U.S. patent application number 16/385657 was filed with the patent office on 2019-10-17 for insulated package.
This patent application is currently assigned to Craft Packaging LLC. The applicant listed for this patent is Craft Packaging LLC. Invention is credited to Eric Gray, Travis Winn.
Application Number | 20190315541 16/385657 |
Document ID | / |
Family ID | 68160685 |
Filed Date | 2019-10-17 |
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United States Patent
Application |
20190315541 |
Kind Code |
A1 |
Gray; Eric ; et al. |
October 17, 2019 |
INSULATED PACKAGE
Abstract
This disclosure generally describes a method, system, and device
for constructing a packaging device and the package itself. The
packaging device includes one or more insulative interlocking
panels which are affixed to one or more corresponding panels of
packaging material. The insulative interlocking panels may be
assembled together into an insulative packaging device surrounded
by packaging material.
Inventors: |
Gray; Eric; (Draper, UT)
; Winn; Travis; (Draper, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Craft Packaging LLC |
Draper |
UT |
US |
|
|
Assignee: |
Craft Packaging LLC
Draper
UT
|
Family ID: |
68160685 |
Appl. No.: |
16/385657 |
Filed: |
April 16, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62658428 |
Apr 16, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 65/44 20130101;
B65D 85/30 20130101; B65D 81/127 20130101; B65D 81/3823 20130101;
B65D 11/1873 20130101; B65D 2581/051 20130101; B65D 81/025
20130101 |
International
Class: |
B65D 81/02 20060101
B65D081/02; B65D 81/127 20060101 B65D081/127; B65D 6/24 20060101
B65D006/24 |
Claims
1. A package, comprising: a box cutout having a plurality of panels
and a plurality of insulative panels, each of the plurality of
insulated panels being affixed to one of the plurality of
panels.
2. The package of claim 1, wherein an edge of each one of the
insulated panels mates with an edge of another one of the insulated
panels.
3. The package of claim 2, wherein the edge of each one of the
insulated panels includes a lock.
4. The package of claim 3, wherein the edge of each one of the
insulated panels are interlocking with the edge of the another one
of the insulated panels.
5. The package of claim 2, wherein the edge of each one of the
insulated panels has a complimentary angle to the edge of the
another one of the insulated panels.
6. The package of claim 2, wherein the edge of each one of the
insulated panels is beveled at a complimentary angle to the edge of
the another one of the insulated panels.
7. The package of claim 1, wherein the box cutout is a packing
backing material.
8. The package of claim 7, wherein the packing backing material is
cardboard.
9. The package of claim 7, wherein the packing backing material is
corrugated cardboard.
10. The package of claim 7, wherein the packing backing material is
corrugated plastic.
11. The package of claim 1, wherein the box cutout is a cutout for
a square box.
12. The package of claim 1, wherein the box cutout is a cutout for
a rectangular box.
13. The package of claim 1, wherein the package is flat.
14. The package of claim 1, wherein the package is assembled into
an insulated box.
15. The package of claim 13, wherein the insulated box includes a
cavity.
16. The package of claim 1, wherein the plurality of insulated
panels are foam panels.
17. The package of claim 15, wherein the foam panels include a
reflective surface.
18. The package of claim 15, wherein the foam panels have an
insulation value that exceeds R4.
19. The package of claim 1, wherein the plurality of insulated
panels are air bladders.
20. A system, comprising: a box cutout having a plurality of panels
and a plurality of insulative panels, each of the plurality of
insulated panels being affixed to one of the plurality of panels.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/658,428, filed Apr. 16, 2018, which is
incorporated herein by reference in its entirety, including but not
limited to those portions that specifically appear hereinafter, the
incorporation by reference being made with the following exception:
In the event that any portion of the above-referenced provisional
application is inconsistent with this application, this application
supersedes said above-referenced provisional application.
BACKGROUND
1. Technical Field
[0002] This disclosure relates generally to a system, device, and
method of making an insulated packaging device which includes one
or more interlocking panels of insulated material, affixed to the
sides of a box. In one embodiment, the insulated packaging device
includes a box cutout which lays essentially flat and to which
various interlocking panels of insulative material are affixed,
such that when the box cutout is assembled, the box cutout and the
interlocking panels of insulative material are assembled into an
insulated packing box to maintain a temperature of an item placed
in the insulated packing box.
2. Description of the Related Art
[0003] Since the advent of the trade of goods over long distances,
man has been designing various containers and vessels for
transporting the goods while ensuring that the goods arrive at
their destination in the same unspoiled condition in which they
were shipped. Historically, spices, for example, were contained
within an earthenware container and placed in a wood box or crate
loaded with straw as packing material with the intent that the
straw would absorb shock that may be encountered during shipping of
the spices and prevent the earthenware container from breaking
during transport.
