U.S. patent application number 15/991962 was filed with the patent office on 2019-12-05 for shipping container with compostable insulation.
The applicant listed for this patent is Vericool, Inc.. Invention is credited to Darrell Jobe.
Application Number | 20190367208 15/991962 |
Document ID | / |
Family ID | 68694322 |
Filed Date | 2019-12-05 |
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United States Patent
Application |
20190367208 |
Kind Code |
A1 |
Jobe; Darrell |
December 5, 2019 |
Shipping Container With Compostable Insulation
Abstract
A shipping container includes a plurality of thermally
insulating pads positioned in a cavity in a box. Each pad of the
plurality of thermally insulating pads includes a solid compostable
panel formed primarily of extruded milled sorghum, the panel
providing a rectangular plate, and a recyclable film formed
primarily of paper. The recyclable film forms a pocket enclosing
the panel. The panel is loose within the pocket. At least one of
the plurality of thermally insulating pads includes a multi-section
panel including a score across its width in at least one location.
The score extends partially, but not entirely through the thickness
of the multi-section panel. The multi-section panel is folded at a
right angle at the score such that the panel provides a plurality
of rectangular plates dimensioned to substantially span whichever
of the floor, plurality of side walls or cover that the plurality
of plates is adjacent.
Inventors: |
Jobe; Darrell; (Pleasanton,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Vericool, Inc. |
Livermore |
CA |
US |
|
|
Family ID: |
68694322 |
Appl. No.: |
15/991962 |
Filed: |
May 29, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/64 20130101; Y02W
90/10 20150501; B65D 81/3858 20130101; B65D 81/3834 20130101; B65D
5/56 20130101; B65D 81/3862 20130101; B65D 65/466 20130101; Y02W
30/80 20150501; B65D 81/3813 20130101 |
International
Class: |
B65D 5/56 20060101
B65D005/56; B65D 5/64 20060101 B65D005/64; B65D 81/38 20060101
B65D081/38 |
Claims
1. A thermal insulation article for placement in a shipping
container to hold an item, the system comprising: a thermally
insulating pad shaped to be positioned in a cavity of a rectangular
prism shipping container to be adjacent to and cover one or more of
a floor, four side walls and cover of the container while leaving
an interior space to receive the item, wherein the thermally
insulating pad includes: a solid compostable panel formed primarily
of starch, the panel holding together as a single unit, the panel
providing a rectangular plate dimensioned to substantially span
whichever of the floor, plurality of side walls or cover that the
rectangular plate is adjacent, and a recyclable film formed
primarily of paper, the recyclable film forming a pocket enclosing
the panel such that when positioned in the cavity of the
rectangular prism shipping container adjacent a respective floor,
side wall or cover, wherein the recyclable film wraps around the
panel and provides both an interior surface of the pad facing the
interior space and an exterior surface of the thermally insulating
pad facing the respective floor, side wall or cover, and wherein
the recyclable film is adhered to a portion of the panel that has
become sticky by application of water to the starch.
2. The thermal insulation article of claim 1, wherein the
recyclable film is coated with a coating of one or more
water-retardant materials.
3. The thermal insulation article of claim 2 wherein a thickness of
the coating applied to the recyclable film is between about 0.001
and 0.090 inch.
4. The thermal insulation article of claim 3, wherein the one or
more water-retardant materials include water-resistant materials,
water-repellent materials, and water-proof materials.
5. The thermal insulation article of claim 1, wherein the
recyclable film is substantially pure paper.
6. The thermal insulation article of claim 1, wherein the
recyclable film is formed primarily of paper mixed with one or more
water-retardant materials.
7. The thermal insulation article of claim 6, wherein a thickness
of the recyclable film is between about 0.001 and 0.090 inch.
8. The thermal insulation article of claim 7, wherein the one or
more water-retardant materials include water-resistant materials,
water-repellent materials, and water-proof materials.
9. The thermal insulation article of claim 1, wherein the paper
comprises a wood pulp paper.
10. The thermal insulation article of claim 1, wherein the
recyclable film forms the pocket enclosing the panel without being
bonded to the panel.
11. The thermal insulation article of claim 10, wherein an interior
of the pocket is evacuated of air.
12. The thermal insulation article of claim 1, wherein the panel is
slidable within the pocket.
13. The thermal insulation article of claim 1, wherein the starch
comprises corn starch, wheat starch or milled sorghum.
14. A method of fabricating an insulative insert for placement in a
shipping container to hold an item, the method comprising: placing
a solid compostable panel formed primarily of grain start between
two sheets of recyclable film, the panel holding together as a
single unit, wherein the two sheets of recyclable film are formed
primarily of paper, wherein the recyclable film is adhered to the
panel by applying water to the panel; and heat sealing the two
sheets such that the panel is enclosed in a pocket of recyclable
film that completely surrounds the panel to form a thermally
insulating pad shaped to be positioned in a cavity of a rectangular
prism shipping container to be adjacent to and cover one or more of
a floor, four side walls and cover of the container.
15. The method of claim 14, the method comprising: forming a
plurality of thermally insulating pads according to the method of
claim 14.
