U.S. patent application number 15/981533 was filed with the patent office on 2018-11-22 for fully recyclable insulated shipping container.
This patent application is currently assigned to tForm, Inc.. The applicant listed for this patent is tForm, Inc.. Invention is credited to Wesley Robert Johnson, Benjamin Edward Lee Moore.
Application Number | 20180334308 15/981533 |
Document ID | / |
Family ID | 64269956 |
Filed Date | 2018-11-22 |
United States Patent
Application |
20180334308 |
Kind Code |
A1 |
Moore; Benjamin Edward Lee ;
et al. |
November 22, 2018 |
FULLY RECYCLABLE INSULATED SHIPPING CONTAINER
Abstract
The present invention generally relates to an insulated shipping
container made entirely of standard recyclable materials for use in
transporting heated or cooled payloads. The entire container and
its insulation may be placed in a standard recycling bin after use,
without any disassembly or separation of materials. The container
comprises multiple layers that are easily folded together by the
transporter prior to the additional of a payload for delivery to an
end user. The container contains multiple formed paper panels that
provide a tight seal for insulation purposes.
Inventors: |
Moore; Benjamin Edward Lee;
(Central, SC) ; Johnson; Wesley Robert;
(Greenville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
tForm, Inc. |
Williamston |
SC |
US |
|
|
Assignee: |
tForm, Inc.
|
Family ID: |
64269956 |
Appl. No.: |
15/981533 |
Filed: |
May 16, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62506934 |
May 16, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2203/00 20130101;
B65D 2565/386 20130101; B65D 81/3813 20130101; B65D 5/64 20130101;
B65D 65/38 20130101; B65D 81/3858 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 65/38 20060101 B65D065/38; B65D 5/64 20060101
B65D005/64 |
Claims
1. An insulated shipping container comprising: an outer shell
defined by a series of foldable interconnected wall sections,
wherein said wall sections include at least a bottom wall and a
plurality of side walls when folded into an operable position; an
inner shell defined by a series of insulation-containing panels
carried by selected said wall sections, wherein at least one of
said insulation-containing panels is carried on a selected said
wall section and defines an enclosed insulation cavity between said
wall section of said outer shell and an interior side of said
insulation-containing panels; wherein said insulation-containing
panels carried on at least said bottom wall and side walls abut
each other to defining a cargo receiving area when said wall
sections are folded into said operable position; an insulation
material defining an insulated liner disposed in said insulation
cavity that extends directly between said outer shell and an
interior side of said inner shell; wherein said outer shell, said
inner shell and said insulated liner are comprised of a cellulose
based material to provide single channel recycling of the entire
shipping container.
2. The insulated shipping container of claim 1 wherein said
foldable interconnected wall sections include a top wall defining a
lid section that encloses said cargo receiving area when folded
into said operable position.
3. The insulated shipping container of claim 1 including a detached
lid section mounted to said side walls; wherein said lid section
encloses said cargo receiving area when said foldable
interconnected wall sections are folded into said operable
position.
4. The insulated shipping container of claim 1 including a lid
section having at least one said insulation-containing panel that
abuts said insulation-containing panels carried by said side walls
for enclosing said cargo receiving area.
5. The insulated shipping container of claim 4 wherein said
plurality of insulation-containing panels define a uniform
insulation cavity so that a uniform insulation thickness of said
insulated liner is formed among said wall sections and said lid
section.
6. The insulated shipping container of claim 1 wherein each of said
insulation-containing panels includes a chamfered surface that
abuts a complementary chamfered surface of an adjacent said
insulation-containing panel when said wall sections are folded into
said operable position.
7. The insulated shipping container of claim 6 wherein said
chamfered surfaces are formed at approximately a 45.degree. angle
along a perimeter edge portion of each said insulation-containing
panels.
8. The insulated shipping container of claim 7 wherein said
chamfered surfaces on adjacent insulation-containing panels abut
when a given said wall section is folded to approximately
90.degree. relative to adjacent wall sections.
9. The insulated shipping container of claim 6 including an
adhesive disposed along said chamfered surface of said
insulation-containing panels, wherein said adhesive interlocks and
seals together abutting said insulation-containing panels when said
wall sections are folded into said operable position so that said
cargo receiving area is sealed to resist air movement between
abutting insulation-containing panels.
10. The insulated shipping container of claim 1 wherein said outer
shell is comprised of a corrugated paperboard.
11. The insulated shipping container of claim 1 wherein said inner
shell is comprised of a rigid or semi-rigid paper based
material.
12. The insulated shipping container of claim 11 wherein said inner
shell is comprised of food grade based paper material.
13. The insulated shipping container of claim 1 wherein said
insulated liner comprises a loose fill cellulose based insulation
material.
14. The insulated shipping container of claim 13 wherein said loose
fill cellulose based insulation material comprises shredded
paper.
15. The insulated shipping container of claim 1 wherein an air
chamber extends around a perimeter of each of said
insulation-containing panels and is defined by side surfaces of
abutting said insulation-containing panels and said outer shell
when said wall sections are folded into said operable position.