[0004] Until around the advent of air travel, most packaging of
various breakable goods to be protected was straw, or cotton, or
some other natural compressible and soft material. However, when
airplanes began to travel across the world in less than a day,
trade changed and the things that could be shipped changed along
with it. For example, with an airplane, a crate of fruit could be
shipped from warm weather climates to cold weather climates such
that fresh fruit of virtually any variety became available all year
long. Similarly, beef farmed on another continent could be
butchered and packed in a container on ice to be prepared on
another continent in less time than it took the ice in the
container to melt.
[0005] One difficulty in shipping has always been shipping
temperature sensitive items from one place to another. Before the
advent of the steam engine, it was virtually impossible to
transport any temperature sensitive items any meaningful distance
except during an appropriate season. For example, fresh oysters
harvested on the Eastern Shore of Virginia were transported by rail
to market only during winter months when shippers could be assured
that the product would not be tainted by heat. During summer
months, only canned oysters could be shipped because the canning
process protected the oysters from heat they would be exposed to
during transport. Occasionally, fresh oysters could be shipped in
the summer months in small quantities if an ice box and sufficient
ice were available on a train.
[0006] Even today, ice boxes, known as coolers, are the most common
form of keeping food (or other temperature sensitive items) cold in
situations where electricity is not available. Each new cooler
company clamors to redesign coolers to produce more insulative,
more transportable, more rigid coolers to protect temperature
sensitive items at their proper temperature (either cold or hot).
However, these various cooler designs have become, in at least some
situations, outrageously expensive requiring a long serviceable
lifespan to make an investment in such a cooler worthwhile. Thus,
these coolers are unsuitable for shipping because of the high cost
of purchase and, in many cases, the weight of such coolers.
[0007] For shipping and packaging situations, it became necessary
to create a cooler that was light, inexpensive, insulative for
temperature sensitive items, and rigid enough to survive the
shipping process. The generally accepted solution to these issues
became lidded boxes made from a closed-cell extruded polystyrene
foam ("EPS foam"), also known as Styrofoam.RTM.. EPS foam has not
only been used within conventional coolers as insulation, but also
has been molded into boxes which serve as effective temporary
coolers when combined with a molded lid that closes the box. For
shipping purposes, these EPS foam boxes are typically installed
within a cardboard box for transportation. Airlines have
specifically approved certain box/EPS foam coolers as baggage to
transport seafood, for example. In one example, these box/EPS foam
coolers are ubiquitous in Alaska during the summer fishing season,
to allow many sport fishermen to return home with their prized
catches safely contained and cold within these box/EPS foam
coolers.
[0008] FIG. 1 illustrates one of these prior art cardboard box/EPS
foam coolers 100. As shown in FIG. 1, a corrugated cardboard box
105 is provided along with a molded EPS foam cooler box 110.
Corrugated cardboard box 105 includes a recess 115 which is sized
virtually precisely to receive EPS foam cooler box 110 inside
recess 115 of corrugated cardboard box 105. EPS foam cooler box 110
further includes a recess 120 which may contain temperature
sensitive items, such as fillets from a prized chinook salmon
caught by a sport fisherman in Alaska, for example. EPS foam cooler
box 110 may include a lid 125 which may enclose the prized chinook
salmon fillets inside recess 120 of EPS foam cooler box 110 along
with frozen gel packs to provide an insulated cool box which can be
safely shipped for up to 24 hours before refreshing the frozen gel
packs.
[0009] FIG. 2A illustrates an embodiment of a cardboard box/EPS
foam cooler 200 which provides additional insulation and shock
protection over cardboard box/EPS foam cooler 100, shown in FIG. 1,
for more sensitive items (in terms of temperature and physical
shock) than salmon fillets, such as, for example, human organs.
Cardboard box/EPS foam cooler 200 includes a cardboard box 205, and
an EPS foam cooler box 210 disposed inside cardboard box 205.
However, in FIG. 2A, a secondary layer of insulative and or
protective material 215 is installed around EPS foam cooler 210.
For example, foam peanuts or packing peanuts may be layered between
cardboard box 205 and EPS foam cooler 210. Foam peanuts may also be
formed using expanded polystyrene, providing further insulation
while also providing cushioning by virtue of their respective
shapes. The foam peanuts are designed to nest because of their
respective shapes when compressed and to freely move when
uncompressed which is an efficient method to absorb shock during
shipping, for example.
[0010] Otherwise, EPS foam cooler 210 is similar to EPS foam cooler
110, shown in FIG. 1, and includes a cavity 220 for enclosing a
temperature sensitive and shock sensitive item inside EPS foam
cooler 210. EPS foam cooler 210 may also include a molded lid which
connects to a lip of EPS foam cooler 210 in a manner that tends to
retain lid 225 on EPS foam cooler 210.
