U.S. patent application number 15/977520 was filed with the patent office on 2018-09-13 for insulated container.
The applicant listed for this patent is Menzel Diversified Enterprises, LLC. Invention is credited to Robert W. s, JR., David Kevin Vance.
Application Number | 20180257844 15/977520 |
Document ID | / |
Family ID | 63446105 |
Filed Date | 2018-09-13 |
United States Patent
Application |
20180257844 |
Kind Code |
A1 |
s, JR.; Robert W. ; et
al. |
September 13, 2018 |
INSULATED CONTAINER
Abstract
An insulated container may include a rigid container surrounding
an insulation layer formed from a post-industrial, pre-consumer
card waste. The insulation layer may include a natural fiber
lamination layer on an outer surface of the insulation layer or may
be housed in a biodegradable plastic. The insulated layer may be
manufactured in a capital "T" shape such that it may be folded for
compact transportation prior to end use. The folded insulation
layer may bound by a separable band. The separable band may be
removed when folded insulation layer is placed in the rigid
container. The insulation layer and the band may be biodegradable
in an anaerobic environment.
Inventors: |
s, JR.; Robert W.;
(Mooresville, NC) ; Vance; David Kevin; (Concord,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Menzel Diversified Enterprises, LLC |
Mooresville |
NC |
US |
|
|
Family ID: |
63446105 |
Appl. No.: |
15/977520 |
Filed: |
May 11, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US18/32101 |
May 10, 2018 |
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15977520 |
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PCT/US2017/018461 |
Feb 17, 2017 |
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PCT/US18/32101 |
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62609102 |
Dec 21, 2017 |
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62338136 |
May 18, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 81/3862 20130101;
B32B 2439/80 20130101; B32B 37/18 20130101; B65D 81/3858 20130101;
B65D 65/466 20130101; Y02W 90/10 20150501; Y02W 90/13 20150501;
B32B 2439/62 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 65/46 20060101 B65D065/46; B32B 37/18 20060101
B32B037/18 |
Claims
1. An insulation layer for an insulated container comprising: an
insulation layer, operating from an unfolded position, to a folded
position, to a partially folded operating position and comprising a
capital "T" shape in the unfolded position; and a band wrapped
around the insulation layer in the folded position; wherein the
insulation layer is formed from a post-industrial, pre-consumer
cotton waste.
2. The insulation layer of claim 1 wherein the insulation layer is
characterized by a lack of any wrapping material and an outer
contact surface is the post-industrial, pre-consumer cotton
waste.
3. The insulation layer of claim 1 wherein the insulation further
comprises a natural fiber lamination layer attached to contact
surface of the post-industrial, pre-consumer cotton waste.
4. The insulation layer of claim 1 wherein the insulation layer
further comprises a biodegradable plastic wrapping which envelops
the insulation layer.
5. The insulation layer of claim 1 wherein the band completely
encircles the insulation pad in the folded position.
6. The insulation layer of claim 5 wherein the band has a width
which is less than 20 percent of a width of the insulation layer in
the folded position. The insulation layer of claim 6 wherein the
band is made from a biodegradable material.
8. The insulation layer of claim 6 wherein the band is made from
paper.
9. The insulation layer of claim 6 wherein the band further
comprises a first end and a second end which are attached when the
band is wrapped around the insulation layer in the folded
position.
10. The insulation layer of claim 1 wherein the insulation layer is
capable of maintaining a constant internal temperature for 48 hours
where three 500 ML and two 250 ML IV bags are cooled by four 24 oz
frozen ice packs placed at the top and bottom below a payload.
11. A method of preparing an insulated container comprising the
steps of: providing an insulation layer formed in a capital "T"
shape in an unfolded, flat position; folding the insulation layer
into a folded, compact position; and wrapping and securing a band
around the insulation layer in the folded position.
12. The method of preparing an insulated container of claim 11
further comprising the steps of: providing a rigid container;
placing the insulation layer, in the folded position, into the
rigid container; separating the band; partially unfolding the
insulation layer to form a void in the center of the insulation
layer; and placing a product in the void.
