U.S. patent application number 13/633543 was filed with the patent office on 2013-02-07 for cold chain packaging.
This patent application is currently assigned to MONTEREY BAY ASSOCIATES. The applicant listed for this patent is Monterey Bay Associates. Invention is credited to David Roberts.
Application Number | 20130031874 13/633543 |
Document ID | / |
Family ID | 41567720 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130031874 |
Kind Code |
A1 |
Roberts; David |
February 7, 2013 |
COLD CHAIN PACKAGING
Abstract
A method of making a cold chain package, includes, providing
corresponding rolls of dissimilar insulating packaging material;
forming separate panels from sheets of dissimilar insulating
packaging material provided by the corresponding rolls; enclosing
the panels in a membrane, the membrane defining a hinge between the
panels that are adjacent to each other; and folding the panels
along each hinge to form a box-shaped chamber.
Inventors: |
Roberts; David; (Aptos,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Monterey Bay Associates; |
Aptos |
CA |
US |
|
|
Assignee: |
MONTEREY BAY ASSOCIATES
Aptos
CA
|
Family ID: |
41567720 |
Appl. No.: |
13/633543 |
Filed: |
October 2, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12508803 |
Jul 24, 2009 |
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13633543 |
|
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61083814 |
Jul 25, 2008 |
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Current U.S.
Class: |
53/452 |
Current CPC
Class: |
B65B 55/20 20130101;
B65D 81/3858 20130101; Y10T 428/239 20150115; Y10T 428/23
20150115 |
Class at
Publication: |
53/452 |
International
Class: |
B65B 3/02 20060101
B65B003/02 |
Claims
1. A method of making a cold chain package, the method comprising:
providing corresponding rolls of dissimilar insulating packaging
material; forming separate panels from sheets of dissimilar
insulating packaging material provided by said corresponding rolls;
enclosing said panels in a membrane, said membrane defining a hinge
between said panels that are adjacent to each other; and folding
said panels along each said hinge to form a box-shaped chamber.
2. The method of claim 1, wherein said insulating packaging
material includes at least one of foam, foam laminated to foil,
cushioning material laminated to foil and polyester film laminated
to fiberfill filling material.
3. The cold chain package of claim 1, further comprising forming
said panels to have a thickness of 1.5 to 2.5 inches.
4. A method for distributing cold chain packaging comprising:
producing and assembling a cold chain package having a pre-printed
address identifier that identifies a shipping location; inserting a
cold chain package and an article to be delivered in a shipping
container at the shipping location, the cold chain package
maintaining the article at a desired temperature during shipping;
delivering the shipping container to a designated location;
returning the cold chain package to the shipping location
identified by the pre-printed address identifier via a package
courier; and reusing the cold chain package in another shipping
container.
5. The method of claim 4, further comprising at least one of the
steps of checking the cold chain package for damage and repairing
the cold chain package prior to reusing the cold chain package.
Description
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/508,803, filed Jul. 24, 2009, which claims priority
under 35 USC 119(e) from Provisional Application 61/083,814 filed
Jul. 25, 2008.
BACKGROUND
[0002] The present invention relates generally to thermally
insulated packaging, and more specifically to packaging designed
for maintaining packaged items in a refrigerated state.
[0003] There is an increasing demand for so-called "cold chain"
packaging that is suitable for maintaining items at temperatures in
the range of 34-48.degree. F. for at least as long as 8 days.
Typical items shipped via cold chain packaging include
pharmaceuticals, foodstuffs and similar perishable items.
[0004] Conventional cold chain packaging typically consists of an
outer container, such as a corrugated carton, provided with a
lining of either Styrofoam or resilient foam in the form of formed,
molded or precut pads, and at least one pre-chilled gel pack, which
is a sealed bag-like container of heavy plastic filled with a gel
which freezes upon chilling and maintains a relatively low
temperature in the container. An exemplary cold chain package is
sold by TCP Reliable (www.tcpreliable.com) under the "Timesaver"
brand. When a package is desired that has a longer cooling period,
a larger outer container is provided, and more layers of foam and
gel packs create a thicker insulated compartment.
