U.S. patent application number 15/279355 was filed with the patent office on 2017-03-30 for method and apparatus for providing an insulated shipping container.
The applicant listed for this patent is Package Depot, Inc.. Invention is credited to Steven H. Smith.
Application Number | 20170088337 15/279355 |
Document ID | / |
Family ID | 58409225 |
Filed Date | 2017-03-30 |
United States Patent
Application |
20170088337 |
Kind Code |
A1 |
Smith; Steven H. |
March 30, 2017 |
Method and Apparatus for Providing an Insulated Shipping
Container
Abstract
Disclosed is an insulated shipping container for transporting
temperature-controlled materials and method of making the same. In
a preferred embodiment, the insulated shipping container comprises
an outer box or housing and a plurality of insulated inserts
configured to be snugly and removably received in the outer box or
housing. The plurality of insulated inserts are shaped to define a
rectangular cavity bounded by a bottom wall and a plurality of
rectangular side walls and top closure flaps. The insulated inserts
as well the outer box or housing of the disclosed device can be
stored flat and reused.
Inventors: |
Smith; Steven H.; (Superior,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Package Depot, Inc. |
Louisville |
CO |
US |
|
|
Family ID: |
58409225 |
Appl. No.: |
15/279355 |
Filed: |
September 28, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62233440 |
Sep 28, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 55/20 20130101;
B65D 81/3813 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65B 5/04 20060101 B65B005/04; B65B 7/20 20060101
B65B007/20 |
Claims
1. An insulated shipping container for temperature-sensitive
transport, the container comprising: an outer box or housing and a
plurality of insulated inserts configured to be snugly and
removably received in the outer box or housing; the plurality of
insulated inserts being shaped to define a rectangular cavity of
the outer box or housing, the cavity bounded by a bottom wall and a
plurality of rectangular side walls and top closure flaps; each of
the plurality of insulated inserts comprising a polystyrene core
encapsulated within a metallized polyethylene material on all
sides; the polystyrene core further comprising a scoring at ends
thereof to form a thermal packaging product when the core is
encapsulated within a metallized polyethylene material; and wherein
the thermal packaging product may bend or crack at a predetermined
spot to minimize voids in packaging and to ensure a snug fit in the
outer box or housing.
2. An insulated shipping insert for a temperature-sensitive
transport container, the insulated insert comprising: a polystyrene
core encapsulated within a metallized polyethylene material on all
sides; the insulated insert is removably inserted into a
rectangular cavity of an outer box or housing, the cavity bounded
by a bottom wall and a plurality of rectangular side walls and top
closure flaps; each of the plurality of insulated inserts
comprising a polystyrene core encapsulated within a metallized
polyethylene material on all sides; the polystyrene core further
comprising a scoring at ends thereof to form a thermal packaging
product when the core is encapsulated within a metallized
polyethylene material; and wherein the thermal packaging product
may bend or crack at a predetermined spot to minimize voids in
packaging and to ensure a snug fit in the outer box or housing.
3. A method of providing an insulated shipping container for
temperature-sensitive transport, the method comprising the steps
of: providing an outer box or housing; removably inserting a first
insulated insert into a rectangular cavity of the outer box or
housing, wherein a portion of the insulated insert forms a bottom
wall, a first rectangular side wall and a top closure flap; and
removably inserting a second insulated insert into a rectangular
cavity of the outer box or housing, wherein a portion of the second
insulated insert forms a second, third and fourth rectangular side
wall, thereby creating all insulated cavity.
4. The method of claim 3 further comprising the step of inserting a
transportable
5. The method of claim 3 further comprising the closing of the top
closure flap to house a transportable item.
6. The method of claim 5 further comprising sealing the outer box
or housing for shipment.
Description
FIELD OF ART
[0001] The disclosed device relates generally to an insulated
shipping container for use in shipping temperature sensitive
products or to help maintain product freshness and efficacy, and
more particularly to insulated shipping containers of the type
which are formed at least in part of foamed polymer material.