13. The method of preparing an insulation container of claim 11
wherein the insulation layer is formed from postindustrial,
pre-consumer cotton waste and is capable of maintaining a constant
internal temperature for 48 hours where three 500 ML and two 250 ML
IV bags are cooled by four 24 oz frozen ice packs placed at the top
and bottom below a payload.
14. A method of preparing an insulated container comprising the
steps of: providing an insulation layer formed in a pair of
rectangular pads in an unfolded, flat position; folding the
insulation layer into a folded, compact position; and wrapping and
securing a band around the insulation layer in the folded
position.
15. The method of preparing an insulated container of claim 14
further comprising the steps of: providing a rigid container;
placing the insulation layer, in the folded position, into the
rigid container; separating the band; partially unfolding the
insulation layer to form a void in the center of the insulation
layer; and placing a product in the void.
16. The method of preparing an insulation container of claim 14
wherein the insulation layer is formed from postindustrial,
pre-consumer cotton waste and is capable of maintaining a constant
internal temperature for 48 hours where three 500 ML and two 250 ML
IV bags are cooled by four 24 oz frozen ice packs placed at the top
and bottom below a payload.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation application claiming
priority to International Application No. PCT/US18/32101, filed on
May 10, 2018, which claims priority to U.S. Provisional Application
No. 62/609,102, filed on Dec. 21, 2017. This application also
claims priority as a continuation-in-part of Hague Design
Application No. 35/001,472, filed on Dec. 22, 2017. This
application also claims priority to U.S. Divisional patent
application Ser. No. 15/959,801 filed on Apr. 23, 2018, which
claims priority to U.S. patent application Ser. No. 15/436,417,
filed on Feb. 17, 2017 which claims priority to U.S. Provisional
Application No. 62/338,136, filed on May 18, 2016. This application
is also a Continuation-in-Part of PCT/US2017/018461, filed on Feb.
17, 2017, which claims priority to U.S. Provisional Application No.
62/338,136, filed on May 18, 2016. The contents of each application
are hereby incorporated by reference in their entireties.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to the field of containers and
to the field of insulated containers. More particularly, the
present invention relates to the field of insulated shipping
containers utilizing sustainable materials including recycled
post-industrial, pre-consumer natural fiber. The containers
according to the present invention may be used in transporting and
storing objects which may be at a temperature that is different
from the temperature outside the container.
[0003] Temperature sensitive products need to be transported from
time to time. For instance, certain medications may need to be kept
cool relative to temperatures outside of the container. In other
instances, food may need to be kept warm relative to temperatures
outside of the container. As a result of these needs, packaging has
been designed to maintain an internal temperature according the
requirements of the product. Some packaging may utilize
electro-mechanical devices such as refrigeration, heat exchangers,
or heat sinks in order to provide a required steady temperature.
Other packaging may utilize foams, plastics, and other polymers
along with cool packs, water ice, or dry ice in order to maintain
the required temperature environment inside the packaging.
[0004] However, many of these packages and devices are expensive
and heavy (as with the refrigeration and heat sinks) or are harmful
to the environment (as with some refrigeration and also the foams
and plastics) or both. Because of these problems, some have devised
products which may be made from post-consumer waste such as
recycled cotton gathered from used clothing. However, these
products may be prone to contamination from yarn dies, applied
chemicals, and other contaminants which the clothing may have
acquired during the period of use. The post-consumer material must
be cleaned and shredded ahead of reprocessing, however, this
process does not eliminate yarn dies and the possibility of
contaminants. Most post-consumer waste retains a blue colorization
after processing. Therefore, because of the contamination and
residual colorization issues these products require that any
insulation manufactured from post-consumer cotton be wrapped in
another material such as plastic. This use of plastic and other
barriers undermines the environmental incentive for using a
recycled product by posing additional environmental concerns. It
may also further add to the manufacturing costs.
[0005] Accordingly, there is a long felt need in the art for a
packaging material which affords safe transportation of temperature
sensitive materials, which has a consistent density, which
maintains an in internal temperature relative an external
temperature, which is efficiently and economically manufactured,
which is lightweight, and which minimizes negative impacts to the
environment.
[0006] Another problem in the art is that insulated containers are
often manufactured by a different company than a packager who sends
products. Or, the insulated containers may be made in a different
facility which may be some geographic distance away from where the
packager may ultimately place products in the package for shipment
to a consumer.