16. The method of claim 15, further comprising a method of
insulating a shipping container, the method of insulating a
shipping container comprising: inserting the plurality of thermally
insulating pads into a cavity of the shipping container such that
each of the floor, plurality of side walls and cover of a box is
adjacent to and covered by a pad from the plurality of thermally
insulating pads and the plurality of thermally insulating pads
provide an interior space to receive the item, and wherein each
rectangular plate is dimensioned to substantially span whichever of
the floor, plurality of side walls or cover that the rectangular
plate is adjacent.
Description
TECHNICAL FIELD
[0001] This invention relates to an insulated shipping container,
and more particularly to a shipping container in which the
insulating material is compostable.
BACKGROUND
[0002] A conventional container for shipping temperature sensitive
products includes a cardboard box, inside of which is a thermally
insulating material. A conventional thermally insulating material
is expanded polystyrene (EPS), e.g., Styrofoam. For example, panels
of the expanded polystyrene can line the walls of the box, and
another packing material, e.g., bubble wrap, can be placed surround
and cushion the item being shipped inside the panels.
Alternatively, expanded polystyrene can be machined or molded to
form a "cooler" into which the item being shipped can be
placed--this does not need an external box. In either case, a
coolant, e.g., ice, dry ice or a gel pack, is placed in the cavity
in the box with the item being shipped.
[0003] EPS is relatively inexpensive and easily formed into a
variety of shapes, but is not compostable. Consequently, disposing
of the material of the container can be a problem.
SUMMARY
[0004] A container is described that provides for thermal
insulation of an item being shipped while the components are still
recyclable or compostable.
[0005] In one aspect, a thermal insulation article for placement in
a shipping container to hold an item includes: a thermally
insulating pad shaped to be positioned in a cavity of a rectangular
prism shipping container to be adjacent to and cover one or more of
a floor, four side walls and cover of the container while leaving
an interior space to receive the item, wherein the thermally
insulating pad includes: a solid compostable panel formed primarily
of grain starch, the panel holding together as a single unit, the
panel providing a rectangular plate dimensioned to substantially
span whichever of the floor, plurality of side walls or cover that
the rectangular plate is adjacent, and a recyclable film formed
primarily of paper, the recyclable film forming a pocket enclosing
the panel such that when positioned in the cavity of the
rectangular prism shipping adjacent a respective floor, side wall
or cover, wherein the recyclable film wraps around the panel and
provides both an interior surface of the pad facing the interior
space and an exterior surface of the thermally insulating pad
facing the respective floor, side wall or cover.
[0006] Implementations may include one or more of the following
features. The recyclable film is coated with a coating of one or
more water-retardant materials. A thickness of the coating applied
to the recyclable film is between about 0.001 and 0.090 inch. The
one or more water-retardant materials include water-resistant
materials, water-repellent materials, and water-proof materials.
The recyclable film is substantially pure paper. The recyclable
film is formed primarily of paper mixed with one or more
water-retardant materials. A thickness of the recyclable film is
between about 0.001 and 0.090 inch. The one or more water-retardant
materials include water-resistant materials, water-repellent
materials, and water-proof materials. The paper comprises a wood
pulp paper. The recyclable film forms the pocket enclosing the
panel without being bonded to the panel. An interior of the pocket
is evacuated of air. The panel is slidable within the pocket. The
starch comprises corn starch, wheat starch or milled sorghum.
[0007] In another aspect, a method of fabricating an insulative
insert for placement in a shipping container to hold an item, the
method includes: placing a solid compostable panel formed primarily
of grain start between two sheets of recyclable film, the panel
holding together as a single unit, wherein the two sheets of
recyclable film are formed primarily of paper; and heat sealing the
two sheets such that the panel is enclosed in a pocket of
recyclable film that completely surrounds the panel to form a
thermally insulating pad shaped to be positioned in a cavity a
rectangular prism shipping container to be adjacent to and cover
one or more of a floor, four side walls and cover of the
container.
[0008] Implementations may include one or more of the following
features. The method includes: forming a plurality of thermally
insulating pads according to the method described above. The method
includes: inserting the plurality of thermally insulating pads into
the cavity such that each of the floor, plurality of side walls and
cover of a box is adjacent to and covered by a pad from the
plurality of thermally insulating pads and the plurality of
thermally insulating pads provide an interior space to receive the
item, and wherein each rectangular plate is dimensioned to
substantially span whichever of the floor, plurality of side walls
or cover that the rectangular plate is adjacent.
[0009] Potential advantages may include (and are not limited to)
one or more of the following.
[0010] The insulating material is compostable, and the exterior box
is recyclable, so all of the components of the container are easily
disposable. The film containing the insulating material is
compostable or recyclable, and also easily disposed. If the film is
recyclable, e.g., formed of paper (rather than a biodegradable
material), then the starch of the insulating material can dissolve
easily during the recycling process. This makes the panel
compatible with existing paper-recycling techniques, such that the
entire pad can be fed into a paper-recycling process without having
to separate the paper film from the starch panel.
[0011] The film also can be water-retardant such that liquid, e.g.,
condensation, cannot pass through the film. The water-retardant
film can protect a pad or a box from liquid.
[0012] The container can be easily assembled, and the insulating
pads that fit inside the container can be manufactured at low cost.
The insulating pads can provide equivalent thermal insulation to
expanded polystyrene, and can be disposed in commercial and
residential composting or recycling bins or garbage cans. The
container components can be shipped in bulk in an unassembled state
with minimal cost increase, and assembly of the container can be
performed by the user.
