U.S. patent application number 15/987497 was filed with the patent office on 2018-11-29 for insulated container liner and method of insulating a container.
The applicant listed for this patent is WW Thermal Designs, LLC. Invention is credited to Christopher Edward Hall.
Application Number | 20180339838 15/987497 |
Document ID | / |
Family ID | 64400827 |
Filed Date | 2018-11-29 |
United States Patent
Application |
20180339838 |
Kind Code |
A1 |
Hall; Christopher Edward |
November 29, 2018 |
INSULATED CONTAINER LINER AND METHOD OF INSULATING A CONTAINER
Abstract
An insulated liner for a container and method of insulating a
container are disclosed. The insulated liner may include a
recyclable first panel, a recyclable second panel, at least one
cavity defined by the first panel and the second panel, and a
recyclable insulating material provided within the at least one
cavity. The insulated liner may be adapted to line and insulate the
container to keep a temperature within the container within a range
of temperatures. The method may include providing the container,
the container including a top wall, a bottom wall, a first end
wall, a second end wall, a first sidewall, and a second sidewall,
opening the container, and providing an insulated liner including a
recyclable first panel, a recyclable second panel, at least one
cavity defined by the first panel and the second panel, and a
recyclable insulating material provided within the at least one
cavity.
Inventors: |
Hall; Christopher Edward;
(North Huntingdon, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WW Thermal Designs, LLC |
North Huntingdon |
PA |
US |
|
|
Family ID: |
64400827 |
Appl. No.: |
15/987497 |
Filed: |
May 23, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62603354 |
May 26, 2017 |
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62604536 |
Jul 11, 2017 |
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62605097 |
Aug 1, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2565/385 20130101;
B65B 55/20 20130101; B65D 5/603 20130101; B65B 5/04 20130101; B65B
61/22 20130101; B65D 65/38 20130101; B65D 81/3858 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 65/38 20060101 B65D065/38; B65B 5/04 20060101
B65B005/04 |
Claims
1. An insulated liner for a container comprising: a recyclable
first panel; a recyclable second panel; at least one cavity defined
by the first panel and the second panel; and a recyclable
insulating material provided within the at least one cavity;
wherein the insulated liner is adapted to line and insulate the
container to keep a temperature within the container within a range
of temperatures.
2. The insulated liner of claim 1, wherein the range of
temperatures is between about approximately two degrees Celsius and
eight degrees Celsius.
3. The insulated liner of claim 1, wherein the recyclable first
panel and the recyclable second panel are kraft paper.
4. The insulated liner of claim 3, wherein the insulating material
is cellulose.
5. The insulated liner of claim 1, further comprising: a coating
layer provided on the first panel and the second panel; wherein the
coating layer is adapted to repel moisture and allow a thermal bond
between the first panel and the second panel.
6. The insulated liner of claim 5, wherein the coating layer is at
least one of a polypropylene polymer, a polyethylene polymer, and a
biodegradable polymer.
7. The insulated liner of claim 1, further comprising: an outer
seam connecting, at least in part, the first panel to the second
panel; wherein the at least one cavity is a first cavity; a second
cavity defined by the first panel and the second panel; a third
cavity defined by the first panel and the second panel; a first
inner seam connecting, at least in part, the first panel to the
second panel and positioned between the first cavity and the second
cavity; and a second inner seam connecting, at least in part, the
first panel to the second panel and positioned between the second
cavity and the third cavity.
8. The insulated liner of claim 7, further comprising: an operating
position of the insulated liner; a first lining portion bounding
the first cavity and defining a vertical first wall when the
insulated liner is in the operating position; a second lining
portion bounding the second cavity and defining a horizontal second
wall when the insulated liner is in the operating position; and a
third lining portion bounding the third cavity and defining a
vertical third wall when the insulated liner is in the operating
position.
9. The insulated liner of claim 8, further comprising: a first
surface of the first lining portion; a first surface of the second
lining portion that is perpendicular to the first surface of the
first lining portion when the insulated liner is in the operating
position; and a first surface of the third lining portion that is
facing and parallel to the first surface of the first lining
portion when the insulated liner is in the operating position.
10. The insulated liner of claim 8, further comprising: a first
side edge of the first lining portion; a first side edge of the
second lining portion positioned at a first angle of approximately
ninety degrees to the first side edge of the first lining portion
when the insulated liner is in the operating position; and a first
side of edge of the third lining portion positioned at a second
angle of approximately ninety degrees to the first side edge of the
second lining portion when the insulated liner is in the operating
position.
11. The insulated liner of claim 7, further comprising: a fourth
cavity defined by the first panel and the second panel; a fifth
cavity defined by the first panel and the second panel; a sixth
cavity defined by the first panel and the second panel; a third
inner seam connecting, at least in part, the first panel to the
second panel and positioned between the fourth cavity and the fifth
cavity; and a fourth inner seam connecting, at least in part, the
first panel to the second panel and positioned between the fifth
cavity and the sixth cavity.
12. The insulated liner of claim 11, further comprising: an
operating position of the insulated liner; a first lining portion
bounding the first cavity and defining a vertical first wall when
the insulated liner is in the operating position; a second lining
portion bounding the second cavity and defining a vertical second
wall when the insulated liner is in the operating position; a third
lining portion bounding the third cavity and defining a vertical
third wall when the insulated liner is in the operating position; a
fourth lining portion bounding the fourth cavity and defining a
vertical fourth wall when the insulated liner is in the operating
position; a fifth lining portion bounding the fifth cavity and
defining a horizontal fifth wall when the insulated liner is in the
operating position; and a sixth lining portion bounding the sixth
cavity and defining a vertical sixth wall when the insulated liner
is in the operating position.
13. The insulated liner of claim 12, further comprising: a first
side edge of the first lining portion; a first side edge of the
second lining portion positioned at a first angle of approximately
ninety degrees to the first side edge of the first lining portion
when the insulated liner is in the operating position; a first side
of edge of the third lining portion positioned at a second angle of
approximately ninety degrees to the first side edge of the second
lining portion when the insulated liner is in the operating
position; a first side edge of the fourth lining portion; a first
side edge of the fifth lining portion positioned at a third angle
of approximately ninety degrees to the first side edge of the
fourth lining portion when the insulated liner is in the operating
position; and a first side of edge of the sixth lining portion
positioned at a fourth angle of approximately ninety degrees to the
first side edge of the fifth lining portion when the insulated
liner is in the operating position.
14. The insulated liner of claim 12, further comprising: a first
surface of the first lining portion; a first surface of the second
lining portion that is perpendicular to the first surface of the
first lining portion when the insulated liner is in the operating
position; a first surface of the third lining portion that is
facing and parallel to the first surface of the first lining
portion when the insulated liner is in the operating position; a
first surface and a second surface of the fourth lining portion; a
first surface and a second surface of the fifth lining portion, the
second surface of the fifth lining portion is positioned
perpendicular to the second surface of the fourth lining portion
when the insulated liner is in the operating position; and a first
surface and a second surface of the sixth lining portion, the
second surface of the sixth lining portion facing and parallel to
the second surface of the fourth lining portion.
15. An insulated shipping system comprising: a recyclable
container; a first recyclable member formed from kraft paper filled
with cellulose and inserted into the recyclable container and
supporting objects for shipment thereon; a second recyclable member
formed from kraft paper filled with cellulose and inserted into the
recyclable container such that the second recyclable member
nestingly cooperates with the first recyclable member; wherein the
first recyclable member and the second recyclable member insulate
the object and all portions of the shipping system may be
recycled.
16. The insulated shipping system of claim 15, further comprising:
a first panel and a second panel of the first recyclable member; a
first outer seam connecting, at least in part, the first panel to
the second panel; a first cavity defined by the first panel and the
second panel; a second cavity defined by the first panel and the
second panel; a third cavity defined by the first panel and the
second panel; a first inner seam connecting, at least in part, the
first panel to the second panel and positioned between the first
cavity and the second cavity; and a second inner seam connecting,
at least in part, the first panel to the second panel and
positioned between the second cavity and the third cavity.
