U.S. patent application number 15/335144 was filed with the patent office on 2017-11-16 for thermal liner and thermal container comprising same.
The applicant listed for this patent is CASCADES CANADA ULC. Invention is credited to Stephane Morasse, Philippe Perron.
Application Number | 20170327298 15/335144 |
Document ID | / |
Family ID | 60295053 |
Filed Date | 2017-11-16 |
United States Patent
Application |
20170327298 |
Kind Code |
A1 |
Morasse; Stephane ; et
al. |
November 16, 2017 |
THERMAL LINER AND THERMAL CONTAINER COMPRISING SAME
Abstract
A thermal liner comprising a plurality of planar panel sections
and being configurable in an operative configuration defining a
closed inner chamber delimited by a bottom wall, four side walls
and a top wall. Each one of the bottom wall, the side walls and the
top wall comprises an inner sheet, an outer sheet and at least one
intermediate sheet. A first core layer extends between the inner
sheet and a respective one of the at least one intermediate sheet
and defines a plurality of geometrically patterned structures
inbetween. A second core layer extends between the outer sheet and
a respective one of the at least one intermediate sheet and defines
a plurality of geometrically patterned structures inbetween. A
container having a thermal liner such as the one described above is
also provided.
Inventors: |
Morasse; Stephane; (Kingsey
Falls, CA) ; Perron; Philippe; (Victoriaville,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CASCADES CANADA ULC |
Montreal |
|
CA |
|
|
Family ID: |
60295053 |
Appl. No.: |
15/335144 |
Filed: |
October 26, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62335345 |
May 12, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/566 20130101;
B65D 81/386 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 5/56 20060101 B65D005/56 |
Claims
1. A thermal liner comprising: two panels configurable between an
extended configuration and an operative C-shaped configuration, the
two panels being engageable with one another when configured in the
operative configuration in order to define a closed inner chamber,
each one of the two panels comprising: an inner sheet; an outer
sheet; and a core separating the inner sheet from the outer sheet,
the core comprising at least two core layers separated by a layer
separation sheet, each one of the at least two core layers
including a geometrically patterned structure.
2. The thermal liner of claim 1, wherein each one of the at least
two core layers of the two panels has a surface area and wherein
the surface area of the at least two core layers of the two panels
is substantially the same.
3. The thermal liner of claim 1, wherein each one of the at least
two core layers of the two panels has a surface area and wherein
the at least two core layers includes an inner core layer, the
surface area of the inner core layer of at least one of the two
panels being smaller than the surface area of the other core layers
thereof and the inner core layer being inset with regard to the
other core layers.
4. The thermal liner of claim 3, wherein the two panels have a
thickness and wherein the inner core layer is inset with regard to
the other core layers of a distance substantially corresponding to
the thickness of the two panels.
5. The thermal liner of claim 1, wherein at least one of the inner
sheet and the outer sheet of each one of the two panels comprises a
reflective surface.
6. The thermal liner of claim 5, wherein the inner sheet of each
one of the two panels has an inner facing surface, the inner facing
surface of the inner sheet of each one of the two panels comprising
the reflective surface.
7. The thermal liner of claim 1, wherein the layer separation sheet
of each one of the two panels comprises an intermediate reflective
surface.
8. The thermal liner of claim 7, wherein the layer separation sheet
of each one of the two panels comprises an outer sheet facing
surface facing the outer sheet and wherein the outer sheet facing
surface of the layer separation sheet of each one of the two panels
comprises the intermediate reflective surface.
9. The thermal liner of claim 1, wherein the inner sheet and the
outer sheet of each one of the two panels comprise a liquid/vapor
resistant barrier.
10. The thermal liner of claim 1, wherein each one of the at least
two core layers of each one of the two panels comprises a honeycomb
structure defining a grid of hexagonal open-ended core cells.
11. A thermal liner comprising: a least two panels configurable
between an extended configuration and an operative configuration,
the at least two panels each including panel sections superposable
onto corresponding panel sections of another one of the least two
panels when configured in the operative configuration, the at least
two panels defining a closed inner chamber delimited by a bottom
wall, four side walls and a top wall when configured in the
operative configuration and each one of the bottom wall, the side
walls and the top wall including at least two core layers, each one
of the at least two panels comprising: an inner sheet; an outer
sheet; a core separating the inner sheet from the outer sheet, the
core comprising at least one core layer including a geometrically
patterned structure.
12. The thermal liner of claim 11, wherein at least one of the
inner sheet and the outer sheet of at least one of the at least two
panels comprises a reflective surface.
13. The thermal liner of claim 12, wherein the inner sheet of each
one of the at least two panels has an inner facing surface, the
inner facing surface of the inner sheet of each one of the at least
two panels comprising the reflective surface.
14. The thermal liner of claim 12, wherein the outer sheet of each
one of the at least two panels has an outer facing surface and
wherein the outer facing surface of the layer separation sheet of
the outer sheet of each one of the at least two panels comprises
the reflective surface.
15. The thermal liner of claim 11, wherein the inner sheet and the
outer sheet of at least one of the at least two panels comprises a
liquid/vapor resistant barrier.
16. The thermal liner of claim 15, wherein the inner sheet and the
outer sheet of each one of the at least two panels comprises a
liquid/vapor resistant barrier.
17. The thermal liner of claim 11, wherein the at least one core
layer of each one of the at least two panels comprises a honeycomb
structure defining a grid of hexagonal open-ended core cells.
18. A thermal liner comprising a plurality of planar panel sections
and being configurable in an operative configuration defining a
closed inner chamber delimited by a bottom wall, four side walls
and a top wall, wherein each one of the bottom wall, the side walls
and the top wall comprises an inner sheet, an outer sheet and at
least one intermediate sheet, with a first core layer extending
between the inner sheet and a respective one of the at least one
intermediate sheet and defining a plurality of geometrically
patterned structures inbetween and a second core layer extending
between the outer sheet and a respective one of the at least one
intermediate sheet and defining a plurality of geometrically
patterned structures inbetween.
19. The thermal liner of claim 18, wherein at least one of the
inner sheet and the outer sheet of each one of the bottom wall, the
side walls and the top wall comprises a reflective surface.
20. The thermal liner of claim 19, wherein the inner sheet of each
one of the bottom wall, the side walls and the top wall has an
inner facing surface, the inner facing surface of the inner sheet
of each one of the bottom wall, the side walls and the top wall
comprising the reflective surface.
21. The thermal liner of claim 18, wherein the at least one
intermediate sheet of each one of the bottom wall, the side walls
and the top wall comprises an intermediate reflective surface.
22. The thermal liner of claim 21, wherein the at least one
intermediate sheet comprises an outer sheet facing surface facing
the outer sheet, the outer sheet facing surface of the at least one
intermediate sheet comprising the intermediate reflective
surface.
23. The thermal liner of claim 18, wherein the inner sheet and the
outer sheet of each one of the bottom wall, the side walls and the
top wall comprises a liquid/vapor resistant barrier.
24. The thermal liner of claim 18, wherein each one of the first
core layer and the second core layer comprises a honeycomb
structure defining a grid of hexagonal open-ended core cells.
25. The thermal liner of claim 18, wherein each one of the bottom
wall, the side walls and the top wall comprises at least one
intermediary core layer extending between adjacent intermediate
sheets and defining a plurality of geometrically patterned
structures inbetween.
26. The thermal liner of claim 25, wherein the at least one
intermediary core layer comprises a honeycomb structure defining a
grid of hexagonal open-ended core cells.
