U.S. patent application number 17/712295 was filed with the patent office on 2022-07-21 for thermal insulation liners.
The applicant listed for this patent is TemperPack Technologies Inc.. Invention is credited to James MCGOFF, Brian POWERS, Charles VINCENT.
Application Number | 20220228694 17/712295 |
Document ID | / |
Family ID | |
Filed Date | 2022-07-21 |
United States Patent
Application |
20220228694 |
Kind Code |
A1 |
MCGOFF; James ; et
al. |
July 21, 2022 |
THERMAL INSULATION LINERS
Abstract
Provided herein are products, methods, and kits, for use in
regulating the temperature of an object. The present invention
relates to thermal insulating liners for regulating the temperature
of perishable goods or temperature sensitive products. The thermal
insulating liners generally may be dimensioned to fit within a
container. The thermal insulating liners may be quickly collapsed
and reconstructed to improve stackability and diminish the amount
of space required to store the thermal insulating liners prior to
use.
Inventors: |
MCGOFF; James; (Silver
Spring, MD) ; VINCENT; Charles; (St. Bruno De
Montarville, CA) ; POWERS; Brian; (Adelphi,
MD) |
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Applicant: |
Name |
City |
State |
Country |
Type |
TemperPack Technologies Inc. |
Richmond |
VA |
US |
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Appl. No.: |
17/712295 |
Filed: |
April 4, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17080364 |
Oct 26, 2020 |
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17712295 |
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15575114 |
Nov 17, 2017 |
10816128 |
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PCT/US2016/033294 |
May 19, 2016 |
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17080364 |
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62164416 |
May 20, 2015 |
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62296763 |
Feb 18, 2016 |
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62164416 |
May 20, 2015 |
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International
Class: |
F16L 59/00 20060101
F16L059/00; B65D 90/04 20060101 B65D090/04 |
Claims
1. A thermal insulation liner comprising: an insulating layer
comprising recycled cellulose fibers, wherein the recycled
cellulose fibers comprise pre-consumer recycled cellulose fibers,
post-consumer recycled cellulose fibers, or combinations thereof;
and polymeric fibers in an amount of 5 to 15% by weight; and a
barrier covering at least one surface of the insulating layer.
2. The thermal insulation liner of claim 1, wherein the barrier
comprises paper.
3. The thermal insulation liner of claim 1, wherein the barrier
comprises a hydrocarbon film.
4. The thermal insulation liner of claim 1, wherein the barrier
comprises kraft paper coated with petroleum plastics, resins, or
one or more biodegradable polymers.
5. The thermal insulation liner of claim 1, wherein the barrier
comprises paper and plastic.
6. The thermal insulation liner of claim 1, wherein the barrier
comprises polyhydroxyalkanoates (PHA).
7. The thermal insulation liner of claim 1, wherein the barrier
comprises polylactic acid (PLA).
8. The thermal insulation liner of claim 1, wherein the barrier
comprises polyethylene.
9. The thermal insulation liner of claim 1, wherein the recycled
cellulose fibers comprise both pre-consumer recycled cellulose
fibers and post consumer recycled cellulose fibers.
10. The thermal insulation liner of claim 1, wherein the polymeric
fibers comprise polypropylene.
11. The thermal insulation liner of claim 1, wherein the polymeric
fibers comprise polyethylene.
12. The thermal insulation liner of claim 1, wherein the polymeric
fibers comprise polyethylene terephthalate (PET).
13. The thermal insulation line of claim 1, wherein the polymeric
fibers comprise polylactic acid (PLA).
14. The thermal insulation line of claim 1, wherein the polymeric
fibers comprise polyhydroxyalkanoates (PHA).
15. The thermal insulation liner of claim 1, wherein the insulating
layer is fully enclosed by the barrier.
16. The thermal insulation liner of claim 1, wherein the insulating
layer comprises a first side portion, a second side portion, a
middle portion separating the first and second side portions,
wherein the one or more of the first side or second side portions
comprises opposing first and second side flaps, and wherein the
insulating layer is folded such that the first side portion, second
side portion, and middle portion create an open mouth substantially
polygonal box form comprising a cavity, with the first and second
side portions defining opposing sides of the polygonal box form,
the middle portion defining a bottom of the polygonal box form, and
the opposing first and second side flaps defining at least part of
opposing sides of the polygonal box form.
17. The thermal insulation liner of claim 1, wherein the insulating
layer comprises a first side portion, a second side portion, a
middle portion separating the first and second side portions, and
wherein the insulating layer is folded such that the first side
portion, second side portion, and middle portion create an open
mouth pouch comprising a cavity with the first and second side
portions defining opposing sides of the pouch, the middle portion
defining a bottom of the pouch.
18. A thermal insulation liner comprising: an insulating layer
comprising: recycled cellulose fibers, wherein the recycled
cellulose fibers comprise pre-consumer recycled cellulose fibers,
post-consumer recycled cellulose fibers, or combinations thereof;
and polymeric fibers in an amount of 5 to 15% by weight; and a
barrier disposed on at least one surface of the insulating layer
and comprising paper, wherein the insulating layer comprises a
first side portion, a second side portion, a middle portion
separating the first and second side portions, wherein the one or
more of the first side or second side portions comprises opposing
first and second side flaps, and wherein the insulating layer is
folded such that the first side portion, second side portion, and
middle portion create an open mouth substantially polygonal box
form comprising a cavity, with the first and second side portions
defining opposing sides of the polygonal box form, the middle
portion defining a bottom of the polygonal box form, and the
opposing first and second side flaps defining at least part of
opposing sides of the polygonal box form.
19. The thermal insulation liner of claim 18, wherein the recycled
cellulose fibers comprise both pre-consumer recycled cellulose
fibers and post consumer recycled cellulose fibers.
20. The thermal insulation liner of claim 18, wherein the polymeric
fibers comprise polypropylene.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority
under 35 U.S.C. .sctn. 120 to, U.S. patent application Ser. No.
17/080,364, filed Oct. 26, 2020, which is a continuation of U.S.
patent application Ser. No. 15/575,114, now U.S. Pat. No.
10,816,128, filed Nov. 17, 2017, which is a U.S. national stage
entry of an International Application Serial No. PCT/US2016/033294
filed May 19, 2016, which claims the benefit of U.S. Provisional
Patent Application Nos. 62/296,763, filed on Feb. 18, 2016, and
62/164,416 filed on May 20, 2015 the entireties of each of which
are fully incorporated herein by reference.
BACKGROUND
[0002] A multitude of industries produce and transport goods that
are temperature sensitive. Such industries include but are not
limited to the food industry, confectioneries, meat and seafood
industry, medical diagnostics industry, pharmaceutical industry,
and industrial goods industry. These goods are generally packaged
at the plant where they are produced and prepared for shipping to
customers or forwarded into a distribution channel. Containers such
as boxes, steel drums, and wooden crates, are widely utilized for
the packaging and transport of temperature sensitive goods.
Additionally, a very effective and commonly utilized packaging
material for the transport of temperature sensitive goods is
polyurethane foam and/or polystyrene foam, such as expanded
polystyrene ("EPS") and extruded polystyrene ("XPS") such as
STYROFOAM.RTM.. Ideally, it would be desirable to provide
insulation systems which have reliable thermal performance over
extended time periods, are leak-proof, can be shipped and stored in
a manner requiring limited space, and are fabricated from
cost-competitive, environmentally-friendly materials in a
cost-effective manner.
SUMMARY OF THE DISCLOSURE
[0003] Novel thermal insulating liners are presented. The thermal
insulating liner may comprise an insulating layer and a barrier.
The insulating layer may comprise a layer of flexible fibrous
material. The layer of flexible fibrous material may comprise
natural fibers and may be configured to form a cavity. The
insulating layer may be compostable or biodegradable, made from
recycled content, or recyclable. The thermal insulating liner may
comprise 100% recycled materials. Flexible fibrous material may
comprise seed, bast, animal, or synthetic fibers. The barrier may
cover an inner surface of the cavity. The thermal insulating liner
may have a thermal conductivity ranging from about 0.01 W/mK to
about 0.05 W/mK. The thermal insulating liner may have a thermal
conductivity ranging from about 0.01 W/mK to about 0.1 W/mK. The
fibrous material may comprise nonwoven fibers and/or woven fibers.
The insulating layer may comprise a single continuous layer of
fibrous material. The insulating layer may comprise multiple
discontinuous layers of fibrous material. The fibrous material may
be produced by one or more of: needling, spunbonding, melt blowing,
bonded carded, thermal bonding, garnett processed, or wet laid. The
natural fiber may comprise plant fibers such as jute fibers. The
natural fiber may comprise animal fibers such as wool. Synthetic
fiber may comprise recycled plastics such as PET fibers. The
fibrous material may comprise post-consumer recycled fibers and/or
pre-consumer recycled fiber. The insulating layer may have a
thickness of at least about 0.2 cm, for example, about 2.5 cm. The
barrier may have a thickness ranging from about 1 to about 5 MIL.
The barrier may have a thickness ranging from about 1 to about 2
MIL. The barrier may be flexible or rigid. The barrier may be
transparent and/or hydrophobic. The barrier may be made of a
variety of materials. The barrier may comprise paper such as kraft
paper. The barrier may comprise polyethylene. The barrier may
comprise recycled materials such as post-consumer recycled
materials and/or pre-consumer recycled materials. The barrier may
comprise a biodegradable, recyclable or compostable polymer. The
barrier may comprise a copolymer. The biodegradable polymer may
comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled. In some embodiments, a thermal insulating liner may
comprise one or more backing.
[0004] Disclosed herein are thermal insulating liners. The thermal
insulating liner may comprise an insulating layer and a barrier.
The insulating layer may comprise a layer of flexible fibrous
material. The layer of flexible fibrous material may comprise
needled fibers. The layer of flexible fibrous material may be
configured to form a cavity. The insulating layer may be
compostable or biodegradable. The thermal insulating liner may
comprise 100% recycled materials. Flexible fibrous material may
comprise bast fibers. The barrier may comprise a flexible material.
The flexible material may cover an inner surface of the cavity. The
barrier may have a thickness ranging from about 1 to about 5 MIL.