[0011] Once the temperature sensitive items have been placed within
cavity 220 of foam cooler 210 and lid 225 installed on a lip of EPS
foam cooler 210, cardboard box/EPS foam cooler 200 may be prepared
for shipping, as shown in FIG. 2B. FIG. 2B illustrates cardboard
box 205, EPS foam cooler 210 and insulative/protective layer 215
assembled together with lid 225 to provide a cavity 220 for
containing temperature sensitive items within cardboard box/EPS
foam cooler 200. Cardboard box 205 has been closed using various
flaps to ensure that cardboard box 205 completely encloses EPS foam
cooler 210. At this point, cardboard box/EPS foam cooler 200 are
safely installed and ready for shipping.
[0012] One unexpected aspect of the prior art technologies shown in
FIG. 1, FIG. 2A and FIG. 2B is the storage space required to store
foam box 210 and lid 225. For many retailers, entire warehouses are
filled with foam boxes, such as foam box 210, which themselves are
empty, waiting to portage a prized chinook salmon fillet from
Alaska to Texas, for example. Standard airline approved cardboard
box/EPS foam coolers may be approximately 18'' wide, 18'' deep and
30'' long. Thus, when stacked one on top of another, these
cardboard box/EPS foam coolers may be stacked 8 or 9 units high
before a person of average height can no longer stack further units
on top without a ladder, for example. Thus, one drawback of these
prior art technologies is that the foam coolers are spatially
inefficient and incur significant storage cost to store until
sold.
[0013] Further, it should be noted that many of these prior art
technologies are first shipped to, Alaska, for example, on
container ships or other conveyance as full
18''.times.18''.times.28'' boxes which requires significant amounts
of space on a container ship. Thus, not only is the amount of space
required to store these prior art technologies oppressive but
shipping these prior art technologies to their respective storage
locations is also a spatially intense undertaking. Simply put,
space constraints minimize the number of cardboard box/EPS foam
coolers that can be shipped at a price that makes their use as a
shipping package feasible.
[0014] Accordingly, it is one object of this disclosure to provide
a packaging system that includes interlocking insulative panels
that may be assembled into a package. It is another object of this
disclosure to provide a device which includes interlocking
insulative panels affixed to a box cutout which may lay
substantially flat during shipping to a storage destination, but
which may be assembled into a box/EPS foam cooler when needed. It
is another object of this disclosure to provide a method of making
a shipping container with interlocking panels affixed to a box
cutout.
SUMMARY
[0015] Disclosed herein is a package. The package includes a box
cutout having a plurality of panels. The package further includes a
plurality of insulative panels, each of which are affixed to one of
the plurality of panels of the box cutout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings illustrate various embodiments of
an insulated packaging system disclosed herein.
[0017] FIG. 1 illustrates a prior art cardboard box/EPS foam
cooler.
[0018] FIG. 2A illustrates another prior art embodiment of a
cardboard box/EPS foam cooler.
[0019] FIG. 2B illustrates another prior art embodiment of a
cardboard box/EPS foam cooler prepared for shipping.
[0020] FIG. 3 illustrates one exemplary insulated packaging system
which includes insulative interlocking panels affixed to a box
cutout.
[0021] FIG. 4 illustrates the exemplary insulated packaging system
of FIG. 3 which includes insulative interlocking panels affixed to
a box cutout in an assembled condition.
[0022] FIG. 5 illustrates an alternative exemplary insulated
packaging system which includes insulative interlocking panels
affixed to a box cutout.
[0023] FIG. 6 illustrates the exemplary insulated packaging system
of FIG. 5 which includes insulative interlocking panels affixed to
a box cutout in an assembled condition.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] In the following description, for purposes of explanation
and not limitation, specific techniques and embodiments are set
forth, such as particular techniques and configurations, in order
to provide a thorough understanding of the device disclosed herein.
While the techniques and embodiments will primarily be described in
context with the accompanying drawings, those skilled in the art
will further appreciate that the techniques and embodiments may
also be practiced in other similar devices.
[0025] Reference will now be made in detail to the exemplary
embodiments, examples of which are illustrated in the accompanying
drawings. Wherever possible, the same reference numbers are used
throughout the drawings to refer to the same or like parts. It is
further noted that elements disclosed with respect to particular
embodiments are not restricted to only those embodiments in which
they are described. For example, an element described in reference
to one embodiment or figure, may be alternatively included in
another embodiment or figure regardless of whether or not those
elements are shown or described in another embodiment or figure. In
other words, elements in the figures may be interchangeable between
various embodiments disclosed herein, whether shown or not.