[0007] Accordingly, there is a long felt need in the art for a
package may be efficiently transported from a manufacturing
facility to a packaging facility for shipment to an end user.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is an insulated shipping container
which affords safe transportation of temperature sensitive
products, which has a consistent density, which maintains an in
internal temperature relative to an external temperature, which is
efficiently and economically manufactured, which is lightweight,
and which minimizes negative impacts to the environment.
[0009] The present invention may utilize post-industrial,
pre-consumer cotton waste. Post-industrial, pre-consumer cotton
waste may include fiber material gleaned and/or trimmed as part of
cotton manufacturing, and converting process.
[0010] Such fiber material, collected from the manufacturing
process, may contain small pieces of cotton seed pods and stems
removed as part of the manufacturing process. These fiber materials
have not been converted into finished products (such as clothing or
other fabrics). Thus, the present invention is directed to an
insulated shipping container utilizing unwrapped cotton waste as
the thermal insulating layer.
[0011] However, the invention is not limited only to waste
generated from a single manufacturing or converting process. As
such, post-industrial, pre-consumer waste may be from raw cotton
processing, cotton yarn manufacturing, cotton fabric manufacturing
and related processes such as carding, airlay, garneting, and other
similar methods of manufacturing.
[0012] According to one aspect of the invention, the use of
polyethylene film wrapped around pads manufactured from cotton
waste can be eliminated. No wrapping is required by the present
invention and exposed fibers alone can be utilized. Because the
fibers are pre-consumer, according to the present invention, the
risk of cross contamination from post-consumer recycled products is
eliminated.
[0013] Alternatively, a natural fiber lamination may be applied to
surfaces in order to provide a smoother surface wherein images and
indicia may be applied. The elimination of poly wrap may provide an
environmental benefit and also be a cost saving measure. The
entirety of the insulation layer, whether including fibers alone or
also including the laminated layer is biodegradable in anaerobic
environments.
[0014] According to one embodiment of the invention, the insulating
layer may have applied to it one or more natural fiber lamination
layers. The natural fiber lamination layer may be applied to an
outer surface of the insulating layer which may be a contact
surface. In some embodiments, the natural fiber lamination layer
may be applied to only one surface or may be applied to two
surfaces but need not be applied to side edge surfaces.
[0015] According to one embodiment of the invention, an insulated
container may include a rigid container surrounding an insulation
layer formed from a post-industrial cotton waste. The insulation
layer may be characterized by a lack of any wrapping material.
[0016] According to another embodiment of the invention, the rigid
container may be made from cardboard.
[0017] According to another embodiment of the invention, the rigid
container may be made from plastic. The plastic may be a reusable
plastic.
[0018] According to another embodiment of the invention, the
insulation layer may include a pair of interlocking C-shaped
members forming an enclosed cube shaped cavity. The interior of the
cube may form an interior portion of the insulated container.
[0019] According to another embodiment of the invention, the
interlocking C-shaped members, referred to as an "A" and a "B" pad,
may have a top portion which is integrally and hingedly formed in
the member for providing access to an interior portion of the
insulated container.
[0020] According to a method of practicing the invention, an
insulated container may be manufactured by providing a rigid
container and providing a quantity of post-industrial cotton waste.
This post-industrial cotton waste may then be processed into a
fiber sheet. The sheet made from the waste may be formed using a
variety of converting processes including, carding, airlay, and
needle punch to achieve a specified thickness and density. Next,
the sheet may be cut into rectangular sections. A pair of sections
may be arranged to form interlocking C-shaped members. The pair of
sections, referred to as an "A" pad and a "B" pad, may then be
placed into the rigid container.
[0021] According to another aspect of the method, the method may
further include the step of laminating a natural fiber lamination
layer to the fiber sheet.
[0022] According to another aspect of the method, the cotton waste
includes cotton waste generated from one or more of cotton
processing, cotton manufacturing, and/or cotton converting.
[0023] According to another aspect of the method, the insulation
layer is capable of maintaining a constant internal temperature for
48 hours where three 500 ML and two 250 ML IV bags are cooled by
four 24 oz frozen ice packs placed at the top and bottom below a
payload.