16. The insulated shipping container of claim 1 including an insert
panel carrying a secondary insulation container disposed in said
cargo receiving area for providing layered insulation within said
cargo receiving area.
17. The insulated shipping container of claim 16 wherein said
secondary insulation container comprises one of said
insulation-containing panels with loose fill cellulose based
insulation material contained within an insulation cavity defined
between said insert panel and an inner surface of said
insulation-containing panel.
18. The insulated shipping container of claim 16 wherein said
secondary insulation container comprises a bag containing loose
fill cellulose based insulation material.
19. A method of forming an insulated shipping container, said
method comprising the steps of: providing an outer shell having a
series of foldable interconnected wall sections, wherein said wall
sections include at least a bottom wall and a plurality of side
walls when folded into an operable position; mounting a series of
insulation-containing panels to selected said wall sections to form
an inner shell; inserting an insulation material into an insulation
cavity disposed between said outer shell and an interior side of
said inner shell; wherein said outer shell, said inner shell and
said insulation material are comprised of a cellulose based
material to provide single channel recycling of the entire shipping
container.
20. The method of claim 19 including the step folding said outer
shell so that said insulation-containing panels carried on said
wall sections abut each other to define a cargo receiving area when
said wall sections are folded into said operable position.
Description
BACKGROUND OF THE INVENTION
1) Field of the Invention
[0001] The present invention generally relates to insulated
shipping containers and, more particularly, to a fully recyclable
insulated paper box for transport of heated or cooled payloads
constructed of 100% recycled materials.
2) Background of the Invention
[0002] Prior art insulated shipping containers have been known for
some time. Insulated boxes are used regularly for transport of
heated or cooled payloads. Recently, the demand for such containers
has risen sharply due to the rise in demand for food delivery
services such as HelloFresh.RTM. and Blue Apron.RTM.. These
services deliver portioned and curated food ingredients and recipes
to customers' homes multiple times a week. The raw ingredients
include meats and vegetables that must be kept cool to maintain
freshness.
[0003] To accomplish this, raw ingredients are packed into a
corrugate box, along with single or multiple ice packs. Surrounding
the ingredients and ice packs is also typically a thermal
insulating barrier that can consist of Styrofoam, PLA, or textile
based insulating products. In the case of the latter two, a
flexible container or wrapping consisting of paper or plastic is
required to contain the loose insulating material, allowing for the
easy insertion of the insulation liner in the box, and avoiding
contact with the payload inside.
[0004] In addition to meal delivery services, pharmaceutical firms
also utilize thermally insulated packaging to ship medicine that
must stay below a certain temperature threshold. And some companies
ship heated payloads, which require the same insulating
effectiveness.
[0005] Regardless of the intended user, there are numerous
deficiencies in these prior art insulated shipping products. They
are expensive to manufacture and ship to customers, and they are
made of multiple materials, many of which are not recyclable, or
require multiple recycle channels.
[0006] What is needed is a fully recyclable insulated shipping
container that customers may place directly into standard recycling
containers after use without separating the container into
individual parts or pieces. This is a solution that uses what is
sometimes called a single channel recycling method.
[0007] What is also needed is a less expensive insulated shipping
container that food distributors, and others, may receive in
compact flat configurations or folded shipping configurations and
then easily assemble on-site.
[0008] What is also needed is a less expensive insulated shipping
container that integrates the insulation directly into the
container to avoid additional assembly steps when used by food and
pharmaceutical distributors for faster and simpler
construction.
[0009] An object of the present invention is to provide a fully
recyclable shipping container that will allow customers to simply
place the entire product directly into current recycling containers
without separation and without disassembly.
[0010] Another object of the present invention is to provide a less
expensive shipping container that can itself save money by being
capable of being placed flat for shipping to food and
pharmaceutical suppliers.
[0011] Another object of the present invention is to provide a less
expensive shipping container that will allow food and
pharmaceutical suppliers to utilize unskilled labor for assembly of
the product.
SUMMARY OF THE INVENTION
[0012] The present invention accomplishes the foregoing objects by
providing a fully recyclable shipping container that customers may
simply place into standard, single-channel recycling receptacles
for disposal and recycling. The present invention also accomplishes
the foregoing objects by providing a shipping container that may be
stacked and shipped to food and pharmaceutical distributors in a
flat configuration. The present invention also accomplishes the
foregoing objects by providing an insulated shipping container that
may be easily assembled by unskilled labor employed by food and
pharmaceutical distributors.