[0026] FIG. 3 illustrates an alternative exemplary insulated
packaging system 300 which includes insulative interlocking panels
355a-355f affixed to a box cutout 305. Box cutout 305 may be cut
into a form that may be easily shaped into a box, for example, and
made of any conventional packaging material such as paper,
cardstock, cardboard, corrugated cardboard, plastics (rigid or
soft), corrugated plastic, or any other conventional packaging
backing material. Box cutout 305 is formed in such a shape as to
form a square box having six sides. It is noted, however, that a
square box is only one possible implementation of insulated
packaging system 300. Insulated packaging system 300 may be
implemented in any three-dimensional shape when assembled,
including whimsical shapes, as desired for any particular
implementation. For example, insulated packaging system 300 may
form a rectangular box, a spherical box, a tetrahedral box, a box
having any number of sides, or may, in some shapes be formed to
represent cartoon characters, fictional characters, representations
of fantastical creatures, or any other implementation that may be
desirable for a package. However, for purposes of explanation,
insulated packaging system 300 is shown as a box cutout 305 which
may be assembled into a six-sided square box.
[0027] Box cutout 305 may include a plurality of panels 360a-360f
which form the six sides of the exemplary square box. Box cutout
305 may further include pre-installed creases or indentations to
facilitate assembly of insulated packaging system 300. For example,
box cutout 305 may include a first vertical crease 310 and a second
vertical crease 315 which extend along a length of box cutout 305
to facilitate assembly of the other various panels, tabs, and flaps
of insulated packaging system 300, as will be discussed below.
Similarly, box cutout 305 may include a first horizontal crease
320, a second horizontal crease 325, a third horizontal crease 330,
and a fourth horizontal crease 335 which extend along a width of
box cutout 305 to facilitate assembly of the other various panels,
tabs, and flaps of insulated packaging system 300, as will be
discussed below.
[0028] Some of the other various panels, tabs, and flaps on box
cutout 305 may include a first support tab 340 and a second support
tab 345 which serve to add structural rigidity to insulated
packaging system 300 when assembled into an exemplary six-sided
square box. box cutout 305 may further include a plurality of
flaps, such as flaps 350a-350d which may be used to provide access
points into or provide structural rigidity for insulated packaging
system 300 when assembled into an exemplary six-sided square box.
For example, flaps 350a-350d may fold over a top or bottom portion
of insulated packaging system 300 and be connected together by, for
example, packaging tape, that is used to seal insulated packaging
system 300 when assembled into an exemplary six-sided box.
[0029] box cutout 305 may further include one or more interlocking
insulative panels 355a-355f affixed in a permanent manner to panels
360a-360f. Interlocking insulative panels 355a-355f may be
constructed from EPS foam and formed into panels that have male and
female interlocking parts, in this embodiment. More simply,
interlocking insulative panels 355a-355f may include one or more
locks that connect at least one of interlocking insulative panels
355a-355f to at least one other of interlocking insulative panels
355a-355f. Alternatively, interlocking insulative panels 355a-355f
may include one or more locks that connect to each adjacent one of
interlocking insulative panels 355a-355f. One example of a lock may
include a male connection in one of interlocking insulative panels
355a-355f which corresponds to a female recess of appropriate size
and shape in another of interlocking insulative panels 355a-355f to
receive the male connection. Another example of a lock may include
interlocking insulative panels 355a-355f having edge portions that
are cut or beveled into complimentary angles such that each of the
interlocking insulative panels 355a-355f fits squarely into a
recess created by corresponding beveled angles in adjacent
interlocking insulative panels 355a-355f. Interlocking insulative
panels 355a-355f may be fashioned in any number of possible
configurations to facilitate interlocking of panels. These examples
are merely representative of these possible configurations. It
should also be noted that interlocking panels need not necessarily
include male and female interlocking portions to be considered
interlocking. For example, in the embodiment shown in FIG. 3,
interlocking insulative panels 355a-355f may be implemented as
simple squares having flat square surfaces around the periphery of
the insulative panel. In this manner, when box cutout 305 is
assembled, insulative panels 355a-355f may merely butt against
other panels (e.g., mating 90.degree. edges), forming an insulated
cube inside an assembled box cutout 305. Optionally, insulative
panels that butt against other panels may include an adhesive to
seal the panels to each other in an assembled state to prevent
leaking or condensation. For purposes of this disclosure, an
"interlocking" insulative panel is intended to describe any
insulative panel affixed to a box cutout that may include edges
that mate with edges of other insulative panels (e.g., include
edges with complimentary angles) affixed to the box cutout to
create an insulated area within a box when the box cutout is
assembled into a box.
[0030] Insulative interlocking panels 355a-355f may be implemented,
as previously discussed, using EPS foam having an insulation rating
above R-4 (or equivalent). Alternatively, insulative interlocking
panels 355a-355f may use an EPS foam that has an insulative rating
of between R-4 and R-7. In one embodiment, insulative interlocking
panels 355a-355f may include a reflective lining along one or more
surfaces to increase its insulative rating. Further, insulative
interlocking panels 355a-355f may also be implemented using
conventional insulative materials other than EPS foam, as described
herein.