[0013] The details of one or more embodiments are set forth in the
accompanying drawings and the description below. Other features,
objects, and advantages of the invention will be apparent from the
description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is an exploded perspective view of an example of an
insulated shipping container.
[0015] FIGS. 2A-2G illustrate an example of construction of the
pads of the insulating shipping container of FIG. 1.
[0016] FIGS. 3A-3I illustrate an example that includes two
three-sectioned pads for the insulating shipping container.
[0017] FIGS. 4A-4D illustrate an example that includes six
individual pads for the insulating shipping container.
[0018] FIGS. 5A-5H illustrate an example that includes a
three-sectioned pad and three individual pads for the insulating
shipping container.
[0019] FIG. 6 illustrates an example that includes a single
six-sectioned pad.
[0020] FIGS. 7A and 7B illustrates an example of multiple
multi-section panels enclosed in a water-retardant film, in an
unfolded and folded state, respectively.
[0021] FIG. 8 illustrates an example of using solid compostable
panels, without a water-retardant film, for an insulated shipping
container.
[0022] FIG. 9 illustrates multiple panels that are laminated
together.
[0023] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0024] Initially, some terminology may be beneficial.
"Biodegradable" simply means that a product will eventually
disintegrate into to innocuous material. "Recyclable" indicates
that a product can be reused or treated in order to be made
suitable for reuse. "Compostable" indicates both that a product
will decompose quickly, e.g., within 180 days, and that the product
will decompose into material that can be used as fertilizer (e.g.,
per ASTM D6400 or EN 13432). Products that are "biodegradable" need
not be (and usually aren't) "compostable." First, since there is no
particular time limit for a "biodegradable" product to
disintegrate, it need not decompose quickly. For example, even
aluminum cans will biodegrade given several centuries. Moreover,
even a biodegradable product that decomposes quickly might not
provide a material that is suitable as fertilizer.
[0025] Most conventional thermally insulating materials for
packaging, e.g., EPS, are not compostable. One technique for using
a compostable insulating packaging material is to fill a volume
between an inner wall and an outer wall of a box with loose-fill
compostable cornstarch foam pellets (e.g., packing "peanuts") using
layered stratification, and then compress each layer of foam
pellets in within this volume to compact them. This technique
requires either multiple boxes or a specialized box having both
inner and outer walls, and also requires specialized machinery for
layered stratification compaction of the pellets. The additional or
specialized boxes increase the cost. In addition, the loose fill
pellets are difficult to compost because they are messy when
removed from the box. Moreover, a large amount of pressure, e.g.,
25 lbs. or more, needs to be applied to close the top flaps of the
box due to the resistance from the pellets.
[0026] However, instead of loose-fill foam pellets, a solid
compostable panel formed primarily of extruded starch can be
enclosed by a film to provide a thermally insulating pad, and this
pad can be used as the insulating packaging in the container. The
film can be a liner, sheet or similarly thin layer. In some
implementations, the film is air-tight.
[0027] In some implementations, the film is compostable film. For
example, the film can be a bioplastic that meets ASTM D6400
standards.
[0028] In some implementations, the film is a recyclable film. For
example, the film can be a plastic film, e.g., polyethylene. As
another example, the film can be formed primarily of paper.
[0029] The paper film can be substantially pure paper, or can be
primarily paper but mixed with other materials. The paper can be
formed from wood pulp, but the paper can include other plant fiber
pulps, e.g., hemp, linen or cotton.
[0030] In some implementations, the paper film can be coated with a
coating of one or more water-retardant materials such that liquid,
e.g., the condensation, cannot pass through the film. The
water-retardant materials can include water-resistant,
water-repellent, or water-proof materials. For example,
water-retardant materials include rubber, polyvinyl chloride,
polyurethane, silicon elastomer, fluoropolymers, and wax. In some
implementations, the film can be primarily formed of paper mixed
with one or more water-retardant materials such that liquid, e.g.,
the condensation, cannot pass through the film.
[0031] In some implementations, a thickness of the paper can be
between about 0.001 and 0.090 inch. In addition, a thickness of the
coating applied to the paper can be between about 0.001 and 0.090
inch.
[0032] The coating can be applied by spraying onto the paper,
pouring a liquid onto the paper and curing, or forming a separate
layer of the coating and bonding the coating, e.g., by heat, to the
paper.
[0033] FIG. 1 is an exploded perspective view of an example of an
insulated shipping container 10. The shipping container 10 includes
a box 20 and multiple thermally insulating pads 30 that fit inside
an interior cavity 22 of the box 20. The thermally insulating pads
30 are shaped such that when positioned in the box 20 they provide
an interior space to receive the item and optionally a coolant,
e.g., ice, dry ice or a gel pack.
[0034] The box 20 can be a rectangular prism, and can includes
rectangular side walls 24 that define the interior cavity 22. The
bottom of the box may similarly be closed off by one or more flaps
(not shown due to the perspective view). The top of the box 20
provides an opening to the interior cavity 22. A cover for the box
20 can be provided by one or more flaps 26 that can be folded
inwardly from the side walls 24 to close off the top of the cavity
22. In some implementations, the side walls 24, flaps 26 and bottom
of the box are all part of a single integral sheet that is folded
into an appropriate shape. Alternatively, the cover for the box 20
can be provided by a separate lid that fits over the side walls
24.
[0035] The box 20 is a recyclable material. For example, the box 20
can be a cardboard box, e.g., paper board or corrugated
cardboard.