The barrier may have a thickness ranging from about 1 to about 2
MIL. The barrier may comprise a biodegradable polymer. The barrier
may comprise a copolymer. The biodegradable polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. The
biodegradable polymer may comprise polyhydroxyalkanoate. The
barrier may comprise a 3-hydroxybutyrate polymer, copolymer or
blends thereof. The barrier may comprise a 4-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
polyhydroxyalkanoate copolymer. The barrier may comprise a
3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The barrier may
comprise a biodegradable polylactic acid. The barrier may be a
moisture resistant barrier. The barrier may be an oxygen barrier.
The barrier may comprise a wax. The wax may be at least one of
carnauba, candelilla, beeswax, or paraffin. In some embodiments,
the barrier described herein can be coated with a biodegradable
polymer, copolymer or blends thereof. In some embodiments, the
coating can comprise a biodegradable copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The coating may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The coating may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a polyhydroxyalkanoate copolymer. The coating may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
coating may comprise a biodegradable polylactic acid. In some
embodiments, the coating can be moisture resistant. In some
embodiments, the coating can be impermeable to oxygen. In some
embodiments, the coating can comprise a wax. In some embodiments,
the coating can comprise carnauba, candelilla, beeswax, or
paraffin. The insulating layer may comprise a single continuous
layer of fibrous material. The insulating layer may comprise
multiple discontinuous layers of fibrous material. The insulating
layer may have a thermal conductivity ranging from about 0.01 W/mK
to about 0.05 W/mK. The insulating layer may have a thermal
conductivity ranging from about 0.01 W/mK to about 0.1 W/mK. The
fibrous material may comprise plant fibers such as jute fibers. The
fibrous material may comprise synthetic fibers. The fibrous
material may comprise recycled fibers such as post-consumer
recycled fibers and/or pre-consumer recycled fibers. The insulating
layer may comprise a thickness of at least about 0.2 cm, for
example about 2.5 cm. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0005] Disclosed herein are insulating layers. The insulating layer
may comprise a first side portion, a second side portion, and a
middle portion separating the first and second side portions. One
or more of the first side, and/or second side portions may comprise
opposing first and/or second side flaps. The insulating layer may
be folded such that the first side portion, second side portion and
middle portion create an open mouth substantially polygonal box
form. The open mouth substantially polygonal box form may comprise
a cavity. The first and second side portions may define opposing
sides of the polygonal box form. The middle portion may define a
bottom of the polygonal box form. The opposing first and second
side flaps may define at least part of opposing sides of the
polygonal box form. The insulating layer may comprise a continuous
layer of nonwoven fibrous material. The continuous layer of
nonwoven fibrous material may have a thickness ranging from about
0.2 cm to about 9.0 cm. The insulating layer may have a density
ranging from about 200 g/m.sup.2 to about 3500 g/m.sup.2. The
insulating layer may have a thermal conductivity ranging from about
0.01 W/mK to about 0.05 W/mK. The insulating layer may have a
thermal conductivity ranging from about 0.01 W/mK to about 0.1
W/mK. The fibrous material may be produced by one or more of:
needling, spunbonding, melt blowing, bonded carded, thermal
bonding, garnett processed and wet laid. The fibrous material may
comprise plant fibers such as jute fibers. The fibrous material may
comprise synthetic fibers. The fibrous material may comprise
recycled fibers such as post-consumer and or pre-consumer recycled
fibers. The insulating layer may comprise one or more types of
fibers. The polygonal box form may be a box comprising 5, 6, 7, 8,
9, or 10 sides. The box may be a rectangular box. The box may have
a triangular face. The insulating layer may be compostable. The
insulating layer may compost in the same manner as yard waste. The
insulating layer may decompose within 4-8 months. 80% of the
insulating layer may decompose within 2 to 4 weeks of composting
the insulating layer. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner may comprise one or more backing.
[0006] Disclosed herein are thermal insulating liners. The thermal
insulating liner may comprise an insulating layer and a barrier.
The insulating layer may comprise a first side portion, a second
side portion, and a middle portion. The middle portion may separate
the first and second side portions. One or more of the first side,
and/or second side portions may comprise opposing first and/or
second side flaps. The insulating layer may be folded such that the
first side portion, second side portion and middle portion create
an open mouth substantially polygonal box form. The open mouth
substantially polygonal box form may comprise a cavity. The first
and second side portions may define opposing sides of the polygonal
box form. The middle portion may define a bottom of the polygonal
box form. The opposing first and/or second side flaps may define at
least part of opposing sides of the polygonal box form. The
insulating layer may comprise a continuous layer of nonwoven
fibrous material. The continuous layer of nonwoven fibrous material
may have a thickness ranging from about 0.2 cm to about 9.0 cm. The
barrier may cover an inner surface of the polygonal box form. The
fibrous material may be produced by one or more of: needling,
spunbonding, melt blowing, bonded carded, thermal bonding, garnett
processed and wet laid. The fibrous material may comprise plant
fibers such as jute fibers. The fibrous material may comprise
synthetic fibers. The fibrous material may comprise recycled fibers
such as post-consumer and/or pre-consumer recycled fibers. The
insulating layer may comprise a thickness of at least about 0.2 cm,
for example about 2.5 cm. The barrier may have a thickness ranging
from about 1 to about 5 MIL. The barrier may have a thickness
ranging from about 1 to about 2 MIL. The barrier may be flexible.
The barrier may be rigid. The barrier may be transparent. The
barrier may be hydrophobic. The barrier may comprise paper such as
kraft paper. The barrier may comprise polyethylene. The barrier may
comprise recycled materials such as post-consumer and/or
pre-consumer recycled materials. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled. In some embodiments, a thermal insulating liner may
comprise one or more backing.
[0007] Disclosed herein are insulating layers. The insulating layer
may comprise a flexible first side portion, a second side portion,
and a middle portion. The middle portion may separate the first and
second side portions. The insulating layer may be folded such that
the first side portion, second side portion and middle portion
create an open mouth pouch. The open mouth pouch may comprise a
cavity. The first and second side portions may define opposing
sides of the pouch. The middle portion may define a bottom of the
pouch. The insulating layer may comprise a continuous layer of
nonwoven fibrous material. The continuous layer of nonwoven fibrous
material may comprise a bast fiber. The continuous layer of
nonwoven fibrous material may have a density ranging from about 200
g/m.sup.2 to about 3500 g/m.sup.2. The insulating layer may have a
thickness ranging from about 0.2 cm to about 9.0 cm. The fibrous
material may be produced by one or more of: needling, spunbonding,
melt blowing, bonded carded, thermal bonding, garnett processed and
wet laid. The fibrous material may comprise plant fibers such jute
fibers. The fibrous material may comprise synthetic fibers. The
fibrous material may comprise post-consumer recycled fibers. The
fibrous material may comprise pre-consumer recycled fibers. The
insulating layer may comprise one or more types of fibers. The
insulating layer may be compostable. The insulating layer may
compost in the same manner as yard waste. The insulating layer may
decompose within 2 to 8 weeks. 80% of the insulating layer may
decompose within 2 to 4 weeks of composting the insulating
layer.
[0008] Disclosed herein are thermal insulating liners. The thermal
insulating liner may comprise an insulating layer and a barrier.
The insulating layer may comprise a flexible first side portion, a
second side portion, and a middle portion. The middle portion may
separate the first and second side portions. The insulating layer
may be folded such that the first side portion, second side portion
and middle portion create an open mouth pouch. The open mouth pouch
may comprise a cavity. The first and second side portions may
define opposing sides of the pouch. The middle portion may define a
bottom of the pouch. The insulating layer may comprise a continuous
layer of nonwoven fibrous material. The continuous layer of
nonwoven fibrous material may comprise a bast fiber. The continuous
layer of nonwoven fibrous material may have a density ranging from
about 200 g/m.sup.2 to about 3500 g/m.sup.2. The barrier may cover
an inner surface of the pouch. The fibrous material may be produced
by one or more of: needling, spunbonding, melt blowing, bonded
carded, thermal bonding, garnett processed and wet laid. The
fibrous material may comprise plant fibers such as jute fibers. The
fibrous material may comprise synthetic fibers. The fibrous
material may comprise post-consumer recycled fibers. The fibrous
material may comprise pre-consumer recycled fibers. The insulating
layer may have a thickness of at least about 0.5 cm, for example
about 2.5 cm. The barrier may have a thickness ranging from about 1
to about 5 MIL. The barrier may have a thickness ranging from about
1 to about 2 MIL. The barrier may be flexible. The barrier may be
rigid. The barrier may be transparent. The barrier may be
hydrophobic. The barrier may comprise paper such as kraft paper.
The barrier may comprise polyethylene. The barrier may comprise
recycled materials. The recycled materials may comprise
post-consumer recycled materials. The recycled materials may
comprise pre-consumer recycled materials. The barrier may comprise
a biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0009] Disclosed herein are methods for regulating a temperature of
a sample, the method may comprise placing the sample into a cavity
of a thermal insulating liner. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a layer of flexible fibrous material. The layer of
flexible fibrous material may comprise natural fibers. The layer of
flexible fibrous material may be configured to form the cavity. The
barrier may cover an inner surface of the cavity. The barrier may
comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The thermal insulating liner may have a
thermal conductivity ranging from about 0.01 W/mK to about 0.05
W/mK. The thermal insulating liner may have a thermal conductivity
ranging from about 0.01 W/mK to about 0.1 W/mK. The fibrous
material may comprise nonwoven fibers. The fibrous material may
comprise woven fibers. The insulating layer may comprise a single
continuous layer of fibrous material. The insulating layer may
comprise multiple discontinuous layers of fibrous material. The
sample may be a temperature sensitive sample. The temperature
sensitive sample may be a food product. The method of regulating
the temperature of a sample may further comprise placing a heating
agent into the cavity. The heating agent may comprise a gel pack.