[0013] The present invention is a fully recyclable shipping
container referred to herein as an integrated box and insulation
solution, where the outer shell of the box (preferably a corrugated
paperboard or other such cellulose based material) is attached to
an inner shell defined by a plurality of insulation containing
panels (preferably molded paper form or other such cellulose based
material) that holds an insulation material defining an insulated
liner (preferably loose fill shredded paper or other cellulose
based insulation material) between the outer shell and the inner
shell panels. This integrated insulated box design consists of
multiple sides which may or may not be of equal length, but is not
limited to square or rectangular designs. In an illustrated
embodiment, the unfolded interconnected wall sections of the out
shell are arranged in a folding cross design, but could consist of
other initial constructions as needed. The individual sides of the
box can then be folded and attached to each other via
interconnecting flaps and/or flaps with adhesive, tape, staples,
straps, or other methods, leaving a final opening on one side that
will allow the ice packs and payload to be placed inside a cargo
receiving area when the wall sections are folded into an operable
position, and finally sealed shut with a lid for transport.
[0014] The materials selected for the outer shell box structure,
the inner shell insulation-containing panels, and the insulation
material that forms the insulated liner are selected to be capable
of disposal in the same recycling stream or channel, such that the
entire assembled device can be placed by the consumer in a
recycling stream without need for deconstruction or disassembly.
For example, a corrugated paperboard outer shell box structure,
paper or cellulose based insulation and paper-based inner shell
insulation-containing panel material. Another example could be a
corrugated PET outer shell box structure, PET inner shell panels,
and a granulated PET plastic insulation material. The combination
of similar materials for all components of the device creates an
advantage in recycling, whereas other thermal insulating solutions
which consist of nonbiodegradable or recyclable products that are
mixed together i.e. plastic liners with paper corrugated boxes,
causes recycling supply chain issues.
[0015] The integrated design also creates fundamental advantages in
cost, because where other thermal insulating solutions must
encapsulate the insulation material with a liner that is on all
sides, the fully integrated design utilizes the outer shell box
structure as one side of the insulation liner, eliminating one
layer of material for each side of the container.
[0016] Another advantage of the integrated thermal insulation is in
thermal performance. By positioning the insulation material
directly against the outer shell structure and shaping the
plurality of inner shell insulation-containing panels to conform to
each other when folded into an operable position defining a
shipping container, the thickness of the insulation material can be
maintained in a uniform arrangement on all sides and corners of the
device. This improves thermal performance by minimizing areas where
gaps of insulation material are present, which is common in designs
which use flexible insulating liners. The folds in the paper add
structural stiffness to the overall assembly and leave less air
gaps in the structure.
[0017] The above objectives are accomplished according to the
present invention by providing an insulated shipping container
comprising an outer shell defined by a series of foldable
interconnected wall sections, wherein said wall sections include at
least a bottom wall and a plurality of side walls when folded into
an operable position; an inner shell defined by a series of
insulation-containing panels carried by selected said wall
sections, wherein at least one of said insulation-containing panels
is carried on a selected said wall section and defines an enclosed
insulation cavity between said wall section of said outer shell and
an interior side of said insulation-containing panels; wherein said
insulation-containing panels carried on at least said bottom wall
and side walls abut each other to defining a cargo receiving area
when said wall sections are folded into said operable position; an
insulation material defining an insulated liner disposed in said
insulation cavity that extends directly between said outer shell
and an interior side of said inner shell; wherein said outer shell,
said inner shell and said insulated liner are comprised of a
cellulose based material to provide single channel recycling of the
entire shipping container.
[0018] In a further advantageous embodiment, said foldable
interconnected wall sections include a top wall defining a lid
section that encloses said cargo receiving area when folded into
said operable position.
[0019] In a further advantageous embodiment, a detached lid section
is mounted to said side walls; wherein said lid section encloses
said cargo receiving area when said foldable interconnected wall
sections are folded into said operable position.
[0020] In a further advantageous embodiment, a lid section is
included having at least one said insulation-containing panel that
abuts said insulation-containing panels carried by said side walls
for enclosing said cargo receiving area.
[0021] In a further advantageous embodiment, said plurality of
insulation-containing panels define a uniform insulation cavity so
that a uniform insulation thickness of said insulated liner is
formed among said wall sections and said lid section.
[0022] In a further advantageous embodiment, each of said
insulation-containing panels includes a chamfered surface that
abuts a complementary chamfered surface of an adjacent said
insulation-containing panel when said wall sections are folded into
said operable position.
[0023] In a further advantageous embodiment, said chamfered
surfaces are formed at approximately a 45.degree. angle along a
perimeter edge portion of each said insulation-containing
panels.
[0024] In a further advantageous embodiment, said chamfered
surfaces on adjacent insulation-containing panels abut when a given
said wall section is folded to approximately 90.degree. relative to
adjacent wall sections.
[0025] In a further advantageous embodiment, an adhesive is
disposed along said chamfered surface of said insulation-containing
panels, wherein said adhesive interlocks and seals together
abutting said insulation-containing panels when said wall sections
are folded into said operable position so that said cargo receiving
area is sealed to resist air movement between abutting
insulation-containing panels.
[0026] In a further advantageous embodiment, said outer shell is
comprised of a corrugated paperboard.
[0027] In a further advantageous embodiment, said inner shell is
comprised of a rigid or semi-rigid paper based material.
