U.S. patent application number 16/852996 was filed with the patent office on 2020-10-08 for compostable or recyclable cooler.
The applicant listed for this patent is Vericool, Inc.. Invention is credited to Darrell Jobe.
Application Number | 20200317425 16/852996 |
Document ID | / |
Family ID | 1000004905752 |
Filed Date | 2020-10-08 |
United States Patent
Application |
20200317425 |
Kind Code |
A1 |
Jobe; Darrell |
October 8, 2020 |
COMPOSTABLE OR RECYCLABLE COOLER
Abstract
A tub for a container includes an inner tub and an outer tub,
each formed of a solid compostable or recyclable sheet formed
primarily of plant fiber. Both the inner tub and the outer tub
include a floor, a plurality of side walls that are coupled to the
floor along common edges and each coupled to two adjacent side
walls along common edges, and a rim provided at a top of the side
walls. The rim of the inner tub rests on and is secured to the rim
of the outer tub such that the side walls of the inner tub extend
downwardly into the space between the side walls outer tub, with
the side walls of the outer tub surrounding and spaced apart from
the side walls of the inner tub. A volume between the side walls of
the inner and outer tub provides a cavity.
Inventors: |
Jobe; Darrell; (Livermore,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Vericool, Inc. |
Livermore |
CA |
US |
|
|
Family ID: |
1000004905752 |
Appl. No.: |
16/852996 |
Filed: |
April 20, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16172571 |
Oct 26, 2018 |
10625925 |
|
|
16852996 |
|
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62738556 |
Sep 28, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 81/3818 20130101;
B65D 65/466 20130101; B65D 2565/386 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 65/46 20060101 B65D065/46 |
Claims
1-22. (canceled)
23. A container comprising: a tub formed of a solid compostable or
recyclable sheet formed primarily of plant fiber, the tub including
a floor having a top surface to receive material to be held in the
container, a plurality of side walls that are continuously and
seamlessly coupled to the floor along first common edges and each
continuously and seamlessly coupled to two adjacent side walls
along second common edges to surround an interior space of the tub,
the side walls inclined at an oblique angle relative to the floor
to slant outwardly from bottom to top, and a rim provided at the
top of the first side walls, wherein a pair of side walls on
opposite sides of the floor each have an indentation that projects
inwardly into the interior space and extends vertically down from
the rim while leaving the interior space as a substantially open
and continuous volume.
24. The container of claim 23, further comprising a lid configured
to sit on the rim of the tub to enclose the material in the
interior space.
25. The container of claim 23, wherein the lid is a substantially
flat cover.
26. The container of claim 23, wherein for each respective side
wall of the pair of side walls, the indentation is positioned on
the respective side wall about equidistant from two side walls
adjacent to the respective side walls.
27. The container of claim 23, wherein the indentation is wider at
a lower end than a top end of the indentation.
28. The container of claim 25, wherein the indentation is
trapazoidal.
29. The container of claim 23, wherein the indentation is of
substantially uniform depth from a top to a bottom of the
indentation.
30. The container of claim 23, wherein the indentation extends
vertically from the rim to the floor.
31. The container of claim 23, wherein the indentation on each side
wall of the pair of side walls form hand-holds.
32. The container of claim 23, wherein the plant fiber comprises a
paper pulp.
33. The container of claim 23, wherein the tub has a thickness of
1.5 mm to 3 mm.
34. The container of claim 23, comprising a moisture barrier film
formed over at least an inner surface of the inner tub.
35. The container of claim 23, comprising a moisture barrier film
formed over an outer surface of the outer tub.
36. The container of claim 23, comprising a moisture barrier
material mixed with the plant fiber.
37. The container of claim 23, wherein portions of the side wall on
opposite sides of the recess are substantially flat between the
recess and the second common edges with the adjacent side
walls.
37. The container of claim 23, wherein the side wall includes a
pair of projections that extend outwardly from recessed side
surfaces, and the indentation is formed in the outer surface of the
projections.