27. A thermal container comprising: a container comprising: a
container bottom wall; and four container side walls extending
substantially perpendicularly from the container bottom wall; a
thermal liner insertable into the container and comprising a
plurality of planar panel sections, the thermal liner being
configurable in an operative configuration defining a closed inner
chamber delimited by a bottom wall, four side walls and a top wall,
wherein each one of the bottom wall, the side walls and the top
wall comprises an inner sheet, an outer sheet and at least one
intermediate sheet, with a first core layer extending between the
inner sheet and a respective one of the at least one intermediate
sheet and defining a plurality of geometrically patterned
structures inbetween and a second core layer extending between the
outer sheet and a respective one of the at least one intermediate
sheet and defining a plurality of geometrically patterned
structures inbetween, wherein each one of the bottom wall and the
side walls of the thermal liner is superposed respectively to the
container bottom wall and the four container side walls when the
thermal liner is inserted in the container with the inner chamber
being closed at least by the top wall of the thermal liner.
28. The thermal container of claim 27, wherein at least one of the
inner sheet and the outer sheet of each one of the bottom wall, the
side walls and the top wall defining the inner chamber of the
thermal liner comprises a reflective surface.
29. The thermal container of claim 28, wherein the inner sheet of
each one of the bottom wall, the side walls and the top wall
defining the inner chamber of the thermal liner has an inner facing
surface, the inner facing surface of the inner sheet of each one of
the bottom wall, the side walls and the top wall comprising the
reflective surface.
30. The thermal container of claim 27, wherein the at least one
intermediate sheet of each one of the bottom wall, the side walls
and the top wall defining the inner chamber of the thermal liner
comprises an intermediate reflective surface.
31. The thermal container of claim 30, wherein the at least one
intermediate sheet of each one of the bottom wall, the side walls
and the top wall defining the inner chamber of the thermal liner
comprises an outer sheet facing surface facing the outer sheet, the
outer sheet facing surface of the at least one intermediate sheet
of each one of the bottom wall, the side walls and the top wall
comprising the intermediate reflective surface.
32. The thermal container of claim 27, wherein each one of the
first core layer and the second core layer of each one of the
bottom wall, the side walls and the top wall defining the inner
chamber of the thermal liner comprises a honeycomb structure
defining a grid of hexagonal open-ended core cells.
33. The thermal container of claim 27, wherein each one of the
bottom wall, the side walls and the top wall defining the inner
chamber of the thermal liner comprises at least one intermediary
core layer extending between adjacent intermediate sheets and
defining a plurality of geometrically patterned structures
inbetween.
34. The thermal container of claim 33, wherein the at least one
intermediary core layer comprises a honeycomb structure defining a
grid of hexagonal open-ended core cells.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. .sctn.
119(e) of U.S. provisional patent application No. 62/335.345 which
was filed on May 12, 2016. The entirety of the aforementioned
application is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of thermal
containers. More particularly, it relates to a thermal liner for a
container and to a container including the thermal liner.
BACKGROUND
[0003] It is known in the art to provide a container with an inner
thermal liner in order to define a thermal container. For example
and without being limitative, such thermal containers can be used
for packing perishable goods along with a refrigerant such as ice,
frozen gel packs or the like, to maintain the perishable goods in a
refrigerated state for temporary storage and/or shipping
thereof.
[0004] Numerous material which offer good thermal insulation
properties can be used in the construction of the thermal liners.
For example and without being limitative, such materials include
polystyrene, polyurethane foam, or the like. However, in many
cases, such materials do not allow recycling thereof, once the
thermal container has been used, and must be disposed of through
landfill or the like, which is undesirable.
[0005] In order to alleviate this problem, it is known to
manufacture thermal liners including foldable cellulosic fiber
based thermal liners with a single layer of corrugated and/or
honeycomb material separating outer sheets. In an embodiment, a
surface of the outer sheets can be covered by a reflective layer
such as an aluminum foil layer or a metallized film layer. Such
thermal liners are commonly initially manufactured as a liner blank
in which crease lines are defined between specific planar panel
sections, to allow the easy folding between the sections. The liner
blank is foldable between an unfolded configuration and a folded
configuration and defines a closed inner chamber, when configured
in the closed configuration.
[0006] It is also known to provide multiple panels thermal liners,
with panels each having a single layer of corrugated and/or
honeycomb material and being combined with one another to define
the thermal liner. In such multiple panel thermal liners, the
sections thereof can be connected with one another such that they
collaborate to define a closed inner chamber having a suitable
thermal protection.
[0007] Known cellulosic fiber based thermal liners and
corresponding thermal containers however also tend to suffer from
several drawbacks. For example and without being limitative, in
many cases the thermal protection properties of the cellulosic
fiber based thermal liners and the resulting thermal containers
have proved unsatisfactory to maintain the goods in a refrigerated
state for sufficient time periods.
[0008] In view of the above, there is a need for a thermal liner
and a thermal container comprising the thermal liner which would be
able to overcome or at least minimize some of the above-discussed
prior art concerns.
BRIEF SUMMARY OF THE INVENTION
[0009] In accordance with an embodiment, there is provided a
thermal liner. The thermal liner comprises two panels configurable
between an extended configuration and an operative C-shaped
configuration. The two panels are engageable with one another when
configured in the operative configuration in order to define a
closed inner chamber. Each one of the two panels comprises an inner
sheet; an outer sheet; and a core separating the inner sheet from
the outer sheet. The core comprises at least two core layers
separated by a layer separation sheet. Each one of the at least two
core layers includes a geometrically patterned structure.
[0010] In an embodiment, each one of the at least two core layers
of the two panels has a surface area and the surface area of the at
least two core layers of the two panels is substantially the
same.
[0011] In an embodiment, each one of the at least two core layers
of the two panels has a surface area and the at least two core
layers includes an inner core layer. The surface area of the inner
core layer of at least one of the two panels is smaller than the
surface area of the other core layers thereof and the inner core
layer is inset with regard to the other core layers.
[0012] In an embodiment, the two panels have a thickness and the
inner core layer is inset with regard to the other core layers of a
distance substantially corresponding to the thickness of the two
panels.
[0013] In an embodiment, at least one of the inner sheet and the
outer sheet of each one of the two panels comprises a reflective
surface.
[0014] In an embodiment, the inner sheet of each one of the two
panels has an inner facing surface. The inner facing surface of the
inner sheet of each one of the two panels comprises the reflective
surface.
[0015] In an embodiment, the layer separation sheet of each one of
the two panels comprises an intermediate reflective surface.
[0016] In an embodiment, the layer separation sheet of each one of
the two panels comprises an outer sheet facing surface facing the
outer sheet and the outer sheet facing surface of the layer
separation sheet of each one of the two panels comprises the
intermediate reflective surface.
[0017] In an embodiment, the inner sheet and the outer sheet of
each one of the two panels comprise a liquid/vapor resistant
barrier.
[0018] In an embodiment, each one of the at least two core layers
of each one of the two panels comprises a honeycomb structure
defining a grid of hexagonal open-ended core cells.
[0019] In accordance with another general aspect, there is also
provided a thermal liner. The thermal liner comprises a least two
panels configurable between an extended configuration and an
operative configuration. The at least two panels each include panel
sections superposable onto corresponding panel sections of another
one of the least two panels when configured in the operative
configuration. The at least two panels define a closed inner
chamber delimited by a bottom wall, four side walls and a top wall
when configured in the operative configuration and each one of the
bottom wall, the side walls and the top wall include at least two
core layers. Each one of the at least two panels comprises an inner
sheet; an outer sheet; and a core separating the inner sheet from
the outer sheet. The core comprises at least one core layer
including a geometrically patterned structure.
[0020] In an embodiment, at least one of the inner sheet and the
outer sheet of at least one of the at least two panels comprises a
reflective surface.
[0021] In an embodiment, the inner sheet of each one of the at
least two panels has an inner facing surface. The inner facing
surface of the inner sheet of each one of the at least two panels
comprises the reflective surface.
[0022] In an embodiment, the outer sheet of each one of the at
least two panels has an outer facing surface and the outer facing
surface of the layer separation sheet of the outer sheet of each
one of the at least two panels comprises the reflective
surface.
[0023] In an embodiment, the inner sheet and the outer sheet of at
least one of the at least two panels comprises a liquid/vapor
resistant barrier.