The method of regulating the temperature of a sample may further
comprise placing a cooling agent into the cavity. A cooling agent
may comprise at least one or more of: wet ice, dry ice, ice packs,
ice tubes, ice gel, BLUE ICE.RTM., frozen gel, and a gel pack. The
method of regulating the temperature of a sample may further
comprise covering the cavity containing the sample. Covering may
comprise folding a portion of the thermal insulating liner on
itself or placing a lid onto the thermal insulating liner. The
method of regulating the temperature of a sample may further
comprise placing the thermal insulating liner into a container. The
fibrous material may be produced by one or more of: needling,
spunbonding, melt blowing, bonded carded, thermal bonding, garnett
processed and wet laid. The natural fiber may comprise plant fibers
such as jute fibers. The natural fiber may comprise animal fibers
such as wool. The fibrous material may comprise post-consumer
recycled fibers. The fibrous material may comprise pre-consumer
recycled fibers. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0010] Disclosed herein are methods for regulating a temperature of
a sample, the method may comprise placing the sample into a cavity
of a thermal insulating liner. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a layer of flexible fibrous material. The layer of
flexible fibrous material may comprise needled fibers. The layer of
flexible fibrous material may be configured to form the cavity. The
barrier may comprise a flexible material. The flexible material may
cover an inner surface of the cavity. The barrier may have a
thickness ranging from about 1 to about 5 MIL. The barrier may have
a thickness ranging from about 1 to about 2 MIL. The barrier may
comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The insulating layer may comprise a single
continuous layer of fibrous material. The insulating layer may
comprise multiple discontinuous layers of fibrous material. The
sample may comprise a temperature sensitive sample. The temperature
sensitive sample may be a food product. The method of regulating
the temperature of a sample may further comprise placing a heating
agent into the cavity. The heating agent may comprise a gel pack.
The method of regulating the temperature of a sample may further
comprise placing a cooling agent into the cavity. The cooling agent
may comprise at least one or more of: wet ice, dry ice, ice packs,
ice tubes, ice gel, BLUE ICE.RTM., frozen gel, and a gel pack. The
method of regulating the temperature of a sample may further
comprise covering the cavity containing the sample. Covering may
comprise folding a portion of the thermal insulating liner on
itself. The method of regulating the temperature of a sample may
further comprise placing the thermal insulating liner into a
container. The fibrous material may comprise plant fibers such as
jute fibers. The fibrous material may comprise post-consumer
recycled fibers. The fibrous material may comprise pre-consumer
recycled fibers. The fibrous material may comprise synthetic
fibers. In some embodiments, an insulating layer may comprise a
binder. In some embodiments, an insulating layer may be bonded by a
binder. In some embodiments, a bonding agent may comprise sap,
cornstarch, polylactates, polyester, nylon, honey, polyvinyl
alcohol (PVA), polyvinyl chloride, polyvinyl acetate, acrylic
bonding agents or combinations thereof. In some embodiments, a
bonding agent may comprise a biodegradable polymers of the
following types: polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0011] Disclosed herein are methods for regulating a temperature of
a sample, the method may comprise placing the sample into a cavity
of a thermal insulating liner. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a first side portion, a second side portion, and a
middle portion. The middle portion may separate the first and
second side portions. One or more of the first side, and/or second
side portions may comprise opposing first and/or second side flaps.
The insulating layer may be folded such that the first side
portion, second side portion and middle portion create an open
mouth substantially polygonal box form. The open mouth
substantially polygonal box form may comprise a cavity. The first
and second side portions may define opposing sides of the polygonal
box form. The middle portion may define a bottom of the polygonal
box form. The opposing first and/or second side flaps may define at
least part of opposing sides of the polygonal box form. The
insulating layer may comprise a continuous layer of nonwoven
fibrous material. The continuous layer of nonwoven fibrous material
may have a thickness ranging from about 0.2 cm to about 9.0 cm. The
barrier may cover an inner surface of the polygonal box form. The
barrier may comprise a biodegradable polymer. The barrier may
comprise a copolymer. The biodegradable polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. The
biodegradable polymer may comprise polyhydroxyalkanoate. The
barrier may comprise a 3-hydroxybutyrate polymer, copolymer or
blends thereof. The barrier may comprise a 4-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
polyhydroxyalkanoate copolymer. The barrier may comprise a
3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The barrier may
comprise a biodegradable polylactic acid. The barrier may be a
moisture resistant barrier. The barrier may be an oxygen barrier.
The barrier may comprise a wax. The wax may be at least one of
carnauba, candelilla, beeswax, or paraffin. In some embodiments,
the barrier described herein can be coated with a biodegradable
polymer, copolymer or blends thereof. In some embodiments, the
coating can comprise a biodegradable copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The coating may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The coating may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a polyhydroxyalkanoate copolymer. The coating may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
coating may comprise a biodegradable polylactic acid. In some
embodiments, the coating can be moisture resistant. In some
embodiments, the coating can be impermeable to oxygen. In some
embodiments, the coating can comprise a wax. In some embodiments,
the coating can comprise carnauba, candelilla, beeswax, or
paraffin. The sample may comprise a temperature sensitive sample.
The temperature sensitive sample may be a food product. The method
of regulating the temperature of a sample may further comprise
placing a heating agent into the cavity. The heating agent may
comprise a gel pack. The method of regulating the temperature of a
sample may further comprise placing a cooling agent into the
cavity. The cooling agent may comprise at least one or more of: wet
ice, dry ice, ice packs, ice tubes, ice gel, BLUE ICE.RTM., frozen
gel, and a gel pack. The method of regulating the temperature of a
sample may further comprise covering the cavity containing the
sample. Covering may comprise folding a portion of the thermal
insulating liner on itself. The method of regulating the
temperature of a sample may further comprise placing the thermal
insulating liner into a container. The fibrous material may be
produced by one or more of: needling, spunbonding, melt blowing,
bonded carded, thermal bonding, garnett processed and wet laid. The
fibrous material may comprise plant fibers such as jute fibers. The
fibrous material may comprise post-consumer recycled fibers. The
fibrous material may comprise pre-consumer recycled fibers. The
fibrous material may comprise synthetic fibers. Synthetic fiber may
comprise recycled plastics such as PET fibers. In some embodiments,
an insulating layer may comprise a binder. In some embodiments, an
insulating layer may be bonded by a binder. In some embodiments, a
bonding agent may comprise sap, cornstarch, polylactates,
polyester, nylon, honey, polyvinyl alcohol (PVA), polyvinyl
chloride, polyvinyl acetate, acrylic bonding agents or combinations
thereof. In some embodiments, a bonding agent may comprise a
biodegradable polymers of the following types: polylactates,
polymalates, polyhydroxyalkanoates, polycaprolactones,
polyesteramides (PEA), aliphatic copolyesters (PBSA),
aliphatic-co-terephthalate copolyesters, celluloses or starches. In
some embodiments, an insulating layer does not comprise a binder.
In some embodiments, a thermal insulating liner can be closed via
an adhesive. In some embodiments, an adhesive may comprise
polymers. In some embodiments, a polymer may comprise at least one
of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0012] Disclosed herein are methods for regulating a temperature of
a sample, the method may comprise placing the sample into a cavity
of a thermal insulating liner. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a flexible first side portion, a second side portion,
and a middle portion. The middle portion may separate the first and
second side portions. The insulating layer may be folded such that
the first side portion, second side portion and middle portion
create an open mouth pouch. The open mouth pouch may comprise a
cavity. The first and second side portions may define opposing
sides of the pouch. The middle portion may define a bottom of the
pouch. The insulating layer may comprise a continuous layer of
nonwoven fibrous material. The continuous layer of nonwoven fibrous
material may comprise a bast fiber. The continuous layer of
nonwoven fibrous material may have a density ranging from about 200
g/m.sup.2 to about 3500 g/m.sup.2. The barrier may covers an inner
surface of the pouch. The barrier may comprise a biodegradable
polymer. The barrier may comprise a copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The sample may comprise a temperature
sensitive sample. The temperature sensitive sample may be a food
product. The method of regulating the temperature of a sample may
further comprise placing a heating agent into the cavity. The
heating agent may comprise a gel pack. The method of regulating the
temperature of a sample may further comprise placing a cooling
agent into the cavity. The cooling agent may comprise at least one
or more of: wet ice, dry ice, ice packs, ice tubes, ice gel, BLUE
ICE.RTM., frozen gel, and a gel pack. The method of regulating the
temperature of a sample may further comprise covering the cavity
containing the sample. Covering may comprise folding a portion of
the thermal insulating liner on itself. The method of regulating
the temperature of a sample may further comprise placing the
thermal insulating liner into a container. The fibrous material may
be produced by one or more of: needling, spunbonding, melt blowing,
bonded carded, thermal bonding, garnett processed and wet laid. The
fibrous material may comprise plant fibers such as jute fibers. The
fibrous material may comprise post-consumer recycled fibers. The
fibrous material may comprise pre-consumer recycled fibers. The
fibrous material may comprise synthetic fibers. Synthetic fiber may
comprise recycled plastics such as PET fibers. In some embodiments,
an insulating layer may comprise a binder. In some embodiments, an
insulating layer may be bonded by a binder. In some embodiments, a
bonding agent may comprise sap, cornstarch, polylactates,
polyester, nylon, honey, polyvinyl alcohol (PVA), polyvinyl
chloride, polyvinyl acetate, acrylic bonding agents or combinations
thereof. In some embodiments, a bonding agent may comprise a
biodegradable polymers of the following types: polylactates,
polymalates, polyhydroxyalkanoates, polycaprolactones,
polyesteramides (PEA), aliphatic copolyesters (PBSA),
aliphatic-co-terephthalate copolyesters, celluloses or starches. In
some embodiments, an insulating layer does not comprise a binder.
In some embodiments, a thermal insulating liner can be closed via
an adhesive. In some embodiments, an adhesive may comprise
polymers. In some embodiments, a polymer may comprise at least one
of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0013] Disclosed herein are kits. The kit may comprise a thermal
insulating liner and a container. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a layer of flexible fibrous material. The layer of
flexible fibrous material may comprise natural fibers. The layer of
flexible fibrous material may be configured to form a cavity. The
barrier may cover an inner surface of the cavity. The barrier may
comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The thermal insulating liner may have a
thermal conductivity ranging from about 0.01 W/mK to about 0.05
W/mK. The thermal insulating liner may have a thermal conductivity
ranging from about 0.01 W/mK to about 0.1 W/mK. The thermal
insulating liner may be placed in the container. The fibrous
material may comprise nonwoven fibers. The fibrous material may
comprise woven fibers. The insulating layer may comprise a single
continuous layer of fibrous material. The insulating layer may
comprise multiple discontinuous layers of fibrous material. The kit
may further comprise a heating agent. The heating agent may
comprise a gel pack. The kit may further comprise a cooling agent.