38. The container of claim 37, wherein the recessed side surfaces
are substantially flat between the projections and the second
common edges with the adjacent side walls.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 16/172,571, filed Oct. 26, 2018, which claims priority to U.S.
Provisional Application Ser. No. 62/738,556, filed on Sep. 28,
2018, the disclosures of which are incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to a compostable or recyclable
container.
BACKGROUND
[0003] A conventional cooler has a body with inner and outer walls
formed of a molded plastic, e.g., polyethylene. Sandwiched between
the walls is an insulating material, e.g., another plastic, or
expanded polystyrene (EPS), e.g., Styrofoam. Alternatively, the
cooler can be a single unitary body, e.g., entirely plastic or EPS,
with no separate walls to hold the insulating material. For
example, a cooler can be formed out of molded polystyrene. A
coolant, e.g., ice, dry ice or a gel pack, can be placed in the
cavity in the body of the cooler with the items being stored.
[0004] EPS is relatively inexpensive and easily formed into a
variety of shapes, but is not recyclable or compostable. Similarly,
plastics used for insulation are generally not recyclable.
Consequently, disposing of the cooler can be a problem.
SUMMARY
[0005] A container that is compostable or recyclable, e.g., using
curbside composting or recycling bins, is described.
[0006] In one aspect, a tub for a container includes an inner tub
formed of a solid compostable or recyclable sheet formed primarily
of plant fiber and/or starch, and an outer tub formed of a solid
compostable or recyclable sheet formed primarily of plant fiber
and/or starch. The inner tub includes a first floor, a plurality of
first side walls that are coupled to the first floor along first
common edges and each coupled to two adjacent first side walls
along second common edges to surround an interior space of the tub,
and a first rim provided at a top of the side walls. The outer tub
includes a second floor, a plurality of second side walls that are
coupled to the second floor along third edges and each coupled to
two adjacent second side walls along fourth common edges, and a
second rim provided at a top of the second side walls. The first
rim of the inner tub rests on and is secured to the second rim of
the outer tub such that the plurality of first side walls extend
downwardly into the space between the plurality of second side
walls with the plurality of second side walls surrounding and
spaced apart from the plurality of first side walls. A volume
between the plurality of first side walls and the plurality of
second side walls provides a cavity.
[0007] Implementations may include one or more of the following
features.
[0008] The plurality of first side walls may be inclined at an
oblique angle relative to the first floor, and the plurality of
second side walls may be inclined at the oblique angle relative to
the second floor. At least two opposite sidewalls of the plurality
of first side walls may include an inwardly extending first
protrusion defining a recess in an outer side of the at least two
opposite sidewalls. At least another two opposite sidewalls of the
plurality of second side walls may include an inwardly extending
second protrusion that fits into a complementary recess of an
adjacent sidewall of the at least two opposite sidewalls. The
second protrusion may be friction fit in the complementary recess.
The second protrusion and the complementary recess may be wider at
a lower end than an top end of the recess. The recess and the
second protrusion may be trapezoidal.
[0009] The first rim of the inner tub may be secured to the second
rim of the of the sidewall by an adhesive.
[0010] The cavity may be empty. A compostable or recyclable loose
material may be placed in the cavity. The inner tub may be formed
primarily of a first plant fiber, the outer tub may be formed
primarily of the first plant fiber, and the loose material may
include a starch or a different second plant fiber. The loose
material may include starch pellets. The inner tub may be formed
primarily of plant fiber, the outer tub may be formed primarily of
plant fiber. The inner tub and the outer tub may be formed of a
same plant fiber, e.g., a paper pulp or a vegetable fiber pulp.
[0011] A moisture barrier film may be formed over at least an inner
surface of the inner tub. A moisture barrier film may be formed
over an outer surface of the outer tub. A moisture barrier material
may be mixed with the plant fiber and/or starch.