[0031] Insulative interlocking panels 355a-355f may be affixed to
box cutout 305. For example, in one embodiment, insulative
interlocking panels 355a-355f may be attached using an adhesive
material to corresponding panels 360a-360f in box cutout 305. In
one embodiment, the adhesive material may be a peel and stick tape,
an epoxy resin, a glue, or any other adhesive known in the art. For
example, insulative interlocking panel 355a may be affixed to panel
360a using glue, an epoxy resin, or a peel and stick double sided
tape in a position that allows insulative interlocking panel 355a,
for example, to align a corresponding locking point on insulative
interlocking panel 355b (which is affixed to panel 360b) while also
simultaneously aligning a corresponding locking point on insulative
interlocking panel 355c (which is affixed to panel 360c). In this
manner, panel 360a may be folded (bent along first horizontal
crease 320) up at 90.degree. to panel 360c, forming a first side
panel of insulative packaging system 300, and interlock by the
corresponding male and female connections installed into edges of
insulative interlocking panels 355a and 355c. In this manner, a
bottom panel 360c and a first side panel 360a are interlocked. In
one embodiment, edges of insulative interlocking panels 355a-355f
may be attached to each other with waterproof adhesive to seal or
ensure that water within insulative packaging system 300 (e.g.,
from condensation or melting ice) does not leak between the edges
of insulative interlocking panels 355a-355f, preventing dripping
and ensuring that water does not compromise the structural
integrity of surrounding packaging backing material.
[0032] Once insulative interlocking panel 355a has been attached to
insulative interlocking panel 360c, insulative interlocking panel
355b may be similarly installed to both insulative interlocking
panel 355a and insulating interlocking panel 355c by folding
(bending along second vertical crease 315 and first horizontal
crease 320) interlocking corresponding male and female connections
installed into edges of insulative interlocking panels 355a-355c,
forming a second side panel of insulating packaging system 300. In
this manner, panel 360b is disposed to be 90.degree. to both panel
360a and panel 360c.
[0033] A similar process may be performed with respect to
insulative interlocking panels 355d-355f on panels 360d-360f.
Insulative interlocking panel 355e may be attached to insulative
interlocking panel 355c using the aforementioned aligned male and
female connections in the edges of insulating interlocking panel
355e and by folding (bending along second horizontal crease 325)
panel 360e at 90.degree. to panel 360c such that panel 360a is
parallel to panel 360e. Insulative interlocking panel 355e may
further adjoin insulative interlocking panel 355b along
corresponding male and female connections in the edges of
insulating interlocking panels 355e and 355b. Insulating
interlocking panel 355e becomes a third side panel of insulated
packaging system 300.
[0034] Insulative interlocking panel 355d may also be interlocked
using corresponding male and female connections to both insulative
interlocking panel 355e and insulative interlocking panel 355c by
folding panel 360d (bending along first vertical crease 310) such
that panel 360d is 90.degree. to both panel 360e (parallel to panel
360b) and panel 360c, and adjoining panel 360a. Insulative
interlocking panel 355d becomes a fourth side panel of insulated
packaging system 300 and completes the periphery and base of the
exemplary six-sided box.
[0035] Insulative interlocking panel 355f may be a top for
insulated packaging system 300 by adjoining using corresponding
male and female connection in the edges of insulative interlocking
panel 355f with insulative interlocking panels 355a, 355b, 355d,
and 355e by folding (bending along third horizontal crease 335)
panel 360f at 90.degree. to insulative interlocking panel 355e such
that insulative interlocking panel 355f is parallel to insulative
interlocking panel 355c. When so installed, adhesive strips 365,
may be used to seal insulated packaging system 300 for shipping by
folding the adhesive strip tab along fourth horizontal crease 335
to affix adhesive strips to an outside surface of panel 360a.
[0036] One benefit of insulated packaging system 300 is that since
each one of insulative interlocking panels 355a-355f is may be
mated or not mated with the other panels on box cutout 305,
insulated packaging system 300 may be stored flat. In other words,
vertical storage space required to store a single insulated
packaging system 300 is only the combined thickness of the
thickness of box cutout 305 and the thickness of the insulative
interlocking panels. In one embodiment, the total thickness of
insulated packaging system 300 may be approximately one and a
quarter inches (e.g., flat). Thus, insulated packaging system 300
provides all of the insulative and packaging benefits of
conventional systems while making both storage and shipping of
unused units of insulated packaging system 300 far more manageable.
It is conceivable that ten or more units of insulated packaging
system 300, when stored in a flat unassembled configuration, may
occupy approximately the same storage and shipping space as one of
cardboard box/EPS foam cooler 100, shown in FIG. 1 which provides
significant cost savings in shipping, storage, and use while
retaining all the insulative and packaging benefits of prior art
solutions.
[0037] FIG. 4 illustrates exemplary insulated packaging system 300
of FIG. 3 which includes interlocking panels 455a-455f affixed to a
box cutout 405 in an assembled condition. As discussed with respect
to FIG. 3, interlocking insulative panels 455a-455f may be affixed
to box cutout 405 and interlocked one with another to form an
exemplary six-sided box, having a first side panel, a second side
panel, a third side panel, a fourth side panel, a bottom panel, and
a top panel.