[0036] As noted above, the container includes multiple thermally
insulating pads 30 that fit inside the box 20. Each pad 30 is
formed by sealing a solid recyclable or compostable panel (or
multiple solid compostable panels) within a film.
[0037] As described above, in some implementations, the film is
recyclable or compostable such that the entire pad 30 covered by
the film is recyclable or compostable. Thus, a user can easily
dispose the pad 30 covered by the film without separating the film
from the pad 30.
[0038] In some implementations, the film can be coated with a
coating of one or more water-retardant materials. The film coated
with water-retardant materials can prevent liquid, e.g., the
condensation, from passing through the film. For example, where the
pad 30 holds goods that contain liquid, e.g., seafood, the film
coated with a coating of water-retardant materials prevents liquid
from passing through the film such that liquid does not make the
paper film, the pad 30, or the box 20 wet.
[0039] In some implementations, the pad includes a single panel.
Each pad 30 is relatively thin, e.g., about 0.25-4 inch thick, as
compared to the length and width of the pad. The thickness of a pad
30 is considered to be along its narrowest dimension, whereas the
length and width of the pad 30 are considered to be along the two
directions along the primary face, perpendicular to the
thickness.
[0040] Each panel can be formed primarily of starch, e.g., an
extruded starch. The starch can be a grain starch, e.g., corn
starch, wheat starch or sorghum (sorghum is also known as milo), a
root starch, e.g., potato starch, a vegetable starch, or
combinations thereof. Other materials that do not interfere with
the compostable nature of the panel, e.g., a softener to improve
adhesion of the starch, or a preservative or anti-fungal agent, can
be present, but only in small quantities. For example, at least
85%, e.g., at least 90-95%, by weight of the panel is starch.
Polyvinyl alcohol can be present, e.g., 5-10% by weight.
[0041] Each panel is "solid", which in this context indicates that
the panel holds together as a single unit, rather than being formed
of loose-fill pellets. It may be noted that compressed starch
pellets would not form a solid part; upon removal of pressure the
pellets would disassemble, and increased pressure only fractures or
pulverizes the pellets. A solid panel of extruded starch provides
significant thermal insulation, while still being compostable.
[0042] It is possible for the panels to be a foam material, e.g.,
to include small pores or voids spread substantially uniformly
through the panel. For example, 10-80% of the volume of the panel
can be pores or voids, e.g., 25-75%, 25-50%, 10-25%, 50-75%. The
maximum size of the pores or voids can be about 1 mm. Although the
panel could be a foam material, it is generally incompressible. The
density of a panel can be about 0.4-3.5 g/cm.sup.3, e.g., 0.6-1.0
g/cm.sup.3, 0.8-2.0 g/cm.sup.3, 1.0-3.5 g/cm.sup.3.
[0043] Each panel can be of a uniform homogenous composition.
Furthermore, each panel can be a unitary body--that is the body of
the panel holds together by itself without adhesives or fasteners
to join multiple sections together to form the panel.
[0044] The thickness of a panel can be about 0.25-1.0 inches, e.g.,
0.25-0.75 inches. Any given panel can have substantially uniform
thickness across its primary surface. The surfaces of the panel can
be generally flat, or one or more surfaces can be corrugated.
Corrugation can increase the effective thickness of the pad, e.g.,
by a factor of up to 4. In this case, the thickness of the panel
can still be uniform, but the panel is shaped with
corrugations.
[0045] Each panel can include one or more rectangular plates
dimensioned to substantially span whichever of the floor, plurality
of side walls or cover that the rectangular plate is adjacent. In
some implementations, the whole of the panel, when in an unfolded
configuration, is also rectangular.
[0046] The panels can be formed by an extrusion process. After
extrusion, each panel can be cut to the appropriate size. In
addition, the edges can optionally be beveled as to provide the
beveling of the pads described above. In addition, the panel that
provides the collar can be scored, as described below.
[0047] In some implementations, the film is compostable, e.g., a
bioplastic that meets ASTM D6400 standards. Suitable materials for
a compostable film include polymers based on one or more of
polylactic acid (PLA), poly(beta-amino) esters (PBAE),
polyhydroxyalkanoate (PHA), polycapralactones (PCL), polybutyrate
adipate terephthalate (PBAT) polyvinylalcohol (PVA), or ethylene
vinyl alcohol (EVOH). For example, a combination of PBAT and PE may
be suitable. As another example, a combination of PE and PLA may be
suitable. In some implementations, the polymer can be mixed with an
organic product, e.g., a starch, such as corn starch.
[0048] In some implementations, the film is recyclable and
biodegradable. A suitable material for the recyclable film is
polyethylene. For example, the film can be a low-density
polyethylene (LDPE), a medium-density polyethylene (MDPE) or a
high-density polyethylene (HDPE). An advantage of polyethylene is
ease of fabrication and good water resistance.
[0049] A problem with starch-based insulation is that it dissolves
easily in water. If the item being shipped is cold or a coolant is
placed in the interior of the container 10, condensation can form
on the interior surfaces of the pad 30. However, the film prevents
liquid, e.g., the condensation, from reaching the starch panel,
thus enabling the starch panel to be usable as a thermal insulator
in the container.