[0012] The first floor may be suspended above and spaced apart from
the second floor, and a volume between of first floor and the
second floor may provide a portion of the cavity. At least one of
the first floor and the second floor may include projections
extending to contact the other of the first floor and the second
floor.
[0013] A container may include the tub and a lid. The lid may
include an upper lid formed of a solid compostable or recyclable
sheet formed primarily of plant fiber and/or starch, and a lower
lid formed of a solid compostable or recyclable sheet formed
primarily of plant fiber and/or starch. The upper lid may a first
center portion, and a third rim portion surrounding the first
center portion. The lower lid may include a second center portion,
and a fourth rim portion surrounding the second center portion. The
third rim of the upper lid may rest on and be secured to the fourth
rim of the lower lid such that the first center portion is
suspended above and spaced apart from the second center portion. A
volume between the upper lid and the lower lid may provide a second
cavity.
[0014] A rim of one of the tub or lid may include a projection to
snap fit to a recess in a rim of the other of the tub or lid. A
moisture barrier layer may coat at least a bottom surface of the
lower lid.
[0015] Potential advantages may include (and are not limited to)
one or more of the following. The container may be entirely
compostable or recyclable, so all of the components of the
container are easily disposable. The container may be thermally
insulating, so the container can store cool materials, such as
food. The container may be water resistant, so that condensation
inside the container or leakage of water from wet materials does
not degrade the container.
[0016] Optionally, liquid inside can drain from the container
through one or more holes formed on a bottom surface of the
container. Thus, danger of the material becoming soggy or soaking
in accumulated water can be reduced.
[0017] The details of one or more embodiments are set forth in the
accompanying drawings and the description below. Other features,
objects, and advantages will be apparent from the description and
drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0018] FIGS. 1A, 1B and 1C are each an exploded perspective view of
a container.
[0019] FIG. 1D is a perspective view of an assembled container.
[0020] FIGS. 2A and 2B are each a schematic exploded
cross-sectional side view of the container.
[0021] FIG. 2C is a schematic cross-sectional side view of the
assembled container.
[0022] FIG. 3 is a schematic cross-sectional side view of the
assembled container having a filler material disposed in the lid
and tub.
[0023] FIG. 4 is a schematic cross-sectional view of a sheet that
provides a component from the container.
[0024] FIG. 5 is a schematic cross-sectional top view of the
container.
[0025] FIG. 6 is a schematic cross-sectional side view of another
implementation of the assembled container.
[0026] FIG. 7 is a schematic cross-sectional side view of another
implementation of the container.
[0027] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0028] Initially, some terminology may be beneficial.
"Biodegradable" simply means that a product will eventually
disintegrate into innocuous material. "Recyclable" indicates that a
product can be reused or treated in order to be made suitable for
reuse. While many materials could be recycled by special processes,
"street-side recyclable" indicates materials commonly permitted to
be disposed in street-side residential or business recycling bins
for collection and recycling by municipal waste disposal agencies
(i.e., as of 2018). "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.
[0029] Most conventional thermally insulating materials for
containers, e.g., EPS, are not compostable or street-side
recyclable.
[0030] One technique for forming a container having at least some
thermal insulative capability is to form inner and outer walls of
the container from a compostable or street-side recyclable
material, e.g., a compressed organic fiber pulp, e.g., plant fiber
pulp. The space between the inner and outer walls can be empty, or
could be filled with another compostable or street-side recyclable
insulating material in loose form, e.g., starch pellets or organic
fibers. At least the inner wall of the container can be coated with
a moisture barrier, which can be a biodegradable or street-side
recyclable layer.
[0031] FIGS. 1A, 1B and 1C are exploded perspective views of a
container 100. FIG. 1D is a perspective view of an assembled
container 100.
[0032] In some implementations, the container 100 is entirely
compostable, i.e., consists of compostable materials. In some
implementations, the container 100 is entirely street-side
recyclable, i.e., consists of street-side recyclable materials. In
some implementations, the container is formed of a combination of
compostable and street-side recyclable materials.