[0024] In an embodiment, the inner sheet and the outer sheet of
each one of the at least two panels comprises a liquid/vapor
resistant barrier.
[0025] In an embodiment, the at least one core layer of each one of
the at least two panels comprises a honeycomb structure defining a
grid of hexagonal open-ended core cells.
[0026] In accordance with another general aspect, there is also
provided a thermal liner. The thermal liner comprises a plurality
of planar panel sections and is configurable in an operative
configuration defining a closed inner chamber delimited by a bottom
wall, four side walls and a top wall. Each one of the bottom wall,
the side walls and the top wall comprises an inner sheet, an outer
sheet and at least one intermediate sheet, with a first core layer
extending between the inner sheet and a respective one of the at
least one intermediate sheet and defining a plurality of
geometrically patterned structures inbetween and a second core
layer extending between the outer sheet and a respective one of the
at least one intermediate sheet and defining a plurality of
geometrically patterned structures inbetween.
[0027] In an embodiment, at least one of the inner sheet and the
outer sheet of each one of the bottom wall, the side walls and the
top wall comprises a reflective surface.
[0028] In an embodiment, the inner sheet of each one of the bottom
wall, the side walls and the top wall has an inner facing surface.
The inner facing surface of the inner sheet of each one of the
bottom wall, the side walls and the top wall comprises the
reflective surface.
[0029] In an embodiment, the at least one intermediate sheet of
each one of the bottom wall, the side walls and the top wall
comprises an intermediate reflective surface.
[0030] In an embodiment, the at least one intermediate sheet
comprises an outer sheet facing surface facing the outer sheet. The
outer sheet facing surface of the at least one intermediate sheet
comprises the intermediate reflective surface.
[0031] In an embodiment, the inner sheet and the outer sheet of
each one of the bottom wall, the side walls and the top wall
comprises a liquid/vapor resistant barrier.
[0032] In an embodiment, each one of the first core layer and the
second core layer comprises a honeycomb structure defining a grid
of hexagonal open-ended core cells.
[0033] In an embodiment, each one of the bottom wall, the side
walls and the top wall comprises at least one intermediary core
layer extending between adjacent intermediate sheets and defining a
plurality of geometrically patterned structures inbetween.
[0034] In an embodiment, the at least one intermediary core layer
comprises a honeycomb structure defining a grid of hexagonal
open-ended core cells.
[0035] In accordance with another general aspect, there is further
provided a thermal container. The thermal container comprises a
container comprising: a container bottom wall; and four container
side walls extending substantially perpendicularly from the
container bottom wall. The thermal container also comprises a
thermal liner insertable into the container and comprising a
plurality of planar panel sections. The thermal liner is
configurable in an operative configuration defining a closed inner
chamber delimited by a bottom wall, four side walls and a top wall.
Each one of the bottom wall, the side walls and the top wall
comprises an inner sheet, an outer sheet and at least one
intermediate sheet, with a first core layer extending between the
inner sheet and a respective one of the at least one intermediate
sheet and defining a plurality of geometrically patterned
structures inbetween and a second core layer extending between the
outer sheet and a respective one of the at least one intermediate
sheet and defining a plurality of geometrically patterned
structures inbetween. Each one of the bottom wall and the side
walls of the thermal liner is superposed respectively to the
container bottom wall and the four container side walls when the
thermal liner is inserted in the container with the inner chamber
being closed at least by the top wall of the thermal liner.
[0036] In an embodiment, at least one of the inner sheet and the
outer sheet of each one of the bottom wall, the side walls and the
top wall defining the inner chamber of the thermal liner comprises
a reflective surface.
[0037] In an embodiment, the inner sheet of each one of the bottom
wall, the side walls and the top wall defining the inner chamber of
the thermal liner has an inner facing surface, the inner facing
surface of the inner sheet of each one of the bottom wall, the side
walls and the top wall comprises the reflective surface.
[0038] In an embodiment, the at least one intermediate sheet of
each one of the bottom wall, the side walls and the top wall
defining the inner chamber of the thermal liner comprises an
intermediate reflective surface.
[0039] In an embodiment, the at least one intermediate sheet of
each one of the bottom wall, the side walls and the top wall
defining the inner chamber of the thermal liner comprises an outer
sheet facing surface facing the outer sheet, the outer sheet facing
surface of the at least one intermediate sheet of each one of the
bottom wall, the side walls and the top wall comprises the
intermediate reflective surface.
[0040] In an embodiment, each one of the first core layer and the
second core layer of each one of the bottom wall, the side walls
and the top wall defining the inner chamber of the thermal liner
comprises a honeycomb structure defining a grid of hexagonal
open-ended core cells.
[0041] In an embodiment, each one of the bottom wall, the side
walls and the top wall defining the inner chamber of the thermal
liner comprises at least one intermediary core layer extending
between adjacent intermediate sheets and defining a plurality of
geometrically patterned structures inbetween.
[0042] In an embodiment, the at least one intermediary core layer
comprises a honeycomb structure defining a grid of hexagonal
open-ended core cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Other objects, advantages and features will become more
apparent upon reading the following non-restrictive description of
embodiments thereof, given for the purpose of exemplification only,
with reference to the accompanying drawings in which:
[0044] FIGS. 1 and 1 a are perspective views of a first panel of a
thermal liner, according to an embodiment wherein all layers of all
the panels of the thermal liner substantially have the same surface
area, and wherein the first panel is shown in an extended
configuration in FIG. 1 and in an operative configuration (or "C"
shaped configuration) in FIG. 1a.
[0045] FIGS. 2 and 2a are perspective views of a second panel of
the thermal liner of the embodiment of FIGS. 1 and 1a, wherein the
second panel is shown in an extended configuration in FIG. 2 and in
an almost operative configuration (or "C" shaped configuration) in
FIG. 2a, i.e. the second panel is being folded into the operative
configuration.
[0046] FIG. 3 is a perspective view of the thermal liner comprising
the first panel of FIG. 1 and the second panel of FIG. 2, wherein
the thermal liner is shown with the first and second panels engaged
and defining a closed inner chamber (not shown).
[0047] FIGS. 4a to 4d are perspective views of the successive
insertion stages of the thermal liner of FIG. 3 in a container to
form a thermal container, wherein FIG. 4a shows the first panel
being inserted in the container, FIG. 4b shows the second panel
being inserted in the container with the first panel already
inserted therein, FIG. 4c shows the first panel and the second
panel inserted in the container and exposing the inner chamber and
FIG. 4d shows the container in a closed configuration.
[0048] FIGS. 5 and 5a are perspective views of a horizontally
extending first panel of a thermal liner, according to an
alternative embodiment wherein all layers of the first panel
substantially have the same surface area and an inner layer of a
second panel has a smaller surface area, and wherein the first
panel is shown in an extended configuration in FIG. 5 and in an
operative configuration (or "C" shaped configuration) in FIG.
5a.
[0049] FIGS. 6 and 6a are perspective views of the second panel of
the thermal liner of the embodiment of FIGS. 5 and 5a, wherein the
second panel is shown in an extended configuration in FIG. 6 and in
an almost operative configuration (or "C" shaped configuration) in
FIG. 6a, i.e. the second panel is being folded into the operative
configuration.
[0050] FIG. 7 is a perspective view of the thermal liner comprising
the first panel of FIG. 5 and the second panel of FIG. 6, wherein
the thermal liner is shown with the panels engaged and defining a
closed inner chamber (not shown).
[0051] FIGS. 8 to 10 are top plan views of the panels of a thermal
liner, according to another alternative embodiment wherein the
panels are superposable to define a multi-layer thermal liner, with
FIG. 8 showing an outer panel, FIG. 9 showing an inner panel and
FIG. 10 showing an annular panel of the thermal liner.
[0052] FIG. 11 is a perspective view of the outer panel, inner
panel and annular panel of FIGS. 8 to 10 shown with the panels
partially engaged and defining a closeable inner chamber.