[0050] To fabricate a pad 30, the starch panel can be placed
between two sheets of the film. The edges of the film can be
heat-sealed to each other, e.g., along the entire perimeter of the
panel, thus enclosing and sealing the panel in a pocket of the film
that has only slightly larger dimension than the panel itself. A
suitable sealing temperature is above 100.degree. C. Excess film
outside the heat seal can be cut away.
[0051] In the directions parallel to the primary surface of the
panels, the pocket can be up to about 0.5 inches larger on each
side than the panel.
[0052] Alternatively, the film can be provided in a tubular form.
To fabricate a pad 30, the panel is slid inside the tube of the
film, and the two open ends of the tube are heat sealed. This forms
a pocket in which the panel sits.
[0053] In some implementations, the panel sits loose inside the
pocket formed by the film. That is, the panel is not bonded or
otherwise fixed to the film. Thus, the panel can slide inside the
pocket relative to the film. For example, the film can be in
sliding contact with the panel. The interior of the pocket can
include a small amount of air. In some implementations, the air is
vacuumed out before the pocket is sealed.
[0054] In some implementations, the panel is affixed to the film.
For example, the film can be secured to the panel by heat bonding
the film to the panel. As another example, the film can be secured
to the panel by an adhesive. The adhesive can be a separate
additive, or the adhesive can be provided by applying water to the
panel to cause the starch in a portion of the panel at the surface
to become tacky such that the film sticks to the panel.
[0055] The film can be affixed on both the interior and exterior
surface of the panel, or on just one surface of the panel, e.g.,
just the interior surface or just the exterior surface of the
panel. In addition, for each of the interior and exterior surface
of the panel, the film can be affixed across the entire surface, or
on just a portion of the surface, e.g., a perimeter portion along
the edge or a central portion that is spaced away from the edge of
the panel.
[0056] Other than one or panels, there need not be any other
thermally insulating material within the film. For example, unless
one of the panels fractures due to applied stress, there are no
loose pellets or pieces of other insulating material in the volume
enclosed by the film. In some implementations, the pad 30 consists
of, i.e., includes only, one or more panels, the film, and
optionally some air inside the volume enclosed by the film.
[0057] Where both the panel and film are compostable, the entire
pad can be disposed of as a unit in a composting bin. Where the
panel is compostable and the film are is recyclable, the film can
be ripped off the panel manually by the recipient of the package,
and then the panel can be disposed of in a composting bin and the
film can be disposed of a recycling bin.
[0058] In the implementation shown in FIG. 1, the thermally
insulating pads 30 include a bottom pad 32, a collar 34, and a top
pad 36.
[0059] The bottom pad 32 has a length and width that match the
bottom of the box 20, or are slightly smaller, e.g., by about an
1/8 inch tolerance, so that bottom pad 32 fits snugly at the bottom
of the cavity 22 on the bottom of the box 20.
[0060] The collar 34 includes a single panel that is folded into
four wall members 40. Each wall member 40 has a height (in the
vertical direction) about equal to the height of the box 20, less
the combined thickness of the top pad 32 and bottom pad 36. Each
wall member 40 has a width (in the lateral direction) that matches
the adjacent side wall 24 of the box 20, or is slightly smaller,
e.g., e.g., by about an 1/8 inch tolerance. Thus, the collar 34
fits snugly into cavity 22 on top of the bottom pad 32, with each
wall member 40 adjacent, e.g., in contact with, one of the side
walls 24.
[0061] The top pad 36 has a length and width that match the top of
the box 20, or are slightly smaller, e.g., e.g., by about an 1/8
inch tolerance, so that the perimeter of the top pad 36 can sits on
the wall members 40 of the collar 34 and the top pad 36 itself fits
snugly at the cavity 22. When the top of the box 20 is closed,
e.g., by closing the flaps 26 or placing a lid, the top pad 36 sits
adjacent, e.g., in contact with, the top of the box 20.
[0062] In some implementations, the surfaces of the pads 30 are
basically flat up to and including their edges. "Basically flat" is
used to indicate flat at the scale of the thickness of the pad, but
still encompasses the possibility of small scale surface texturing.
Thus, the lower rim of the collar 34 simply sits basically flat on
the perimeter of the top surface of the bottom pad 32, and the
perimeter of the top pad 36 simply sits basically flat on the upper
rim of the collar 34. Alternatively, the interior surfaces of each
pad, i.e., the surface of the pad facing the cavity and further
from the box 20, can be beveled at the edge that is adjacent
another pad. Thus, the beveled lower rim of the collar 34 sits on
the beveled perimeter of the bottom pad 32, and the beveled
perimeter of the top pad 36 sits of the beveled upper rim of the
collar 34. In this latter case, the outer surface of each wall
member 40 can have a height about equal to the height of the box
20.
[0063] FIGS. 2A-2G illustrate an example of construction of the
pads 30 of the insulating shipping container 10 shown in FIG.
1.
[0064] Referring to FIG. 2A, an exploded perspective view, the
collar 34 can be fabricated by forming a solid compostable panel 50
that has a length L approximately equal to or slightly less than
the length of the lateral perimeter of the box 20, and a width W
approximately equal or slightly less than the height of the box 20.
The panel 50 is then placed between two sheets 60 of the
compostable film. Referring to FIG. 2B, a cross-sectional side
view, the two sheets 60 are heat sealed along a path than extends
around the entire perimeter of the panel 50. The seal can be
positioned no more than about 1 inch, e.g., no more than about 1/2
inch, from the edge of the panel 50. Excess film outside the heat
seal can be cut away.