[0033] The container includes a tub 110 and a cover 140 that fits
on the top of the tub 110. The tub 110 is a generally a frustrum,
e.g., a right rectangular frustrum, that is open at the wider end.
That is, the tub has a horizontal rectangular bottom and side walls
that extend at an oblique angle from the outer edges of the bottom.
The oblique angle may be 45-80.degree. relative to the bottom. The
tub 110 is open at its top to provide access to an interior space
114 of the container to store items.
[0034] The cover 140 is generally a flat panel, e.g., generally a
rectangular solid. The cover 140 can fit over the opening in the
top of the tub 110 to seal the interior space 114. A width of the
interior space 114 can be 3-48 inches. In some implementations, the
interior space 114 can have a square shape. In some other
implementations, the interior space 114 can have a rectangular
shape. In some other implementations, the interior area 114 can
have a circular shape. The interior space 114 can have a volume of
8-400 quarts, e.g., 16-64 quarts.
[0035] The edges of the tub and cover can be beveled or rounded
without departing from the general shapes noted above.
[0036] Referring to FIGS. 1A-1C and 2A-2B, the tub 110 is formed
out of an outer tub 120 and an inner tub 130. Each of the outer tub
120 and the inner tub 130 is a relatively thin sheet formed into a
generally right rectangular frustrum that is open at its wider
end.
[0037] For example, the outer tub 120 includes a generally
rectangular floor 122 and side walls 124 that extend at the oblique
angle from the outer edges of the floor 122. Rims 126 can extend
outwardly from the upper edges of the side walls 124.
[0038] Similarly, the inner tub 130 includes a generally
rectangular floor 132 and side walls 134 that extend at the oblique
angle from the outer edges of the floor 132. Rims 136 can extend
outwardly from the upper edges of the side walls 134.
[0039] As shown in FIG. 2B, the rim 136 of the inner tub 130 sits
on the rim 126 of the outer tub 120. The rims 126, 136 can be
secured, e.g., by an adhesive. The frustum portion of the inner tub
130 is narrower than the frustrum portion of the outer tub 120, so
as to leave a gap between the side walls 126 and 136 of the inner
tub 130 and outer tub 120, respectively. Optionally there can be a
gap between the floor 132 of the inner tub 130 and the floor 126 of
the outer tub 120. The gap between the outer tub 120 and the inner
tub 130 defines a cavity 112 enclosed by the tub 110. The outer tub
120 and the inner tub 130 provide shell of material surrounding the
cavity 112. The width of the gap G1 between the inner tub 130 and
the outer tub 120 can be about 0.25-2 inches, e.g., 0.5-1 inch.
Although the gap is illustrated as having a uniform width, this is
not necessary.
[0040] Returning to FIGS. 1A-1C and 2A-2B, the lid 140 is formed
out of an upper lid 150 and a lower lid 160. Each of the upper lid
150 and the lower lid 160 is a relatively thin sheet formed into a
generally flat rectangle.
[0041] The upper lid 150 includes a generally rectangular center
portion 152 and rims 156 that extend outwardly from the outer edges
of the center portion 152. Similarly, the lower lid 160 includes a
generally rectangular center portion 162 and rims 166 that extend
outwardly from the outer edges of the center portion 162.
[0042] As shown in FIG. 2B, the rim 156 of the upper lid 150 sits
on the rim 166 of the lower lid 160. The rims 156, 166 can be
secured, e.g., by an adhesive. The rims are shaped such that when
the rims are in contact, there is a gap between the center portion
152 of the upper lid 150 and the center portion 166 of the lower
lid 160. The gap between the upper lid 150 and the lower lid 160
defines a cavity 142 within the lid 140. The upper lid 150 and
lower lid 160 provide shell of material surrounding the cavity
142.