The cooling agent may comprise at least one or more of: wet ice,
dry ice, ice packs, ice tubes, ice gel, BLUE ICE.RTM., frozen gel,
and a gel pack. The fibrous material may be produced by one or more
of: needling, spunbonding, melt blowing, bonded carded, thermal
bonding, garnett processed and wet laid. The natural fiber may
comprise plant fibers such as jute fibers. The natural fiber may
comprise animal fibers such as wool. The fibrous material may
comprise synthetic fibers. Synthetic fiber may comprise recycled
plastics such as PET fibers. The fibrous material may comprise
post-consumer recycled fibers. The fibrous material may comprise
pre-consumer recycled fibers. In some embodiments, an insulating
layer may comprise a binder. In some embodiments, an insulating
layer may be bonded by a binder. In some embodiments, a bonding
agent may comprise sap, cornstarch, polylactates, polyester, nylon,
honey, polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl
acetate, acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0014] Disclosed herein are kits. The kit may comprise a thermal
insulating liner and a container. The thermal insulating liner may
comprise an insulating layer, and a barrier. The insulating layer
may comprise a layer of flexible fibrous material. The layer of
flexible fibrous material may comprise needled fibers. The layer of
flexible fibrous material may be configured to form a cavity. The
barrier may comprise a flexible material that covers an inner
surface of the cavity. The barrier may have a thickness ranging
from about 1 to about 5 MIL. The barrier may have a thickness
ranging from about 1 to about 2 MIL. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The insulating layer may comprise a single
continuous layer of fibrous material. The kit may further comprise
a heating agent. The insulating layer may comprise multiple
discontinuous layers of fibrous material. The heating agent may
comprise a gel pack. The kit may further comprise a cooling agent.
The cooling agent may comprise at least one or more of: wet ice,
dry ice, ice packs, ice tubes, ice gel, BLUE ICE.RTM., frozen gel,
and a gel pack. The fibrous material may comprise plant fibers such
as jute fibers. The fibrous material may comprise synthetic fibers.
Synthetic fiber may comprise recycled plastics such as PET fibers.
The fibrous material may comprise recycled fibers. The recycled
fibers may comprise post-consumer and/or pre-consume recycled
fibers. The container may be a corrugated box. The container may
comprise polystyrene. The container may be rigid. The container may
be flexible. In some embodiments, an insulating layer may comprise
a binder. In some embodiments, an insulating layer may be bonded by
a binder. In some embodiments, a bonding agent may comprise sap,
cornstarch, polylactates, polyester, nylon, honey, polyvinyl
alcohol (PVA), polyvinyl chloride, polyvinyl acetate, acrylic
bonding agents or combinations thereof. In some embodiments, a
bonding agent may comprise a biodegradable polymers of the
following types: polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0015] Disclosed herein are kits. The kit may comprise a thermal
insulating liner and a container. The thermal insulating liner may
comprise an insulating layer and a barrier. The barrier may
comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The insulating layer may comprise a first
side portion, a second side portion, and a middle portion. The
middle portion may separate the first and second side portions. One
or more of the first side, and/or second side portions may comprise
opposing first and/or second side flaps. The insulating layer may
be folded such that the first side portion, second side portion and
middle portion create an open mouth substantially polygonal box
form. The open mouth substantially polygonal box form may comprise
a cavity. The first and second side portions may define opposing
sides of the polygonal box form. The middle portion may define a
bottom of the polygonal box form. The opposing first and/or second
side flaps may define at least part of opposing sides of the
polygonal box form. The insulating layer may comprise a continuous
layer of nonwoven fibrous material. The continuous layer of
nonwoven fibrous material may have a thickness ranging from about
0.2 cm to about 9.0 cm. The barrier may cover an inner surface of
the polygonal box form. The kit may further comprise a heating
agent. The heating agent may comprise a gel pack. The kit may
further comprise a cooling agent. The cooling agent may comprise at
least one or more of: wet ice, dry ice, ice packs, ice tubes, ice
gel, BLUE ICE.RTM., frozen gel, and a gel pack. The fibrous
material may be produced by one or more of: needling, spunbonding,
melt blowing, bonded carded, thermal bonding, garnett processed and
wet laid. The fibrous material may comprise plant fibers such as
jute fibers. The fibrous material may comprise synthetic fibers.
Synthetic fiber may comprise recycled plastics such as PET fibers.
The fibrous material may comprise post-consumer recycled fibers.
The fibrous material may comprise pre-consumer recycled fibers. The
container may be a corrugated box. The container may comprise
polystyrene. The container may be rigid. The container may be
flexible. In some embodiments, an insulating layer may comprise a
binder. In some embodiments, an insulating layer may be bonded by a
binder. In some embodiments, a bonding agent may comprise sap,
cornstarch, polylactates, polyester, nylon, honey, polyvinyl
alcohol (PVA), polyvinyl chloride, polyvinyl acetate, acrylic
bonding agents or combinations thereof. In some embodiments, a
bonding agent may comprise a biodegradable polymers of the
following types: polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0016] Disclosed herein are kits. The kit may comprise a thermal
insulating liner and a container. The thermal insulating liner may
comprise an insulating layer and a barrier. The insulating layer
may comprise a flexible first side portion, a second side portion,
and a middle portion. The middle portion may separate the first and
second side portions. The insulating layer may be folded such that
the first side portion, second side portion and middle portion
create an open mouth pouch. The open mouth pouch may comprise a
cavity. The first and second side portions may define opposing
sides of the pouch. The middle portion may define a bottom of the
pouch. The insulating layer may comprise a continuous layer of
nonwoven fibrous material. The continuous layer of nonwoven fibrous
material may comprise a bast fiber. The continuous layer of
nonwoven fibrous material may have a density ranging from about 200
g/m.sup.2 to about 3500 g/m.sup.2. The barrier may cover an inner
surface of the pouch. The barrier may comprise a biodegradable
polymer. The barrier may comprise a copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The kit may further comprise a heating agent.
The heating agent may comprise a gel pack. The kit may further
comprise a cooling agent. The cooling agent may comprise at least
one or more of: wet ice, dry ice, ice packs, ice tubes, ice gel,
BLUE ICE.RTM., frozen gel, and a gel pack. The fibrous material may
be produced by one or more of: needling, spunbonding, melt blowing,
bonded carded, thermal bonding, garnett processed and wet laid. The
fibrous material may comprise plant fibers such as jute fibers. The
fibrous material may comprise synthetic fibers. Synthetic fiber may
comprise recycled plastics such as PET fibers. The fibrous material
may comprise post-consumer recycled fibers. The fibrous material
may comprise pre-consumer recycled fibers. The container may be a
corrugated box. The container may comprise polystyrene. The
container may be rigid. The container may be flexible. In some
embodiments, an insulating layer may comprise a binder. In some
embodiments, an insulating layer may be bonded by a binder. In some
embodiments, a bonding agent may comprise sap, cornstarch,
polylactates, polyester, nylon, honey, polyvinyl alcohol (PVA),
polyvinyl chloride, polyvinyl acetate, acrylic bonding agents or
combinations thereof. In some embodiments, a bonding agent may
comprise a biodegradable polymers of the following types:
polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0017] Disclosed herein are methods of making thermal insulating
liners. The method of making a thermal insulating liner may
comprise producing an insulating layer. The insulating layer may
comprise a continuous layer of nonwoven fibrous material. The
continuous layer of nonwoven fibrous material may comprise a bast
fiber. The continuous layer of nonwoven fibrous material may have a
density ranging from about 200 g/m.sup.2 to about 3500 g/m.sup.2.
The insulating layer may be folded on itself whereby the insulating
layer comprises a flexible first side portion, a second side
portion, and a middle portion. The middle portion may separate the
first and second side portions. The first side portion, second side
portion and middle portion may create an open mouth pouch. The open
mouth pouch may comprise a cavity. The first and second side
portions may define opposing sides of the pouch. The middle portion
may define a bottom of the pouch. An inner surface of the first
side portion, second side portion and the middle portion may be
covered with a barrier. The barrier covering the inner surface of
the first side portion, second side portion and the middle portion
may be sealed. The fibrous material may be produced by one or more
of: needling, spunbonding, melt blowing, bonded carded, thermal
bonding, garnett processed and wet laid. The fibrous material may
comprise plant fibers such as jute fibers. The fibrous material may
comprise post-consumer recycled fibers. The fibrous material may
comprise pre-consumer recycled fibers. The fibrous material may
comprise synthetic fibers. Synthetic fiber may comprise recycled
plastics such as PET fibers. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0018] Disclosed herein are methods of making thermal insulating
liners. The method of making a thermal insulating liner may
comprise producing an insulating layer. The insulating layer may
comprise a continuous layer of nonwoven fibrous material. The
continuous layer of nonwoven fibrous material may have a thickness
ranging from about 0.2 cm to about 9.0 cm. An excised portion of
the insulating layer may be removed whereby the insulating layer
comprises a first side portion, a second side portion, and a middle
portion. The middle portion may separate the first and second side
portions. One or more of the first side, and/or second side
portions may comprise opposing first and/or second side flaps. An
inner surface of the first side portion, second side portion and
the middle portion may be covered with a barrier. The barrier
covering the inner surface of the first side portion, second side
portion and the middle portion may be sealed. The insulating layer
may be folded such that the first side portion, second side portion
and middle portion create an open mouth substantially polygonal box
form. The open mouth substantially polygonal box form may comprise
a cavity. The first and second side portions may define opposing
sides of the polygonal box form. The middle portion may define a
bottom of the polygonal box form. The opposing first and/or second
side flaps may define at least part of opposing sides of the
polygonal box form. The excised portion may have a length equal to
the width of a container that the insulating liner will be placed
in and a width equal to half a width of the container that the
insulating liner will be placed. The insulating layer may be folded
along its length before an excised portion is removed. The
insulating layer may be folded along its width before an excised
portion is removed. One or more excised portions may be removed.