[0024] According to another aspect of the method, the insulation
layer is biodegradable in an anaerobic environment.
[0025] According to another aspect of the invention, both the rigid
container and the pair of sections of the insulation layer may be
provided to an end user in sheet form and may be assembled into the
insulated container by the end user.
[0026] According to another embodiment of the invention, the
insulated container may include an insulation layer formed from a
post-industrial, pre-consumer cotton waste, a rigid cardboard
container surrounding the insulation layer, and a natural fiber
lamination layer applied to a contact surface of the insulation
layer. According to such an embodiment, the cotton waste may
include cotton waste generated from one or more of cotton
processing, cotton manufacturing, and/or cotton converting.
According to such an embodiment, the insulation layer may be
biodegradable in an anaerobic environment. According to such an
embodiment, the insulation layer may be capable of maintaining a
constant internal temperature for 48 hours where three 500 ML and
two 250 ML IV bags are cooled by four 24 oz frozen ice packs placed
at the top and bottom below a payload.
[0027] According to one embodiment, the term biodegradable may mean
that the insulation layer will biodegrade completely within one
year or less when subjected to the biodegration dynamics contained
in ASTM D5511. According to the ASTM D5511 protocol, test reaction
mixture consisted of 10% shredded nitrile gloves, 10% Trypticase
Soy Broth, 10% Thioglycollate medium, 60% municipal solid waste,
and inoculated with concentrated inoculum (1.2.times.106 CFU/ml) of
aerobic and anaerobic mixed culture in 0.01 M phosphate buffer at
pH 7.2 placed in aerobic and anaerobic glass digesters, and
incubated at 37.5.degree.. Positive controls consisted of reaction
mixture above with lab-grade cellulose (100%, Aldrich) instead of
shredded test sample(s) while negative controls contained EDTA
lab-grade (100%, Aldrich) instead of shredded test sample(s) in the
test above. Reaction mixture was monitored at least daily, often
more frequently, and sampled weekly for CO2 production, trapped in
3 KOH bottles connected in series, over a period of 15 weeks when
cumulative CO2 production was observed. Biodegradation was deemed
to be positive (passed P test, 95 or >95% biodegradation) or
negative (failed test, 5 or <5% biodegradation), based on carbon
conversion. Percentages (%), actual observed versus theoretical
possible -based on total carbon content- were determined on a dry
weight basis.
[0028] According to another embodiment of the invention, an
insulation layer for an insulated container may include an
insulation layer, operating from an unfolded position, to a folded
position, to a partially folded operating position and having a
capital "T" shape in the unfolded position. A band may be wrapped
around the insulation layer in the folded position. The insulation
layer may be formed from a post-industrial, pre-consumer cotton
waste.
[0029] According to another embodiment of the invention, the
insulation layer is characterized by a lack of any wrapping
material and an outer contact surface is the post-industrial,
pre-consumer cotton waste.
[0030] According to another embodiment of the invention, the
insulation further may include a natural fiber lamination layer
attached to contact surface of the post-industrial, pre-consumer
cotton waste.
[0031] According to another embodiment of the invention, the
insulation layer may further include a biodegradable plastic
wrapping which envelops the insulation layer.
[0032] According to another embodiment of the invention, the band
may completely encircle the insulation pad in the folded
position.
[0033] According to another embodiment of the invention, the band
may have a width which is less than 20 percent of a width of the
insulation layer in the folded position.
[0034] According to another embodiment of the invention, the band
may be made from a biodegradable material.
[0035] According to another embodiment of the invention, the band
may be made from paper.
[0036] According to another embodiment of the invention, the band
may further comprise a first end and a second end which are
attached when the band is wrapped around the insulation layer in
the folded position.
[0037] According to another embodiment of the invention, the
insulation layer is capable of maintaining a constant internal
temperature for 48 hours where three 500 ML and two 250 ML IV bags
are cooled by four 24 oz frozen ice packs placed at the top and
bottom below a payload.
[0038] According to another embodiment of the invention, a method
of preparing an insulated container may include the steps of
providing an insulation layer formed in a capital "T" shape in an
unfolded, flat position; folding the insulation layer into a
folded, compact position; and wrapping and securing a band around
the insulation layer in the folded position.