[0053] FIG. 12 is a graph showing the test results regarding the
insulation performance of the thermal container having different
thermal liner configurations, as a function of the quantity of
humidity.
DETAILED DESCRIPTION
[0054] In the following description, the same numerical references
refer to similar elements. The embodiments, geometrical
configurations, materials mentioned and/or dimensions shown in the
figures or described in the present description are embodiments
only, given solely for exemplification purposes.
[0055] Moreover, although the embodiments of the thermal liner and
thermal container comprising the thermal liner consist of certain
components and geometrical configurations, as explained and
illustrated herein, not all of the components and geometries are
essential and thus should not be taken in their restrictive sense.
It is to be understood, as also apparent to a person skilled in the
art, that other suitable components and cooperation thereinbetween,
as well as other suitable geometrical configurations, may be used
for thermal liner and thermal container comprising the thermal
liner, as will be briefly explained herein and as can be easily
inferred herefrom by a person skilled in the art. Moreover, it will
be appreciated that positional descriptions such as "above",
"below", "left", "right" and the like should, unless otherwise
indicated, be taken in the context of the figures and should not be
considered limiting.
[0056] In general terms, there is provided a thermal liner and a
thermal container, such as a cardboard box or the like, comprising
the thermal liner, wherein the thermal liner includes a plurality
of insulating and superposed core layers (i.e. the core of the
thermal liner includes at least two superposed layers). In an
embodiment, each one of the core layers includes geometrically
patterned cells and the core layers are separated by at least one
layer separation sheet (or intermediate sheet). The thermal liner
includes a plurality of planar panel sections, each lining a
corresponding wall of the container when the thermal liner is
inserted inside the container. The combination of the thermal liner
and container defines a thermal container having a thermal liner
with at least two layers of geometrically patterned cells lining
each wall of the container, thereby providing advantageous thermal
properties.
[0057] One skilled in the art will understand that such a thermal
liner having a plurality of insulating core layers can have many
different configurations. For example and without being limitative,
according to different embodiments, the thermal liner having a
plurality of insulating core layers can include only one or a
plurality of panels engageable with one another to form the thermal
liner. Some of the possible embodiments are described below, but
one skilled in the art will understand that several additional
embodiments, different from the ones described below could also be
provided.
[0058] Referring generally to FIGS. 1 to 3, a first embodiment of
the thermal liner 10 for providing thermal insulation in a
container 15 (see FIG. 4) is shown. The thermal liner 10 includes a
first panel 20 and a second panel 40 engageable with one another in
order to form the thermal liner 10 defining a closable inner
chamber 11 (See FIG. 4c). Each one of the first panel 20 and the
second panel 40 is formed from a liner blank.
[0059] The liner blank of the first panel 20 includes an inner
sheet 22, an outer sheet 24 and a core 26. The core 26 separates
the inner sheet 22 from the outer sheet 24 and creates an array of
cells therebetween. In the embodiment shown, the core 26 is
composed of at least two core layers 27, 28 of geometrically
patterned structures, separated by a layer separation sheet 29 (or
intermediate sheet). In the embodiment shown, the core 26 includes
a first core layer 27 extending between the inner sheet 22 and the
layer separation sheet 29 and defining an array of cells
therebetween and a second core layer 28 extending between the layer
separation sheet 29 and the outer sheet 24 and defining an array of
cells therebetween. In the embodiment shown, the two core layers
27, 28 of the thermal liner have substantially the same surface
area.
[0060] The liner blank of the second panel 40 also includes an
inner sheet 42, an outer sheet 44 and a core 46 separating the
inner sheet 42 from the outer sheet 44 to create an array of cells
therebetween. Once again, the core 46 is composed of at least two
core layers 47, 48 of geometrically patterned structures, separated
by a layer separation sheet 49. In the embodiment shown, the core
46 of the second panel 40 once again includes a first core layer 47
extending between the inner sheet 42 and the layer separation sheet
49 and defining an array of cells therebetween and a second core
layer 48 extending between the layer separation sheet 49 and the
outer sheet 44 and defining an array of cells therebetween. One
skilled in the art will once again understand that, in alternative
embodiments (not shown), the core 46 can include more than two core
layers, with each additional core layer being separated from an
adjacent core layer by an additional layer separation sheet. In the
embodiment shown, the two core layers 47, 48 of the thermal liner
also have substantially the same surface area.
[0061] One skilled in the art will also understand that, in an
alternative embodiment (not shown), the core 26, 46 of the first
panel 20 and/or the second panel 40 can include more than two core
layers, with each additional core layer being separated from an
adjacent core layer by an additional layer separation sheet.
Together, the inner sheet 22, 42, the outer sheet 24, 44 and the
core 26, 46 of the first panel 20 and the second panel 40 define
the thickness of the liner blank of the first panel 20 and the
second panel 40 in an expanded (or uncrushed) state.
[0062] In an embodiment, the inner sheets 22, 42 and/or the outer
sheets 24, 44 of the first panel 20 and second panel 40 include a
reflective surface 17. For example and without being limitative, in
an embodiment, the inner sheets 22, 42 and/or the outer sheets 24,
44 can include a metallized film, which can be laminated to a
cellulosic fiber based sheet, such as a Kraft liner board paper or
the like. In an embodiment, the metallized film can include a film
such as, for example and without being limitative, a polyethylene
film, a polypropylene film or the like, onto which aluminum is
vaporized. In an alternative embodiment, the inner sheets 22, 42
and/or the outer sheets 24, 44 can rather include a foil layer, or
a layer of other material offering reflective characteristics,
laminated to a plastic substrate, such as a polyethylene substrate,
a polyester substrate or the like which can further be laminated to
the cellulosic fiber based sheet. One skilled in the art will also
understand that, in other alternative embodiments, other
combinations of materials, such as reflective coatings, offering
reflective properties can also be used to provide a reflective
surface 17 of the inner sheets 22, 42 and/or the outer sheets 24,
44. In an embodiment, the reflective surface 17 is an outer surface
(e.g. the reflective film, layer or coating can line an outer
surface of the inner sheets 22, 42 and/or the outer sheets 24, 44,
facing away from the core 26, 46). One skilled in the art will
however understand that, in an alternative embodiment, the
reflective surface 17 can be an inner surface (e.g. the reflective
film, layer or coating can line an inner surface of the inner
sheets 22, 42 and/or the outer sheets 24, 44, facing towards the
core 26, 46).
[0063] One skilled in the art will understand that, in an
embodiment, the layer separation sheets 29, 49 can also include a
reflective surface (not shown). One skilled in the art will
understand that the reflective surface of the layer separation
sheets 29, 49 can be similar to the reflective surface described
above regarding the inner sheets 22, 42 and/or the outer sheets 24,
44. Hence, the possible alternatives for the reflective surface
described above regarding the inner sheets 22, 42 and/or the outer
sheets 24, 44 also apply to the reflective surface of the layer
separation sheets 29, 49. It will be understood that the reflective
surface of the layer separation sheets 29, 49 can be positioned on
either side or on both sides of the layer separation sheets 29,
49.
[0064] In an embodiment, the inner face of the inner sheet 22, 42
and an outer sheet facing surface of the layer separation sheet 29,
49 include the reflective surface. In other words, in such an
embodiment the reflective surface is an inner surface provided on
the inner sheet 22, 42 of the first panel 20 and second panel 40,
and an outer surface provided on the layer separation sheets 29, 49
of the first panel 20 and second panel 40.
[0065] One skilled in the art will understand that, in an
embodiment any one of the inner sheets 22, 42, outer sheets 24, 44
and/or layer separation sheets 29, 49 or all of these elements can
be free of reflective surface. In such an embodiment, the
corresponding ones of the inner sheets 22, 42, outer sheets 24, 44
and/or layer separation sheets 29, 49 can include only a cellulosic
fiber based layer, such as a Kraft liner board paper or the like.