17. The insulated shipping system of claim 16, further comprising:
a top wall, a bottom wall, a first end wall, a second end wall, a
first sidewall, and a second sidewall of the recyclable container;
wherein when the first recyclable member is inserted into the
recyclable container, the first cavity is adjacent to the first
sidewall of the recyclable container, the second cavity is adjacent
the bottom wall of the recyclable container, and the third cavity
is adjacent the second sidewall of the recyclable container.
18. The insulated shipping system of claim 16, further comprising:
a third panel and a fourth panel of the second recyclable member; a
second outer seam connecting, at least in part, the third panel to
the fourth panel; a fourth cavity defined by the third panel and
the fourth panel; a fifth cavity defined by the third panel and the
fourth panel; a sixth cavity defined by the third panel and the
fourth panel; a third inner seam connecting, at least in part, the
third panel to the fourth panel and positioned between the fourth
cavity and the fifth cavity; and a fourth inner seam connecting, at
least in part, the third panel to the fourth panel and positioned
between the fifth cavity and the sixth cavity.
19. The insulated shipping system of claim 18, wherein when the
second recyclable member is inserted into the recyclable container,
the fourth cavity is adjacent to the first end wall of the
recyclable container, the fifth cavity is adjacent the top wall of
the recyclable container, and the sixth cavity is adjacent the
second end wall of the recyclable container.
20. A method of insulating a container comprising: providing an
insulated liner including a recyclable first panel, a recyclable
second panel, a first cavity defined by the recyclable first panel
and the recyclable second panel; an outer seam connecting, at least
in part, the first panel to the second panel, a second cavity
defined by the first panel and the second panel, a third cavity
defined by the first panel and the second panel, a first inner seam
connecting, at least in part, the first panel to the second panel
and positioned between the first cavity and the second cavity, a
second inner seam connecting, at least in part, the first panel to
the second panel and positioned between the second cavity and the
third cavity, a first lining portion bounding the first cavity, a
second lining portion bounding the second cavity, a third lining
portion bounding the third cavity, a fourth cavity defined by the
first panel and the second panel, a fifth cavity defined by the
first panel and the second panel, a sixth cavity defined by the
first panel and the second panel, a third inner seam connecting, at
least in part, the first panel to the second panel and positioned
between the fourth cavity and the fifth cavity, a fourth inner seam
connecting, at least in part, the first panel to the second panel
and positioned between the fifth cavity and the sixth cavity, a
fourth lining portion bounding the fourth cavity, a fifth lining
portion bounding the fifth cavity, and a sixth lining portion
bounding the sixth cavity; filling the first cavity, the second
cavity, the third cavity, the fourth cavity, the fifth cavity and
the sixth cavity with an insulating material; positioning the first
lining portion adjacent a first sidewall of a container;
positioning the second lining portion adjacent a bottom wall of the
container; positioning the third lining portion adjacent a second
sidewall of the container; wherein the first lining portion, the
second lining portion, and the third lining portion form a U-shape;
positioning an object on at least a portion of the second lining
portion; positioning the fourth lining portion adjacent a first end
wall of the container; positioning the fifth lining portion
vertically above the object; positioning the sixth lining portion
adjacent a second end wall of the container; wherein the fourth
lining portion, the fifth lining portion, and the sixth lining
portion form a U-shape and enclose the object; and closing the
container such that the top wall of the container is adjacent the
fifth lining portion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 62/603,354, filed on May 18, 2017; U.S.
Provisional Application Ser. No. 62/604,528, filed on Jul. 11,
2017; and U.S. Provisional Application Ser. No. 62/605,097, filed
on Aug. 1, 2017; the disclosures of which are incorporated herein
by reference.
BACKGROUND
Technical Field
[0002] The present disclosure relates generally to containers. More
particularly, the present disclosure relates to a liner for
containers. Specifically, the present disclosure relates to a
recyclable insulated liner for containers.
Background Information
[0003] Generally, temperature sensitive materials, such as foods,
pharmaceuticals, organs, blood, biologic materials, chemicals, and
the like, are shipped in insulated shipping containers.
[0004] Some typical insulated shipping containers include molded,
expanded polystyrene coolers, as well as multi-part panel systems
incorporating two, four or even six panels of material constructed
from rigid pre-fabricated panels of expanded polystyrene,
semi-rigid panels of cellulose, or similar mat fiber panels,
encapsulated in a polyethylene film or the like. Other typical
insulated shipping containers include flexible insulated container
liners made entirely of polyethylene and flexible foams and/or
semi-rigid panels of cellulose, cotton, or similar mat fiber
panels. Typical insulated shipping liners are approximately one
fourth of an inch thick and have a density of approximately one
pound per cubic foot.
[0005] One drawback associated with the above-mentioned typical
insulated containers incudes that they are not are not readily
accepted in various recycling programs, including municipal
recycling programs, because, among other reasons, the comingling of
the materials of the typical insulated shipping containers is not
readily recyclable (e.g. the comingling of multiple categories of
polyethylene or polyethylene and paper combined). This leads to
another drawback which includes that the insulated shipping
containers typically need to be retrieved at the end of the transit
period instead of being recycled.
SUMMARY
[0006] A need continues to exist for insulated liners for
containers. The insulated liner of the present disclosure addresses
the shortcomings of previously known insulated liners.
[0007] In one aspect, the present disclosure may provide an
insulated liner for a container comprising a recyclable first
panel, a recyclable second panel, at least one cavity defined by
the first panel and the second panel and a recyclable insulating
material provided within the at least one cavity; wherein the
insulated liner is adapted to line and insulate the container to
keep a temperature within the container within a range of
temperatures. In one example, the range of temperatures may be
between about approximately two degrees Celsius and eight degrees
Celsius. The recyclable first panel and the recyclable second panel
may be made out of kraft paper. The insulating material may be made
out of cellulose.
[0008] The insulated liner may further include a coating layer
provided on the first panel and the second panel. The coating layer
may be adapted to repel moisture and allow a thermal bond between
the first panel and the second panel. The coating layer may be made
of at least one of a polypropylene polymer, a polyethylene polymer,
and a biodegradable polymer.
[0009] The insulated liner may further include an outer seam
connecting, at least in part, the first panel to the second panel,
wherein the at least one cavity is a first cavity, a second cavity
defined by the first panel and the second panel, a third cavity
defined by the first panel and the second panel, a first inner seam
connecting, at least in part, the first panel to the second panel
and positioned between the first cavity and the second cavity, and
a second inner seam connecting, at least in part, the first panel
to the second panel and positioned between the second cavity and
the third cavity.
[0010] The insulated liner may further include an operating
position, a first lining portion bounding the first cavity, a
second lining portion bounding the second cavity, and a third
lining portion bounding the third cavity. In one example, when the
insulated liner is in the operating position, the first lining
portion may define a vertical first wall, the second lining portion
may define a horizontal second wall, and the third lining portion
may define a vertical third wall.
[0011] In one example, the first lining portion may include a first
surface, the second lining portion may include a first surface, and
the third lining portion may include a first surface. When the
insulated liner is in the operating position, the first surface of
the first lining portion may be generally perpendicular to the
first surface of the second lining portion, and the first surface
of the first lining portion may face and may be generally parallel
to the first surface of the third lining portion.
[0012] The first lining portion may include a first side edge, the
second lining portion may include a first side edge, and the third
lining portion may include a first side edge. When the insulated
liner is in the operating position, the first side edge of the
first lining portion may be at a first angle of approximately
ninety degrees to the first side edge of the second lining portion,
and the first side edge of the third lining portion may be at a
second angle of approximately ninety degrees to the first side edge
of the second lining portion.
[0013] The insulated liner may further include a fourth cavity
defined by the first panel and the second panel, a fifth cavity
defined by the first panel and the second panel, a sixth cavity
defined by the first panel and the second panel, a third inner seam
connecting, at least in part, the first panel to the second panel
and positioned between the fourth cavity and the fifth cavity, and
a fourth inner seam connecting, at least in part, the first panel
to the second panel and positioned between the fifth cavity and the
sixth cavity.
[0014] The insulated liner may further include a fourth lining
portion bounding the fourth cavity, a fifth lining portion bounding
the fifth cavity, and a sixth lining portion bounding the sixth
cavity. When the insulated liner is in the operating position, the
fourth lining portion may define a vertical fourth wall, the fifth
lining portion may define a horizontal fifth wall, and the sixth
lining portion may define a vertical sixth wall.