[0039] According to another embodiment of the invention, the method
may further include the steps of providing a rigid container;
placing the insulation layer, in the folded position, into the
rigid container; separating the band; partially unfolding the
insulation layer to form a void in the center of the insulation
layer and; placing a product in the void.
[0040] According to another embodiment of the invention, a method
of preparing an insulated container comprising the steps of:
providing an insulation layer formed in a pair of rectangular pads
in an unfolded, flat position; folding the insulation layer into a
folded, compact position; and wrapping and securing a band around
the insulation layer in the folded position.
[0041] According to another embodiment of the invention, the method
may further include the steps of: providing a rigid container;
placing the insulation layer, in the folded position, into the
rigid container; separating the band; partially unfolding the
insulation layer to form a void in the center of the insulation
layer; and placing a product in the void.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Features, aspects and advantages of the present invention
are understood when the following detailed description of the
invention is read with reference to the accompanying drawings, in
which:
[0043] FIG. 1 is an exploded view of the insulated container in a
partially assembled state;
[0044] FIG. 2 is an exploded view of the insulated container in a
partially assembled state;
[0045] FIG. 3 is an exploded view of the insulated container in an
unassembled state;
[0046] FIG. 4 is an exploded view of the insulated container in a
partially assembled state;
[0047] FIG. 5 is an exploded view of the insulated container in a
partially assembled state;
[0048] FIG. 6 is an exploded view of the insulated container in a
partially assembled state;
[0049] FIG. 7 is an exploded view of the insulated container in a
partially assembled state;
[0050] FIG. 8 is an exploded view of the insulated container in a
partially assembled state;
[0051] FIG. 9 is a perspective view of the insulated container in
an assembled state;
[0052] FIG. 10 is a perspective view of the insulated container in
an assembled state;
[0053] FIG. 10A is sectional view of the insulated container;
[0054] FIG. 11 is an exploded view of the insulated container in a
partially assembled state and where the insulation layer does not
include the natural fiber lamination;
[0055] FIG. 12 is a heat stress chart;
[0056] FIG. 13 is a heat stress chart;
[0057] FIG. 14 is a cold stress chart;
[0058] FIG. 15A is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0059] FIG. 15B is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0060] FIG. 15C is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0061] FIG. 16 is a perspective view of an embodiment of the
insulated container in partially folded orientation;
[0062] FIG. 17 is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0063] FIG. 18 is a perspective view of an embodiment of the
insulated container in partially folded orientation;
[0064] FIG. 19 is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0065] FIG. 20 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0066] FIG. 21 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0067] FIG. 22 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0068] FIG. 23 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0069] FIG. 24 is a perspective view of an embodiment of the
insulated container in a folded orientation and being placed in a
rigid container;
[0070] FIG. 25 is a perspective view of an embodiment of the
insulated container in a folded orientation and placed in a rigid
container;
[0071] FIG. 26 is a perspective view of an embodiment of the
insulated container in a folded orientation, placed in a rigid
container, and being opened;
[0072] FIG. 27 is a perspective view of an embodiment of the
insulated container in an open position within the rigid
container;
[0073] FIG. 28 is a perspective view of an embodiment of the
insulated container in an open position within the rigid container
and having contents placed therein;
[0074] FIG. 29A is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0075] FIG. 29B is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0076] FIG. 29C is a perspective view of an embodiment of the
insulated container in an unfolded orientation;
[0077] FIG. 30 is a perspective view of an embodiment of the
insulated container in a partially folded orientation;
[0078] FIG. 31 is a perspective view of an embodiment of the
insulated container in a partially folded orientation;
[0079] FIG. 32 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0080] FIG. 33 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0081] FIG. 34 is a perspective view of an embodiment of the
insulated container in a folded orientation;
[0082] FIG. 35 is a perspective view of an embodiment of the
insulated container in a partially folded orientation and being
placed in a rigid container;
[0083] FIG. 36 is a perspective view of an embodiment of the
insulated container in a folded orientation and placed in a rigid
container;
[0084] FIG. 37 is a perspective view of an embodiment of the
insulated container in a folded orientation, placed in a rigid
container, and being opened;
[0085] FIG. 38 is a perspective view of an embodiment of the
insulated container in an open position within the rigid container;
and
[0086] FIG. 39 is a perspective view of an embodiment of the
insulated container in an open position within the rigid container
and having contents placed therein.