Moreover, in an embodiment, different types of reflective surfaces
can be provided for each one of the inner sheets 22, 42, outer
sheets 24, 44 and/or layer separation sheets 29, 49.
[0066] In an embodiment, the inner sheets 22, 42, layer separation
sheets 29, 49 and/or the outer sheets 24, 44 of the first panel and
second panel can also include a liquid/vapor resistant barrier 18.
For example and without being limitative, in an embodiment, the
inner sheets 22, 42, layer separation sheets 29, 49 and/or the
outer sheets 24, 44 can include a liquid/vapor resistant film
laminated to a cellulosic fiber based sheet, such as a Kraft liner
board paper or the like. For example and without being limitative,
the liquid/vapor resistant film can be a polyethylene film, a
polypropylene film or the like. In an alternative embodiment, the
inner sheets 22, 42, layer separation sheets 29, 49 and/or the
outer sheets 24, 44 can rather include a liquid/vapor resistant
coating applied to the cellulosic fiber based sheet. Numerous types
of liquid/vapor resistant coating could be applied to the
cellulosic fiber based sheet. For example and without being
limitative, coatings including aqueous dispersion of polymers or
copolymers which are capable to provide the above mentioned
properties could be used, such as Michem.RTM.Coat 81 and
Michem.RTM.Coat 82 which comprise a styrene-butadiene copolymer;
VaporCoat.RTM. 2200R from the company Michelman, the products
Spectra-Guard.TM. 3007BK and Spectra-Guard.TM. 3003 both from the
company Spectra-kote Corp., Tribinder from the company Tri-Tex Co
inc., and Aqualene.RTM. 5050 from Aqua Based Technologies which all
are acrylic based products; ESACOTE.RTM. PU DP 170/N which comprise
a polyurethane; or Cartabond.RTM. SMH Liquid from the company
CLARIANT, which is a polyvinylalcohol based aqueous dispersion. In
another alternative embodiment, the inner sheets 22, 42, layer
separation sheets 29, 49 and/or the outer sheets 24, 44 can also
include a liquid/vapor resistant film such as a polyethylene film
or the like, without cellulosic fiber based sheet.
[0067] One skilled in the art will understand that, in an
embodiment, the above described reflective surface 17 can operate
as liquid/vapor resistant barrier (i.e. the reflective surface 17
can provide the desired liquid/vapor resistant properties).
Therefore, in an embodiment, no specific liquid/vapor barrier 18 is
required along the inner sheets 22, 42, layer separation sheets 29,
49 and/or the outer sheets 24, 44, when a reflective surface 17 is
provided thereon. Hence, in an embodiment where the inner sheets
22, 42 include the reflective surface 17, no additional
liquid/vapor resistant barrier 18 is required along the inner
sheets 22, 42, the reflective surface operating as a liquid/vapor
resistant barrier 18.
[0068] In an embodiment, the inner sheet 22, 42 and the outer sheet
24, 44 include the liquid/vapor resistant barrier 18. As mentioned
above, in an embodiment, the liquid/vapor resistant barrier
provided along the inner sheet 22, 42 can be provided by the
reflective surface 17 thereof.
[0069] In an embodiment, the geometrically patterned structures of
each core layer 27, 28, 47, 48 of the core 26, 46 of the first
panel 20 and second panel 40 include a plurality of cellulosic
fiber based structures extending between the corresponding one of
the inner sheet 22, 42, the outer sheet 24, 44 and the layer
separation sheet 29, 49. For example and without being limitative,
in an embodiment, the plurality of cellulosic fiber based
structures are honeycomb structures (or honeycomb cells) formed by
cellulosic fiber based walls, such as Kraft paper walls or the
like, extending transversely between the inner sheet 22, 42 and the
layer separation sheet 29, 49 for the first layer 27, 47 and
between the layer separation sheet 29, 49 and the outer sheet 24,
44 for the second layer 28, 48. One skilled in the art will
understand that, in alternative embodiments, other structures
providing the array of cells between the corresponding one of the
inner sheet 22, 42, outer sheet 24, 44 and layer separation sheet
29, 49 could also be provided.
[0070] In the course of the present document, the term "honeycomb
structure" is understood to mean a three-dimensional geometrically
patterned structure defining a grid of hexagonal open-ended core
cells and providing an enhanced strength for supporting and
protecting loads. As will be easily understood, the honeycomb
structure creates an air space as a result of the three-dimensional
geometrically patterned structure.
[0071] As will be described in more details below, in the
embodiment shown in FIGS. 1 to 3, each one of the first panel 20
and the second panel 40 is configurable between an extended
configuration, where the panels 20, 40 extend substantially
straight (see FIGS. 1 and 2), and an operative configuration (see
FIGS. 1 a and 2a) where the panels 20, 40 have a substantially "C"
shaped configuration. In order to allow such folding of the panels
20, 40 between the extended configuration and the operative
configuration, in an embodiment, each panel has crease lines formed
in the corresponding liner blank, thereby defining a plurality of
planar panel sections.
[0072] In the embodiment shown in FIGS. 1 to 3, the first panel 20
includes a central section 30, a first end section 32, and a second
end section 34. The first panel 20 has a first crease line 36
defined between the central section 30 and the first end section
32, and a second crease line 38 defined between the central section
30 and the second end section 34. Each one of the first crease line
36 and the second crease line 38 extends between a first
longitudinal edge 33 and a second longitudinal edge 35 opposed to
the first longitudinal edge 33 of the first panel 20, with the
first crease line 36 being substantially parallel to the second
crease line 38. The first crease line 36 and the second crease line
38 are also substantially parallel to the first lateral edge 37 and
the second lateral edge 39 of the second panel 40. One skilled in
the art will understand that, in an alternative embodiment (not
shown), each one of the first crease line 36 and the second crease
line 38 can extend between the first lateral edge 37 and the second
lateral edge 39, rather than between the first longitudinal edge 33
and the second longitudinal edge 35.
[0073] The second panel 40 also includes a central section 50, a
first end section 52 and a second end section 54. Once again, the
second panel has a first crease line 56 defined between the central
section 50 and the first end section 52, and a second crease line
58 defined between the central section 50 and the second end
section 54. Once again, each one of the first crease line 56 and
the second crease line 58 extends between a first longitudinal edge
53 and a second longitudinal edge 55 opposed to the first
longitudinal edge 53 of the second panel 40, with the first crease
line 56 being substantially parallel to the second crease line 58.
The first crease line 56 and the second crease line 58 are also
substantially parallel to the first lateral edge 57 and the second
lateral edge 59 of the second panel 40. One skilled in the art will
understand that, in an alternative embodiment (not shown), each one
of the first crease line 56 and the second crease line 58 can
extend between the first lateral edge 57 and the second lateral
edge 59, rather than between the first longitudinal edge 53 and the
second longitudinal edge 55.
[0074] In the embodiment shown in FIGS. 1 to 3, each one of the
central section 30, first end section 32 and second end section 34
of the first panel 20 and the central section 50, first end section
52 and second end section 54 of the second panel 40 has a square
shape with substantially the same surface area. Hence, the
resulting thermal liner 10 and defined inner chamber 11 thereof
(formed by engaging the first panel 20 and the second panel 40) is
of substantially cubical shape (see FIG. 3).
[0075] One skilled in the art will however understand that, in an
alternative embodiment (not shown) where the thermal liner 10 is of
a cuboid shape (i.e. defining a closed (or closeable) inner chamber
11 with six faces but of a shape different than a cubic shape), the
central section 30 of the first panel 20 can have a different size
and shape than the first end section 32 and the second end section
34 thereof and the central section 50 of the second panel 40 can
have a different size and shape than the first end section 52 and
the second end section 54 thereof. Moreover, the first end section
32 and the second end section 34 of the first panel 20 can have a
different size and shape than the first end section 52 and the
second end section 54 of the second panel 40.