[0015] The fourth lining portion may include a first side edge, the
fifth lining portion may include a first side edge, and the sixth
lining portion may include a first side edge. When the insulated
liner is in the operating position, the first side edge of the
fourth lining portion is at a third angle of approximately ninety
degrees to the first side edge of the fifth lining portion, and the
first side edge of the sixth lining portion is at a fourth angle of
approximately ninety degrees to the first side edge of the fifth
lining portion.
[0016] The fourth lining portion may include a first surface and a
second surface, the fifth lining portion may include a first
surface and a second surface, and the sixth lining portion may
include a first surface and a second surface. When the insulated
liner is in the operating position, the second surface of the
fourth lining portion may be generally perpendicular to the second
surface of the fifth lining portion, and the second surface of the
fourth lining portion may face and may be parallel to the second
surface of the sixth lining portion.
[0017] In another aspect, the present disclosure may provide an
insulated shipping system comprising a recyclable container, a
first recyclable member formed from kraft paper filled with
cellulose and arranged in a U-shaped configuration and inserted
into the recyclable container and supporting objects for shipment
thereon, and a second recyclable member formed from kraft paper
filled with cellulose and arranged in an inverted U-shaped
configuration and rotated ninety degrees about a vertical axis
relative to the first recyclable member such that the second
recyclable member nestingly cooperates with the first recyclable
member when inserted into the recyclable container The first member
and the second member may insulate the object and all portions of
the shipping system may be recycled.
[0018] In another aspect, the present disclosure may provide a
method of insulating a container comprising providing the
container, the container including a top wall, a bottom wall, a
first end wall, a second end wall, a first sidewall, and a second
sidewall and opening the container. The method may further include
providing an insulated liner including a recyclable first panel, a
recyclable second panel, at least one cavity defined by the first
panel and the second panel, and a recyclable insulating material
provided within the at least one cavity. The insulated liner may be
adapted to line and insulate the container to keep a temperature
within the container within a range of temperatures.
[0019] The method may further include providing a coating layer on
the first panel and the second panel and thermally bonding the
first panel to the second panel.
[0020] The method may further include that the at least one cavity
is a first cavity, and the insulated liner further includes an
outer seam connecting, at least in part, the first panel to the
second panel, a second cavity defined by the first panel and the
second panel, a third cavity defined by the first panel and the
second panel, a first inner seam connecting, at least in part, the
first panel to the second panel and positioned between the first
cavity and the second cavity, a second inner seam connecting, at
least in part, the first panel to the second panel and positioned
between the second cavity and the third cavity, a first lining
portion bounding the first cavity, a second lining portion bounding
the second cavity, and a third lining portion bounding the third
cavity. The method may further include positioning the first lining
portion adjacent the first sidewall of the container, positioning
the second lining portion adjacent the bottom wall of the
container, and positioning the third lining portion adjacent the
second sidewall of the container to form a U-shape with the first
lining portion, the second lining portion, and the third lining
portion.
[0021] The method may further include that the insulated liner
further includes a fourth cavity defined by the first panel and the
second panel, a fifth cavity defined by the first panel and the
second panel, a sixth cavity defined by the first panel and the
second panel, a third inner seam connecting, at least in part, the
first panel to the second panel and positioned between the fourth
cavity and the fifth cavity, a fourth inner seam connecting, at
least in part, the first panel to the second panel and positioned
between the fifth cavity and the sixth cavity, a fourth lining
portion bounding the fourth cavity, a fifth lining portion bounding
the fifth cavity, and a sixth lining portion bounding the sixth
cavity. The method may further include positioning an object on at
least a portion of the second lining portion, positioning the
fourth lining portion adjacent the first end wall of the container,
positioning the fifth lining portion vertically above the object,
positioning the sixth lining portion adjacent the second end wall
of the container to form a U-shape with the fourth lining portion,
the fifth lining portion, and the sixth lining portion and enclose
the object, and closing the container such that the top wall of the
container is adjacent to the fifth lining portion.
[0022] The method may further include that the recyclable first
panel and the recyclable second panel may be made out of kraft
paper and that the insulating material may be made out of
cellulose.
[0023] In another aspect, the present disclosure may provide an
insulated liner for a container and method of insulating a
container. The insulated liner may include a recyclable first
panel, a recyclable second panel, at least one cavity defined by
the first panel and the second panel, and a recyclable insulating
material provided within the at least one cavity. The insulated
liner may be adapted to line and insulate the container to keep a
temperature within the container within a range of temperatures.
The method may include providing the container, the container
including a top wall, a bottom wall, a first end wall, a second end
wall, a first sidewall, and a second sidewall, opening the
container, and providing an insulated liner including a recyclable
first panel, a recyclable second panel, at least one cavity defined
by the first panel and the second panel, and a recyclable
insulating material provided within the at least one cavity.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] A sample embodiment of the disclosure is set forth in the
following description, is shown in the drawings and is particularly
and distinctly pointed out and set forth in the appended claims.
The accompanying drawings, which are fully incorporated herein and
constitute a part of the specification, illustrate various
examples, methods, and other example embodiments of various aspects
of the disclosure. It will be appreciated that the illustrated
element boundaries (e.g., boxes, groups of boxes, or other shapes)
in the figures represent one example of the boundaries. One of
ordinary skill in the art will appreciate that in some examples one
element may be designed as multiple elements or that multiple
elements may be designed as one element. In some examples, an
element shown as an internal component of another element may be
implemented as an external component and vice versa. Furthermore,
elements may not be drawn to scale.
[0025] FIG. 1 is an isometric perspective view of a conventional
corrugated fiberboard container in an open configuration;
[0026] FIG. 2 is an isometric perspective view of one embodiment of
a first member of an insulated container liner in accordance with
one aspect of the present disclosure;
[0027] FIG. 3 is an isometric perspective view of one embodiment of
a second member of an insulated container liner in accordance with
one aspect of the present disclosure;
[0028] FIG. 4 is an enlarged fragmentary cross-section view taken
along line 4-4 of FIG. 3 showing a coating layer;
[0029] FIG. 5 is an operational view of the first member being
provided within the corrugated fiberboard container;
[0030] FIG. 6 is an isometric perspective view of the first member
provided within the corrugated fiberboard container, objects being
retained within the corrugated fiberboard container, and the second
member above the corrugated fiberboard container;
[0031] FIG. 7 is an operational view of the second member being
provided within the corrugated fiberboard container;
[0032] FIG. 8 is an isometric perspective view of the corrugated
fiberboard container in a closed configuration;
[0033] FIG. 9 is a diagrammatic longitudinal cross-section taken
along line 9-9 of FIG. 8 with, among other things, a coating layer
removed for clarity;
[0034] FIG. 10 is a diagrammatic transverse cross-section taken
along line 10-10 of FIG. 8 with, among other things, the coating
layer removed for clarity, and with the exception that only one
object is retained by the insulated container liner within the
corrugated fiberboard container;
[0035] FIG. 11 is an is an isometric perspective view of one
embodiment of an insulated container liner in accordance with one
aspect of the present disclosure;
[0036] FIG. 11A is an is an isometric perspective view of one
embodiment of an insulated container liner in accordance with one
aspect of the present disclosure;
[0037] FIG. 12 is a diagrammatic cross-section view of one
embodiment of an insulated container liner in accordance with one
aspect of the present disclosure; and
[0038] FIG. 13 is a cross-section view of one embodiment of an
insulated container liner in accordance with one aspect of the
present disclosure.
[0039] FIG. 14 is a flow chart depicting an exemplary method of
insulating a container.
[0040] Similar numbers refer to similar parts throughout the
drawings.
DETAILED DESCRIPTION
[0041] The teachings of the present disclosure may be utilized with
various containers, such as a conventional corrugated fiberboard
container, which is generally indicated at 100 in FIG. 1. As shown
in FIG. 1, the corrugated fiberboard container 100 may include a
top wall 102a, a bottom wall 102b, a first sidewall 102c, a second
sidewall 102d, a first end wall 102e, and a second end wall 102f.
The top wall 102a, bottom wall 102b, first sidewall 102c, second
sidewall 102d, first end wall 102e, and second end wall 102f may
define an interior cavity 102g adapted to retain various objects
104 (FIG. 6, FIG. 9, FIG. 10, FIG. 12 and FIG. 13) for transport,
storage or the like.