[0043] The lower lid 160 can be formed to have an upwardly
extending recess 168 at the periphery of the lid lower 160. In
addition, the inner tub 130 can be formed to have an upwardly
extending protrusion 138 at the periphery of the inner tub 130. The
protrusion 138 on the tub 110 can be shaped to provide a
friction-fit or snap-fit into the recess 168 in the cover 150 so
that the lid 140 can be removably secured to the tub 110.
Alternatively or in addition, a downwardly extending recess can
formed in the inner tub and a downwardly extending protrusion can
be formed in the cover.
[0044] Each component of the container 100, i.e., the outer tub
120, the inner tub 130, the upper lid 150, and the lower lid 160,
is a body primarily formed of a compostable and/or street-side
recyclable material. In this context, "solid" indicates that the
component holds together as a single unit.
[0045] As noted above, each component is formed out of a relatively
thin "sheet." That is, although formed into various non-planar
shapes (e.g., the inner tub, the outer tub, etc.), each component
has a thickness that is relatively uniform. Projections or recesses
can be provided by shaping of the sheet (rather than by protrusions
or depressions that increase or decrease the thickness of the
sheet).
[0046] Each sheet can have a thickness of about 0.5 mm to 25 mm,
e.g., 1.5 mm to 25 mm, e.g., 3 mm to 25 mm, e.g., 1.5 mm to 3 mm. A
sufficiently thick sheet, e.g., 1.5 mm or more, can improve the
structural rigidity of the container to enable the container to
hold significantly greater weight, e.g., at least 50 lb., e.g.,
50-200 lb, 50-100 lb or 100-200 lb.
[0047] Each component can be formed of the same material. Each
component can have a uniform homogenous composition.
[0048] Examples of the compostable and/or street-side recyclable
material(s) for forming the components are plant fibers, starch, or
a combination of thereof. The plant fiber can be a paper pulp or a
vegetable fiber pulp. For example, the plant fibers could be fibers
from coconut husk, corn husk, linen, cotton, bamboo or bagasse. In
some cases, a combination of plant fibers from different plants can
be used. The starch can be a grain starch, e.g., a corn starch, a
wheat starch or sorghum (sorghum is also known as milo), a root
starch, e.g., a potato starch, or a vegetable starch. In some
cases, a combinations of different starches can be used.
[0049] In some implementations, the components consist of plant
fiber. In some cases, a combination of starch and plant fiber can
be used; the components can consist of starch and plant fiber.
[0050] Other materials that do not interfere with the compostable
or street-side recyclable nature of the components, e.g., a
preservative or anti-fungal agent, an adhesive, or a softener, can
be present, but only in small quantities. For example, at least
85%, e.g., at least 90-95%, by weight of the body 110 is plant
fiber and/or starch. Polyvinyl alcohol can be present, e.g., 5-10%
by weight.
[0051] Each component is a "continuous" unitary layer. In this
context, "continuous" indicates that the portions are joined
without a discontinuity in material composition; there is no gap,
adhesive, melted region, or similar disruption in the material
composition to indicate a seam.
[0052] For the outer tub 120, the floor 122 is joined
"continuously" to the side walls 124 along the outer edges of the
floor 122, and each of the side walls 124 is joined "continuously"
to its adjacent side walls along common edges. Similarly, for the
inner tub 130, the floor 132 is joined "continuously" to the side
walls 134 along the outer edges of the floor 132, and each of the
side walls 134 is joined "continuously" to its adjacent side walls
along common edges.
[0053] In some implementations, the surfaces of the tub 110 are
generally flat. In some other implementations, the inner tub 130
has one or more outwardly extending recesses, e.g., to hold an ice
pack or gel pack. Similarly, in some implementations, the inner tub
130 has various inwardly extending projections, e.g., tabs or
struts, e.g., to assist in positioning of the item to held or for
increased structural support. In addition, in some implementations,
the outer surfaces of the body can have various projections, e.g.,
pads or struts, e.g., to provide increased structural support or
cushioning.
[0054] Referring to FIG. 2C, in some implementations, the cavity
112 inside the tub 110 and the cavity 142 inside the lid 140 can be
empty, i.e., air filled.