DETAILED DESCRIPTION OF THE INVENTION
[0087] Generally, FIGS. 1 through 8, show embodiments of the
invention with insulation layer 20 having a natural fiber
lamination layer 26 applied to contact surfaces. The contact
surfaces are surfaces which may come into contact with contents of
the container. Generally, FIG. 11 shows an alternate embodiment of
the invention where there is no natural fiber lamination layer and
the fibers of the insulation layer 20 are exposed to the contents
of the container. The embodiment utilizing the natural lamination
layer 26 may be preferred to the embodiment of FIG. 11 when a
shipper desires that the contents not come into contact with the
insulation layer, such as when shipping raw, unwrapped produce. The
natural fiber lamination layer 26 is sustainable and is
biodegradable. The natural fiber lamination layer 26 thus provides
a helpful option to companies seeking a smoother, more consistent
surface. The natural fiber lamination layer 26 may be made from a
coffee filter paper, kraft paper, and the like. Text and images
(not shown) may be printed on the lamination layer 26.
[0088] Referring to FIG. 1, an insulated container 10 is shown in a
partially assembled state. The insulated container 10 includes
rigid container 50 and insulation layer 20. The rigid container 50
may be a cardboard box as shown. The insulation layer 20 is made
from cotton waste. The cotton waste is processed into a sheet
formed using a variety of converting processes including, carding,
airlay, and needle punch to form a non-woven sheet. The insulation
layer 20 is formed to maintain uniform density and of a thickness
optimized for particular applications.
[0089] The sheet may then be cut into rectangles which may be bent
into a pair of C-shaped members, 22, 24. The first C-shaped member,
referred to as an "A" pad 22 forms lid portion 30 which is
connected to back side portion 32 via first hinge portion 31.
Bottom portion 34 is connected to back portion 32 via second hinge
portion 33.
[0090] Similarly, the second C-shaped member, referred to as a "B"
pad 24 forms first side portion 40 which is connected to front side
portion 24 via hinge 41. Second side portion 44 is connected to
front side portion 24 via hinge portion 43.
[0091] When assembled, as shown in FIG. 2, second C-shaped member
24 fits into a cavity formed by first C-shaped member 22 to form
the interlocking C-shapes of the insulation layer 20. As shown in
FIGS. 3-8, the insulation layer 20 of the insulated container 10
may be assembled by folding respective C-shaped members 22, 24. As
shown in FIG. 3, the C-shaped members 22, 24 may have in unfolded
state that is a flat rectangular shape. As shown in FIGS. 4-7,
hinges 31, 33 and 41, 43 may be formed by folding. These folds
separate the portions 30, 32, 34, 40, 42, 44 of each C-shaped
member 22, 24.
[0092] FIG. 9 shows the fully assembled insulated container 10 with
the lid of the rigid container 50 open. FIG. 10 visualizes the
cross-section A-A which is shown in FIG. 10A. In particular, the
cross section A-A shows the insulation layer 20 inside the rigid
container 50. The natural fiber lamentation layer 26 is shown on
the contact surfaces. Importantly, there is no plastic or
non-biodegradable layer between the insulation layer 20 and the
rigid container 50 as is present in the prior art of FIG. 2. That
is, there is no additional plastic housing surrounding the
insulation layer 20. Both to the rigid container 50 and the
internal cavity of the insulate container.
[0093] FIG. 11 shows the insulated container 10 of FIGS. 1-10A but
where the natural fiber insulation layer has not been added during
the manufacturing process. Accordingly, the cotton waste of the
insulation layer 20 is exposed.
[0094] An embodiment of the invention may be created wherein the
container is capable of maintaining a constant internal temperature
for 48 hours where three 500 ML and two 250 ML IV bags are cooled
by four 24 oz frozen ice packs. The ice packs are placed at the top
and bottom below the payload. FIG. 12 shows heat stress test
results which were recorded by individual data loggers within and
outside the test package as well as in proximity to the IV bags.
The top line shows the ambient temperature outside the insulated
container. The other lines show "wrapped white cotton" "molded 1.5
inch foam" and "unwrapped white cotton."