[0076] In an embodiment, each crease line 36, 38, 56, 58 of the
first panel 20 and second panel 40 is formed into the liner blank
from the inner sheet 22, 42 and defines a "V" shaped channel
therein. In an embodiment, the angle between the walls of the "V"
shaped channel is such that the walls of the "V" shaped channels
defined by the crease lines 36, 38, 56, 58 are substantially
pressed against one another when the panels 20, 40 are configured
in the operative configuration. Such contact of the walls of the
"V" shaped channels against one another prevents the formation of
thermal bridges between adjacent sections 30, 32, 34, 50, 52, 54,
when the thermal liner 10 is used inside the container for
providing thermal insulation. In other words, the "V" shaped
channels are sized and shaped in accordance with the thickness of
the core 26, 46 of the first panel 20 and the second panel 40, to
allow folding of the panels 20, 40, between adjacent ones of the
sections 30, 32, 34, 50, 52, 54, while substantially preventing
thermal exchange at these junctions when the panels 20, 40 are
configured in the operative configuration.
[0077] In an embodiment and as can be seen more clearly in FIG. 3,
the first panel 20 and second panel 40 are sized such that when the
first panel 20 and the second panel 40 are configured in the
operative configuration and engaged together to form the thermal
liner 10, the edges 33, 35, 37 and 39 of the first panel 20 abut
against the inner sheet 42 of the second panel 40. Such abutment of
the edges 33, 35, 37 and 39 of the first panel 20 against the inner
sheet 42 of the second panel results in the first panel 20 and the
second panel 40 defining a closed (or closeable) inner chamber 11
therebetween. One skilled in the art will understand that, in an
alternative embodiment (not shown), the first panel 20 and second
panel 40 can also be sized such that when the first panel 20 and
the second panel 40 are configured in the operative configuration
and engaged together to form the thermal liner 10, the edges 53,
55, 57 and 59 of the second panel 40 abut against the inner sheet
22 of the first panel 40 to define the closed (or closeable) inner
chamber 11.
[0078] In view of the above, the closed (or closeable) inner
chamber 11 is defined by a bottom wall 11a, four side walls 11b and
a top wall 11c. Each one of the bottom wall 11a, side walls 11b,
and the top wall 11c includes an inner sheet 22, 42, an outer sheet
24, 44 and a layer separation sheet 29, 49. Moreover, a first core
layer 27, 47 extends between the inner sheet 22, 42 and the layer
separation sheet 29, 49 and defines a plurality of geometrically
patterned structures inbetween. A second core layer 28, 48 extends
between the outer sheet 24, 44 and the layer separation sheet 29,
49 and defines a plurality of geometrically patterned structures
inbetween. One skilled in the art will understand that, in
alternative embodiments (not shown), additional core layers and
corresponding layer separation sheets can also be provided.
[0079] In an embodiment (not shown), the bottom wall 11a, four side
walls 11b and top wall 11c can each include a different amount of
core layers. For example and without being limitative, in an
embodiment, the bottom wall 11a can include more core layers than
the four side walls 11b and top wall 11c.
[0080] Now referring to FIGS. 4a to 4d, a sequence of successive
insertion stages of the thermal liner 10 of FIGS. 1 to 3 into a
container 15, in accordance with an embodiment, will be described
in more details below. In the embodiment shown, the second panel 40
is initially inserted in the container 15, with the first end
section 52 lining the bottom of the container 15 (i.e. the first
end section 52 being juxtaposed to the bottom wall of the container
15), the central section 50 lining one of the sides of the
container 15 (i.e. the central section being juxtaposed to one of
the container side walls), and the second end section 54 unfolded
away from the entrance of an inner cavity of the container 15 to
allow access therein (see FIGS. 4a and 4b). Subsequently, the first
panel 20 is inserted in the container 15, with each one of the
sections 34, 30, 32 lining a corresponding one of the sides of the
container 15 (i.e. each one of the sections 34, 30, 32 being
juxtaposed to one of the container side walls) (see FIGS. 4b and
4c). Finally, the second end section 54 of the second panel 40 is
folded to close the thermal liner 10 (i.e. to define the closed
inner chamber 11) and the container flaps are closed over the
second end section 54 to close the container 15 with the second end
section 54 lining the container flaps (i.e. the second end section
54 being juxtaposed to the closed container flaps). One skilled in
the art will understand that, in alternative embodiments (not
shown), other insertion sequences can be performed in order to
insert the above-described thermal liner 10 into the container 15
where the thermal liner 10 substantially lines the inner surface of
the walls of the container 15.
[0081] One skilled in the art will understand that, as mentioned
above other panel assemblies or configuration thereof, different
from the above-described assembly defining the thermal liner 10 can
be foreseen in order to provide a thermal liner 10 defining the
closed inner chamber delimited by a bottom wall 11a, four side
walls 11b and a top wall 11c, each having multiple core layers. For
example and without being limitative, alternative embodiments are
described below.
[0082] Referring to FIGS. 5 to 7, there is shown an alternative
embodiment of the thermal liner 110 wherein similar features are
numbered using the same reference numerals in the 100 series. In
the alternative embodiment of FIGS. 5 to 7, the thermal liner 110
once again includes a first panel 120 and a second panel 140
engageable with one another in order to define the thermal liner
110. The first panel 120 and second panel 140 of this alternative
embodiment are similar to those of the above-described embodiment
and the teachings regarding the above-described first panel 20 and
second panel 40 and components thereof also apply and need not be
repeated herein.
[0083] The first panel 120 of this alternative embodiment is
similar to the first panel 20 of the previously described
embodiment and includes an inner sheet 122, an outer sheet 124 and
a core 126 composed of at least two core layers 127, 128 of
geometrically patterned structures, separated by a layer separation
sheet 129. The first panel 120 also includes a first crease line
136 defined between the central section 130 and the first end
section 132 and a second crease line 138 defined between the
central section 130 and the second end section 134. As can be seen
in FIGS. 5 and 5a, the two layers 127, 128 of the core 126 of the
first panel 120 have substantially the same surface area.
[0084] The second panel 140 also includes an inner sheet 142, an
outer sheet 144 and a core 146 having at least two core layers 147,
148 of geometrically patterned structures, separated by a layer
separation sheet 149. The second panel 140 also includes a first
crease line 156 defined between the central section 150 and the
first end section 152 and a second crease line 158 defined between
the central section 150 and the second end section 154. In this
alternative embodiment and as can be seen in FIGS. 6 and 6a, the
surface area of the inner layer 147 is smaller than the surface
area of the outer layer 148 of the core 146, such that the inner
layer 147 is inset with regard to the outer layer 148 (i.e. the
peripheral edge of the inner layer 147 is inwardly offset from the
peripheral edge of the outer layer 148).
[0085] In an embodiment, the distance of which the inner layer 147
is inset with regard to the outer layer 148, substantially
corresponds to the thickness of the first panel 120, such that the
edges 133, 135, 137 and 139 of the first panel 120 abut against the
layer separation sheet 149 of the second panel 140 rather than onto
the inner sheet 122. In such an embodiment, the resulting thermal
liner 110 once again has a double layer core along substantially
the entire bottom wall 111a, four side walls 111b and top wall 111c
defining the inner chamber 111. As will be understood, the
peripheral sections of the bottom wall 111a, side wall 111b and/or
top wall 111c where the core 146 of the second panel 140 includes
only the outer layer 148, has the first panel 120 juxtaposed
thereon, such that no single layer section is provided along the
bottom wall 111a, four side walls 111b and top wall 111c defining
the inner chamber 111.
[0086] One skilled in the art will understand that, in an
alternative embodiment (not shown), the first panel 120 can have an
inner core layer 127 inset with regard to the outer layer 128,
while the two core layers 147, 148 of the core 146 of the second
panel 140 have substantially the same surface area. In another
alternative embodiment (not shown), both the first panel 120 and
the second panel 140 can have an inner core layer 127, 147 inset
with regard to the outer layer 128, 148 along opposed connecting
edges (i.e. the inner core layer 127, 147 of one of the first panel
120 and the second panel 140 can be inset along a portion thereof,
with the inner core layer 127, 147 of the other one of the first
panel 120 and the second panel 140 being inset along a
complementary portion thereof).