[0038] Interlocking insulative panel 455a may be interlocked with
interlocking insulative panels 455b, 455c, 455d, and 455f to form a
first side panel. Interlocking insulative panel 455b may be
interlocked with interlocking insulative panels 455a, 455c, 455e,
and 455f to form a second side panel. Interlocking insulative panel
455c may be interlocked with interlocking insulative panels 455a,
455b, 455d, and 455e to form a bottom panel. Interlocking
insulative panel 455d may be interlocked with interlocking
insulative panels 455a, 455c, 455e, and 455f to form a third side
panel. Interlocking insulative panel 455e may be interlocked with
interlocking insulative panels 455b, 455c, 455d, and 455f to form a
fourth side panel. Interlocking insulative panel 455f may be
interlocked with interlocking insulative panels 455a, 455b, 455d,
and 455e to form a top panel.
[0039] FIG. 5 illustrates an alternative exemplary insulated
packaging system 500 which includes insulative interlocking panels
555a-555f affixed to a box cutout 505. Box cutout 505 may be cut
into a form that may be easily shaped into a box, for example, and
may be made of any conventional packaging material such as paper,
cardstock, cardboard, corrugated cardboard, plastics (rigid or
soft), or any conventional packaging material. Box cutout 505 is
formed in such a shape as to form a square box having six sides. It
is noted, however, that a square box is only one possible
implementation of insulated packaging system 500. Insulated
packaging system 500 may be implemented in any three-dimensional
shape when assembled, including whimsical shapes, as desired for
any particular implementation. For example, insulated packaging
system 500 may form a rectangular box, a spherical box, a
tetrahedral box, a box having any number of sides, or may, in some
shapes be formed to represent cartoon characters, fictional
characters, representations of fantastical creatures, or any other
implementation that may be desirable for a package. However, for
purposes of explanation, insulated packaging system 500 is shown as
a box cutout 505 which may be assembled into a six-sided square
box.
[0040] Box cutout 505 may include a plurality of panels 560a-560f
which form the six sides of the exemplary square box. Box cutout
505 may further include pre-installed creases or indentations to
facilitate assembly of insulated packaging system 500. For example,
box cutout 505 may include a first vertical crease 510 and a second
vertical crease 515 which extend along a length of box cutout 505
to facilitate assembly of the other various panels, tabs, and flaps
of insulated packaging system 500, as will be discussed below.
Similarly, box cutout 505 may include a first horizontal crease
520, a second horizontal crease 525, a third horizontal crease 530,
and a fourth horizontal crease 535 which extend along a width of
box cutout 505 to facilitate assembly of the other various panels,
tabs, and flaps of insulated packaging system 500, as will be
discussed below.
[0041] Some of the other various panels, tabs, and flaps on box
cutout 305 may include a first support tab 540 and a second support
tab 545 which serve to add structural rigidity to insulated
packaging system 500 when assembled into an exemplary six-sided
square box. box cutout 505 may further include a plurality of
flaps, such as flaps 550a-550d which may be used to provide access
points into or provide structural rigidity for insulated packaging
system 500 when assembled into an exemplary six-sided square box.
For example, flaps 550a-550d may fold over a top or bottom portion
of insulated packaging system 500 and be connected together by, for
example, packaging tape, that is used to seal insulated packaging
system 500 when assembled into an exemplary six-sided box.
[0042] Box cutout 505 may further include one or more interlocking
insulative panels 555a-555f affixed in a permanent manner to panels
560a-560f. Interlocking insulative panels 555a-555f may be
constructed from EPS foam and formed into panels that are beveled
at complimentary angles, in this embodiment. More simply,
interlocking insulative panels 555a-555f may include one or more
locks that connect at least one of interlocking insulative panels
555a-555f to at least one other of interlocking insulative panels
555a-555f. Alternatively, interlocking insulative panels 555a-555f
may include one or more locks that connect to each adjacent one of
interlocking insulative panels 555a-555f. One example of a lock may
include a beveled edge at a complimentary angle installed along one
of interlocking insulative panels 555a-555f which corresponds to a
beveled edge at a complimentary angle installed along another of
interlocking insulative panels 555a-555f. For example, a lock may
include the interlocking insulative panels 555a-555f having edge
portions that are cut or beveled into complimentary angles such
that each of interlocking insulative panels 555a-555f fits squarely
into a recess created by corresponding beveled angles in adjacent
interlocking insulative panels 555a-555f. Interlocking insulative
panels 555a-555f may be fashioned in any number of possible
configurations to facilitate interlocking of panels. These examples
are merely representative of these possible configurations.