[0042] Referring to FIG. 2-FIG. 7, there is shown one embodiment of
an insulated container liner in accordance with one aspect of the
present disclosure, with the insulated container liner generally
indicated at 10. In one example, the insulated container liner 10
may be configured to line the corrugated fiberboard container 100
(FIG. 1); however, the insulated container liner 10 may be utilized
with any suitable container. More particularly, the insulated
container liner 10 may be configured to line the various walls
102a, 102b, 102c, 102d, 102e, and 102f, as more fully described
below.
[0043] With continued reference to FIG. 2-FIG. 7, the insulated
container liner 10 may include a first member 12A and a second
member 12B.
[0044] The first member 12A may include a first panel 14, a second
panel 16, at least one cavity 18, which, in this embodiment is a
first cavity having the same reference numeral 18, a second cavity
20, a third cavity 22, an outer seam 24, a first inner seam 26, a
second inner seam 28, a coating layer 30, an insulating material
32, a first lining portion 34, a second lining portion 36, and a
third lining portion 38.
[0045] The first member 12A may further include a first end edge
12a, a second end edge 12b, a first side edge 12c, and a second
side edge 12d each of which are formed by the outer seam 24 which
connects, at least in part, the first panel 14 to the second panel
16. The first end edge 12a and the second end edge 12b may define a
longitudinal direction therebetween and the first side edge 12c and
the second side edge 12d may define a transverse direction
therebetween. When the first panel 14 and the second panel 16 are
connected to one another as more fully described below, the first
panel 14 and the second panel 16 may define a vertical direction
therebetween.
[0046] The first end edge 12a and the second end edge 12b may
extend in the transverse direction and the first side edge 12c and
the second side edge 12d may extend in the longitudinal direction.
The first end edge 12a may be generally parallel with the second
end edge 12b. The first end edge 12a and the second end edge 12b
may be generally perpendicular to the first side edge 12c and the
second side edge 12d. The first side edge 12c may be generally
parallel to the second side edge 12d. The first side edge 12c and
the second side edge 12d may be generally perpendicular to the
first end edge 12a and the second end edge 12b. The first end edge
12a may be spaced a distance D1 away from the second end edge 12b
and the first side edge 12c may be spaced a distance D2 away from
the second side edge 12d. In one example, distance D1 is greater
than distance D2; however, distances D1 and D2 may be any suitable
distances.
[0047] The first member 12A may further include a first imaginary
vertical plane P1 defined by the first end edge 12a extending
transversely through the first end edge 12a, a second imaginary
vertical plane P2 defined by a transverse midline of the first
inner seam 26 extending transversely through the midline of the
first inner seam 26, a third imaginary vertical plane P3 defined by
a transverse midline of the second inner seam 28 extending
transversely through the midline of the second inner seam 28, and a
fourth imaginary vertical plane P4 defined by the second end edge
12b extending transversely through the second end edge 12b.
[0048] The first plane P1, the second plane P2, the third plane P3,
and the fourth plane P4 may be generally parallel with one another.
The first plane P1 may be spaced a distance D3 away from the second
plane P2, the second plane P2 may be spaced a distance D4 away from
the third plane P3, and the third plane P3 may be spaced a distance
D5 away from the fourth plane P4. In some embodiments, distance D3
is equal to distance D4. In other embodiments, distance D4 is less
than distance D3 and distance D4 is less than distance D5. However,
it is envisioned that distances D3, D4, and D5 may be any suitable
distances.
[0049] With primary reference to FIG. 4, the first panel 14 may
include an outer surface 14a and an inner surface 14b, and the
second panel 16 may include an outer surface 16a and an inner
surface 16b. In one example, the inner surface 14b of the first
panel 14 may be connected to the inner surface 16b second panel 16
at the outer seam 24, the first inner seam 26, and the second inner
seam 28, via a thermal bond; however, the first panel 14 may be
connected to the second panel 16 in any suitable manner, including,
but not limited to, being connected at different locations and
being connected via a chemical bond, such as an adhesive, or the
like.
[0050] With continued reference to FIG. 4, when the first panel 14
and the second panel 16 are connected to one another, the first
panel 14 and the second panel 16 may include a maximum thickness
T1. In one example, the thickness T1 may be between a range of
approximately one inch to two inches in length. In another example,
the thickness T1 may be approximately one inch in length. In
another example, the thickness T1 may be approximately one and one
half inch in length. In another example, the thickness T1 may be
approximately two inches in length. Although particular thicknesses
of T1 have been described, thickness T1 may be any suitable
thickness.
[0051] In one example, the first panel 14 and the second panel 16
may be made out of a recyclable material, such as kraft paper,
which may be defined as paper or paperboard (i.e. cardboard)
produced from chemical pulp. More particularly, kraft paper may be
made by converting wood into wood pulp, which includes cellulose
fibers. Although the first panel 14 and the second panel 16 have
been described as being made out of kraft paper, the first panel 14
and the second panel 16 may be made out of any suitable
materials.
[0052] The coating layer 30 may be provided on the first panel 14
and the second panel 16 via extrusion coating, lamination, or any
other suitable method of providing a coating (FIG. 4). In one
example, the coating layer 30 may be provided on the outer surface
14a of the first panel 14. In another example, the coating layer 30
may be provided on the outer surface 16a of the second panel 16. In
another example, the coating layer 30 may be provided on the outer
surface 14a of the first panel 14 and the outer surface 16a of the
second panel 16. Although the coating layer 30 has been described
as being provided on particular portions of the first panel 14 and
the second panel 16, the coating layer 30 may be provided on the
first panel 14 and the second panel 16 at any location in any
suitable manner.
[0053] In one example, the coating layer 30 may be made out of a
recyclable material, such as a polyethylene polymer extrusion, a
polypropylene polymer extrusion, or a bio-based and biodegradable
polymer extrusion. Although the coating layer 30 has been described
as being made out of particular materials, the coating layer 30 may
be made out of any suitable materials.
[0054] With continued reference to FIG. 2-FIG. 7, the first cavity
18 may be bounded by the first panel 14, the second panel 16, the
outer seam 24, and the first inner seam 26. The second cavity 20
may be bounded by the first panel 14, the second panel 16, the
first inner seam 26, and the second inner seam 28. The third cavity
22 may be bounded by the first panel 14, the second panel 16, the
outer seam 24, and the second inner seam 28. More specifically, the
first cavity 18 may be bounded by the inner surface 14b of the
first panel 14, the inner surface 16b of the second panel 16, the
outer seam 24, and the first inner seam 26, the second cavity 20
may be bounded by the inner surface 14b of the first panel 14, the
inner surface 16b of the second panel 16, the first inner seam 26,
and the second inner seam 28, and the third cavity 22 may be
bounded by the inner surface 14b of the first panel 14, the inner
surface 16b of the second panel 16, the outer seam 24, and the
second inner seam 28. In one embodiment, each cavity 18, 20, and 22
is distinct and separate such that no portion of one cavity 18, 20
and 22 is in open communication with an adjacent cavity 18, 20, and
22. Thus, the second cavity 20 is positioned longitudinally between
the first cavity 18 and the third cavity 22.
[0055] In accordance with one aspect of the present disclosure, the
first cavity 18, the second cavity 20, and the third cavity 22 may
be configured to hold a volume of the insulating material 32. In
one example, the first cavity 18, the second cavity 20, and the
third cavity 22 may be filled with insulating material 32 such that
once the insulating material 32 is inserted within the cavities 18,
20, and 22, the insulating material 32 does not move within the
cavities 18, 20, and 22. In one example, this may be accomplished,
at least in part, by completely filling each cavity 18, 20, and 22
with the insulating material 32. Typically, the same mass of
insulating material 32 is deposited into each cavity 18, 20, and
22. In one example, the density of the filled cavities 28, 20, and
22 is approximately two to three pounds per cubic foot; however,
the density may be any suitable density. The first cavity 18, the
second cavity 20, and the third cavity 22 may be configured to hold
any suitable volume of the insulating material 32. The insulating
material 32 may be configured to maintain certain temperatures
within the container 100. In one example, the temperature may be
maintained between about approximately two degrees Celsius and
eight degrees Celsius; however, the temperature may be maintained
in any between any suitable temperature range.