[0005] Thus, current cold chain packaging is limited by size of the
package and/or the length of time items can be kept cold. Also,
conventional cold chain packages are largely single use, and as
such are environmentally inefficient.
SUMMARY
[0006] The present cold chain package includes an arrangement of
layers having dissimilar materials that keeps shipped items that
need to be kept cold at a designated temperature for a longer
period of time than existing packaging. This allows such items to
be shipped via ground transportation, i.e., truck, as well as air
transportation. The package is also reusable and has a compact
design that saves space and minimizes the size of the shipping
containers needed to ship items.
[0007] Specifically, the present cold chain package includes a
plurality of panels surrounded by an overwrap, where each of the
panels includes a plurality of layers of dissimilar materials. The
package also includes a hinge formed between adjacent panels of the
plurality of panels for facilitating folding of the panels to fit
in a shipping container.
[0008] Another embodiment provides a method of making a cold chain
package that includes providing corresponding rolls of dissimilar
insulating packaging material, forming separate panels from sheets
of dissimilar insulating packaging material provided by the
corresponding rolls, enclosing the panels in a membrane where the
membrane defines a hinge between the panels that are adjacent to
each other, and folding the panels along each hinge to form a
box-shaped chamber.
[0009] A further embodiment provides a method for distributing cold
chain packaging that includes producing and assembling a cold chain
package having a pre-printed address identifier that identifies a
shipping location, inserting a cold chain package and an article to
be delivered in a shipping container at the shipping location, the
cold chain package maintaining the article at a desired temperature
during shipping, delivering the shipping container to a designated
location, returning the cold chain package to the shipping location
identified by the pre-printed address identifier via a package
courier and reusing the cold chain package in another shipping
container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an overhead plan view of a disassembled package
incorporating the present invention;
[0011] FIG. 2 is a schematic sectional view of the package of FIG.
1 taken along the line 2-2 of FIG. 1 in the direction generally
indicated;
[0012] FIG. 3 is an overhead plan view of the present package shown
assembled;
[0013] FIG. 4 is a schematic representation of a production line
suitable for use in manufacturing the composite packaging material
used in the present package; and
[0014] FIG. 5 is a schematic representation of a distribution
system suitable for use with the present package.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring now to FIGS. 1-3, the present composite cold chain
package is generally designated 10 and is made of a web 12 formed,
as by die cutting or similar technology into designated panels
including front 14, bottom 16, left side 18, right side 20, rear 22
and top 24. Overlying each panel 14-24 is a bag-like membrane 26,
preferably of a heavy gauge polyethylene overwrap that is heat
sealed to form a hinge 26a between adjacent panels. It is
contemplated that the overwrap material may change depending on the
application. The hinge 26a facilitates the folding of the panels
14-24 into a box shape forming a cold-chain chamber 28. An
advantage of the overwrap 26 is that, after each use, the package
web 12 can be cleaned with disinfectant to address microbial growth
resulting from condensation during shipment.
[0016] A feature of the present package 10 is that it occupies
significantly less space than conventional cold chain packaging for
obtaining a designated degree of insulation lasting a specified
amount of time. This more efficient cooling power is achieved by
creating a composite of dissimilar materials formed into each of
the multi-layer panels 14-24. Some of the layers in the present
package 10 are novel combinations of otherwise conventional
packaging materials.
[0017] Referring now to FIG. 2, the preferred layers, which are
schematically shown, include material A, including a combination of
a sheet of aluminum foil 30 laminated to a corresponding sheet of
Bubble Wrap.RTM. brand cushioning material 32, with a transition
material 34 therebetween. Suitable cushioning material of this type
is manufactured by Sealed Air Corp., www.sealedair.com under the
trademark TEMPSHIELD.TM.. As is known in the plastic thermoforming
arts, transition materials facilitate thermal bonding between
otherwise dissimilar materials. A representative transition
material 34 is a heat sealable polyethylene or polyvinylchloride
(PVC). A second optional insulating layer is material B, including
a combination of preferably polyethylene closed cell foam 36 to
which is laminated a sheet of aluminum foil 38 with a transition
layer 40 therebetween. Suitable material is also manufactured by
Sealed Air Corp under the designation CA-250. It is preferred that
the foil 38 face the interior of the package 10.