[0028] In a further advantageous embodiment, said inner shell is
comprised of food grade based paper material.
[0029] In a further advantageous embodiment, said insulated liner
comprises a loose fill cellulose based insulation material.
[0030] In a further advantageous embodiment, said loose fill
cellulose based insulation material comprises shredded paper.
[0031] In a further advantageous embodiment, an air chamber extends
around a perimeter of each of said insulation-containing panels and
is defined by side surfaces of abutting said insulation-containing
panels and said outer shell when said wall sections are folded into
said operable position.
[0032] In a further advantageous embodiment, an insert panel is
included carrying a secondary insulation container disposed in said
cargo receiving area for providing layered insulation within said
cargo receiving area.
[0033] In a further advantageous embodiment, said secondary
insulation container comprises one of said insulation-containing
panels with loose fill cellulose based insulation material
contained within an insulation cavity defined between said insert
panel and an inner surface of said insulation-containing panel.
[0034] In a further advantageous embodiment, said secondary
insulation container comprises a bag containing loose fill
cellulose based insulation material.
[0035] The above objectives are further accomplished according to
the present invention by providing a method of forming an insulated
shipping container, said method comprising the steps of providing
an outer shell having a series of foldable interconnected wall
sections, wherein said wall sections include at least a bottom wall
and a plurality of side walls when folded into an operable
position; mounting a series of insulation-containing panels to
selected said wall sections to form an inner shell; inserting an
insulation material into an insulation cavity disposed between said
outer shell and an interior side of said inner shell; wherein said
outer shell, said inner shell and said insulation material are
comprised of a cellulose based material to provide single channel
recycling of the entire shipping container.
[0036] In a further advantageous embodiment, the method includes
the step of folding said outer shell so that said
insulation-containing panels carried on said wall sections abut
each other to define a cargo receiving area when said wall sections
are folded into said operable position.
DESCRIPTION OF THE DRAWINGS
[0037] The invention will be more readily understood from a reading
of the following specification and by reference to the accompanying
drawings forming a part thereof, wherein an example of the
invention is shown and wherein:
[0038] FIG. 1 is an exploded view showing the main components of
the container according to the present invention.
[0039] FIG. 2 is an isometric view of an embodiment of an outer
shell box structure showing the flaps and creases for the sides of
the box according to the present invention.
[0040] FIG. 3 is an exploded view showing the insulation material
filled in the panels, with the outer shell box structure ready to
be attached according to the present invention.
[0041] FIG. 4 is an isometric view of the outer box structure with
the panel to box adhesive, and the box side to box flap adhesive
according to the present invention.
[0042] FIG. 5 is an isometric view of the container pre-assembled
according to the present invention.
[0043] FIG. 6 is a cross section view of the container
pre-assembled according to the present invention.
[0044] FIG. 7 is a cross section view of the container
pre-assembled according to the present invention.
[0045] FIG. 8 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0046] FIG. 9 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0047] FIG. 10 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0048] FIG. 11 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0049] FIG. 12 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0050] FIG. 13 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0051] FIG. 14 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0052] FIG. 15 is an isometric view of the partially folded
container in the process of assembly according to the present
invention.
[0053] FIG. 16 is an isometric view of the fully folded and
assembled container according to the present invention.
[0054] FIG. 17 is an isometric view of the fully folded and
assembled container, with logo applied to outer box structure
according to the present invention.
[0055] FIG. 18 is a view of an inner shell panel, showing the
container, the attachment flanges and a formed logo according to
the present invention.
[0056] FIG. 19 is a bottom and side view of an inner shell panel
according to the present invention.
[0057] FIG. 20 is a close-up view of the assembled container,
highlighting an adhesive applied to the chamfered sealing surface
on the panels and the foldable tabs according to the present
invention.
[0058] FIG. 21 is a close-up view of an inner shell panel,
highlighting the foldable tabs according to the present
invention.
[0059] FIG. 22 is a close-up view of an inner shell panel,
highlighting the foldable tabs according to the present
invention.
[0060] FIG. 23 is a view of two inner shell panels, illustrating
the chamfered corner sealing interface and the multiple layers of
the inner shell according to the present invention.
[0061] FIG. 24 is a view of two inner shell panels, illustrating
the chamfered corner sealing interface and the multiple layers of
the inner shell according to the present invention.
[0062] FIG. 25 is a perspective cross section view of an embodiment
of the insert panel and secondary insulation container illustrating
the insulation material disposed therein according to the present
invention.
[0063] FIG. 26 is a side view of an embodiment of the insert panel
and secondary insulation container according to the present
invention.
[0064] FIG. 27 is a chart illustrating temperature of the container
over time.
[0065] FIG. 28 shows a perspective view of an embodiment of the
container pre-assembled according to the present invention.
[0066] FIG. 29a shows a front perspective view of the container in
an assembled condition with the outer shell folded into an
operational position according to the present invention.