[0056] In one example, the insulating material 32 may be made out
of a recyclable material, such as loose fill cellulose. In another
example, the insulating material 32 may be made out of loose fill
plant-based fibers and blends, such as cotton fiber, jute fiber or
other similar loose fill plant based fibers. Although the
insulating material 32 has been described as being made out of
particular materials, the insulating material 32 may be made out
any suitable recyclable insulating materials.
[0057] As shown in FIG. 2-FIG. 4, the first lining portion 34 may
include a first surface 34a, a second surface 34b, a first end edge
34c, a second end edge 34d, a first side edge 34e, and a second
side edge 34f. In one example, the first end edge 34c may be formed
by the outer seam 24, the second end edge 34d may be formed by the
first inner seam 26, the first side edge 34e may be formed by the
outer seam 24, and the second side edge 34f may be formed by the
outer seam 24.
[0058] The second lining portion 36 may include a first surface
36a, a second surface 36b, a first end edge 36c, a second end edge
36d, a first side edge 36e, and a second side edge 36f. In one
example, the first end edge 36c may be formed by the first inner
seam 26, the second end edge 36d may be formed by the second inner
seam 28, the first side edge 36e may be formed by the outer seam
24, and the second side edge 36f may be formed by the outer seam
24.
[0059] The third lining portion 38 may include a first surface 38a,
a second surface 38b, a first end edge 38c, a second end edge 38d,
a first side edge 38e, and a second side edge 38f. In one example,
the first end edge 38c may be formed by the second inner seam 28,
the second end edge 38d may be formed by the outer seam 24, the
first side edge 38e may be formed by the outer seam 24, and the
second side edge 38f may be formed by the outer seam 24.
[0060] In one example, the first member 12A may be configurable
between a first position 40 (FIG. 2) and a second position 42 (FIG.
5). When the first member 12A is in the first position 40, angles
.alpha.1 between the first side edge 34e of the first lining
portion 34, the first side edge 36e of the second lining portion
36, and the first side edge 38e of the third lining portion 38 may
be approximately zero degrees (FIG. 2).
[0061] When configuring the first member 12A from the first
position 40 to the second position 42, the first lining portion 34
may be folded in a vertically upward direction along a first
transverse axis X1 defined by the first inner seam 26 such that an
angle .alpha.2 between the first side edge 34e of the first lining
portion 34 and the first side edge 36e of the second lining portion
36 may be approximately ninety degrees (FIG. 5). When configuring
the first member 12A from the first position 40 to the second
position 42, the third lining portion 38 may be folded in a
vertically upward direction along a second transverse axis X2
defined by the second inner seam 28 such that an angle .alpha.3
between the first side edge 38e of the third lining portion 38 and
the first side edge 36e of the second lining portion 36 may be
approximately ninety degrees (FIG. 5).
[0062] In one example, when the first member 12A is in the second
position 42, the first surface 34a of the first lining portion 34
may be generally perpendicular to the first surface 36a of the
second lining portion 36 and generally parallel to the first
surface 38a of the third lining portion 38. In one example, when
the first member 12A is in the second position 42, the first
surface 38a of the third lining portion 38 may be generally
perpendicular to the first surface 36a of the second lining portion
36 and generally parallel to the first surface 34a of the first
lining portion 34. Further, when the first member 12A is in the
second position 42, the first lining portion 34 may define a
vertical first wall by the first surface 34a and the second surface
34b, the second lining portion 36 may define a horizontal second
wall by the first surface 36a and the second surface 36b, and the
third lining portion 38 may define a vertical third wall defined by
the first surface 38a and the second surface 38b.
[0063] In one example, when the first member 12A is in the second
position 42, the first surface 34a of the first lining portion 34
may be generally facing the first surface 38a of the third lining
portion 38.
[0064] As shown in FIG. 3, the second member 12B is substantially
identical to the first member 12A of FIG. 2 in structure and
function with a few exceptions/additions that will be discussed
hereafter in greater detail. As such, the reference numbers used to
describe the first member 12A are the same reference numbers used
to describe the second member 12B except as otherwise described
herein. Further, certain terms may be referred to differently in
the appended claims. For example, in the appended claims, the first
cavity 18 may be referred to as the fourth cavity 18, the second
cavity 20 may be referred to as the fifth cavity 20, the third
cavity 22 may be referred to as the sixth cavity 22, the first
lining portion 34 may be referred to as the fourth lining portion
34, the second lining portion 36 may be referred to as the fifth
lining portion 36, and the third lining portion 38 may be referred
to as the sixth lining portion 38. Any other usage of certain terms
may be determined from the context of the usage in accordance with
the specification herein.
[0065] The second member 12B may include a first imaginary vertical
plane P1' defined by the first end edge 12a extending transversely
through the first end edge 12a, a second imaginary vertical plane
P2' defined by a transverse midline of the first inner seam 26
extending transversely through the midline of the first inner seam
26, a third imaginary vertical plane P3' defined by a transverse
midline of the second inner seam 28 extending transversely through
the midline of the second inner seam 28, and a fourth imaginary
vertical plane P4' defined by the second end edge 12b extending
transversely through the second end edge 12b.
[0066] The first plane P1', the second plane P2', the third plane
P3', and the fourth plane P4' may be generally parallel with one
another. The first plane P1' may be spaced a distance D6 away from
the second plane P2', the second plane P2' may be spaced a distance
D7 away from the third plane P3', and the third plane P3' may be
spaced a distance D8 away from the fourth plane P4'. With reference
to second member 12B, and in some embodiments, distance D7 may be
greater than distance D6 and distance D8. However, it is envisioned
that distances D6, D7, and D8 may be any suitable distances.
[0067] In one example, the second member 12B may be configurable
between the first position 40 (FIG. 2) and the second position 42
(FIG. 6). When the second member 12B is in the first position 40,
angles .alpha.1 between the first side edge 34e of the first lining
portion 34, the first side edge 36e of the second lining portion
36, and the first side edge 38e of the third lining portion 38 may
be approximately zero degrees (FIG. 3).
[0068] When configuring the second member 12B from the first
position 40 to the second position 42, the first lining portion 34
may be folded in a vertically downward direction along the first
transverse axis X1 defined by the first inner seam 26 such that the
angle .alpha.2 between the first side edge 34e of the first lining
portion 34 and the first side edge 36e of the second lining portion
36 may be approximately ninety degrees (FIG. 6). When configuring
the second member 12B from the first position 40 to the second
position 42, the third lining portion 38 may be folded in a
vertically downward direction along a second transverse axis X2
defined by the second inner seam 28 such that the angle .alpha.3
between the first side edge 38e of the third lining portion 38 and
the first side edge 36e of the second lining portion 36 may be
approximately ninety degrees (FIG. 6).
[0069] In one example, when the second member 12B is in the second
position 42, the first surface 34a of the first lining portion 34
may be generally perpendicular to the first surface 36a of the
second lining portion 36 and generally parallel to the first
surface 38a of the third lining portion 38. In one example, when
the first member 12A is in the second position 42, the first
surface 38a of the third lining portion 38 may be generally
perpendicular to the first surface 36a of the second lining portion
36 and generally parallel to the first surface 34a of the first
lining portion 34. Further, when the second member 12B is in the
second position 42, the first lining portion 34 may define a
vertical first wall by the first surface 34a and the second surface
34b, the second lining portion 36 may define a horizontal second
wall by the first surface 36a and the second surface 36b, and the
third lining portion 38 may define a vertical third wall by the
first surface 38a and the second surface 38b.
[0070] In one example, when the second member 12B is in the second
position 42, the second surface 34b of the first lining portion 34
may be generally facing the second surface 38b of the third lining
portion 38.
[0071] In operation, and with primary reference to FIG. 5-FIG. 10,
the insulated container liner 10 may be utilized to line the
corrugated fiberboard container 100. As shown in FIG. 5, the
corrugated fiberboard container 100 may be in an open configuration
and capable of receiving the insulated container liner 10 within
the interior cavity 102g.