BACKGROUND
[0002] Conventional insulated shipping containers known as a
box-within-a-box are well-known. These conventional
box-within-a-box containers typically have an outer box formed of
corrugated cardboard and a smaller, open-topped, inner box also
formed of corrugated cardboard, the outer and inner boxes defining
a void space therebetween. During manufacture of such shipping
containers, the void space is filled with a foamed-in-place polymer
material, said polymer material typically being a light-to-medium
density foamed polyurethane material. The polymer material in a
liquid pre-foamed condition is then sprayed or poured into the void
space between the two boxes and is allowed to foam in place. The
foaming of the polymer material takes a sufficient period of time
and as this polymer material foams in place, it bonds to both the
inner and outer boxes and exerts a considerable pressure against
both the inner and outer boxes.
[0003] With such conventional insulated shipping containers, it is
common for one or more articles being shipped therein to be
inserted into the inner box of the container, together with dry ice
or other temperature stabilizing packs and packing material. A
form-fitting block of thick, open-cell foam is then inserted into
the opening of the inner box. This open-cell foam serves as a
thermal insulator and prevents the infusion of ambient air into the
inner box and the escape of temperature-controlled air from within
the inner box. Next, the top closure flaps of the outer box are
closed and taped, and the shipping container is ready for shipment
with the attachment of a shipping label thereto.
[0004] Unfortunately, conventional box-within-a-box containers have
certain shortcomings. One significant shortcoming is that the
materials of the container are not recyclable because the foamed
polymer material bonds directly to the inner and outer cardboard
boxes and cannot thereafter easily be separated therefrom.
Moreover, if the outer box becomes damaged or otherwise marked, it
cannot be replaced in such a way as to permit the container to be
reused.
[0005] Common also in the industry for shipping perishable items is
a molded polystyrene cooler. While this is currently the most
economical and efficient product available, there are several
shortcomings with this product. First, these coolers require an
expensive mold to be produced. Next, each cooler has a particular
size and wall thickness, which results in a shipper having to
purchase and keep in stock a variety of cooler sizes. In addition,
these coolers ship pre-molded, so they take up a lot of space.
[0006] The disclosed device provides for an improved and
inexpensive thermal packaging product comprising a polystyrene core
encapsulated within a metallized polyethylene material on all
sides. The disclosed device is configured to be compact and
accommodates flat storage. If the outer box becomes damaged or
otherwise marked, the insulated inserts can easily be placed into
another outer box or housing, thereby allowing for reuse. In
addition, each cooler can be composed of inserts of customizable
sizes and wall thicknesses.
SUMMARY OF THE DISCLOSURE
[0007] The disclosed device provides for an improved thermal
packaging product comprising a polystyrene core encapsulated within
a metallized polyethylene material on all sides.
[0008] The disclosed device comprises scoring of an
internally-based sheet of polystyrene before it is inserted into or
encapsulated by a metallized polyethylene material, the scoring
allowing the polystyrene sheet to bend or crack at a predetermined
spot to reduce the likelihood of voids in packaging.
[0009] The disclosed device provides for a thermal packaging
product that utilizes a metallized polyethylene material such as
"bubble foil".
[0010] The disclosed device provides for a thermal packaging
product that utilizes a metallized polyethylene material with
reflective properties that reflect radiant heat.
[0011] The disclosed device provides for a thermal packaging
product that adds two (2) layers of additional material to a
polystyrene base, thereby further limiting heat transfer through
conduction.
[0012] The disclosed device provides for a thermal packaging
product that may be reused.
[0013] The disclosed device provides for a thermal packaging
product that does not readily absorb odors or fluids.
[0014] The disclosed device provides for a thermal packaging
product that can be easily cleaned and/or disinfected for
reuse.
[0015] The disclosed device allows for a user to determine the
appropriate amount of insulation thickness to be used without
having to be confined to using a pre molded container that consists
of too little or too much insulation.
[0016] The disclosed device can be manufactured to a shipper's size
requirements.
[0017] The disclosed device can be manufactured to accommodate flat
storage.
[0018] The disclosed device can be stored in a flat configuration
until it is folded into a usable expanded unit, .i.e., a
3-dimensional unit.