[0065] FIG. 2C is a cross-sectional side view, and FIG. 2D is a
perspective view. Referring to FIGS. 2C and 2D, before or after
sealing the panel 50 between the sheets 60, one surface of the
panel 50 (which will be the inward facing surface of the panel) can
be scored in three locations to divide the panel 50 into four
rectangular plates 52, which correspond to the four side walls of
the collar 34. The length of each plate 52 corresponds to the width
of the corresponding side wall 50 of the collar 34. Scoring can be
performed by compression with an angled rigid body.
[0066] Each score can create a recess 56 that extends across the
width W of the panel. The recess 56 extends partially, but not
entirely through the thickness of the panel 50. For example, the
recess 56 can extend through about 50-75% of the thickness of the
panel 50. The scoring can be angled, so the recess has a triangular
cross-section.
[0067] The reduced thickness of the panel 50 in the scored areas
increases the flexibility of the panel so that the panel 50 can be
bent at a right angle without breaking. In particular, the panel 50
can be folded inwardly (with the inside surface being the side with
the recess 56). This permits the panel 50 to remain as a single
unitary part when the collar 34 is folded and placed in the box 20,
which can improve thermal insulation by reducing creation of gaps
in the insulating material.
[0068] FIG. 2E is a schematic exploded perspective view. FIG. 2F is
a schematic cross-sectional side view. FIG. 2G is a schematic
perspective view. Referring to FIGS. 2E-2G, construction of the top
pad 32 and bottom pad 36 is even simpler. A panel 50 is formed
having lateral dimensions approximately equal to or slightly less
than the corresponding dimensions of the top or bottom the box 20.
This panel 50 is then placed between two sheets 60 of the film (see
FIG. 2E), and the two sheets 60 are heat sealed along a path than
extends around the entire perimeter of the panel 50 (see FIG. 2F)
to provide the top pad 32 or bottom pad 36. Excess film outside the
heat seal can be cut away.
[0069] FIGS. 3A-3I illustrate another example of construction of
the pads 30 for the insulating shipping container 10. In the
example of FIGS. 3A-3I, rather than three pads, the thermally
insulating pads 30 include a first three-sectioned pad 70 and a
second three-sectioned pad 72.
[0070] FIGS. 3A and 3B are schematic exploded perspective views of
the two three-sectioned pads. FIGS. 3C-3F are schematic
cross-sectional side view of the two three-sectioned pads. FIGS. 3G
and 3H are schematic perspective views of the two three-sectioned
pads. FIG. 3I is a schematic exploded perspective view showing how
the two three-sectioned pads are positioned relative to each
other.
[0071] These pads 30 are constructed similarly to the pads
discussed above for FIGS. 2A-2D, with each pad 70, 72 formed by
sealing a solid compostable panel within a film. In particular,
each three-sectioned pad 70, 72 is constructed in a manner similar
to the collar 34 discussed above, but with scoring in two locations
rather than three locations.
[0072] In particular, referring to FIG. 3A, the first
three-sectioned pad 70 can be fabricated by forming a solid
compostable panel 50 that has a length L approximately equal to or
slightly less than the length of three side walls of the box 20,
and a width W approximately equal or slightly less than the height
of the box 20. Referring to FIG. 3B, the second three-sectioned pad
70 can be fabricated by forming a solid compostable panel 50 that
has a length L approximately equal to or slightly less than the
length of top and bottom of the box 20 plus the height of one of
the side walls of the box, and a width W approximately equal or
slightly less than the lateral length of one of the side walls of
the box 20.
[0073] Referring to FIGS. 3A-3D, each panel 50 is then placed
between two sheets 60 of the film, and the two sheets 60 are heat
sealed, as discussed above.
[0074] Referring to FIGS. 3E-3G, before or after sealing each panel
50 between the sheets 60, one surface of the panel 50 (which will
be the inward facing surface of the panel) can be scored in two
locations to divide the panel 50 into three rectangular plate 52,
which correspond to the four side walls of the collar 34. The
length of the plates 52 of the first three-section pad 70
correspond to the width of the three corresponding side walls of
the box 20. The length of the plates 52 of the second three-section
pad 72 correspond to the width of the top side, the length of the
remaining side wall, and the width of the bottom side,
respectively, of the box 20.
[0075] Together, the resulting two three-sectioned pads 70, 72
cover each of the six sides of the box 20 when inserted in the
interior 22 of the box 20.
[0076] It should be realized that other configurations are possible
for the two three-sectioned pads 70, 72. For example, the first
three-sectioned pad could cover the bottom and two opposing sides
of the box, and the second three-sectioned pad could cover the top
and the other two opposing sides of the box.
[0077] FIGS. 4A-4D illustrate yet another example of construction
of the pads 30 for the insulating shipping container 10. In the
example of FIGS. 4A-3D, rather than three pads, the thermally
insulating pads 30 include six pads 80, one for each of the six
sides of the box 20.
[0078] FIG. 4A is a schematic exploded view of one of the pads.
FIG. 4B is a schematic cross-sectional side view of one of the
pads. FIG. 4C is a schematic perspective view of one of the pads.
FIG. 4D is a schematic exploded perspective view showing how the
two three-sectioned pads are positioned relative to each other.