[0055] Referring to FIG. 2D, in some implementations, the cavity
112 inside the tub 110 and/or and the cavity 142 inside the lid 140
contains a filler material 180. In particular, the cavity 112
and/or cavity 142 can contain compostable or street-side recyclable
material(s).
[0056] In some implementations, the filler is loose material, e.g.,
pellets, shredded material, fibers, powder, etc. For example, the
core can be composed of starch pellets, shredded paper, loose plant
fibers, starch powder, etc. Optionally the loose material can be
compacted within the shell of material surrounding the cavity 112
and/or cavity 142.
[0057] In some implementations, the shell and the filler have
different compositions. For example, the shell can be primarily
formed plant fiber whereas the filler is primarily formed of
starch. As another example, the shell can be primarily formed of a
first kind of plant fiber, e.g., a paper, and the filler can be
formed of a second kind of plant fiber, e.g., coconut husk or corn
husk. As another example, the shell can be primarily formed of a
starch, while the filler can be primarily formed of a plant fiber.
As another example, the shell can be primarily formed of a first
kind of starch, e.g., corn starch, while the filler can be
primarily formed of a second kind of starch, e.g., root starch.
[0058] As another example, the shell can be primarily formed of
starch or plant fiber while the filler is formed primarily of a
street-side recyclable plastic, e.g., polyethylene. For example,
the filler can be shredded polyethylene or polyethylene pellets. In
this example, the shell is compostable and recyclable while the
core is recyclable. As another example, the shell can be formed of
a street-side recyclable plastic, e.g., polyethylene, and the
filler can be primarily formed of starch or plant fiber.
[0059] In some implementations, the shell and the filler can have
the same composition, but the composition of the shell and the
composition of the filler can be differently processed. For
example, both the shell and the filler can be primarily formed of a
plant fiber. However, the plant fiber used for the shell can be
processed at a first temperature during a drying process while the
plant fiber used for the filler can be processed at a second
temperature during a drying process.
[0060] In some implementations, the shell and the filler can have
different firmness. For example, the shell can be primarily formed
of a material that is harder than the material that provides the
filler.
[0061] Alternatively, the shell and the filler can have the same
compositions.
[0062] In some implementations, the size of the cavity 112, the
material in the cavity (if any), and the material of the tub 110
can act in conjunction to provide sufficient thermal insulation for
the container to act as a cooler for common leisure applications,
e.g., keeping perishable food cool for 4-24 hours.
[0063] Referring to FIG. 4, one or more of the component sheets
(e.g., inner tub 130, outer tub 120, upper cover 150, lower cover
160) can include a moisture barrier layer. As shown in FIG. 4, the
component can include a sheet 180, e.g., formed of the plant fiber,
and a moisture barrier layer 182 formed on one or both sides of the
sheet 180. The moisture barrier layer 1820 can be water-proof,
water-resistant or water-repellant layer.
[0064] Referring to FIGS. 3 and 4, in some implementations, the
moisture barrier layer 182 is formed only on the interior surface
of the tub 100 that surround the interior space 114, i.e., the
inner surface of the inner tub 130 and the lower surface of the
lower cover 160. In some implementations, the moisture barrier
layer 182 is formed only on the exterior surfaces of the tub 110
and the cover 150, i.e., the inner surface of inner tub 130, the
outer surface of outer tub 120, the upper surface of upper cover
150, and the lower surface of lower cover 160. In some
implementations, the moisture barrier layer 182 fully encloses each
component.
[0065] The moisture barrier layer 182 can be a biodegradable or
compostable layer. The layer 182 prevents or inhibits water from
penetrating the layer 182, e.g., from escaping the interior 114. In
some implementations, the moisture barrier layer 182 can be
air-tight. The moisture barrier 182 need not impart any particular
significant stability to the component; rigidity of the component
comes from the material of the sheet 180.