One excised portion may be removed. Two excised portions may be
removed. The fibrous material may be produced by one or more of:
needling, spunbonding, melt blowing, bonded carded, thermal
bonding, garnett processed and wet laid. The fibrous material may
comprise plant fibers such as jute fibers. The fibrous material may
comprise post-consumer recycled fibers. The fibrous material may
comprise pre-consumer recycled fibers. The fibrous material may
comprise synthetic fibers. Synthetic fiber may comprise recycled
plastics such as PET fibers. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0019] Disclosed herein are apparatus. The apparatus may comprise a
thermal insulating liner and a lid. The thermal insulating liner
may comprise an insulating layer and a barrier. The insulating
layer may comprise a layer of flexible fibrous material. The layer
of flexible fibrous material may comprise natural fibers. The layer
of flexible fibrous material may be configured to form a cavity.
The barrier may cover the interior surface of the cavity. The lid
may be attached to the thermal insulating liner. The lid may be
movable from a closed state to an open state. The apparatus may
have a thermal conductivity ranging from about 0.01 W/mK to about
0.05 W/mK. The apparatus may have a thermal conductivity ranging
from about 0.01 W/mK to about 0.1 W/mK. The fibrous material may
comprise nonwoven fibers. The fibrous material may comprise woven
fibers. The insulating layer may comprise a single continuous layer
of fibrous material. The insulating layer may comprise multiple
discontinuous layers of fibrous material. The barrier may be
flexible. The lid may comprise natural fibers such as jute fibers.
The lid may comprise synthetic fibers. The lid may comprise
recycled fibers such as post-consumer and/or pre-consumer recycled
fibers. The fibrous material may comprise recycled fibers such as
post-consumer and/or pre-consumer recycled fibers. The natural
fiber may comprise plant fibers such as jute fibers. The natural
fiber may comprise animal fibers such as wool. The fibrous material
may comprise synthetic fibers. Synthetic fiber may comprise
recycled plastics such as PET fibers. The insulating layer may have
a thickness of at least about 0.2 cm. The insulating layer may have
a density ranging from about 200 g/m.sup.2 to about 3500 g/m.sup.2.
The barrier may be rigid. The barrier may be transparent. The
barrier may be hydrophobic. The barrier may comprise paper such as
kraft paper. The barrier may comprise polyethylene. The barrier may
comprise recycled materials such as post-consumer and/or
pre-consumer recycled fibers. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0020] Disclosed herein are apparatus. The apparatus may comprise a
thermal insulating liner and a lid. The thermal insulating liner
may comprise an insulating layer and a barrier. The insulating
layer may comprise a layer of flexible fibrous material. The layer
of flexible fibrous material may comprise needled fibers. The layer
of flexible fibrous material may be configured to form a cavity.
The barrier may comprise a flexible material that covers the
interior surface of the cavity. The barrier may have a thickness
ranging from about 1 to about 5 MIL. The barrier may have a
thickness ranging from about 1 to about 2 MIL. The lid may be
attached to the thermal insulating liner. The lid may be movable
from a closed state to an open state. The insulating layer may
comprise a single continuous layer of fibrous material. The
insulating layer may comprise multiple discontinuous layers of
fibrous material. The insulating layer may have a thermal
conductivity ranging from about 0.01 W/mK to about 0.05 W/mK. The
insulating layer may have a thermal conductivity ranging from about
0.01 W/mK to about 0.1 W/mK. The insulating layer and the lid may
be a single continuous layer of fibrous material. The lid may
comprise natural fibers. The lid may comprise synthetic fibers. The
lid may comprise recycled fibers. Recycled fibers may comprise
post-consumer recycled fibers. The natural fiber may comprise plant
fibers such as jute fibers. The natural fiber may comprise animal
fibers such as wool. The fibrous material may comprise recycled
fibers. The fibrous material may comprise post-consumer recycled
fibers. The fibrous material may comprise pre-consumer recycled
fibers. The fibrous material may comprise plant fibers such as jute
fibers. The fibrous material may comprise synthetic fibers.
Synthetic fiber may comprise recycled plastics such as PET fibers.
The insulating layer may have a thickness of at least about 0.2 cm.
The insulating layer may have a density ranging from about 200
g/m.sup.2 to about 3500 g/m.sup.2. The barrier may be rigid. The
barrier may be transparent. The barrier may be hydrophobic. The
barrier may comprise paper such as kraft paper. The barrier may
comprise polyethylene. The barrier may comprise recycled materials.
The recycled materials may comprise post-consumer recycled
materials. The recycled materials may comprise pre-consumer
recycled materials. The barrier may comprise a biodegradable
polymer. The barrier may comprise a copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. In some embodiments, an insulating layer may
comprise a binder. In some embodiments, an insulating layer may be
bonded by a binder. In some embodiments, a bonding agent may
comprise sap, cornstarch, polylactates, polyester, nylon, honey,
polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl acetate,
acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0021] Disclosed herein are systems. The system may comprise a
thermal insulating liner and a container. The thermal insulating
liner may comprise an insulating layer and a barrier. The
insulating layer may comprise a layer of flexible fibrous material.
The layer of flexible fibrous material may comprise natural fibers.
The layer of flexible fibrous material may be configured to form a
cavity. The barrier may cover an inner surface of the cavity. The
barrier may comprise a biodegradable polymer. The barrier may
comprise a copolymer. The biodegradable polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. The
biodegradable polymer may comprise polyhydroxyalkanoate. The
barrier may comprise a 3-hydroxybutyrate polymer, copolymer or
blends thereof. The barrier may comprise a 4-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
polyhydroxyalkanoate copolymer. The barrier may comprise a
3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The barrier may
comprise a biodegradable polylactic acid. The barrier may be a
moisture resistant barrier. The barrier may be an oxygen barrier.
The barrier may comprise a wax. The wax may be at least one of
carnauba, candelilla, beeswax, or paraffin. In some embodiments,
the barrier described herein can be coated with a biodegradable
polymer, copolymer or blends thereof. In some embodiments, the
coating can comprise a biodegradable copolymer. The biodegradable
polymer may comprise at least one of a polylactate, polymalate,
polyhydroxyalkanoate, polycaprolactone, polyesteramide, aliphatic
copolyester, aliphatic-co-terephthalate copolyester, cellulose or
starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The coating may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The coating may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a polyhydroxyalkanoate copolymer. The coating may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
coating may comprise a biodegradable polylactic acid. In some
embodiments, the coating can be moisture resistant. In some
embodiments, the coating can be impermeable to oxygen. In some
embodiments, the coating can comprise a wax. In some embodiments,
the coating can comprise carnauba, candelilla, beeswax, or
paraffin. The thermal insulating liner may have a thermal
conductivity ranging from about 0.01 W/mK to about 0.05 W/mK. The
thermal insulating liner may have a thermal conductivity ranging
from about 0.01 W/mK to about 0.1 W/mK. The thermal insulating
liner may be placed in the container. The fibrous material may
comprise nonwoven fibers. The fibrous material may comprise woven
fibers. The insulating layer may comprise a single continuous layer
of fibrous material. The insulating layer may comprise multiple
discontinuous layers of fibrous material. The system may further
comprise a heating agent. The heating agent may comprise a gel
pack. The system may further comprise a cooling agent. The cooling
agent may comprise at least one or more of: wet ice, dry ice, ice
packs, ice tubes, ice gel, BLUE ICE.RTM., frozen gel, and a gel
pack. The fibrous material may be produced by one or more of:
needling, spunbonding, melt blowing, bonded carded, thermal
bonding, garnett processed and wet laid. The natural fiber may
comprise plant fibers such as jute fibers. The natural fiber may
comprise animal fibers such as wool. The fibrous material may
comprise synthetic fibers. Synthetic fiber may comprise recycled
plastics such as PET fibers. The fibrous material may comprise
post-consumer recycled fibers. The fibrous material may comprise
pre-consumer recycled fibers. In some embodiments, an insulating
layer may comprise a binder. In some embodiments, an insulating
layer may be bonded by a binder. In some embodiments, a bonding
agent may comprise sap, cornstarch, polylactates, polyester, nylon,
honey, polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl
acetate, acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0022] Disclosed herein are systems. The system may comprise a
thermal insulating liner and a container. The thermal insulating
liner may comprise an insulating layer, and a barrier. The
insulating layer may comprise a layer of flexible fibrous material.
The layer of flexible fibrous material may comprise needled fibers.
The layer of flexible fibrous material may be configured to form a
cavity. The barrier may comprise a flexible material that covers an
inner surface of the cavity. The barrier may have a thickness
ranging from about 1 to about 5 MIL. The barrier may have a
thickness ranging from about 1 to about 2 MIL. The barrier may
comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The insulating layer may comprise a single
continuous layer of fibrous material. The system may further
comprise a heating agent. The insulating layer may comprise
multiple discontinuous layers of fibrous material. The heating
agent may comprise a gel pack. The system may further comprise a
cooling agent. The cooling agent may comprise at least one or more
of: wet ice, dry ice, ice packs, ice tubes, ice gel, BLUE ICE.RTM.,
frozen gel, and a gel pack. The fibrous material may comprise plant
fibers such as jute fibers. The fibrous material may comprise
synthetic fibers. Synthetic fiber may comprise recycled plastics
such as PET fibers. The fibrous material may comprise recycled
fibers. The recycled fibers may comprise post-consumer and/or
pre-consume recycled fibers. The container may be a corrugated box.
The container may comprise polystyrene. The container may be rigid.
The container may be flexible. In some embodiments, an insulating
layer may comprise a binder. In some embodiments, an insulating
layer may be bonded by a binder. In some embodiments, a bonding
agent may comprise sap, cornstarch, polylactates, polyester, nylon,
honey, polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl
acetate, acrylic bonding agents or combinations thereof. In some
embodiments, a bonding agent may comprise a biodegradable polymers
of the following types: polylactates, polymalates,
polyhydroxyalkanoates, polycaprolactones, polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters, celluloses or starches. In some embodiments, an
insulating layer does not comprise a binder. In some embodiments, a
thermal insulating liner can be closed via an adhesive. In some
embodiments, an adhesive may comprise polymers. In some
embodiments, a polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. In some embodiments, an adhesive comprise
cornstarch. In some embodiments, an adhesive comprise a resin. In
some embodiments, an adhesive is water proof and can be a sealant
when heated. In some embodiments, an adhesive may be waterproof. In
some embodiments, an adhesive may be a sealant when heated or
chilled.