[0095] Another embodiment of the invention may be created wherein
the container is capable of maintaining a constant internal
temperature for 48 hours where six 600 ML IV bags are cooled by
four 24 oz frozen ice packs. The ice packs are placed at the top
and bottom below the payload. FIG. 13 shows heat stress test
results which were recorded by individual data loggers within and
outside the test package as well as in proximity to the IV gabs.
The top line shows the ambient temperature outside the insulated
container. The lower line shows the internal temperature.
[0096] Another embodiment of the invention may be created wherein
the container is capable of maintaining a constant internal
temperature for 48 hours where six 600 ML IV bags are cooled by two
24 oz frozen ice packs and two 24 oz ambient ice packs. The ice
packs are placed at the top and bottom below the payload. FIG. 14
shows cold stress test results which were recorded by individual
data loggers within and outside the test package as well as in
proximity to the IV gabs. The top line shows the ambient
temperature outside the insulated container. The lower line shows
the internal temperature.
[0097] Another embodiment may be created where the insulated
container 10 complies with test scope protocol ISTA 7D such that it
maintains temperature above 2.degree. C. and below 8.degree. C.,
without freezing, in simulated summer/heat stress conditions for a
48 hour distribution cycle. According to the ISTA 7D test, six 24
oz gel ice packs were added to the insulated container 10 with a
payload of six 500 mL IV bags (Lactated Ringer's Solution USP),
conditioned to 3.degree. C.
[0098] Another embodiment may be created where the insulated
container 10 complies with test scope protocol ISTA 7D such that it
maintains temperature above 2.degree. C. and below 8.degree. C.,
without freezing, in simulated winter/cold stress conditions for a
48 hour distribution cycle. According to the ISTA 7D test, four 24
oz gel ice packs were added to the insulated container 10 with a
payload of ten 500 mL IV bags (Lactated Ringer's Solution USP),
condition to 3.degree. C.
[0099] Referring to FIGS. 15A through FIG. 28, another embodiment
of the invention may include an insulated container 100 which is
formed in a capital "T" shape. The T shape may be formed from
natural fibers such as cotton. The fibers may be postindustrial,
pre-consumer recycled cotton. As shown in FIG. 15A, the fibers may
be enclosed in a wrapping. The wrapping may serve to protect
contents of the container and may also allow smaller fibers to be
used which are contained in the wrapping. The wrapping may be a
plastic bag. The plastic bag may be biodegradable.
[0100] As shown in FIG. 15B, rather than the wrapping of FIG. 15A,
the natural fibers 102 are exposed. Large pads of natural fibers
may be created and the T shape cut from the natural fibers.
Multiple T shapes may be cut from a single pad. Any waste material
from the pads may be further recycled to form additional pads or
may be recycled for other purposes.
[0101] As shown in FIG. 15C, a natural fiber lamination layer 126
has been applied to the fibers 103. The natural fiber lamination
layer 126 may be paper and may have markings or other indicia
applied. As with the embodiment of FIG. 15A, pads may be prepared
and the T shape may be cut from the pad. Multiple T shapes may be
cut from a single pad. Any waste material from the pads may be
further recycled to form additional pads or may be recycled for
other purposes.
[0102] FIGS. 16 through 23 show how the insulated container 100
having the T shape may be folded into a compact form for shipment
according to an aspect of the present invention. Though these
figures show the T shape embodiment of FIG. 15A, one of skill in
the art will understand that the same method of folding may be
realized with the embodiments of 15A, 15B, or 15C.
[0103] As shown in FIGS. 16-18, the rear panel 110, left panel 112,
and right panel 114 are folded up together and down onto bottom
panel 116. As shown in FIG. 19, the front panel 118 is folded over
up and, in FIG. 20, is folded over the rear panel 110. The top
panel 120 (or "lid") is then folded over the front panel 118.
[0104] As shown in FIG. 21, a band 122 may be wrapped around the
folded container 100 for transport. The band 122 may keep the
folded container 100 in a compact folded condition for transport.