[0087] The first panel 120 and second panel 140 can also include a
reflective surface 117 and/or a liquid/vapor resistant barrier 118,
similarly to the above described embodiment of FIGS. 1 to 3.
[0088] Now referring to FIGS. 8 to 11, there is shown another
alternative embodiment of the thermal liner 210 wherein similar
features are numbered using the same reference numerals in the 200
series. In the alternative embodiment of FIGS. 8 to 11, the thermal
liner 210 includes an assembly of three panels engageable with one
another to form the thermal liner 210. The assembly includes an
outer panel 260, an inner panel 270 and an annular panel 280.
[0089] Each one of the outer panel 260, inner panel 270 and annular
panel 280 is formed from a liner blank including an inner sheet
262, 272, 282, an outer sheet 264, 274, 284 and a core 266, 276,
286 separating the inner sheet 262, 272, 282 and the outer sheet
264, 274, 284 to create an insulating space therebetween. The core
266, 276, 286 of each panel 260, 270, 280 is composed of at least
one layer of geometrically patterned structures such as, for
example, a plurality of cellulosic fiber based structures. For
example, the plurality of cellulosic fiber based structures can
once again be honeycomb-shaped cells formed by cellulosic fiber
based walls or the like, extending transversally between the inner
sheets 262, 272, 282 and outer sheets 264, 274, 284 (and any layer
separation sheet if more than one core layer is provided).
[0090] Similarly to the above-described embodiment, the inner
sheets 262, 272, 282 and/or the outer sheets 264, 274, 284 of the
outer panel 260, inner panel 270 and annular panel 280 can include
a reflective surface 217. Once again the teaching of the
above-described embodiments regarding possible reflective surface
217 can be applied herein and will not be repeated.
[0091] Moreover, similarly to the above-described embodiment, the
inner sheets 262, 272, 282 and/or the outer sheets 264, 274, 284 of
the outer panel 260, inner panel 270 and annular panel 280 can
include a liquid/vapor resistant barrier (not shown). Once again
the teaching of the above-described embodiments regarding possible
liquid/vapor resistant barriers can be applied herein and will not
be repeated.
[0092] Once again, each one of the outer panel 260, the inner panel
270 and the annular panel 280 is configurable between an extended
configuration, where the panels 260, 270, 280 extend substantially
straight (see FIGS. 8 to 10), and an operative configuration (see
FIG. 11). In order to allow such folding of the panels 260, 270,
280 between the extended configuration and the operative
configuration, each panel has crease lines 268, 278, 288 formed in
the corresponding liner blank, thereby defining a plurality of
planar panel sections for each panel 260, 270, 280.
[0093] In the embodiment shown, each panel 260, 270, 280 includes a
central section 261, 271, 281, two intermediate sections 263, 265,
273, 275, 283, 285 and two end sections 267, 269, 277, 279, 287,
289. Crease lines 268, 278, 288 are defined between each adjacent
sections of each one of the panel such that the central sections
261, 271, 281 are pivotally connected to the corresponding ones of
the intermediate sections 263, 265, 273, 275, 283, 285 and the
intermediate sections 263, 265, 273, 275, 283, 285 are pivotally
connected to the corresponding ones of the end sections 267, 269,
277, 279, 287, 289. Once again, each crease line 268, 278, 288
extends between longitudinal edges of the corresponding panels 260,
270, 280, with the crease lines of each panel being substantially
parallel to one another.
[0094] As can be seen in FIG. 11, when the outer panel 260, the
inner panel 270 and the annular panel 280 are engaged with one
another in order to define the inner chamber 211, the panels are
configured to be arranged such that they combine to provide at
least two layers for each one of the bottom wall 211a, side walls
211b, and the top wall 211c defining the inner chamber 211.
[0095] More particularly, the outer panel 260 and the inner panel
270 are arranged crosswise, with the annular panel 280 being
subsequently inserted transversally in the cavity formed by the
outer panel 260 and the inner panel 270, to line the side walls
thereof. Hence, when the outer panel 260, the inner panel 270 and
the annular panel 280 are engaged with one another in order to form
the thermal liner 210 and define the inner chamber 211, the central
sections 261, 271 of the outer panel 260 and the inner panel 270
are superposed to define the bottom wall 211a, with the
intermediate sections 263, 265, 273, 275 extending substantially
perpendicularly therefrom to define one of the side walls 211b. The
central section 281 and end sections 287, 289 of the annular panel
280 are superposed to the intermediate sections 263, 265, 273, 275
of one of the outer panel 260 and the inner panel 270. The
intermediate sections 283, 285 of the annular panel 280 are
superposed to the intermediate sections 263, 265, 273, 275 of the
other one of the outer panel 260 and the inner panel 270. The end
sections 267, 269, 277, 279 of the outer panel 260 and the inner
panel 270 are superposed to define the top wall of the liner
210.
[0096] In view of the above, each one of the bottom wall 211a, the
side walls 211b and the top wall 211c defining the inner chamber
211 includes two superposed planar sections of two of the outer
panel 260, the inner panel 270 and the annular panel 280. Since
each section has a core of at least one core layer, the resulting
thermal liner 210 defines an inner chamber 211 with walls having at
least two core layers each. As will be easily understood, in such
an embodiment, the superposed inner sheet and outer sheet of the
planar sections of the corresponding ones of the two of the outer
panel 260, the inner panel 270 and the annular panel 280 are
located between the two core layers and hereby define intermediate
sheets extending between the core layers.
[0097] One skilled in the art will once again understand that the
size and shape of the sections of the outer panel 260, the inner
panel 270 and the annular panel 280 can be varied from the
embodiment shown, in order to provide a thermal liner 210 of a
different cuboid shape than the one of the embodiment shown.
[0098] In view of the above, it will be understood that a thermal
liner 10, 110, 210, having multiple core layers advantageously
improves the thermal protection properties of the thermal liner 10,
110, 210. Moreover, in an embodiment, the above described thermal
liner and associated thermal container are substantially entirely
made of recyclable cellulosic fiber based material, such as paper,
and therefore provides a thermal liner and corresponding thermal
container offering a sustainable packaging solution which
substantially avoids the need of sending waste to landfill once the
thermal and/or container has been used and is no longer
required.
EXAMPLE
[0099] Tests were conducted on a thermal liner of an exemplary
embodiment (not shown), which includes the above described
characteristics and, as can be seen in the test results presented
below, the thermal liner of the exemplary embodiment showed
improved thermal properties.
[0100] The thermal liner of the exemplary embodiment included a
double layer core of about 1/2 inch each, with a reflective surface
on the outer facing surface of the layer separation sheet and the
inner facing surface of the inner sheet. In the exemplary
embodiment, the reflective surface 117 was a metallized film
laminated to the cellulosic fiber based sheet of the layer
separation sheet and the inner sheet. Moreover, the thermal liner
of the exemplary included a liquid/vapor resistant barrier on the
inner and outer sheets. In the exemplary embodiment, the metallized
film of the inner facing surface of the inner sheet operated as a
liquid/vapor resistant barrier and a polyethylene film was
laminated to the cellulosic fiber based sheet of the outer
sheet.
[0101] Tests were conducted between a thermal container having a
thermal liner with a multiple layer core and a thermal container
having a thermal liner with a single layer core to compare the time
required for a protein of a meal placed therein to reach 4.degree.