[0067] FIG. 29b shows a rear perspective view of the container in
an assembled condition with the outer shell folded into an
operational position according to the present invention.
[0068] It will be understood by those skilled in the art that one
or more aspects of this invention can meet certain objectives,
while one or more other aspects can meet certain other objectives.
Each objective may not apply equally, in all its respects, to every
aspect of this invention. As such, the preceding objects can be
viewed in the alternative with respect to any one aspect of this
invention. These and other objects and features of the invention
will become more fully apparent when the following detailed
description is read in conjunction with the accompanying figures
and examples. However, it is to be understood that both the
foregoing summary of the invention and the following detailed
description are of a preferred embodiment and not restrictive of
the invention or other alternate embodiments of the invention.
While the invention is described herein with reference to a number
of specific embodiments, it will be appreciated that the
description is illustrative of the invention and is not constructed
as limiting of the invention. Various modifications and
applications may occur to those who are skilled in the art, without
departing from the spirit and the scope of the invention, as
described by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0069] With reference to the drawings, the invention will now be
described in more detail. Unless defined otherwise, all technical
and scientific terms used herein have the same meaning as commonly
understood to one of ordinary skill in the art to which the
presently disclosed subject matter belongs. Although any methods,
devices, and materials similar or equivalent to those described
herein can be used in the practice or testing of the presently
disclosed subject matter, representative methods, devices, and
materials are herein described.
[0070] Unless specifically stated, terms and phrases used in this
document, and variations thereof, unless otherwise expressly
stated, should be construed as open ended as opposed to limiting.
Likewise, a group of items linked with the conjunction "and" should
not be read as requiring that each and every one of those items be
present in the grouping, but rather should be read as "and/or"
unless expressly stated otherwise. Similarly, a group of items
linked with the conjunction "or" should not be read as requiring
mutual exclusivity among that group, but rather should also be read
as "and/or" unless expressly stated otherwise.
[0071] Furthermore, although items, elements or components of the
disclosure may be described or claimed in the singular, the plural
is contemplated to be within the scope thereof unless limitation to
the singular is explicitly stated. The presence of broadening words
and phrases such as "one or more," "at least," "but not limited to"
or other like phrases in some instances shall not be read to mean
that the narrower case is intended or required in instances where
such broadening phrases may be absent.
[0072] Referring now to FIG. 1, an exploded view showing the three
main components of the unassembled insulated shipping container 100
is provided. A preferred embodiment of the shipping container
comprises a foldable outer shell 1, a foldable formed paper inner
shell 2, and an insulation material defining an insulated liner 3.
Outer shell 1, inner shells 2, and insulation material 3 are
constructed an arranged to form a series of foldable
interconnecting sections that when folded into an operable position
form a shipping container, as shown in FIG. 16 in one
embodiment.
[0073] Outer shell 1 is comprised of a series of foldable
interconnected wall sections, 1a, 1b, 1c and the like that when
folded from a flat arrangement to an operable position for a
shipping container which in the illustrated embodiment is a
generally square box. The wall sections include at least a bottom
wall and a plurality of side walls when folded into an operable
position, as shown in FIGS. 16, 17, 29a and 29b.
[0074] Inner shell 2 is comprised of multiple operably associated
insulation-containing panels, 2a, 2b, 2c and the like. These
insulation-containing panels are generally rigid or semi-rigid
paper based material. In one embodiment, inner shell 2 is comprised
of food grade based paper material, including but not limited to
Parchment Paper/Pan Liner Paper/Baking Paper; Waxed Paper; Glassine
Paper; Polycoated Paper such as low density polyethylene, medium
density polyethylene, high density polyethylene, linear low density
polyethylene, ionomers, metallocene, polypropylene, EVA, EMA, acid
copolymers; Board Stock; and Kraft and Butcher Paper.
[0075] At least one of the insulation-containing panels is carried
on a selected wall section 1a, 1b, 1c and the like, and defines an
enclosed insulation cavity between a given wall section of the
outer shell 1 and an interior side of the insulation-containing
panels. When the wall sections are folded into the operable
position forming the shipping container (such as in FIGS. 16, 17,
29a and 29b), insulation-containing panels carried on at least the
bottom wall and side walls abut each other to defining a cargo
receiving area.
[0076] An insulated liner 3 is disposed in an enclosed insulation
cavity formed by each of the insulation-containing panels. In the
illustrated embodiment, insulated liners 3a, 3b, 3c and the like
are positioned in direct contact with wall section 1a, 1b, 1c and
other selected section of out shell 1 and extend to an interior
side of each of the insulation-containing panels comprising the
inner shell.
[0077] The outer shell 1, further depicted in FIG. 2, can begin as
a flat sheet of rigid paper products, including but not limited to
cardboard, or other various paperboard and paper based materials,
with various cuts 1d and creases 1e to constitute the final folded
geometry and to aid in assembly. The flat box (outer shell 1), as
shown in FIG. 2, consists of wall section 1a, 1b, 1c, and the like
which when folded create the three-dimensional box, and flaps if,
which are folded and adhered to the sides of the box to create a
rigid structure, in the illustrated embodiment. In an optional
embodiment, printed logos or other images and text can be placed on
the sides or flaps of the box structure as illustrated in FIG.