[0079] These pads 30 are constructed similarly to the pads
discussed above for FIGS. 2E-2G, with each pad formed by sealing a
solid compostable panel within a film. Each pad (and each panel of
the pad) has a length and width appropriate for the dimensions of
the associated side of the box 20, along the lines discussed
above.
[0080] The example of FIGS. 4A-4D does not require scoring, and
consequently can be easier to manufacture. However, the increased
number of gaps could decrease the effectiveness of the thermal
insulation.
[0081] FIGS. 5A-5H illustrate still another example of construction
of the pads 30 for the insulating shipping container 10. In the
example of FIGS. 5A-5H, rather than three pads, the thermally
insulating pads 30 include a three-sectioned pads 90, and three
individual pads 92.
[0082] FIG. 5A is a schematic exploded perspective view of the
three-sectioned pad. FIGS. 5B and 5C are schematic cross-sectional
side views of the three-sectioned pad. FIG. 3C is a schematic
perspective view of the two three-sectioned pad. FIG. 5E is a
schematic exploded view of one of the individual pads. FIG. 5F is a
schematic cross-sectional side view of one of the individual pads.
FIG. 5G is a schematic perspective view of one of the individual
pads. FIG. 6H is a schematic exploded perspective view showing how
the two three-sectioned pads are positioned relative to each
other.
[0083] Referring to FIGS. 5A-5D, the three-sectioned pad 90 is
constructed similarly to the three-sectioned pads discussed above
for FIGS. 3A-3F, with the pad 90 formed by sealing a solid
compostable panel within a film. Referring to FIG. 5A, the
three-sectioned pad 90 can be fabricated by forming a solid
compostable panel 50 that has a length L approximately equal to or
slightly less than the height of two side walls of the box 20 plus
the length of the bottom of the box 20, and a width W approximately
equal or slightly less than the width of one of the sides of the
box 20.
[0084] Referring to FIGS. 5E-5G, the three individual pads 92 are
constructed similarly to the top and bottom pads 32, 36 discussed
above for FIGS. 2E-2G, with the pads 92 formed by sealing a solid
compostable panel within a film. Each pad 92 (and each panel of the
pad) has a length and width appropriate for the dimensions of the
side of the box 20 which it will line, as generally discussed
above.
[0085] Although FIGS. 5A-5C show the three-sectioned pad having a
center section that corresponds to the bottom of the box, this is
not necessary. The center section could correspond to one of the
side walls or the top of the box.
[0086] Even further configurations are possible for the pads 30,
provided each wall of the box is provided with an individual pad or
a section of a pad. For example, there could be three two-sectioned
pads, or a three-sectioned pad, two-sectioned pad and an individual
pad.
[0087] Moreover, there could be just a single pad 100 that fits
inside the box 20 and covers all six sides of the box 20. For
example, FIG. 6, which is a schematic top view of a pad 100 in an
unfolded configuration, illustrates a single six-sectioned pad. To
fabricate this six-sectioned pad 100, the panel can be formed in a
"cross-shape", or another shape that when folded will correspond to
the sides of the rectangular prism of the box 20. The panel is
sandwiched between two sheets, as discussed above, and the edges
are sealed along a path that runs close to the perimeter of the
panel. Excess material of the sheets can be cut off. The panel can
be scored with cuts 56 in five locations to divide the panel into
six sections. The scoring corresponds to the positions necessary
for the panel to be folded such that each section corresponds to
one of the sides of the box 20. Although the implementation shown
in FIG. 6 is for a cubical box, this is not required.
[0088] The example of FIG. 6 may provide improved good thermal
insulation due to fewer gaps, and there can be a convenience for
the customer to have just a single pad for each box. On the other
hand, this configuration may have a cumbersome form factor.
[0089] The box 20 and pad or pads 30 that form the insulated
shipping container 10 can be provided as an unassembled kit, and be
assembled by a customer. For example, the box 20 and pads 30 could
be shrink-wrapped or otherwise sealed together in packaging.
[0090] In any of the various examples discussed above, one or more
apertures, e.g., about 1/8 to 5 inches across, can be formed
through the film 60 on the side of the pad 30 closer to the box 20,
that is the side opposite the opposite the cavity in which the item
to be shipped is to be positioned. These apertures are not present
on the side facing the cavity in which the item to be shipped is to
be positioned; the film 60 on that side of the pad 30 is unbroken.
The apertures can prevent pocket from acting like a balloon when
the pad is inserted into the box--the film 60 can collapse against
primary surfaces of the panels.
[0091] In some implementations, a pad includes only one panel in
the pocket formed by the film. However, referring to FIGS. 7A and
7B, cross-sectional side views, in some implementations, the pad 30
includes multiple panels 50. The panels 50 are stacked along their
thickness direction, and not arranged side-by-side. This permits
fabrication of a thicker pad 30, thus increasing the thermal
insulating capability. For example, this permits the total
thickness of the pad to be about 1-4 inches. In addition, avoiding
gaps between that would occur with side-by-side panels can improve
thermal insulation. In the example shown in FIG. 7A, there are
three panels 50a, 50b and 50c, but there could be just two panels
or four or more panels.
[0092] For a multi-section panel, when the panels 50 are scored,
the scoring 56 can be performed by compressing the stack of panels
along a line (rather than cutting the panels). As a result, in the
scored region some of the panels can be driven partially into the
underlying panel.
