laminate material.
Different or the same materials can be used on opposite sides of
foam core 6. Further, any polymer used as a material for laminate
facers 7 may be in any of the following forms: extruded, blown,
oriented, non-oriented, metalized, plain, printed, woven,
non-woven, as part of a structured film, or used alone. The
aforesaid laminated foam pieces 2, 3 can be manufactured by a
variety of processes, including, but not limited to: heat
lamination, hot melt lamination, or cold glue lamination (using
urethane, latex, or other glue).
[0021] In accordance with one embodiment of the invention, the
laminated foam pieces are prepared as follows. The desired
thickness of the foam core 6 is selected, and the foam core sized
or cut to the desired size. The laminate facers 7 are joined to the
foam core 6, so that the foam core is at least partially disposed
between laminate facers 7. The inner surface 8 and outer surface 9
of the foam core 6 can be joined to the laminate facers 7 using any
suitable method, including, but not limited to heat-laminating,
cold glue, etc.). In a preferred embodiment of the invention, the
foam core 6 is essentially a sheet of foam, which is at least
partially laminated on the inner and outer surfaces, namely the
broad surfaces, of the sheet. Additionally, the laminate facers 7
on the two sides of a foam core are preferably different materials,
having different melting points. The reason for this is to avoid
having the parts stick together when they are cut or scored to
create hinges. For example, one panel may be laminated with
polypropylene and the other panel may be laminated with polyester.
It would also be possible to only provide lamination on one side of
the panel (the hinged side) but the panel would then have
diminished insulative characteristics.
[0022] Then an operation is performed to cut the laminated foam
into laminated foam pieces having the desired length and width,
which is selected based on the size of the outer container. For
efficiencies in manufacturing and cutting, the laminated foam may
be stacked so that the panel surfaces are face-to-face, but the
surfaces that are touching are not the same laminate material. If
hot wires or other heated devices are used to cut the laminated
foam to the desired length and width, the cut edges of laminate
facers will not become melted together during cutting if the
adjacent laminate facers are not the same material. Of course, if
hot wires or other heated devices are not used to cut the laminated
foam to length and width, the laminate facer materials on each side
of the laminated foam can be the same.
[0023] Once the laminated foam pieces 2, 3, are prepared, they are
then cut or scored to create hinges 4. The hinge positions are
established to make the cut pieces fit properly into the designated
outer container, which is integral to making the insulated shipping
container function as intended. The hinges 4 are cut or scored into
the laminate foam pieces 2, 3 at the appropriate locations using a
slitter blade or hot wire apparatus. In cutting the hinges, it is
imperative that one of the laminate facers remain intact (uncut).
Once hinges are cut, the hinges define subsections of the foam
core. In one embodiment of the invention (see FIGS. 3-5), each
laminated foam piece has three subsections, namely one central
subsection 10, and two outer subsections 11, 12. These subsections
are free to be moved and positioned into an insulating enclosure,
and are held together by the intact laminate facer, which also
functions as a hinge. A variety of methods may be employed in order
to score or cut the laminate facers and foam core to create the
hinges, including, but not limited to: a slitter blade (round,
straight, smooth, toothed,) or a hot wire cut, or any other
suitable way of cutting laminate and foam materials.
[0024] The laminated foam pieces 2, 3 are then prepared into the
desired configuration and packed into the outer containers. There
are multiple simple ways to assemble the laminated foam pieces into
the insulating enclosure. One way is shown in FIGS. 6-10 and
another is shown in FIGS. 11a and 11b. There are, of course, many
other variations of using laminated foam pieces to create an
insulating enclosure, including varying the number of laminated
pieces, the number of hinges, and/or the configuration of the
insulating enclosure.
[0025] FIGS. 3-5, and 10 best illustrate the function of the
hinges. The hinges 4 allow the subsections of the laminated foam
pieces 2, 3 to be positioned so that the edges of the insulating
enclosure 5 are flush with the surfaces of the outer container 1.
FIG. 4 shows laminated foam piece 3 with the outer subsections 11,
12 bent at the hinges 4 (laminated foam piece 2 bends in a similar
manner). FIG. 5 shows laminated foam piece 3 with the outer
subsections 11, 12 bent at the hinges 4 and positioned flush with
the adjacent surface. The same function allows the laminated foam
pieces 2, 3 to be positioned to provide a complete thickness of
insulation at the corner, and can include a complete barrier in the
uncut laminate facer.
[0026] As shown in FIGS. 6-9, and 10, two laminated foam pieces 2,
3 are used to form an insulating enclosure 5. Each laminated foam
piece is scored to have two hinges 4, which define three
subsections of the laminated foam piece 10, 11, 12. One of the
laminated foam pieces 3 (the larger one) is placed into the outer
container 1, for example, a box, so that one of the outer
subsections 12 of the laminated foam piece is flush with the bottom
of the box. See FIG. 6. Central subsection 10 is also pushed down
so that edge of subsection 10 is flush with the bottom of the box.
Laminated foam piece 2 (the smaller one) is then bent at the hinges
to form a C-shape or U-shape and inserted into the outer container
1 so that the two laminated foam pieces 2, 3 form an insulating
enclosure 5. See FIG. 7. The hinges of laminated foam piece 2
function in the same way as those in laminated foam piece 3, and as
shown in FIGS. 4 and 5. In this configuration, subsection 11 of the
laminated foam piece 2 then is capable of functioning as a lid. The
laminated foam pieces may be assembled inside of the outer
container, as just described, or may be assembled outside of the
outer container and inserted into the outer container. Laminated
foam pieces may also be assembled into different configurations, or
in a different order, such as inserting one of the laminated foam
pieces in a U-shape into the bottom of the box, and another
laminated foam piece over it, as shown in FIGS. 11a and 11b.
Materials may be inserted easily into the insulated enclosure for
storing or shipping. The laminated foam pieces and outer container
are also easily reusable.
[0027] As best seen in FIG. 5, the corners that are created by the
present configuration provide a significant advantage over the
known prior art corner configurations in that they are easily
manufactured and then formed in place, provide a complete thickness
of insulation at the corner, and can include a complete barrier in
the uncut laminate facer.
[0028] One additional embodiment of the invention is show in FIGS.
12a and 12b. In this embodiment, laminated foam pieces are cut to
dimensions such that they can snugly fit together in a friction fit
when placed in an outside container. In this embodiment, the
benefits of the additional insulating effects of the laminated foam
are realized but the corners are not sealed to provide the complete
barrier shown in FIG. 5. This embodiment exhibits significantly
improved insulating effects as compared to using conventional foam
insulation.
[0029] The present invention may be used in a variety of
applications. For example, it may be used as a shipping container
to keep its contents hot or cold during shipping or transport.
Contents may include food, beverages, biological materials,
medicines, or chemicals. The thermal properties of the insulation
used will of course depend on the thermal properties of the foam
core and laminate materials. However, the use of a foam core
comprised of graphite impregnated EPS should be sufficient to keep
food or biological products cold, frozen or warm during typical
transport. The shipping container may also be used for storage, and
the insulation used for packing or protection. The laminated foam
pieces may also have other insulating uses in shipping or packing
applications.
[0030] Although the invention has been herein described in what is
perceived to be the most practical and preferred embodiments, it is
to be understood that the invention is not intended to be limited
to the specific embodiments set forth above. Rather, it is
recognized that modifications may be made by one of skill in the
art of the invention without departing from the spirit or intent of
the invention and, therefore, the invention is to be taken as
including all reasonable equivalents to the subject matter of the
appended claims and the description of the invention herein.
* * * * *