17.
[0078] The outer box structure (outer shell 1) of FIGS. 2 and 3
preferably begins as a flat sheet of stiff paper such as cardboard.
With the insulation-containing panels filled with insulation
material 3a, they are attached to selected wall sections of outer
shell 1. The insulation 3a is contained between the panel and box,
creating a thermal insulating barrier. With the insulation 3a
contained within the panels 2a, 2b, 2c and the like, and the panels
attached to the outer shell box structure, a single structure is
created as seen in FIG. 5. The structure can then be folded, as
depicted in FIGS. 8 to 16, into a box shape. The outer flaps 1i,
1j, 1 k and the like can then be folded and adhered to the exterior
side of various walls sections of the box with an adhesive
material, creating a rigid structure. Referring to FIGS. 12 and 16,
the foldable interconnected wall sections 1a, 1 b, 1c, and the like
include a top wall defining a lid section 1m for enclosing the
cargo receiving area when folded into the operable position (FIG.
16). The lid section 1m, allows for the placement of cold packs and
the payload along with any other desired packaging or marketing
materials inside the cargo receiving area of the box. The lid 1m
can then be closed and the flaps folded down and attached via
adhesive, as seen in FIGS. 13 to 16. The fully assembled and sealed
box, ready for transport is shown in FIG. 16. Referring to FIGS. 12
and 13, lid section 1m preferably includes at least one
insulation-containing panel that abuts the insulation-containing
panels carried by the side walls for enclosing the cargo receiving
area. In an alternative embodiment, lid section 1m is detached from
the other wall section forming the rest of the box. Preferably, lid
section 1m includes a handle portion that is integrally form with
or mounted to an exterior side of lid section 1m or to the various
side walls of the box.
[0079] In a preferred embodiment, as illustrated in FIG. 3, the
insulated liner panels/sections 3a, 3b, 3c and the like, are
inserted into the inner panels/sections 2a, 2b, 2c, and the like.
In this preferred embodiment, each of 3a, 3b, 3c and the like, are
form cut and shaped to fit snugly into each of 2a, 2b, 2c and the
like to better aid in the insulation properties of container 100.
The first step of assembly is also indicated in FIG. 3, whereby the
insulating liner 3 is inserted into the foldable formed paper inner
shell 2.
[0080] FIGS. 4 and t shows the next step of assembly from a view of
the outer layer 1. Here, foldable outer shell 1 is now attached to
foldable formed paper shell 2 with insulation liner 3 sandwiched in
between. Prior to the next step of assembly, in a preferred
embodiment, as illustrated in FIG. 4, standard adhesive may be
applied to the side sections 1g of the box structure (outer shell
1) to adhere the insulation containing panels (inner shell 2) to
the box structure, as well as to adhere the folding flaps 1h of the
box to itself to create the final folded assembly, as shown in
later figures. In addition to the adhesive applied to the outer box
structure, as shown in FIG. 4, an adhesive or adhesive strip 17a
can be applied to the chamfered sealing edge of the panels to hold
the entire device together during assembly, and or to improve the
thermal insulation properties of the device by ensuring a tight
seal between the panels, as shown in FIG. 20.
[0081] FIG. 5 provides another view of the same step from a view of
the inner layer 2. Here inner sections, 2a, 2b, 2c and the like are
operably attached to the outer sections 1a, 1b, 1c and the like,
wherein the multiple operably connected insulation sections, 3a,
3b, 3c and the like are sandwiched in between and therefore not
visible. FIGS. 6 and 7 provides a cutaway view that illustrates
insulation section 3a disposed between inner section 2a and outer
section 1a.
[0082] FIG. 8 illustrates the next step of assembly from a view of
the inner liner. Here the various foldable sections of inner
sections and outer sections are illustrated being folded together.
FIGS. 9 and 10 continue the process by further folding the foldable
sections as illustrated.
[0083] FIG. 11 illustrates all but the top section of the various
outer panels now in contact with corresponding inner panels, where
outer panel flaps 1i, 1j, and 1k are not yet folded into final
position. At this point, in a preferred embodiment, a standard
adhesive is applied to the inner portion of each outer flap 1i, 1j,
and 1k, as well as other outer flaps not visible in FIG. 11. The
adhesive chosen is preferably one that is easily recycled with
other paper products so that no portion of container 100 must be
later separated before deposit into a standard recycling
receptacle.
[0084] FIG. 12 continues the assembly process by beginning the fold
of outer panel flaps 1i, 1j, and 1k. FIG. 13 shows outer panel
flaps 1i, 1j, and 1k fully folded, where sections 1i and 1j now
glued to the outer portion of section 1c.