[0093] Where the panels 50 are multi-section panels, sections at
each end of the pad can be shorter than the section immediately
underneath to compensate for the stacking arrangement such that the
ends of panels are substantially aligned. For example, as shown in
FIG. 7A, section 52b1 is shorter than the underlying section 52a1.
In addition, the ends of the sections at the end of each pad can be
cut at an angle. For example, as shown in FIG. 7A, the ends of
sections 52a1 and 52b1 can be cut at an angle, e.g., a 45.degree.
angle. Thus, as shown in FIG. 7B, when the multi-section panels are
folded inwardly, e.g., to form the U-shaped pad, the ends of the
panels 50 align.
[0094] In the various implementations discussed above, the
individual pads 30 will rest on one another when inserted in the
cavity of the box 20. However, the pads 30 are not fixed to each
other, e.g., the pads are not secured by adhesive or interlocking
components to each other.
[0095] In some implementations, the solid compostable panels could
be used, but without enclosing or coating the panels with a film.
FIG. 8 is an exploded perspective view of an example of another
implementation of an insulated shipping container 10. The shipping
container 10 includes a recyclable box 20 and multiple thermally
insulating compostable panels 50 that fit inside the interior
cavity 22 of the box 20. The panels 50 are shaped such that when
positioned in the box 20 they provide an interior space to receive
the item and optionally a coolant, e.g., ice, dry ice or a gel
pack.
[0096] Optionally, a recyclable interior box 90, e.g., a cardboard
box, can fit into a space defined by the interior of the panels 50.
In this case, the interior cavity of the interior box 90 provides
the space to receive the item and optionally a coolant. The
interior box 90 can provide additional thermal insulation, and can
protect the panels from water, e.g., condensation caused by
coolant. However, as noted above, the item and coolant could be
placed into the interior space, without using the interior box.
[0097] Each panel 50 can be fabricated as discussed above, e.g.,
formed primarily of extruded milled sorghum, so as to be
compostable. However, the panels are not coated with, enclosed in,
or otherwise protected by a film. Rather, the panels 50 are simply
inserted into the cavity 22 in the box. One or more of the panels
50 can be a multi-section panel, which is scored as discussed in
the various implementations discussed above, and then folded at
right angle to provide multiple rectangular plates.
[0098] In the implementation shown in FIG. 1, the thermally
insulating panels 50 include a bottom panel 82, a collar 84, and a
top pad 86.
[0099] The bottom panel 82 has a length and width that match the
bottom of the box 20, or are slightly smaller, e.g., by about an
1/8 inch tolerance, so that bottom panel 82 fits snugly at the
bottom of the cavity 22 on the bottom of the box 20.
[0100] The collar 84 includes a single panel that is folded into
four rectangular plates. The four rectangular plates provide four
wall members 40, which are equivalent to the wall members discussed
with respect to FIG. 1, but without the film. Each wall member 40
has a height (in the vertical direction) about equal to the height
of the box 20, less the combined thickness of the top panel 82 and
bottom panel 86. Each wall member 40 has a width (in the lateral
direction) that matches the adjacent side wall 24 of the box 20, or
is slightly smaller, e.g., e.g., by about an 1/8 inch tolerance.
Thus, the collar 84 fits snugly into cavity 22 on top of the bottom
panel 82, with each wall member 40 adjacent, e.g., in contact with,
one of the side walls 24.
[0101] The top panel 86 has a length and width that match the top
of the box 20, or are slightly smaller, e.g., e.g., by about an 1/8
inch tolerance, so that the perimeter of the top panel 86 can sit
on the wall members 40 of the collar 84 and the top panel 86 itself
fits snugly at the top of the cavity 22.
[0102] Although FIG. 8 illustrates a configuration for the panels
50 that is similar to the configuration of pads 30 in FIGS. 1 and
2A-2G, other configurations for the panels, e.g., equivalent to
those shown in FIGS. 3A-3I, FIGS. 4A-4D, FIG. 5A-5H, or 6, are
possible. Similarly, multiple panels 50 can be stacked, e.g., as
illustrated in FIGS. 7A-7B, but again without the film.
[0103] Although milled sorghum is discussed above, as noted it may
be possible to form the panel out of a grain starch, such as corn
starch or wheat starch. However, sorghum is generally superior in
that it can provide superior thermal insulation than corn starch.
In addition, the particulates of milled sorghum may be more
amenable to extrusion.
[0104] Referring to FIG. 9, although in some implementations
multiple panels can be stacked without being joined, it is also
possible for multiple panels 50 to be stacked and laminated
together. This can increase the total thickness of the resulting
panel, e.g., to 1 to 3 inches thick. The stacked panels can be
joined by a thin layer of compostable adhesive 100.
[0105] It should be understood that although various terms such as
"top", "bottom", "vertical" and "lateral" are used, these terms
indicate relative positioning of components under the assumption
that an opening to the box 20 is at the top, and don't necessarily
indicate an orientation relative to gravity; in use, or even during
assembly, the container 10 could be on its side or upside down
relative to gravity. The term "slightly" indicates no more than
about 5%, e.g., no more than 2%.
[0106] A number of embodiments have been described. Nevertheless,
it will be understood that various modifications may be made
without departing from the spirit and scope of the invention.
Accordingly, other embodiments are within the scope of the
following claims.
* * * * *