[0066] In some implementations, the moisture barrier layer 182 can
be compostable. For example, the moisture barrier layer can be a
wax. As another example, the moisture barrier layer can be a
compostable plastic, e.g., a bioplastic that meets ASTM D6400
standards. Example materials for a compostable layer 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). In
addition, any combinations of these materials can be used for the
moisture barrier layer 182. For example, a combination of PBAT and
PE can be used for the moisture barrier layer 182. As another
example, a combination of PE and PLA can be used for the moisture
barrier layer 182.
[0067] In some implementations, the layer 182 can be street-side
recyclable and biodegradable. A suitable material for the layer 182
is polyethylene, e.g., a polyethylene film. For example, the layer
can include LDPE, MIDPE, HDPE, or polyethylene terephthalate. An
advantage of polyethylene is ease of fabrication and good water
resistance.
[0068] In some implementations, there is no separate moisture
barrier layer, but a moisture barrier material, e.g., one of the
polymers discussed above, can be mixed with an organic product,
e.g., the plant fibers or pulp, that provides the components.
[0069] The moisture barrier layer 182 can be applied in liquid form
and then harden on the sheet 180. Alternatively, the layer 182 can
be sprayed onto the sheet 180. The sprayed-on layer can provide a
moisture barrier. For example, a water-proof, water-resistant or
water-repellant material can be sprayed onto the panel. In some
implementations the layer can be polylactic acid (PLA).
[0070] A problem with starch-based insulation is that it dissolves
easily in water. If the item being stored is cold or a coolant is
placed in the interior of the container 100, condensation can form
on the interior surfaces of the container 100. However, the
moisture barrier layer 182 prevents liquid, e.g., the condensation,
from reaching the material of the sheet 180, e.g., the starch or
plant fiber. However, in some implementations, the sheet 180 of the
component is exposed to the environment, i.e., there is no layer
coating or surrounding the component.
[0071] Referring to FIGS. 1A-1D, the side walls of the outer tub
120 and inner tub 130 need not be completely flat. Rather, the side
walls of the outer tub 120 and inner tub 130 can include various
recesses or projections. FIG. 5 illustrates a cross sectional view
through the tub 110, showing both the outer tub 120 and the inner
tub 130.
[0072] Referring to FIGS. 1A-1D and FIG. 5, each sidewall 124 of
the outer tub 120 can include an indentation 202 extending inwardly
from a generally flat portion 200 of the side wall 124. The
indentation 202 can be wider at the bottom of the sidewall 124 (at
the floor 122) than at the top of the sidewall 124. For example,
the indentation 202 can be trapezoidal. The indentation 202 can
terminate before the lip 126 of the outer tub 120.
[0073] Each sidewall 134 of the inner tub 130 can include two
outwardly extending projections 212 from a generally flat portion
210. A portion of the sidewall 134 between the two projections 212
provides a recess 214. The recess 214 can be wider at the bottom of
the sidewall 134 (at the floor 122) than at the top of the sidewall
134. For example, the recess 214 can be trapezoidal. The
indentation 202 can terminate before the lip 126 of the outer tub
120.
[0074] The space between the generally flat portion 210 of the
sidewall 134 of the inner tub 130 and the generally flat portion
200 of the sidewall 124 of the outer tub 120 provide the cavity
112.
[0075] The recess 214 in the inner tub 130 and the indentation 202
in the outer tub 120 have complementary shapes such that
indentation 202 fits tightly into the recess 214 (FIG. 5
illustrates a small gap for clarity of illustration). This permits
the inner tub 130 to be friction fit to the outer tub 120. This can
provide improved structural stability, as compared to using solely
adhesive to attach the inner tub 130 and outer tub 120 at the rims
126, 136. Although FIGS. 1A-1D illustrate one indentation and
recess per side wall, there could be multiple interlocking
indentations and recesses.
[0076] On the interior side of the inner tub 130, the projections
212 provide grooves for air flow to improve uniformity of flow of
cold air across the item held in the interior space 114.