[0085] FIG. 13 also illustrates the next step where the top section
1m of outer shell 1 is now folded to close container 100. It is
also preferable to first insert the payload that is to be shipped,
and then apply adhesive to the outer flaps 1n, 1o, and 1p of the
top section 1m prior to closing container 100.
[0086] In another embodiment of the invention, all outer flaps have
a section of 2-sided tape applied in advance so that the user may
simply remove the non-stick layer of the 2-sided tape to provide an
adhesive surface for gluing the outer flaps to the surface of the
outer shell.
[0087] FIGS. 14 and 15 illustrate the next step in the process of
using the container 100. Here, container 100 is fully assembled and
now in the process of being closed. The user will have placed the
payload of refrigerated or heated materials inside container 100 by
this point, and now the top section 1m of the outer shell 1 is
being closed for shipment, where the only remaining step is to fold
and glue the outer flaps 1m, 1n, 10 to the outer portion of shell
1.
[0088] FIG. 16 illustrates the fully-assembled and ready-to-ship
container 100, where all flaps are glued in place and container 100
is now fully sealed to insulate and maintain temperature of the
heated or cooled payload for delivery.
[0089] FIG. 17 illustrates container 100 with a company logo 4
applied to the top portion 1m. This is a useful feature for the
expected users (food and pharmaceutical companies) to help
distinguish their products and services over competitors.
[0090] By the same token, another useful aspect of the invention is
that the various formed paper inner shell sections are capable of
advertisement by forming these sections during the formed paper
process used to create the formed paper inner shell sections.
Referring now to FIGS. 18 and 19, a formed paper section is
illustrated with a company logo directly formed into the formed
paper section 5a. A preferred embodiment of the panel section 5a
results in a raised inner panel section, wherein the insulation
section can later be inserted. Chamfered surfaces 5b illustrate the
depth of the formed paper inner shell section 5a, leaving flaps 5c
where the adhesive is applied to attach each inner shell panel
section to the outer shell panel sections. Chamfered surfaces 5b
are also formed to provide a tight seal for insulation purposes.
When all the various panels are folded together chamfered surfaces
5b come in direct contact from each of the sides to seal up the
inner portion of container 100. In the illustrated embodiments,
chamfered surfaces are formed at approximately a 45.degree. angle
along a perimeter edge portion of each said insulation-containing
panels. Chamfered surfaces on adjacent insulation-containing panels
abut when a given said wall section is folded to approximately
90.degree. relative to adjacent wall sections. Referring to FIG.
20, an adhesive 17a is disposed along the chamfered surface of
insulation-containing panels 7, wherein the adhesive interlocks and
seals together abutting insulation-containing panels 7 when the
wall sections are folded into the operable position so that the
cargo receiving area is sealed to resist air movement between
abutting insulation-containing panels.
[0091] The inner shell section panels provide a container for the
insulation material, as shown in FIGS. 6 and 7. Referring to FIG.
19, these inner shell panels preferably consist of a container
shelf 5d, may have equal or unequal sides, attachment flanges 5c
for adhering the panel to the outer box structure, and a bottom
side that can include a formed logo, image, or contain stiffening
geometry. The bottom edges of the container can also contain
chamfered surfaces 5b, as illustrated in FIG. 18, around the
perimeter of the container that provide a sealing interface with
surrounding panels when the entire box structure is folded, as
shown in FIG. 23. The inner panel sections are preferably created
out of a formable material that can include traditional paper,
formable paper, or a variety of thermoformable plastics.
[0092] The inner shell panels can be constructed with several
techniques, including, without limitation, forming, cutting,
bending, and adhering. An example construction method, shown in
FIG. 19, begins with a flat formable paper sheet, where the lower
section of the panel container shelf 5d is formed along with any
logos or stiffening geometry on the bottom face of the panel, in
addition to the chamfered lower corners 5b. This geometry in the
lower section of the panel can be created by means of a
thermoforming process, where the panel material is heated and then
inserted between a male and/or female mold that is in the shape of
the desired geometry. An alternate method can involve an embossing
process, where heat is not applied to the panel material, but the
panel material is formed by means of a high application pressure
between two mold pieces.
[0093] To create flanges and flaps in the panel 5c, a cutting
operation by means of a die, or cutting knife may be performed. The
attachment flanges are bent, as well as the main walls of the panel
container, as shown in FIGS. 21 and 22, creating the container
shelf in which the insulation is contained. To increase the
stiffness of the structure, a corner flap 9a, shown in FIGS. 21 and
22, can also be bent on each corner of the container and then
adhered by means of an adhesive to the wall of the container. In
the case of a paper-based panel material, the adhesive can be
applied to the paper after the forming process or could be
integrated into the paper by means of a thermoplastic substrate.
With the thermoplastic substrate case, the corner flap can be
folded onto the container wall, and then a heating element applied
to cause the thermoplastic layer of the corner flap to adhere to
the thermoplastic layer of the container wall.