[0019] The disclosed device does not require the use of expensive
molds for manufacturing purposes, thus reducing potential equipment
set-up and capital costs.
[0020] The disclosed device can be made into large to very large
sizes, unlike pre-molded coolers.
[0021] The disclosed device provides for a thermal packaging
product that even if cracked internally, the metallized
polyethylene material acts as an encapsulating seal to maintain the
efficiency of the product.
[0022] The disclosed device provides for an improved thermal
packaging product that outperforms a comparable molded cooler by
about twenty percent (20%).
[0023] The disclosed device allows for a thermal packaging product
having a desired insulation thickness in the range of about 0.5''
to about 4''.
[0024] The disclosed device is compact.
[0025] The disclosed device provides for an insulated shipping
container for transporting temperature-controlled materials which
can include cold and hot temperature items.
[0026] These and other advantages of the disclosed device will
appear from the following description and/or appended claims,
reference being made to the accompanying drawings that form a part
of this specification wherein like reference characters designate
corresponding parts in the several views.
BRIEF DESCRIPTION OF THE FIGURES
[0027] FIG. 1 depicts various embodiments 100, 200 of the disclosed
thermal packaging product comprising a polystyrene core
encapsulated within a metallized polyethylene material on all
sides.
[0028] FIG. 2 illustrates the ability of the disclosed thermal
packaging product to accommodate flat shipping and storage.
[0029] FIG. 3 illustrates the bendability of the disclosed device
and the ease by which the device can be folded into a 3 dimensional
unit.
[0030] FIG. 4 depicts a standard corrugated cardboard box 300 into
which the disclosed device may be inserted.
[0031] FIG. 5 illustrates the insertion of thermal packaging
product 100 into standard corrugated cardboard box 300.
[0032] FIG. 6 illustrates the insertion of thermal packaging
product 200 into cardboard box 300 which houses thermal packaging
product 100.
[0033] FIG. 7 depicts disclosed apparatus 1 in a semi-assembled
state, ready for receiving a storable or perishable item.
[0034] FIG. 8 depicts the disclosed apparatus 1 in a semi-assembled
state, preparing for closure.
[0035] FIG. 9 depicts the disclosed apparatus 1 in an assembled
state, preparing for shipment.
[0036] FIG. 10 illustrates polystyrene core 50 encapsulated within
a metallized polyethylene material 40.
[0037] FIG. 11 illustrates polystyrene core 50 which has been
scored at an end thereof such that when it is encapsulated within a
metallized polyethylene material 40, the thermal packaging product
100, 200 may bend or crack at a predetermined spot to minimize
voids in packaging.
[0038] Before explaining the disclosed embodiments of the disclosed
device in detail, it is to be understood that the device is not
limited in its application to the details of the particular
arrangements shown, since the device is capable of other
embodiments. Also, the terminology used herein is for the purpose
of description and not of limitation.
DESCRIPTION
[0039] Not every shipping container for perishables requires the
same amount of insulation. With the disclosed device, the shipper
may determine the thickness of insulation needed without the
limitations of a pre-molded container that may provide either too
little insulation or more than necessary.
[0040] Shippers are usually required to use a pre-molded container
that may not actually fit their product. The disclosed device can
be manufactured to a shipper's size requirement.
[0041] Pre-molded coolers typically can take up large amounts of
space because of their rigid shape and structure. The disclosed
device may be collapsed and stored flat until being folded into a
usable expanded unit.
[0042] Pre-molded coolers are also expensive; often the cooler
molds are thousands of dollars and require very expensive machines
for use. The disclosed device requires no molds, eliminating most
setup costs.
[0043] Pre molded coolers are efficient, however the disclosed
device has been shown to be even more efficient. The test results
from a company that manufactures molded coolers show, for example,
that a 1.5'' embodiment of the disclosed device outperformed a
1.5'' pre-molded cooler by about twenty percent (20%).