[0023] Disclosed herein are systems. The system may comprise a
thermal insulating liner and a container. The thermal insulating
liner may comprise an insulating layer and a barrier. The barrier
may comprise a biodegradable polymer. The barrier may comprise a
copolymer. The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The barrier may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The barrier may comprise a polyhydroxyalkanoate copolymer.
The barrier may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The barrier may comprise a biodegradable polylactic
acid. The barrier may be a moisture resistant barrier. The barrier
may be an oxygen barrier. The barrier may comprise a wax. The wax
may be at least one of carnauba, candelilla, beeswax, or paraffin.
In some embodiments, the barrier described herein can be coated
with a biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The insulating layer may comprise a first
side portion, a second side portion, and a middle portion. The
middle portion may separate the first and second side portions. One
or more of the first side, and/or second side portions may comprise
opposing first and/or second side flaps. The insulating layer may
be folded such that the first side portion, second side portion and
middle portion create an open mouth substantially polygonal box
form. The open mouth substantially polygonal box form may comprise
a cavity. The first and second side portions may define opposing
sides of the polygonal box form. The middle portion may define a
bottom of the polygonal box form. The opposing first and/or second
side flaps may define at least part of opposing sides of the
polygonal box form. The insulating layer may comprise a continuous
layer of nonwoven fibrous material. The continuous layer of
nonwoven fibrous material may have a thickness ranging from about
0.2 cm to about 9.0 cm. The barrier may cover an inner surface of
the polygonal box form. The system may further comprise a heating
agent. The heating agent may comprise a gel pack. The system may
further comprise a cooling agent. The cooling agent may comprise at
least one or more of: wet ice, dry ice, ice packs, ice tubes, ice
gel, BLUE ICE.RTM., frozen gel, and a gel pack. The fibrous
material may be produced by one or more of: needling, spunbonding,
melt blowing, bonded carded, thermal bonding, garnett processed and
wet laid. The fibrous material may comprise plant fibers such as
jute fibers. The fibrous material may comprise synthetic fibers.
Synthetic fiber may comprise recycled plastics such as PET fibers.
The fibrous material may comprise post-consumer recycled fibers.
The fibrous material may comprise pre-consumer recycled fibers. The
container may be a corrugated box. The container may comprise
polystyrene. The container may be rigid. The container may be
flexible. In some embodiments, an insulating layer may comprise a
binder. In some embodiments, an insulating layer may be bonded by a
binder. In some embodiments, a bonding agent may comprise sap,
cornstarch, polylactates, polyester, nylon, honey, polyvinyl
alcohol (PVA), polyvinyl chloride, polyvinyl acetate, acrylic
bonding agents or combinations thereof. In some embodiments, a
bonding agent may comprise a biodegradable polymers of the
following types: polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0024] Disclosed herein are systems. The system may comprise a
thermal insulating liner and a container. The thermal insulating
liner may comprise an insulating layer and a barrier. The
insulating layer may comprise a flexible first side portion, a
second side portion, and a middle portion. The middle portion may
separate the first and second side portions. The insulating layer
may be folded such that the first side portion, second side portion
and middle portion create an open mouth pouch. The open mouth pouch
may comprise a cavity. The first and second side portions may
define opposing sides of the pouch. The middle portion may define a
bottom of the pouch. The insulating layer may comprise a continuous
layer of nonwoven fibrous material. The continuous layer of
nonwoven fibrous material may comprise a bast fiber. The continuous
layer of nonwoven fibrous material may have a density ranging from
about 200 g/m.sup.2 to about 3500 g/m.sup.2. The barrier may cover
an inner surface of the pouch. The barrier may comprise a
biodegradable polymer. The barrier may comprise a copolymer. The
biodegradable polymer may comprise at least one of a polylactate,
polymalate, polyhydroxyalkanoate, polycaprolactone, polyesteramide,
aliphatic copolyester, aliphatic-co-terephthalate copolyester,
cellulose or starch. The biodegradable polymer may comprise
polyhydroxyalkanoate. The barrier may comprise a 3-hydroxybutyrate
polymer, copolymer or blends thereof. The barrier may comprise a
4-hydroxybutyrate polymer, copolymer or blends thereof. The barrier
may comprise a polyhydroxyalkanoate copolymer. The barrier may
comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate copolymer. The
barrier may comprise a biodegradable polylactic acid. The barrier
may be a moisture resistant barrier. The barrier may be an oxygen
barrier. The barrier may comprise a wax. The wax may be at least
one of carnauba, candelilla, beeswax, or paraffin. In some
embodiments, the barrier described herein can be coated with a
biodegradable polymer, copolymer or blends thereof. In some
embodiments, the coating can comprise a biodegradable copolymer.
The biodegradable polymer may comprise at least one of a
polylactate, polymalate, polyhydroxyalkanoate, polycaprolactone,
polyesteramide, aliphatic copolyester, aliphatic-co-terephthalate
copolyester, cellulose or starch. The biodegradable polymer may
comprise polyhydroxyalkanoate. The coating may comprise a
3-hydroxybutyrate polymer, copolymer or blends thereof. The coating
may comprise a 4-hydroxybutyrate polymer, copolymer or blends
thereof. The coating may comprise a polyhydroxyalkanoate copolymer.
The coating may comprise a 3-hydroxybutyrate-co-4-hydroxybutyrate
copolymer. The coating may comprise a biodegradable polylactic
acid. In some embodiments, the coating can be moisture resistant.
In some embodiments, the coating can be impermeable to oxygen. In
some embodiments, the coating can comprise a wax. In some
embodiments, the coating can comprise carnauba, candelilla,
beeswax, or paraffin. The system may further comprise a heating
agent. The heating agent may comprise a gel pack. The system may
further comprise a cooling agent. The cooling agent may comprise at
least one or more of: wet ice, dry ice, ice packs, ice tubes, ice
gel, BLUE ICE.RTM., frozen gel, and a gel pack. The fibrous
material may be produced by one or more of: needling, spunbonding,
melt blowing, bonded carded, thermal bonding, garnett processed and
wet laid. The fibrous material may comprise plant fibers such as
jute fibers. The fibrous material may comprise synthetic fibers.
Synthetic fiber may comprise recycled plastics such as PET fibers.
The fibrous material may comprise post-consumer recycled fibers.
The fibrous material may comprise pre-consumer recycled fibers. The
container may be a corrugated box. The container may comprise
polystyrene. The container may be rigid. The container may be
flexible. In some embodiments, an insulating layer may comprise a
binder. In some embodiments, an insulating layer may be bonded by a
binder. In some embodiments, a bonding agent may comprise sap,
cornstarch, polylactates, polyester, nylon, honey, polyvinyl
alcohol (PVA), polyvinyl chloride, polyvinyl acetate, acrylic
bonding agents or combinations thereof. In some embodiments, a
bonding agent may comprise a biodegradable polymers of the
following types: polylactates, polymalates, polyhydroxyalkanoates,
polycaprolactones, polyesteramides (PEA), aliphatic copolyesters
(PBSA), aliphatic-co-terephthalate copolyesters, celluloses or
starches. In some embodiments, an insulating layer does not
comprise a binder. In some embodiments, a thermal insulating liner
can be closed via an adhesive. In some embodiments, an adhesive may
comprise polymers. In some embodiments, a polymer may comprise at
least one of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled
INCORPORATION BY REFERENCE
[0025] All publications, patents, and patent applications mentioned
in this specification are herein incorporated by reference to the
same extent as if each individual publication, patent, or patent
application was specifically and individually indicated to be
incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The novel features described herein are set forth with
particularity in the appended claims. A better understanding of the
features and advantages of the features described herein will be
obtained by reference to the following detailed description that
sets forth illustrative examples, in which the principles of the
features described herein are utilized, and the accompanying
drawings of which:
[0027] FIG. 1A illustrates a rectangular insulating layer,
according to many embodiments.
[0028] FIG. 1B illustrates the rectangular insulating layer of FIG.
1A folded along its width.
[0029] FIG. 1C illustrates the rectangular insulating layer of FIG.
1A folded along its width and having portions excised.
[0030] FIG. 1D illustrates the rectangular insulating layer of FIG.
1A folded along its width and having excised portions removed.
[0031] FIG. 2A illustrates an unfolded small insulating layer with
excised portions removed, according to many embodiments.
[0032] FIG. 2B illustrates the small insulating layer of FIG. 2A
folded along its width and the dimensions of its excised portions,
according to many embodiments.
[0033] FIG. 3A illustrates an unfolded medium insulating layer with
excised portions removed, according to many embodiments.
[0034] FIG. 3B illustrates the medium insulating layer of FIG. 3A
folded along its width and the dimensions of its excised portions,
according to many embodiments.
[0035] FIG. 4A illustrates an unfolded large insulating layer with
excised portions removed, according to many embodiments.
[0036] FIG. 4B illustrates the large insulating layer of FIG. 4A
folded along its width and the dimensions of its excised portions,
according to many embodiments.
[0037] FIG. 5A illustrates a rectangular insulating layer,
according to many embodiments.
[0038] FIG. 5B illustrates the rectangular insulating layer of FIG.
5A folded along its length and portion to be excised indicated.
[0039] FIG. 5C illustrates the rectangular insulating layer of FIG.
5A folded along its length and excised portion removed.
[0040] FIG. 5D illustrates the unfolded insulating layer of FIG. 5C
with excised portion removed.
[0041] FIG. 6 illustrates a collapsed thermal insulating liner,
according to many embodiments.
[0042] FIG. 7 illustrates the thermal insulating liner of FIG. 6
placed in a container, according to many embodiments.
[0043] FIG. 8 illustrates the thermal insulating liner of FIG. 6
placed in a container with samples, according to many
embodiments.
[0044] FIG. 9 illustrates the thermal insulating liner of FIG. 6
placed in a container with samples and covered, according to many
embodiments.
[0045] FIG. 10 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner test. The graph illustrates the
performance of a jute thermal insulating liner and a polyurethane
liner with an A|B configuration at ambient temperature.
[0046] FIG. 11 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner, bubble foil test. The graph
illustrates the performance of a jute thermal insulating liner, a
polyurethane liner with an A|B configuration, and a bubble foil
liner at ambient temperature.