[0072] The first member 12A may be manipulated from the first
position 40 to the second position 42. When the first member 12A is
in the second position 42, the first member 12A is generally
U-shaped and may be lowered in a vertically downward direction, as
shown by arrow A in FIG. 5, and received within the interior cavity
102g. More particularly, the first member 12A may be lowered such
that the second surface 34b of the first lining portion 34 makes
contact with the first sidewall 102c of the corrugated fiberboard
container 100, the second surface 36b of the second lining portion
36 makes contact with the bottom wall 102b of the corrugated
fiberboard container 100, and the second surface 38b of the third
lining portion 38 makes contact with the second sidewall 102d of
the corrugated fiberboard container 100.
[0073] With primary reference to FIG. 6, various objects 104, which
may be temperature sensitive products such as foods,
pharmaceuticals, organs, blood, biologic materials, chemicals, and
the like, may be placed within the corrugated fiberboard container
100. More particularly, the objects 104 may be positioned to make
contact with various portions of the first surface 34a of the first
lining portion 34, the first surface 36a of the second lining
portion 36, and the first surface 38a of the third lining portion
38, depending on, at least in part, the size of the object 104.
[0074] The second member 12B may be manipulated from the first
position 40 to the second position 42. When the second member 12B
is in the second position 42, the second member 12B is generally an
inverted U-shape and rotated ninety degrees about a vertical axis
relative to the first member 12A such that second member 12B may be
lowered in a vertically downward direction, as shown by arrow B in
FIG. 6, and received within the interior cavity 102g. More
particularly, the second member 12B may be lowered such that the
first surface 34a of the first lining portion 34 makes contact with
the second end wall 102f of the corrugated fiberboard container
100, the first surface 36a of the second lining portion 36 faces
the first surface 36a of the second lining portion 36 of the first
member 12A, and the first surface 38a of the third lining portion
38 makes contact with the first end wall 102e of the corrugated
fiberboard container 100.
[0075] As shown in FIG. 8, the top wall 102a of the corrugated
fiberboard container 100 may be closed and sealed. The sealed
container 100 may then be transported, stored, or otherwise
utilized.
[0076] FIG. 9 is a diagrammatic longitudinal cross-section of FIG.
8, which shows the objects 104 being retained within the corrugated
fiberboard container 100. More particularly, FIG. 9 shows the
second lining portion 36 of the first member 12A, the first lining
portion 34 of the second member 12B, the second lining portion 36
of the second member 12B, and the third lining portion 38 of the
second member 12B. The objects 104 contact the first surface 36a of
the second lining portion 36 of the first member 12A and the second
surface 36b of the second lining portion 36 of the first member
12A.
[0077] FIG. 10 is a diagrammatic transverse cross-section similar
to FIG. 8, which shows one of the objects 104 being retained within
the corrugated fiberboard container 100, however, in FIG. 10, there
is only one object 104 being retained. More particularly, FIG. 10
shows the second lining portion 36 of the second member 12B, the
first lining portion 34 of the first member 12A, the second lining
portion 36 of the first member 12A, and the third lining portion 38
of the first member 12A. The object 104 contacts the first surface
36a of the second lining portion 36 of the first member 12A, the
second surface 34b of the first lining portion 34 of the second
member 12B, the second surface 36b of the second lining portion 36
of the second member 12B, and the second surface 38b of the third
lining portion 38 of the second member 12B.
[0078] In one example, the insulated liner 10 may be formed by
automated or semi-automated liner manufacturing equipment. For
example, the first member 12A may be formed by automated or
semi-automated liner manufacturing equipment by unwinding the first
panel 14 and the second panel 16 from a roll of panels, aligning
and thermally bonding the first panel 14 to the second panel 16.
More particularly, the outer seam 24, first inner seam 26, and
second inner seam 28 may be formed on the insulated liner 10 except
for an opening (not shown) which is filled with the insulating
material 32 before being sealed. In one example, the insulating
material 32 may be filled via a weight-based filling process which
deposits a fiberized and metered amount of the insulating material
32) into each cavity of the insulated liner 10. The insulated liner
10 may be cut downstream to form the desired amount of cavities in
the insulated liner 10. Although a particular method of forming the
insulated liner 10 has been described, it is envisioned that the
insulated liner 10 may be formed by any suitable method.
[0079] Referring to FIG. 11, there is shown one embodiment of an
insulated container liner in accordance with one aspect of the
present disclosure, with the insulated container liner generally
indicated at 200. The insulated container liner 200 is
substantially identical to insulated container liner 10 in
structure and function with a few exceptions/additions that will be
discussed hereafter in greater detail. In this embodiment, the
first side edge 36e of the second lining portion 36 of the first
member 12A may be connected to the second end edge 38d of the third
lining portion 38 of the second member 12B. The insulated container
liner 200 operates in a substantially identical manner to insulated
container liner 10, except that the first member 12A and the second
member 12B are unitary.
[0080] Referring to FIG. 11A, there is shown one embodiment of an
insulated container liner in accordance with one aspect of the
present disclosure, with the insulated container liner generally
indicated at 200A. The insulated container liner 200A is
substantially identical to insulated container liner 200 in
structure and function with a few exceptions/additions that will be
discussed hereafter in greater detail. In this embodiment, the
first side edge 36e of the second lining portion 36 of the first
member 12A may be connected to the second end edge 38d of the third
lining portion 38 of the second member 12B, and the second end edge
34d of the first lining portion 34 of the second member 12B may be
connected to the second side edge 36f of the second lining portion
36 of the first member 12A. The insulated container liner 200A
operates in a substantially identical manner to insulated container
liner 200, except that the third lining portion 38 of the second
member 12B is attached in a different position.
[0081] Referring to FIG. 12, there is shown a diagrammatic
cross-section view of one embodiment of an insulated container
liner in accordance with one aspect of the present disclosure, with
the insulated container liner generally indicated at 300. The
insulated container liner 300 is substantially identical to
insulated container liner 10 in structure and function with a few
exceptions/additions that will be discussed hereafter in greater
detail. In this embodiment, the first lining portion 34 of the
first member 12A, the second lining portion 36 of the first member
12A, the third lining portion 38 of the first member 12A, the first
lining portion 34 of the second member 12B, the second lining
portion 36 of the second member 12B, and the third lining portion
38 of the second member 12B may be separate from one another.
[0082] Although the first lining portion 34 of the first member
12A, the second lining portion 36 of the first member 12A, the
third lining portion 38 of the first member 12A, the first lining
portion 34 of the second member 12B, the second lining portion 36
of the second member 12B, and the third lining portion 38 of the
second member 12B are separate from one another in this embodiment,
the same reference numerals are used to refer to each lining
portion 34, 36, and 38 of each member 12A and 12B.
[0083] In this embodiment, the first lining portion 34 of the first
member 12A, the third lining portion 38 of the first member, the
first lining portion 34 of the second member 12B, and the third
lining portion 38 of the second member 12B may be fixedly secured
to the corrugated fiberboard container 100 via a connection
mechanism 44, such as a contact adhesive or the like. The
connection mechanism 44 may be applied on any suitable portion of
the first lining portion 34 of the first member 12A, the third
lining portion 38 of the first member, the first lining portion 34
of the second member 12B, and the third lining portion 38 of the
second member 12B. Although the connection has been described as
being an adhesive, it is envisioned that any suitable connection
mechanism may be utilized. It is further envisioned that the first
lining portion 34 of the first member 12A, the third lining portion
38 of the first member, the first lining portion 34 of the second
member 12B, and the third lining portion 38 of the second member
12B may be adhered to the corrugated fiberboard container 100 after
the corrugated fiberboard container 100 has been erected or at any
other suitable time.
[0084] As shown in FIG. 12, the first lining portion 34 of the
second member 12B and the third lining portion 38 of the second
member 12B are fixedly secured to the corrugated fiberboard
container. More specifically, the first surface 34a of the first
lining portion 34 of the second member 12B and the first surface
38a of the third lining portion 38 of the second member 12B are
fixedly secured to the corrugated fiberboard container 100 with the
connection mechanism 44.
[0085] As shown in FIG. 12, and in this embodiment, the second
lining portion 36 of the first member 12A may be placed within the
corrugated fiberboard container 100 such that the second surface
36b of the second lining portion 36 makes contact with the bottom
wall 102b of the corrugated fiberboard container 100. The second
lining portion 36 of the second member 12B may be placed within the
corrugated fiberboard container 100 such that the second surface
36b makes contact with the first lining portion 34 of the first
member 12A, the third lining portion 38 of the first member 12A,
the first lining portion 34 of the second member 12B, and the third
lining portion 38 of the second member 12B and may make contact
with the objects 104.