Alternatively or in addition, the grooves can provide space to
place a coolant, e.g., ice or a gel pack.
[0077] Referring to FIG. 6, in some implementations, which can be
combined with the features described above, the floor 132 of the
inner tub 130 includes one or more projections 220 that extend
downwardly to contact the floor 122 of the outer tub 120.
Alternatively or in addition, the floor 122 of the outer tub 120
can include one or more projections that extend upwardly to contact
the floor 132 of the inner tub 130. Such projections can provide
structural support to increase the weight that can be held by the
inner tub 130 without damaging the floor 132.
[0078] In some implementations, which can be combined with any of
the features described above, the inner tub 130 has various
projections, e.g., tabs or struts, e.g., to assist in positioning
of the item to be stored or for increased structural support.
[0079] In some implementations, which can be combined with any of
the features described above, the floor 122 of the outer tub 120
can include one or more projections that extend downwardly. Such
projections can provide structural support and/or absorb shock when
the container 100 is placed on a support surface, e.g., the
ground.
[0080] In some implementations, which can be combined with any of
the features described above, the container 100 can include
horizontally extending indentations in two opposite side walls 124
of the outer tub 120. The indentations provide hand-holds for a
user to carry the container 100.
[0081] In some implementations, which can be combined with any of
the features described above, the floor of the tub 110 includes one
or more conduits extending from the floor 132 of the inner tub 130
to the floor 122 of the outer tub 120. Any liquid in the interior
area 114 can be drained to the exterior of the container 100
through the conduits.
[0082] Although the tub 1100 illustrated in FIGS. 1A-1D is
generally trapezoidal, the tub can have box-like shape, e.g., be a
generally rectilinear prism, or have other cross-sectional shapes,
e.g., octagonal, cylindrical, etc., with or without the slant of
the sidewalls.
[0083] Referring to FIG. 7, in some implementations, the tub 110
and the lid 140 are each formed of only a single sheet, and do not
include a cavity 112 or cavity 142. The sheet forming the tub 100
can be similar to the sheet forming the outer tub 120 or the inner
tub 130, and the sheet forming the lid 140 can be sheet forming the
upper lid 150 or the lower lid 160.
[0084] To manufacture the container 100, the plant fibers are
ground to the appropriate size and added to a liquid to form a
slurry. For example, used paper products, e.g., cardboard, can be
recycled by grinding the paper product and adding water to form a
recycled wood pulp. Also if appropriate, the moisture barrier
material is added to the slurry. The slurry is then fed to a vacuum
former to create a mold of the desired shape, e.g., one of the
components described above. In brief, a screen having the desired
shape for the component is lowered into a reservoir of the slurry,
and vacuum is applied to suction the fibrous material (and
additives) onto the screen. The screen is removed from the
reservoir, and can be placed into a mating plate. This can compress
the slurry accumulated on the screen to remove liquid and form the
sheet. Optionally heat can be applied. The components can then be
assembled, e.g., adhesively attached as shown in FIGS. 2A and
2B.
[0085] In some implementations, the container 100 is entirely
compostable, i.e., consists of compostable materials. If both the
tub 110 and cover 150 are compostable, the entire container 100 can
be disposed of as a unit in a composting bin.
[0086] In some implementations, the container 100 is entirely
street-side recyclable, i.e., consists of street-side recyclable
materials. If both the tub 110 and cover 150 are street-side
recyclable, the entire container 100 can be disposed of as a unit
in a recycling bin.
[0087] In some implementations, the container is formed of a
combination of compostable and street-side recyclable materials. In
particular, the various components (outer tub 120, inner tub 130,
upper cover 150, lower cover 160) can consists of street-side
recyclable materials, e.g., plant fiber pulp, whereas the filler
material in the cavities 112, 142 can consist of compostable
materials, e.g., starch in pellet or powder form.
CONCLUSION
[0088] 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%.
[0089] 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.
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