[0044] The disclosed device utilizes polystyrene sheets
encapsulated in a metallized polyethylene material, such as
bubble/foil. Although bubble/foil was used because of its ability
to reflect radiant heat, other suitable materials could be used to
limit heat transfer through conduction.
[0045] The disclosed device is also easy to use. Scoring made in
the polystyrene sheet before it is inserted into the metallized
polyethylene material allows the polystyrene to crack at a
predetermined spot to minimize voids in packaging.
[0046] Pre-molded coolers can be difficult to reuse. Because the
disclosed device comprises a metallized polyethylene material on
all sides, it will not absorb fluids. The thermal packaging
products can easily be cleaned and disinfected for re-use.
[0047] Because molds must be larger than the coolers they produce,
fabrication of pre-molded coolers is limited by the size of their
molds. The disclosed device can be made into very large sizes,
without requiring increasingly larger molds.
[0048] Pre-molded coolers may also crack in transit or at any time.
Although the disclosed device could also crack, the polystyrene
core is encapsulated completely and sealed in flexible metallized
polyethylene material, such as bubble/foil, so the polystyrene
would stay in place, continuing to insulate the perishable
contents.
[0049] Various tests were conducted to determine the ability of the
disclosed device to protect goods shipped under
temperature-stressed conditions. The results of the tests are
included herein to demonstrate the shipped goods were maintained
within predetermined temperature ranges for prescribed
durations.
[0050] The disclosed device provides for an insulated shipping
container for transporting temperature-controlled materials. One
having skill in the art will recognize that the device is capable
of being used for any temperature-sensitive material for which
temperature is to be controlled and can include cold, hot, and/or
temperate items.
[0051] What is claimed is an insulated shipping container for
temperature-sensitive transport, the container comprising an outer
box or housing and a plurality of insulated inserts configured to
be snugly and removably received in the outer box or housing. The
plurality of insulated inserts are shaped to define a rectangular
cavity of the outer box or housing, the cavity bounded by a bottom
wall and a plurality of rectangular side walls and top closure
flaps. Each of the plurality of insulated inserts comprising a
polystyrene core encapsulated within a metallized polyethylene
material on all sides. The polystyrene core further comprising a
scoring at ends thereof such that when it is encapsulated within a
metallized polyethylene material to form a thermal packaging
product, the thermal packaging product may bend or crack at a
predetermined spot to minimize voids in packaging and to ensure a
snug fit in the outer box or housing.
[0052] What is claimed is an insulated shipping insert for a
temperature-sensitive transport container, the insulated insert
comprising a polystyrene core encapsulated within a metallized
polyethylene material on all sides. The insulated insert is
removably inserted into a rectangular cavity of an outer box or
housing, the cavity bounded by a bottom wall and a plurality of
rectangular side walls and top closure flaps. Each of the plurality
of insulated inserts comprising a polystyrene core encapsulated
within a metallized polyethylene material on all sides. The
polystyrene core further comprises a scoring at ends thereof such
that when it is encapsulated within a metallized polyethylene
material to form a thermal packaging product, the thermal packaging
product may bend or crack at a predetermined spot to minimize voids
in packaging and to ensure a snug fit in the outer box or
housing.
[0053] What is claimed is a method of providing an insulated
shipping container for temperature-sensitive transport, the method
comprising the steps of: providing an outer box or housing,
removably inserting a first insulated insert into a rectangular
cavity of the outer box or housing, wherein a portion of the
insulated insert forms a bottom wall, a first rectangular side wall
and a top closure flap, removably inserting a second insulated
insert into a rectangular cavity of the outer box or housing,
wherein a portion of the second insulated insert forms a second,
third and fourth rectangular side wall, thereby creating an
insulated cavity. The method further comprises the step of
inserting a transportable item. The method further comprises the
closing of the top closure flap to house a transportable item. The
method further comprises sealing the outer box or housing for
shipment.
[0054] Although the disclosed device and method have been described
with reference to disclosed embodiments, numerous modifications and
variations can be made and still the result will come within the
scope of the disclosure. No limitation with respect to the specific
embodiments disclosed herein is intended or should be inferred.
* * * * *