[0086] In operation, the insulated container liner 300 operates in
a substantially identical manner to insulated container liner 10,
except that the first lining portion 34 of the first member 12A,
the second lining portion 36 of the first member 12A, the third
lining portion 38 of the first member 12A, the first lining portion
34 of the second member 12B, the second lining portion 36 of the
second member 12B, the third lining portion 38 of the second member
12B are separate from one another.
[0087] In one example, the insulated container liner 300 may be
integrally formed with the container 100 via fully automated carton
erector equipment and sealing equipment via hot melt, cold set
adhesive, contact adhesive or the like.
[0088] Referring to FIG. 13, there is shown a diagrammatic
cross-section view of one embodiment of an insulated container
liner in accordance with one aspect of the present disclosure, with
the insulated container liner generally indicated at 400. The
insulated container liner 400 is substantially identical to
insulated container liner 300 in structure and function with a few
exceptions/additions that will be discussed hereafter in greater
detail. In this embodiment, the first lining portion 34 of the
first member 12A, the second lining portion 36 of the first member
12A, the third lining portion 38 of the first member 12A, the first
lining portion 34 of the second member 12B, the second lining
portion 36 of the second member 12B, the third lining portion 38 of
the second member 12B may be integrally formed with the corrugated
fiberboard container 100.
[0089] In this embodiment, the second surface 34b of the first
lining portion 34 of the first member 12A, the second surface 38b
of the third lining portion 38 of the first member 12A, the first
surface 34a of the first lining portion 34 of the second member
12B, and the first surface 38a of the third lining portion 38 of
the second member 12B may all be removed except for flange portions
46 as shown in FIG. 13. In this embodiment, the first cavity 18 of
the first member 12A may be defined by the first sidewall 102c, the
first surface 34a of the first lining portion 34 of the first
member 12A, the outer seam 24, and the first inner seam 26. The
third cavity 22 of the first member 12A may be defined by the
second sidewall 102d, the first surface 38a of the third lining
portion 38 of the first member 12A, the outer seam 24, and the
second inner seam 28. The first cavity 18 of the second member 12B
may be defined by the second end wall 102f, the second surface 34b
of the first lining portion 34 of the second member 12B, the outer
seam 24, and the first inner seam 26. The third cavity 22 of the
second member 12B may be defined by the first end wall 102e, the
second surface 38b of the third lining portion 38 of the second
member 12B, the outer seam 24, and the second inner seam 28.
[0090] In operation, the insulated container liner 400 operates in
a substantially identical manner to insulated container liner 300,
except that the first lining portion 34 of the first member 12A,
the second lining portion 36 of the first member 12A, the third
lining portion 38 of the first member 12A, the first lining portion
34 of the second member 12B, the second lining portion 36 of the
second member 12B, the third lining portion 38 of the second member
12B are integrally formed with the corrugated fiberboard container
100.
[0091] In one example, the insulated container liner 400 may be
integrally formed with the container 100 via fully automated carton
erector equipment and sealing equipment via hot melt, cold set
adhesive, contact adhesive or the like.
[0092] In one aspect according to the present disclosure, an
insulated shipping system comprising a recyclable container 100 is
disclosed. In this embodiment, the first recyclable member 12A may
be formed from kraft paper filled with cellulose and arranged in a
U-shaped configuration and inserted into the recyclable container
100 and supporting objects 104 for shipment thereon. The system may
further include a second recyclable member 12B formed from kraft
paper filled with cellulose and arranged in an inverted U-shaped
configuration and rotated ninety degrees about a vertical axis
relative to the first recyclable member 12A such that the second
recyclable member 12B nestingly cooperates with the first
recyclable member 12A when inserted into the recyclable container
100.
[0093] The first recyclable member 12A may include a first panel 14
and a second panel 14, a first outer seam 24 connecting, at least
in part, the first panel 14 to the second panel 16; a first cavity
18 defined by the first panel 14 and the second panel 16, a second
cavity 20 defined by the first panel 14 and the second panel 16, a
third cavity 22 defined by the first panel 14 and the second panel
16, a first inner seam connecting 26, at least in part, the first
panel 14 to the second panel 16 and positioned between the first
cavity 18 and the second cavity 20, and a second inner seam
connecting 28, at least in part, the first panel 14 to the second
panel 16 and positioned between the second cavity 20 and the third
cavity 22.
[0094] In one example, when the first recyclable member 12A is in
the U-shaped configuration and inserted into the recyclable
container 100, the first cavity 18 may be adjacent to the first
sidewall 102c of the recyclable container 100, the second cavity 20
may be adjacent the bottom wall 102b of the recyclable container
100, and the third cavity 22 may be adjacent the second sidewall
102d of the recyclable container 100.
[0095] In one example, the second recyclable member 12B may include
a third panel 14 and a fourth panel 16, a second outer seam
connecting 24, at least in part, the third panel 14 to the fourth
panel 16, a fourth cavity 18 defined by the third panel 14 and the
fourth panel 16, a fifth cavity 20 defined by the third panel 14
and the fourth panel 16, a sixth cavity 22 defined by the third
panel 14 and the fourth panel 16, a third inner seam 26 connecting,
at least in part, the third panel 14 to the fourth panel 16 and
positioned between the fourth cavity 18 and the fifth cavity 20,
and a fourth inner seam 28 connecting, at least in part, the third
panel 14 to the fourth panel 16 and positioned between the fifth
cavity 20 and the sixth cavity 22.
[0096] In one example, when the second recyclable member 12B is in
the inverted U-shaped configuration and inserted into the
recyclable container 100, the fourth cavity 18 may be adjacent to
the first end wall 102e of the recyclable container 100, the fifth
cavity 20 may be adjacent the top wall 102a of the recyclable
container 100, and the sixth cavity 22 may be adjacent the second
end wall 102f of the recyclable container 100.
[0097] In one example, when the first recyclable member 12A is in
the U-shaped configuration and inserted into the recyclable
container 100, and the second recyclable member 12B is in the
inverted U-shaped configuration and inserted into the recyclable
container 100, the first inner seam 26 and the second inner seam 28
of the first recyclable member 12A may be perpendicular to the
third inner seam 26 and the fourth inner seam 28 of the second
recyclable member 12B.
[0098] FIG. 14 depicts an exemplary method in accordance with the
present disclosure. In one example, a method of insulating a
container is shown generally at 1400. In this example, the method
1400 describes the operation of the insulated container liner 10.
In one example, the method 1400 may include providing the container
100, the container 100 including a top wall 102a, a bottom wall
102b, a first sidewall 102c, a second sidewall 102d, a first end
wall 102e, and a second end wall 102f, which is shown generally at
1402. The method 1400 may include opening the container 100, which
is shown generally at 1404. The method 1400 may include providing
an insulated liner 10 including a recyclable first panel 14, a
recyclable second panel 16, at least one cavity 18 defined by the
first panel 14 and the second panel 16, and a recyclable insulating
material 32 provided within the at least one cavity 18, which is
shown generally at 1406. In one example, the insulated liner 10 may
be adapted to line and insulate the container 100 to keep a
temperature within the container 100 within a range of
temperatures, which is shown generally at 1408. The method 1400 may
include providing a coating layer 30 on the first panel 14 and the
second panel 16, which is shown generally at 1410. The method 1400
may include thermally bonding the first panel 14 to the second
panel 16, which is shown generally at 1412.
[0099] In one example, the at least one cavity 18 may be a first
cavity 18, and the insulated liner 10 may further include an outer
seam 24 connecting, at least in part, the first panel 14 to the
second panel 16, a second cavity 20 defined by the first panel 14
and the second panel 16, a third cavity 22 defined by the first
panel 14 and the second panel 16, a first inner seam 26 connecting,
at least in part, the first panel 14 to the second panel 16 and
positioned between the first cavity 18 and the second cavity 20, a
second inner seam 28 connecting, at least in part, the first panel
14 to the second panel 16 and positioned between the second cavity
20 and the third cavity 22, a first lining portion 34 bounding the
first cavity 18, a second lining portion 36 bounding the second
cavity 20, and a third lining portion 38 bounding the third cavity
22. The method 1400 may further include positioning the first
lining portion 34 adjacent the first sidewall 102c of the container
100, which is shown generally at 1414. The method may include
positioning the second lining portion 36 adjacent the bottom wall
102b of the container 100, which is shown generally at 1418. The
method 1400 may include positioning the third lining portion 38
adjacent the second sidewall 102d of the container 100 to form a
U-shape with the first lining portion 34, the second lining portion
36, and the third lining portion 38, which is shown generally at
1420.