[0018] Still another optional layer is material C, which is
approximately 1 inch thick foam, preferably closed cell
polyurethane foam; however other foams are considered suitable and
the thickness may vary. Yet another optional layer is material D,
including a layer of Mylar.RTM. polyester film 42 laminated to a
sheet of fiberfill synthetic filling material 44 with a transition
layer 46 therebetween. In some cases, an additional layer of
transition material (not shown) may be placed upon the Mylar.RTM.
film 42 on the opposite side from the transition layer 46.
[0019] As seen in FIG. 2, the web 12 is preferably made of a
composite of materials in layers as follows: DABABAB. It will be
appreciated that the number, orientation and arrangement of layers
may vary to suit the situation. It is also contemplated that at
least some of the layers DABABAB may be secured to each other as by
heat sealing, or the layers may be loosely contained within the
overwrap 26.
[0020] Referring now to FIG. 3, upon assembly, the web 12 is folded
into an outer container 50, typically a corrugated carton so that
each of the panels 14-24 is associated with a panel of the
container. The folded web 12 forms the cold chain chamber 28 into
which an article to be shipped 52 is placed, preferably surrounded
by pre-chilled gel packs 54. It has been found that the assembled
panels, 14-24, each much thinner than conventional cold chain
packaging, have a thickness in the range of 1.5-2.5 inches. It will
be understood that the thickness may vary with the number of layers
and the combination of composite materials selected. In any event,
the package 10 is significantly thinner than conventional cold
chain packages with similar temperature maintenance/insulation
capabilities. Despite this relatively thin profile, the package 10
has been shown to retain a temperature of 48.degree. F. for at
least eight days.
[0021] Referring now to FIG. 4, a schematic of the production of
the composite layers of materials A, B and D is shown. A supply of
each of the insulating materials, such as foam, Bubble Wrap.RTM.
cushioning material, aluminum foil, foam, Mylar.RTM. film, etc. is
each provided in a respective roll 58, 60. The transition material
34, 40, 44, 46 is also provided in a roll 62. A rack 64 is created
to arrange the rolls 58, 60, 62 so that the components of the
composite material are arranged in a web format that is placed on a
conveyor table 66 which conveys the layers to a heat source 68,
where they are laminated together. After lamination, the composite
material is placed upon a take up roll 70.
[0022] Referring now to FIG. 5, besides having reduced weight and
bulk compared to conventional cold chain packaging having similar
temperature insulation qualities, another feature of the present
package 10 is that it is reusable. A network of collection and
refurbishing facilities is envisioned for facilitating the reuse of
such packages, further reducing the cost to the shipper. The
smaller size of the present package facilitates such shipment.
[0023] More specifically, the present network, generally designated
80, includes a Distribution Center 82 where the packages 10 are
produced by assembling the webs 12 into packages and inserting the
packaged articles 52. The packages 10 are shipped by courier, such
as UPS, FedEx, USPS and the like to an end user 84. Due to the
longer temperature retention properties of the present cold chain
packaging, the shipping process can be extended to at least as long
as 7 days. Thus, goods which previously had to be shipped by air
can now travel by ground.
[0024] Since the packages 10 have preprinted return labels, bar
code identification, RFID tags or similar identifiers, the end user
84 can return them to the Distribution Center 82, or to a
Refurbishing facility 86, where the package is disassembled,
checked for damage and reassembled as needed prior to reshipment in
bulk to the Distribution Center 82. In this manner, the packaging
is reused numerous times, reducing packaging and shipping cost
compared to conventional cold chain packaging technology. Due to
the identifiers, the Distribution Center 82 can grant credits,
discounts, rewards or other incentives to the end user 84 to
encourage return of the packages 10. Conversely, the same
identifiers can be used so that the end user 84 is charged if the
package 10 is not returned.
[0025] While a particular embodiment of the present cold chain
package has been described herein, it will be appreciated by those
skilled in the art that changes and modifications may be made
thereto without departing from the invention in its broader aspects
and as set forth in the following claims.
* * * * *
References