[0043] Insulative interlocking panels 555a-555f may be implemented,
as previously discussed, using EPS foam having an insulation rating
above R-4 (or equivalent). Alternatively, insulative interlocking
panels 555a-555f may use an EPS foam that has an insulative rating
of between R-4 and R-7. In one embodiment, insulative interlocking
panels 555a-555f may include a reflective lining along one or more
surfaces to increase its insulative rating. Further, insulative
interlocking panels 555a-555f may also be implemented using
conventional insulative materials other than EPS foam, as described
herein.
[0044] Insulative interlocking panels 555a-555f may be affixed to
box cutout 505. For example, in one embodiment, insulative
interlocking panels 555a-555f may be attached using an adhesive
material to corresponding panels 560a-560f in box cutout 505. In
one embodiment, the adhesive material may be a peel and stick tape,
an epoxy resin, a glue, or any other adhesive known in the art. For
example, insulative interlocking panel 555a may be affixed to panel
560a using an epoxy resin or a peel and stick double sided tape in
a position that allows insulative interlocking panel 555a, for
example, to align a corresponding locking point on insulative
interlocking panel 555b (which is affixed to panel 560b) while also
simultaneously aligning a corresponding locking point on insulative
interlocking panel 555c (which is affixed to panel 560c). In this
manner, panel 560a may be folded (bent along first horizontal
crease 520) up at 90.degree. to panel 560c, forming a first side
panel of insulative packaging system 500, and interlock by the
complimentary beveled angles along the edges of interlocking
insulative panels 555a and 555c. In this manner, a bottom panel
560c and a first side panel 560a are interlocked. In one
embodiment, edges of insulative interlocking panels 555a-555f may
be attached to each other with waterproof adhesive to seal or
ensure that water within insulative packaging system 500 (e.g.,
from condensation or melting ice) does not leak between the edges
of insulative interlocking panels 555a-555f, preventing dripping
and ensuring that water does not compromise the structural
integrity of surrounding package backing material.
[0045] Once insulative interlocking panel 555a has been attached to
insulative interlocking panel 560c, insulative interlocking panel
555b may be similarly installed to both insulative interlocking
panel 555a and insulating interlocking panel 555c by folding
(bending along second vertical crease 515 and first horizontal
crease 520) complimentary beveled angles installed into edges of
insulative interlocking panels 555a-555c, forming a second side
panel of insulating packaging system 500. In this manner, panel
560b is disposed to be 90.degree. to both panel 560a and panel
560c.
[0046] A similar process may be performed with respect to
insulative interlocking panels 555d-555f on panels 560d-560f.
Insulative interlocking panel 555e may be attached to insulative
interlocking panel 555c by complimentary beveled angles cut into
the edges of insulating interlocking panel 555e and by folding
(bending along second horizontal crease 525) panel 560e at
90.degree. to panel 560c such that panel 560a is parallel to panel
560e. Insulative interlocking panel 555e may further adjoin
insulative interlocking panel 555b along complimentary beveled
angles cut into the edges of insulating interlocking panels 555e
and 555b. Insulating interlocking panel 555e becomes a third side
panel of insulated packaging system 500.
[0047] Insulative interlocking panel 555d may also be interlocked
using complimentary beveled angles cut into the edges of both
insulative interlocking panel 555e and insulative interlocking
panel 555c by folding panel 560d (bending along first vertical
crease 510) such that panel 560d is 90.degree. to both panel 560e
(parallel to panel 560b) and panel 560c, and adjoining panel 560a.
Insulative interlocking panel 555d becomes a fourth side panel of
insulated packaging system 500 and completes the periphery and base
of the exemplary six-sided box.
[0048] Insulative interlocking panel 555f may be a top for
insulated packaging system 300 by adjoining using complimentary
beveled angles cut into the edges of insulative interlocking panel
555f with insulative interlocking panels 555a, 555b, 555d, and 555e
by folding (bending along third horizontal crease 535) panel 560f
at 90.degree. to insulative interlocking panel 555e such that
insulative interlocking panel 555f is parallel to insulative
interlocking panel 555c. When so installed, adhesive strips 565,
may be used to seal insulated packaging system 500 for shipping by
folding the adhesive strip tab along fourth horizontal crease 535
to affix adhesive strips to an outside surface of panel 560a.
[0049] One benefit of insulated packaging system 500 is that since
each one of insulative interlocking panels 555a-555f is
disconnected from the other panels on box cutout 505, insulated
packaging system 500 may be stored flat. In other words, vertical
storage space required to store a single insulated packaging system
500 is only the combined thickness of the thickness of box cutout
505 and the thickness of the insulative interlocking panels. In one
embodiment, the total thickness of insulated packaging system 500
may be approximately one and a quarter inches (e.g., flat). Thus,
insulated packaging system 500 provides all of the insulative and
packaging benefits of conventional systems while making both
storage and shipping of unused units of insulated packaging system
500 far more manageable. It is conceivable that ten or more units
of insulated packaging system 500, when stored in a flat
unassembled configuration, may occupy approximately the same
storage and shipping space as one of box/EPS foam cooler 100, shown
in FIG. 1 which provides significant cost savings in shipping,
storage, and use while retaining all the insulative and packaging
benefits of prior art solutions.