[0047] FIG. 12 illustrates a graph showing a thermal insulating
liner, bubble foil test. The graph illustrates the performance of a
jute thermal insulating liner and a bubble foil liner at ambient
temperature.
[0048] FIG. 13 illustrates a graph showing a thermal insulating
liner, EPS foam cooler test. The graph illustrates the performance
of jute thermal insulating liners of varying densities and an EPS
foam cooler at ambient temperature.
[0049] FIG. 14 illustrates a graph showing a thermal insulating
liner density test. The graph illustrates the performance of jute
thermal insulating liners of varying densities at ambient
temperature.
[0050] FIG. 15 illustrates a graph showing a thermal insulating
liner composition test. The graph illustrates the performance of
jute thermal insulating liners of varying densities and fiber
compositions at ambient temperature.
[0051] FIG. 16 illustrates a graph showing a thermal insulating
liner, bubble foil test. The graph illustrates the performance of
jute thermal insulating liners of varying thickness and densities
and a bubble foil liner at ambient temperature.
[0052] FIG. 17 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner test. The graph illustrates the
performance of jute thermal insulating liners of varying densities
and a polyurethane liner with an A|B configuration at ambient
temperature.
[0053] FIG. 18 illustrates a graph showing a thermal insulating
liner, EPS foam test. The graph illustrates the performance of a
jute thermal insulating liner and an EPS foam cooler at ambient
temperature.
[0054] FIG. 19 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner test. The graph illustrates the
performance of jute thermal insulating liners and polyurethane
liner with an A|B configuration at ambient temperature. Gel pack
temperature and the temperature of the top portion of the volume
defined by the cavity created by the thermal insulating liners were
analyzed.
[0055] FIG. 20 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner adhesive test. The graph illustrates
the performance of jute thermal insulating liners and polyurethane
liner with an A|B configuration at ambient temperature. Gel pack
temperature and the temperature of the top portion of the volume
defined by the cavity created by the thermal insulating liners were
analyzed.
[0056] FIG. 21 illustrates a graph showing a gusset/non-gusset
test. The graph illustrates the performance of a jute thermal
insulating liner with gusset and a jute thermal insulating liner
without gusset.
[0057] FIG. 22 illustrates a graph showing an adhesive/non adhesive
test. The graph illustrates the performance of a jute thermal
insulating liner with adhesive, a jute thermal insulating liner
without adhesive and an EPS foam cooler at ambient temperature.
[0058] FIG. 23 illustrates a graph showing a 0.5 inch thermal
insulating liner, 1.0 inch opened cell polyurethane foam A|B liner
test. The graph illustrates the performance of jute thermal
insulating liners of varying densities and a polyurethane liner
with an A|B configuration at ambient temperature.
[0059] FIG. 24 illustrates a graph showing a thermal insulating
liner, polyurethane A|B liner food test. The graph illustrates the
performance of jute thermal insulating liners and a 1.0 inch opened
cell polyurethane foam liner with an A|B configuration at ambient
temperature with sample and varying gel pack quantity.
[0060] FIG. 25 illustrates a graph showing a thermal insulating
liner food test. The graph illustrates the performance of jute
thermal insulating liners of varying thickness at ambient
temperature with sample.
[0061] FIG. 26 illustrates a graph showing a LP Summer, LP Winter,
and Wool liner test. The graph illustrates the performance of jute
thermal insulating liners of varying thickness at ambient
temperature with sample and varying ice quantity.
[0062] FIG. 27 illustrates a continuous folded barrier.
[0063] FIG. 28 illustrates a barrier enclosing an insulating layer
folded in half along the centerline connecting one side length to
the other side length, with the edges formed by the fold joined
together and forming a gusset.
[0064] FIG. 29 illustrates a barrier enclosing an insulating layer
folded in half along the centerline connecting one side length to
the other side length, with the edges formed by the fold joined
together and forming a gusset wherein the gusset is held into place
to give the part a 3D attribute.
[0065] FIG. 30 illustrates a one piece box liner (thermal
insulating liner).
[0066] FIG. 31A illustrates a non-gusseted A|B design, part A and
part B.
[0067] FIG. 31B illustrates a non-gusseted A|B design, part A and
part B positioned in close proximity with closed lid.
[0068] FIG. 31C illustrates a non-gusseted A|B design, part A and
part B positioned in close proximity with an open lid.
[0069] FIG. 32A illustrates a non-gusseted A|B design with ridged
backing part A and part B.
[0070] FIG. 32B illustrates a non-gusseted A|B design with ridged
backing part A and part B, positioned in close proximity with an
open lid.
[0071] FIG. 32C illustrates a non-gusseted A|B design with ridged
backing part A and part B, positioned in close proximity with an
open lid placed into a container.
[0072] FIG. 33 illustrates a non-gusseted A|B design production
line.
[0073] FIG. 34 illustrates a non-gusseted A|B design production
line.
[0074] FIG. 35 illustrates a non-gusseted A|B design production
line.
[0075] FIG. 36 illustrates a non-gusseted A|B design production
line.
[0076] FIG. 37 illustrates a non-gusseted A|B design production
line.
[0077] FIG. 38 illustrates a non-gusseted A|B design production
line.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0078] Several aspects are described below with reference to
example applications for illustration. It should be understood that
numerous specific details, relationships, and methods are set forth
to provide a full understanding of the features described herein.
One having ordinary skill in the relevant art, however, will
readily recognize that the features described herein may be
practiced without one or more of the specific details or with other
methods. The features described herein are not limited by the
illustrated ordering of acts or events, as some acts can occur in
different orders and/or concurrently with other acts or events.
Furthermore, not all illustrated acts or events are required to
implement a methodology in accordance with the features described
herein.
[0079] The terminology used herein is for the purpose of describing
particular cases only and is not intended to be limiting. As used
herein, the singular forms "a", "an" and "the" are intended to
include the plural forms as well, unless the context clearly
indicates otherwise. Furthermore, to the extent that the terms
"including", "includes", "having", "has", "with", or variants
thereof are used in either the detailed description and/or the
claims, such terms are intended to be inclusive in a manner similar
to the term "comprising".
[0080] In this disclosure the term "about" or "approximately" can
mean a range of up to 10% of a given value. In this disclosure the
term "substantially" refers to something which is done to a great
extent or degree.
[0081] In this disclosure, the term "biodegradable" is used herein
to mean degradable over time by water and/or enzymes found in
nature (e.g. compost), without harming, and in fact helping, the
environment. Biodegradable materials include those materials which
biodegrade when composted under compost conditions and materials
which biodegrade without compost conditions. Biodegradable
materials that are compostable will degrade under typical household
or municipal compost conditions. A "biodegradable" material has the
ability to break down, safely and relatively quickly, by biological
means, into the raw materials of nature and disappear into the
environment. A material that is "compostable" is one that can be
placed into a composition of decaying biodegradable materials, and
eventually turns into a nutrient-rich material. The "biodegradable"
or "compostable" material can be tested under a recognized protocol
and with tested methods of established regulatory bodies such as:
EPA, EPA-TSCA, OECD, MITI or other similar or equivalent
organizations in the United States or internationally.
[0082] In this disclosure the term "oxygen barrier" "impermeable to
oxygen" can refer to materials having oxygen transmission rates of
less than about 10 cc/m.sup.2, in 24 hours at 73.degree. F.
(STP).
Overview
[0083] Provided herein are apparatuses, methods, and kits, for use
in regulating the temperature of goods, foodstuffs, samples and
medical items. The apparatuses, methods, and kits may comprise
thermal insulating liners. The thermal insulating liner may be
dimensioned to fit within a container. The thermal insulating liner
may be quickly collapsed and reconstructed to improve stackability
and diminish the amount of space required to store the thermal
insulating liner prior to use.
[0084] The shipment or transport of goods, foodstuffs, samples and
medical items may require that such materials remain at a stable
temperature, or within a specific temperature range. This stable
temperature or temperature range may be either elevated or
decreased with respect to ambient temperatures to which the
packaging is exposed. Because of long transport times for goods,
foodstuffs, samples and medical items and the sensitivity of
certain of these items due to slight temperature fluctuations,
considerable efforts have been made to provide shipping containers
with improved insulating characteristics.
[0085] Provided herein are thermal insulating liners that may
reduce leakage that may lead to degradation of the container
material, and destruction of surrounding property. Provided herein
are thermal insulating liners that may follow the contours of the
outer container.
[0086] Provided herein are thermal insulating liners for use in
regulating the temperature of goods, foodstuffs, samples and
medical items. In some embodiments, the thermal insulating liners
may be flexible. In some embodiments, the thermal insulating liners
may comprise recycled materials. In some embodiments, the thermal
insulating liner may be used where it is essential to keep goods,
foodstuffs, samples and medical items within a relatively defined
thermal range. In some embodiments, the defined thermal range may
be hot, warm, cool or cold, depending upon the goods, foodstuffs,
samples, medical items or the purpose of use.
[0087] Provided herein are thermal insulating liners comprising an
insulating layer that may be partially or fully covered by a
barrier. Fully covered insulating layers may be insulating layers
with a barrier covering the entire interior and/or the entire
exterior portions of the insulating layer. Partially covered
insulating layers may be insulating layers with a barrier covering
a part of the interior or exterior portions of the insulating
layer.
[0088] In some embedment's, an insulating liner, insulating layer,
barrier or a combination there of may be recyclable, compostable
and/or biodegradable.
Insulating Layer
[0089] FIG. 1A illustrates a rectangular insulating layer 200. FIG.
1B illustrates a rectangular insulating layer 200 folded along its
width. FIG. 1C illustrates a rectangular insulating layer 200
folded along its width and having portions excised. FIG. 1D
illustrates a rectangular insulating layer 200 folded along its
width and having excised portions removed. The insulating layer 200
refers to fibrous materials produced by methods known in the art.
The insulating layer 200 may comprise a first side portion 101, a
second side portion 102 and a middle portion 103 separating the
first side portion 101 and second side portion 102. The insulating
layer may be folded along its width and have excised portions 104a,
104b removed.
[0090] FIG. 2A illustrates an unfolded small insulating layer 200
comprising a first side portion 101, and a second side portion 102,
with excised portions removed thus creating a middle portion 103, a
first side portion opposing first side flap 105a and second side
flap 105b, and second side portion opposing first side flap 106a
and second side flap 106b.