The band 122 may be made of paper, plastic, natural fibers, or
other biodegradable material. Alternatively, the band may be made
of a reusable material. The band 122 is designed to be easily
connected when the container 100 is folded and is also designed to
be easily disconnected as shown in FIG. 26. The band 122 may be
connected by way of an adhesive, hook and loop fasteners, snaps,
buttons, and the like. The band 122 may also be disconnected and
unwrapped from the folded container 100 by tearing, cutting,
pulling the band 100. The band 122 may have a perforation which
aids in removal. The band 122 may feature a tab and tongue system
where a tab is pealed from the band 122 to allow an adhesive to
attach the respective ends of the band 122. According to another
embodiment, the band 122 may be attached, detached, and reattached
at a same or different location along the band such that the
attachment point additionally serves the function of a closure of
the top 120 of the container 100 in the unfolded state of FIG.
28.
[0105] Once the band 122 is in place, the folded container is ready
for shipment form the manufacturer to a packager. As shown in FIGS.
24 and 25, once the packager receives the folded container 100, the
packager may place the folded container 100 into a rigid container
150. The rigid container 150 may be a box and it may be mad of
cardboard. Once the folded container 100 is in the rigid container
150, the packager may remove the band 122 as shown in FIG. 26. The
packager may then partially unfold the panels of the container 100
as shown in FIG. 27 to form an inner void which can contain
products as shown in FIG. 28.
[0106] FIGS. 29A, 29B, and 29C show a further embodiment of the
insulated container 200 which utilizes a pair of pads. These pads
are similar to the pads of FIG. 1 in that they ultimate form an
interlocking C shape inside a rigid container. However, the
embodiments of FIGS. 30-34 show how the pair of pads may be folded
for compact transport.
[0107] Additionally, the embodiments of FIGS. 29A, 29B, and 29C may
be formed from natural fibers such as cotton. The fibers may be
postindustrial, pre-consumer recycled cotton. As shown in FIG. 29A,
the fibers may the natural fibers 200 may be covered with a
lamination layer 226. As shown, a natural fiber lamination layer
226 has been applied to the fibers 200. The natural fiber
lamination layer 226 may be paper and may have markings or other
indicia applied. Large pads of natural fibers may be created and
the smaller pads cut from the natural fibers fibers. Multiple pads
200 may be cut from a single pad. Any waste material from the pads
may be further recycled to form additional pads or may be recycled
for other purposes. Any waste material from the pads may be further
recycled to form additional pads or may be recycled for other
purposes.
[0108] As shown in FIG. 29B, according to one embodiment the pads
202 do not have a lamination layer. As show in FIG. 29C, according
to another embodiment, the pads 203 may be enclosed in a wrapping.
The wrapping may serve to protect contents of the container and may
also allow smaller fibers to be used which are contained in the
wrapping. The wrapping may be a plastic bag. The plastic bag may be
biodegradable.
[0109] As shown in FIG. 30-34, the pair of pads 200 may be folded
for compact transport. As shown in FIG. 30, the rear panel 210, the
left panel 212, and the right panel 214 which are part of pad "A"
211 are folded and placed upon the bottom panel 216 of pad "B". As
shown in FIGS. 31 and 32, the front panel 218 of pad "B" is folded
up and over the rear panel 210 of pad "A". The top panel 220 (or
"lid") is then folded over the front panel 218.
[0110] As shown in FIGS. 32 through 34, a band 222 may secure the
folded pads 200 in a folded compact form for transportation from a
manufacturer to a packager. As shown in FIGS. 35 and 36, the
packager may place the folded pads 200 into a rigid container 250.
As shown in FIG. 37, the packager may separate or otherwise remove
the band 222 so that the insulated pads can be partially unfolded
within the rigid container as shown in FIG. 38. As shown in FIG.
39, products may be placed inside the container 200 for
shipment.
[0111] An insulated container 10, 100, 200 according to the
invention has been described with reference to specific embodiments
and examples. Various details of the invention may be changed
without departing from the scope of the invention. Furthermore, the
foregoing description of the preferred embodiments of the invention
and best mode for practicing the invention are provided for the
purpose of illustration only and not for the purpose of limitation,
the invention being defined by the claims. It is envisioned that
other embodiments may perform similar functions and/or achieve
similar results. Any and all such equivalent embodiments and
examples are within the scope of the present invention and are
intended to be covered by the appended claims.
* * * * *