[0050] FIG. 6 illustrates exemplary insulated packaging system 600
of FIG. 5 which includes interlocking panels 655a-655f affixed to a
box cutout 605 in an assembled condition. As discussed with respect
to FIG. 5, interlocking insulative panels 655a-655f may be affixed
to box cutout 605 and interlocked one with another to form an
exemplary six-sided box, having a first side panel, a second side
panel, a third side panel, a fourth side panel, a bottom panel, and
a top panel.
[0051] Interlocking insulative panel 655a may be interlocked with
interlocking insulative panels 655b, 655c, 655d, and 655f to form a
first side panel. Interlocking insulative panel 655b may be
interlocked with interlocking insulative panels 655a, 655c, 655e,
and 655f to form a second side panel. Interlocking insulative panel
655c may be interlocked with interlocking insulative panels 655a,
655b, 655d, and 655e to form a bottom panel. Interlocking
insulative panel 655d may be interlocked with interlocking
insulative panels 655a, 655c, 655e, and 655f to form a third side
panel. Interlocking insulative panel 655e may be interlocked with
interlocking insulative panels 655b, 655c, 655d, and 655f to form a
fourth side panel. Interlocking insulative panel 655f may be
interlocked with interlocking insulative panels 655a, 655b, 655d,
and 655e to form a top panel.
[0052] Other embodiments are possible. For example, in one
embodiment, the application of insulative panels, such as
insulative panels 655a-655e to a box cutout 605 may be performed by
adhesively applying an insulative panel. For example, a box cutout,
such as box cutout 505, shown in FIG. 5, for example, may include
panels, such as panels 560a-560f, which create a top of a box, a
bottom of a box, and four sides of a box. Insulative panels, such
as insulative panels 555a-555f, may be installed by application of
an adhesive substance to panel 560a-560f and/or insulative panels
555a-555f and then affixing one of insulative panels 555a-555f to a
corresponding one of panel 560a-560f on box cutout 505. Optionally,
insulative panels 555a-555f may include an adhesive material
covered with a backing material. The backing material may be
removed from insulative panels 555a-555f exposing an adhesive which
may be used to affix insulative panels 555a-555f to panel 560a-560f
in a permanent fashion. Further, installing the insulative panels
555a-555f allows for box cutout 505 to be assembled into an
insulated box, having a recess therein for containing temperature
sensitive items for shipping.
[0053] In another embodiment, an air bladder may be installed as
insulative panels using techniques similar to those discussed
above. For example, panels 355a-355f, shown in FIG. 3 may
illustrate exemplary insulative panels made of foam, air bladders,
or other materials. The air bladder, for the purposes of
definition, may also be interpreted as constituting "insulative
material" and "insulative panels" and otherwise be defined as
"insulation." In implementation, instead of installing six
individual interlocking panels on to a box cutout, such as box
cutout 505, an air bladder, of the same general size and shape of
box cutout 505 may be affixed to box cutout 505 as a single piece.
The air bladder may be implemented in such a way that as box cutout
505 is assembled into a box, the air bladder may bend to form
interconnected insulative panels for the six sides of the assembled
box. The air bladder may be implemented by forming welded seams
along the entire outside surface of the air bladder, forming an
airtight bond. The air bladder may further include a valve which
selectively allows the air bladder to be inflated and deflated as
desired. For example, once the air bladder is affixed to box cutout
505, the box cutout 505 may be assembled into a box. Once the box
is assembled, the air bladder may be partially inflated until a
temperature sensitive item is placed within a recess created within
the box and the air bladder. Then, the top of the box may be
installed, with an accompanying insulative panel of the air bladder
and closed. In this embodiment, a valve to the air bladder may be
accessed from outside the box and allow the air bladder inside the
box to be fully inflated. Thus, the air bladder may act as an
insulative barrier to protect temperature sensitive items during
shipping.
[0054] It may be also noted that in addition to providing
insulation, the air bladder may further act as a packaging material
that prevents damage to the enclosed temperature sensitive items.
For example, an air bladder may absorb impact damage better than
foam insulation and may therefore be more desirable in certain
implementations where temperature sensitive items are also
susceptible to physical damage.
[0055] The foregoing description has been presented for purposes of
illustration. It is not exhaustive and does not limit the invention
to the precise forms or embodiments disclosed. Modifications and
adaptations will be apparent to those skilled in the art from
consideration of the specification and practice of the disclosed
embodiments. For example, components described herein may be
removed and other components added without departing from the scope
or spirit of the embodiments disclosed herein or the appended
claims.
[0056] Other embodiments will be apparent to those skilled in the
art from consideration of the specification and practice of the
disclosure disclosed herein. It is intended that the specification
and examples be considered as exemplary only, with a true scope and
spirit of the invention being indicated by the following
claims.
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