[0100] In one example, the insulated liner 10 may further include a
fourth cavity 18 defined by the first panel 14 and the second panel
16, a fifth cavity 20 defined by the first panel 14 and the second
panel 16, a sixth cavity 22 defined by the first panel 14 and the
second panel 16, a third inner seam 26 connecting, at least in
part, the first panel 14 to the second panel 16 and positioned
between the fourth cavity 18 and the fifth cavity 20, a fourth
inner seam 28 connecting, at least in part, the first panel 14 to
the second panel 16 and positioned between the fifth cavity 20 and
the sixth cavity 22, a fourth lining portion 34 bounding the fourth
cavity 18, a fifth lining portion 36 bounding the fifth cavity 20,
and a sixth lining portion 38 bounding the sixth cavity 22. The
method 1400 may further include positioning an object 104 on at
least a portion of the second lining portion 36, which is shown
generally at 1422. The method may include positioning the fourth
lining portion 34 adjacent the second end wall 102f of the
container, which is shown generally at 1424. The method may include
positioning the fifth lining portion 36 vertically above the object
104, which is shown generally at 1426. The method 1400 may include
positioning the sixth lining portion 38 adjacent the first end wall
102e of the container to form a U-shape with the fourth lining
portion 34, the fifth lining portion 36, and the sixth lining
portion 38 and enclose the object 104, which is shown generally at
1428. The method 1400 may further include closing the container 100
such that the top wall 102a of the container 100 is adjacent to the
fifth lining portion 36, which is shown generally at 1430.
[0101] In one example, the recyclable first panel and the
recyclable second panel may be made out of kraft paper and the
insulating material may be made out of cellulose.
[0102] In one example, the insulated container liner 10 may be a
flexible. In another example, the insulated container liner 10 may
be rigid.
[0103] In one example, the first lining portion 34, the second
lining portion 36, and the third lining portion 38 may have
thicknesses between a range of approximately one inch to two inches
in length. In another example, the thicknesses may be approximately
one inch in length. In another example, the thicknesses may be
approximately one and one half inch in length. In another example,
the thicknesses may be approximately two inches in length. Although
particular thicknesses have been described, the thicknesses may be
any suitable thicknesses.
[0104] In one example, the first lining portion 34, the second
lining portion 36, and the third lining portion 38 may have a
density of approximately two to three pounds per cubic foot;
however, the first lining portion 34, the second lining portion 36,
and the third lining portion 38 may have any suitable density.
[0105] It is further envisioned that each lining portion, 34, 36,
38 may be split into two lining portions. For example, the first
lining portion 34 may include an additional seam (not shown) which
creates two cavities (not shown) in the first lining portion 34. In
this example, the two cavities of the first lining portion would be
adjacent to a particular wall of the container 100.
[0106] In accordance with one aspect of the present disclosure,
some benefits of the teachings of the present disclosure include,
among others, that the insulated liners 10, 200, 300 and 400,
utilize a combination of materials that are capable of maintaining
the objects within a desired temperature range, are low cost, are
recyclable, and are capable of being used one time instead of being
retrieved at the end of transit. In one example, the insulated
liners 10, 200, 300 and 400 may maintain the temperature within the
container 100 between about approximately two degrees Celsius and
eight degrees Celsius; however, the insulated liners 10, 200, 300,
and 400 may be configured to maintain any suitable desired
temperature range within the container 100. Another benefit of the
teachings of the present disclosure includes, among others, that
each cavity 18, 20, and 22 is distinct and separate such that no
portion of one cavity 18, 20 and 22 is in open communication with
an adjacent cavity 18, 20, and 22.
[0107] It is further envisioned that the insulated liners 10, 200,
300, and 400, may be configured to fit the dimensions of various
containers. For example, the distances D1, D2, D3, D4, D5, D6, D7,
and D8, of the insulated liner 10 may be configured to any desired
dimensions of a container.
[0108] Although the first cavity 18 has been described as being
adjacent to the first sidewall 102c, the second cavity 20 has been
described as being adjacent to the bottom wall 102b, the third
cavity 22 has been described as being adjacent to the second
sidewall 102d, the fourth cavity 18 has been described as being
adjacent to the first end wall 102e, the fifth cavity 20 has been
described as being adjacent to the top wall 102a, and the sixth
cavity 22 has been described as being adjacent to the second end
wall 102f, it is envisioned that each of the cavities 18, 20 and 22
may be configured to be adjacent to any suitable wall 102a, 102b,
102c, 102d, 102e, and 102f of the container 100.
[0109] Although the first lining portion 34 has been described as
being adjacent to the first sidewall 102c, the second lining
portion 36 has been described as being adjacent to the bottom wall
102b, the third lining portion 38 has been described as being
adjacent to the second sidewall 102d, the fourth lining portion 34
has been described as being adjacent to the first end wall 102e,
the fifth lining portion 36 has been described as being adjacent to
the top wall 102a, and the sixth lining portion 38 has been
described as being adjacent to the second end wall 102f, it is
envisioned that each of the lining portions 34, 36 and 38 may be
configured to be adjacent to any suitable wall 102a, 102b, 102c,
102d, 102e, and 102f of the container 100.
[0110] Also, various inventive concepts may be embodied as one or
more methods, of which an example has been provided. The acts
performed as part of the method may be ordered in any suitable way.
Accordingly, embodiments may be constructed in which acts are
performed in an order different than illustrated, which may include
performing some acts simultaneously, even though shown as
sequential acts in illustrative embodiments.
[0111] While various inventive embodiments have been described and
illustrated herein, those of ordinary skill in the art will readily
envision a variety of other means and/or structures for performing
the function and/or obtaining the results and/or one or more of the
advantages described herein, and each of such variations and/or
modifications is deemed to be within the scope of the inventive
embodiments described herein. More generally, those skilled in the
art will readily appreciate that all parameters, dimensions,
materials, and configurations described herein are meant to be
exemplary and that the actual parameters, dimensions, materials,
and/or configurations will depend upon the specific application or
applications for which the inventive teachings is/are used. Those
skilled in the art will recognize, or be able to ascertain using no
more than routine experimentation, many equivalents to the specific
inventive embodiments described herein. It is, therefore, to be
understood that the foregoing embodiments are presented by way of
example only and that, within the scope of the appended claims and
equivalents thereto, inventive embodiments may be practiced
otherwise than as specifically described and claimed. Inventive
embodiments of the present disclosure are directed to each
individual feature, system, article, material, kit, and/or method
described herein. In addition, any combination of two or more such
features, systems, articles, materials, kits, and/or methods, if
such features, systems, articles, materials, kits, and/or methods
are not mutually inconsistent, is included within the inventive
scope of the present disclosure.
[0112] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0113] An embodiment is an implementation or example of the present
disclosure. Reference in the specification to "an embodiment," "one
embodiment," "some embodiments," "one particular embodiment," or
"other embodiments," or the like, means that a particular feature,
structure, or characteristic described in connection with the
embodiments is included in at least some embodiments, but not
necessarily all embodiments, of the invention. The various
appearances "an embodiment," "one embodiment," "some embodiments,"
"one particular embodiment," or "other embodiments," or the like,
are not necessarily all referring to the same embodiments.
[0114] Additionally, any method of performing the present
disclosure may occur in a sequence different than those described
herein. Accordingly, no sequence of the method should be read as a
limitation unless explicitly stated. It is recognizable that
performing some of the steps of the method in an different order
could achieve a similar result.
[0115] In the foregoing description, certain terms have been used
for brevity, clearness, and understanding. No unnecessary
limitations are to be implied therefrom beyond the requirement of
the prior art because such terms are used for descriptive purposes
and are intended to be broadly construed.
[0116] Moreover, the description and illustration of various
embodiments of the disclosure are examples and the disclosure is
not limited to the exact details shown or described.
* * * * *