Celsius. In the test, each layer of the core was a 1/2 inch
honeycomb structure layer and a Kraft liner board paper was used as
a layer separation sheet between each one of the core layer. The
container content remained the same for each one of the tests and
corresponded to approximately two meals for two adults with the ice
initially added being at approximately -18.degree. C. The results
of the test are shown in the table below:
TABLE-US-00001 Time Content Ice Time to reach 4.degree. Celsius to
reach 4.degree. Celsius of the quantity (hours) (hours) container
(pounds) Single Layer Core Double layer core meal 2 13.1 15.8 4
21.5 26.8 6 27.9 33.1 8 29.75 36.5 10 38.7 -- 12 41.5 56.2
[0102] As can be seen from the test results above, for a same
thickness, the thermal liner having a double layer core
significantly outperformed the thermal liner having a single layer
core for every ice quantity. The difference between the two thermal
liners increases with the quantity of ice provided in the thermal
liner inserted in the container. It should be noted that the test
results for the thermal liner having a double layer core with an
ice quantity of 10 pounds have not been included in the present
test results, given that the container has been damaged during the
test and therefore the results obtained were not accurate.
[0103] More importantly, additional tests were performed in order
to measure the thermal conductivity and thermal resistivity of a
section of honeycomb cardboard panel depending on the thickness
thereof and the amount of layer cores.
[0104] In a first test, sections of honeycomb cardboard panels of
different thicknesses (but always having a single core) were
tested. The results are presented in the table below:
TABLE-US-00002 single material diameter thickness conductivity
resistivity # of added (in) (in) (W/mK) (Km/W) layers 0.75 0.442
0.0670 14.945 1 0.75 0.462 0.0690 14.493 1 0.75 0.927 0.1110 8.979
1 0.75 0.945 0.0951 10.520 1 0.75 1.413 0.1101 9.083 1 0.75 2.483
0.1600 6.246 1 0.75 2.496 0.1322 7.564 1 0.75 3.772 0.1498 6.676
1
[0105] As can be seen, these tests show that the thermal
conductivity increases along with increase in thickness of the
panel core. This is an unexpected result given that the increase of
the thickness increases the air quantity in the core (air having
low thermal conductivity of approximately 0.026W (m K).sup.-1).
Hence, in view of these tests, it appears that simply increasing
the thickness of the panels forming the thermal liner would not
result in an increase in thermal protection properties.
[0106] Additional tests were performed in order to measure the
thermal conductivity as a function of the amount of layers of the
core.
[0107] The table below shows the test results for core layers of
about 1 inch
TABLE-US-00003 diameter thickness conductivity resistivity # of
added in (in) (W/mK) (Km/W) layers 0.75 0.945 0.0951 10.520 1 0.75
1.878 0.1000 10 2 0.75 2.823 0.1036 9.653 3 0.75 3.76 0.1046 9.560
4
[0108] The table below shows the test results for core layers of
about 1/2 inch:
TABLE-US-00004 diameter thickness conductivity resistivity # of
added in (in) (W/mK) (Km/W) layers 0.75 0.442 0.0670 14.945 1 0.75
0.462 0.0690 14.493 1 0.75 0.908 0.0720 13.960 2 0.75 0.925 0.0735
13.605 2 0.75 1.366 0.0740 13.484 3 0.75 1.378 0.0752 13.298 3 0.75
1.824 0.0750 13.371 4 0.75 1.713 0.0759 13.175 4 0.75 3.681 0.07803
12.82 8
[0109] The table below shows the test results for core layers of
about 1/4 inch:
TABLE-US-00005 diameter thickness conductivity resistivity # of
added in (in) (W/mK) (Km/W) layers 0.625 0.256 0.05735 17.437 1
0.625 0.528 0.0607 16.464 2 0.625 1.059 0.06452 15.499 4 0.625
2.110 0.06842 14.616 8 0.625 4.055 0.06999 14.288 16
[0110] In view of the above, the tests have shown that
superposition of multiple layers of smaller thicknesses yields a
better insulating capacity (smaller thermal conductivity) than a
corresponding panel with a single layer of a greater thickness
matching the overall thickness of the multiple layers. Hence, in
view of the above, it appears that it is advantageous to provide
the thermal liner with a multiple layer core, in order to increase
the thermal capacities thereof.
[0111] Furthermore simulations were conducted in order to verify
that the position of a reflective surface within the core of a
honeycomb cardboard panel, as is the case in the exemplary
embodiment, impacted on the thermal conductivity thereof.
[0112] In the simulations, four surfaces within the core of a
double layer honeycomb cardboard panel were tested (i.e. tests were
performed with reflective surfaces on the different surfaces of an
inner sheet, outer sheet and layer separation sheet of the panel).
The table below provides the results of the simulations wherein the
surfaces are indicated as follows: (1) the inner facing surface of
an outer sheet (i.e. the surface of the outer sheet facing towards
the inner sheet); (2) the outer facing surface of the layer
separation sheet (i.e. the surface of the layer separation sheet
facing towards the outer sheet); (3) the inner facing surface of
the layer separation sheet (i.e. the surface of the layer
separation sheet facing towards the inner sheet); and (4) the inner
facing surface of the inner sheet (i.e. the surface of the inner
sheet facing towards the outer sheet).
TABLE-US-00006 Reflective surfaces k.sub.eff (W (m K).sup.-1) None
0.0598 1, 2, 3, 4 0.0436 1, 2 0.0510 1, 3 0.0499 1, 4 0.0494 2, 3
0.0496 2, 4 0.0493 3, 4 0.0498
[0113] In view of the above, it is understood that simulations
confirmed that the combination which yields the best results is to
provide a reflective surface on the outer facing surface of the
layer separation sheet and the inner facing surface of the inner
sheet.
[0114] Finally, referring to FIG. 12, tests were also conducted in
order to measure the insulation performance of the thermal
container having different thermal liner configurations, as a
function of the quantity of humidity. Three thermal liner
configurations were tested. In the first configuration (indicated
by hatched dots in FIG. 12), the thermal liner included a
Monaxially Oriented Polypropylene (MOPP) film (providing
liquid/vapor resistant properties) on the inner sheet and outer
sheet of the thermal liner, in the second configuration (indicated
by black dots in FIG. 12), the thermal liner included a MOPP film
(providing liquid/vapor resistant properties) on the inner sheet
and a Polyethylene film (also providing liquid/vapor resistant
properties) on the outer sheet of the thermal liner, and in the
third configuration (indicated by white dots in FIG. 12), the
thermal liner included a MOPP film (providing liquid/vapor
resistant properties) on the inner sheet and an uncoated cellulosic
fiber based sheet (substantially not providing liquid/vapor
resistant properties) as outer sheet.
[0115] As can be seen in FIG. 12, both the first configuration and
the second configuration of the thermal liner (including
liquid/vapor resistant barriers on the inner sheet and outer sheet
of the thermal liner) perform substantially equally and offer no
substantial insulation performance variation even when the quantity
of humidity increases. However, the third configuration (where a
liquid/vapor resistant barrier is provided on the inner sheet only)
shows a significant decrease in insulation performance when the
quantity of humidity increases. Indeed, the test results show that
the insulation performance decreases of about 40% between a
quantity of humidity of about 10 g/kg of dry air and about 20 g/kg
of dry air, which is significant. In view of the above, the test
results that the presence of a liquid/vapor resistant barrier on
the inner and outer sheets improves the insulation performance of
the thermal liner as opposed to only providing a liquid/vapor
resistant barrier on the inner sheet.
[0116] Several alternative embodiments and examples have been
described and illustrated herein. The embodiments of the invention
described above are intended to be exemplary only. A person skilled
in the art would appreciate the features of the individual
embodiments, and the possible combinations and variations of the
components. A person skilled in the art would further appreciate
that any of the embodiments could be provided in any combination
with the other embodiments disclosed herein. It is understood that
the invention may be embodied in other specific forms without
departing from the central characteristics thereof. The present
examples and embodiments, therefore, are to be considered in all
respects as illustrative and not restrictive, and the invention is
not to be limited to the details given herein. Accordingly, while
specific embodiments have been illustrated and described, numerous
modifications come to mind without significantly departing from the
scope of the invention as defined in the appended claims.
* * * * *