[0094] The insulation material 3a of FIGS. 6 and 7 preferably has a
low thermal conductivity. In a preferred embodiment, the material
can be paper-derived, plastic, fiberglass, denim, or similar
insulator. The insulation material can be of a loose fill,
semi-solid, or rigid type, but ultimately fills the volume of the
panel container and creates the thermal barrier to minimize heat
transfer from the payload to the ambient conditions outside of the
device. Preferably, insulation material 3a is a loose fill
cellulose based material, for example, including but not limited to
shredded paper.
[0095] The process of assembling the inner shell sections is
illustrated in more detail in FIGS. 20 to 24. Tabs 6a are released
and folded after the inner shell panel section 7 is formed in the
paper forming process. This allows the various outer flaps 6b to be
folded and/or glued in the assembly process.
[0096] Referring now to FIGS. 21 and 22, the various outer flaps 6b
of a typical inner shell panel 8 are illustrated. Tabs 9a are
folded to add strength to the formed paper structure of inner shell
section 8.
[0097] FIGS. 23 and 24 illustrate the structure of two inner shell
panel sections 10 and 11 as they are folded in the assembly
process. Outer flaps 12 and 13 are visible but now the extra layer
in the formed paper becomes visible as 14. This extra layer
provides strength, rigidity and additional insulation capability
for container 100. More specifically, the interior layer shown as
chamfered edge 16 is disposed on top of the exterior layer 15,
which bends to form the additional structure 14 to add this
strength and rigidity. Further, an air chamber extends 15a is
provided around a perimeter of each of said insulation-containing
panels and is defined by side surfaces of abutting
insulation-containing panels and outer shell when wall sections are
folded into said operable position. Air chamber 15a operates as an
insulation layer around the edges and corners of the box.
[0098] Referring to FIGS. 25 and 26, an insert panel 20 is shown
carrying a secondary insulation container 22 which is placed in the
cargo receiving area of the box for providing layered insulation
within the cargo receiving area. In the embodiment of FIG. 25,
secondary insulation container 22 comprises one of
insulation-containing panels with loose fill cellulose based
insulation material 3a contained within an insulation cavity
defined between insert panel 20 and an inner surface of
insulation-containing panel 22. In an alternative embodiment shown
in FIG. 26, secondary insulation container 22 comprises a bag
containing loose fill cellulose based insulation material.
[0099] While the invention is shown with outer shell 1 forming a
box structure ready for shipping, the container may optionally be
used as an insert placed into another exterior shipping
container.
[0100] Referring to FIG. 27, a chart shows the performance of a
shipping container "tF" made according to the present invention.
The container "tF" provides the same or better insulation over a
period of 45 hours as compared to insulated shipping containers
currently used on the mark that are not made exclusively from paper
based materials to allow for a single channel 100% recycling.
Accordingly, the present invention provides for a more efficient
and environmentally responsible solution to insulated shipping
containers without any sacrifice in performance.
[0101] Referring to FIG. 28, an alternative embodiment of the
shipping container is shown with a different folding arrangement.
In this instance, the insulation-containing panels of the inner
shell are glued to selected portions of the outer shell wall
sections as described herein above, but the wall sections
interconnect with various tabs 24 received in complementary slots
26, as well as, interconnecting flaps 28 that do not require
adhesive to maintain the operation position of the box structure.
The completed folded shipping container is shown in FIGS. 29a and
29b.
[0102] In the manufacturing of the container, the outer shell can
be provided from sheets or rolled stock and cut and creased
appropriately to define a bottom wall or side walls. The side walls
can be cut from the stock so that they are connected to the bottom
wall or an adjacent side wall. Creases for folding can be formed in
the stock. The panels can be formed by molding pulp, fiber or
sheets using a press mold or heated press mold that can result in a
molded panel. The mold can include a design that can be imprinted
in the panel. Insulation material can be placed in a panel and the
panel affixed to a portion of the outer shell. The insulation
material can be loose, matted or other form. The manufacturing
process can include a manufacturing machine that can perform these
steps in parallel or series resulting the insulated shipping
container. The outer shell, panels and insulation can be made from
recycled paper or other cellulose material.
[0103] The panel can be formed from compression molding where the
molding material can be preheated and placed in an open heated mold
cavity having a mold with one or more mold surfaces. The mold is
closed and pressure applied to force the molding material into
contact with all mold areas. Heat and pressure are maintained until
the molding material is partially or completely cured. The panel
can be coated with a water resistance material in some
embodiments.
[0104] While the present subject matter has been described in
detail with respect to specific exemplary embodiments and methods
thereof, it will be appreciated that those skilled in the art, upon
attaining an understanding of the foregoing may readily produce
alterations to, variations of, and equivalents to such embodiments.
Accordingly, the scope of the present disclosure is by way of
example rather than by way of limitation, and the subject
disclosure does not preclude inclusion of such modifications,
variations and/or additions to the present subject matter as would
be readily apparent to one of ordinary skill in the art using the
teachings disclosed herein.
* * * * *