[0091] FIG. 2B illustrates a small insulating layer 200 folded
along its width. Middle portion 103 and excised portions 104a, 104b
dimensions highlighted.
[0092] FIG. 3A illustrates an unfolded medium insulating layer 200
comprising a first side portion 101, and a second side portion 102,
with excised portions removed thus creating a middle portion 103, a
first side portion opposing first side flap 105a and second side
flap 105b, and second side portion opposing first side flap 106a
and second side flap 106b.
[0093] FIG. 3B illustrates a medium insulating layer 200 folded
along its width. Middle portion 103 and excised portions 104a, 104b
dimensions highlighted.
[0094] FIG. 4A illustrates an unfolded large insulating layer 200
comprising a first side portion 101, and a second side portion 102,
with excised portions removed thus creating a middle portion 103, a
first side portion opposing first side flap 105a and second side
flap 105b, and second side portion opposing first side flap 106a
and second side flap 106b.
[0095] FIG. 4B illustrates a large insulating layer 200 folded
along its width. Middle portion 103 and excised portions 104a, 104b
are dimensions highlighted.
[0096] FIG. 5A illustrates a rectangular insulating layer 200. FIG.
5B illustrates a rectangular insulating layer 200 folded along its
length and excised portions 104 indicated. FIG. 5C illustrates a
rectangular insulating layer 200 folded along its length and
portion excised. FIG. 5D illustrates an unfolded insulating layer
with excised portion removed. The insulating layer may comprise a
first side portion 101, a second side portion 102 and a middle
portion 103 separating the first side portion 101 and second side
portion 102. The insulating layer 200 may be folded along its width
and an excised portion 104 removed.
[0097] In some embodiments, the insulating layer 200 may be
flexible. In some embodiments, the insulating layer 200 may be
pliable, bendable, or give way easily under pressure. In some
embodiments, the insulating layer 200 may be one that may be
capable of being bent or flexed repeatedly without significant
damage. In some embodiments, the insulating layer 200 may be rigid.
In some embodiments, the insulating layer 200 may be substantially
rigid.
[0098] In some embodiments, the insulating layer 200 may comprise
nonwoven fibrous materials. Nonwoven may refer to any material made
from the aggregation of fibers which is produced without the use of
conventional weaving, or knitting operations. In some embodiments,
in preparing such fibers, the starting nonwoven fabric may comprise
a web of staple fibers, continuous filaments, plexifilamentary
strands or the like. In some embodiments, the insulating layer 200
may comprise woven fibrous materials. In some embodiments, the
insulating layer 200 may comprise fibers consolidated or bonded by
any method known to one of skill in the art. In some embodiments,
the insulating layer 200 may comprise woven, nonwoven, weaved,
knitted, laced, felted, braided, plaited fibrous materials or
combinations thereof.
[0099] In some embodiments, the nonwoven fibrous materials may be
made by any nonwoven process. In some embodiments, the nonwoven
process may include, but are not limited to, wet laid, air laid,
carding, felting, needling, print bonding, discontinues bonding,
hot calendaring, belt calendaring, through-air thermal bonding,
garnett processed, ultrasonic bonding, radiant heat bonding,
hydroentangling (spunlaced), or combinations thereof.
[0100] In some embodiments, the insulating layer 200 may be
substantially dense. In some embodiments, the insulating layer 200
may be substantially stiff. In some embodiments, the insulating
layer 200 may be substantially light. In some embodiments, the
insulating layer 200 may be voluminous.
[0101] In some embodiments, the insulating layer 200 may comprise a
first fibrous material and a second fibrous material. In some
embodiments, an insulating layer may comprise at least about 1, 2,
3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 20, 30, or 40
different fibrous materials. In some embodiments, an insulating
layer may comprise about 1%, about 2%, about 3%, about 4%, about
5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%,
about 12%, about 13%, about 14%, about 15%, about 16%, about 17%,
about 18%, about 19%, about 20%, about 21%, about 22%, about 23%,
about 24%, about 25%, about 26%, about 27%, about 28%, about 29%,
about 30%, about 31%, about 32%, about 33%, about 34%, about 35%,
about 36%, about 37%, about 38%, about 39%, about 40%, about 41%,
about 42%, about 43%, about 44%, about 45%, about 46%, about 47%,
about 48%, about 49%, about 50%, about 55%, about 60%, about 65%,
about 70%, about 75%, about 80%, about 85%, about 90%, about 95%,
or about 100% of a first fibrous material. In some embodiments, an
insulating layer may comprise about 1%, about 2%, about 3%, about
4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%,
about 11%, about 12%, about 13%, about 14%, about 15%, about 16%,
about 17%, about 18%, about 19%, about 20%, about 21%, about 22%,
about 23%, about 24%, about 25%, about 26%, about 27%, about 28%,
about 29%, about 30%, about 31%, about 32%, about 33%, about 34%,
about 35%, about 36%, about 37%, about 38%, about 39%, about 40%,
about 41%, about 42%, about 43%, about 44%, about 45%, about 46%,
about 47%, about 48%, about 49%, about 50%, about 55%, about 60%,
about 65%, about 70%, about 75%, about 80%, about 85%, about 90%,
about 95%, or about 100% of a second fibrous material.
[0102] In some embodiments, the insulating layer 200 may comprise
virgin material. In some embodiments, virgin material may be
material that has not been previously used or consumed, or
subjected to processing other than for its original production. In
some embodiments, the insulating layer 200 may comprise about 1%,
about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about
8%, about 9%, about 10%, about 11%, about 12%, about 13%, about
14%, about 15%, about 16%, about 17%, about 18%, about 19%, about
20%, about 21%, about 22%, about 23%, about 24%, about 25%, about
26%, about 27%, about 28%, about 29%, about 30%, about 31%, about
32%, about 33%, about 34%, about 35%, about 36%, about 37%, about
38%, about 39%, about 40%, about 41%, about 42%, about 43%, about
44%, about 45%, about 46%, about 47%, about 48%, about 49%, about
50%, about 55%, about 60%, about 65%, about 70%, about 75%, about
80%, about 85%, about 90%, about 95%, or about 100% virgin
material.
[0103] In some embodiments, the insulating layer 200 may be
biodegradable. In some embodiments, an insulating layer may degrade
upon exposure to the conditions of temperature and humidity
commonly encountered in municipal compost. In some embodiments, an
insulating layer may degrade upon exposure to the conditions of
temperature and humidity commonly encountered in household compost.
In some embodiments, the insulating layer 200 may be about 1%,
about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about
8%, about 9%, about 10%, about 11%, about 12%, about 13%, about
14%, about 15%, about 16%, about 17%, about 18%, about 19%, about
20%, about 21%, about 22%, about 23%, about 24%, about 25%, about
26%, about 27%, about 28%, about 29%, about 30%, about 31%, about
32%, about 33%, about 34%, about 35%, about 36%, about 37%, about
38%, about 39%, about 40%, about 41%, about 42%, about 43%, about
44%, about 45%, about 46%, about 47%, about 48%, about 49%, about
50%, about 55%, about 60%, about 65%, about 70%, about 75%, about
80%, about 85%, about 90%, about 95%, or about 100% biodegradable
under municipal or household compost conditions.
[0104] In some embodiments, the insulating layer 200 may be about
1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%,
about 8%, about 9%, about 10%, about 11%, about 12%, about 13%,
about 14%, about 15%, about 16%, about 17%, about 18%, about 19%,
about 20%, about 21%, about 22%, about 23%, about 24%, about 25%,
about 26%, about 27%, about 28%, about 29%, about 30%, about 31%,
about 32%, about 33%, about 34%, about 35%, about 36%, about 37%,
about 38%, about 39%, about 40%, about 41%, about 42%, about 43%,
about 44%, about 45%, about 46%, about 47%, about 48%, about 49%,
about 50%, about 55%, about 60%, about 65%, about 70%, about 75%,
about 80%, about 85%, about 90%, about 95%, or about 100%
biodegradable.
[0105] In some embodiments, the insulating layer 200 may be
compostable. In some embodiments, about 1%, about 2%, about 3%,
about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about
10%, about 11%, about 12%, about 13%, about 14%, about 15%, about
16%, about 17%, about 18%, about 19%, about 20%, about 21%, about
22%, about 23%, about 24%, about 25%, about 26%, about 27%, about
28%, about 29%, about 30%, about 31%, about 32%, about 33%, about
34%, about 35%, about 36%, about 37%, about 38%, about 39%, about
40%, about 41%, about 42%, about 43%, about 44%, about 45%, about
46%, about 47%, about 48%, about 49%, about 50%, about 55%, about
60%, about 65%, about 70%, about 75%, about 80%, about 85%, about
90%, about 95%, or about 100% of the insulating layer 200 may
decompose within the range about 1 to about 50 weeks. In some
embodiments, the insulating layer 200 may decomposes within about 1
week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7 weeks, 8
weeks, 9 weeks, 10 weeks, 11 weeks, 12 weeks, 13 weeks, 14 weeks,
15 weeks, 16 weeks, 17 weeks, 18 weeks, 19 weeks, 20 weeks, 21
weeks, 22 weeks, 23 weeks, 24 weeks, 25 weeks, 26 weeks, 27 weeks,
28 weeks, 29 weeks, 30 weeks, 31 weeks, 32 weeks, 33 weeks, 34
weeks, 35 weeks, 36 weeks, 37 weeks, 38 weeks, 39 weeks, 40 weeks,
41 weeks, 42 weeks, 43 weeks, 44 weeks, 45 weeks, 46 weeks, 47
weeks, 48 weeks, 49 weeks, or about 50 weeks. In some embodiments,
the insulating layer 200 may decompose within at least 50
weeks.
[0106] In some embodiments, the insulating layer 200 may comprise
recycled fibers. In some embodiments, the recycled fibers may be
sourced from burlap bags, garments, jeans or other consumer goods.
In some embodiments, the recycled fibers may be broken down from
highly dense fibers into lower density fibers. In some embodiments,
the insulating layer 200 may comprise 100% post-consumer recycled
fibers. Post-consumer recycling refers to materials of
manufacturing that are recycled after reaching a consumer. In some
embodiments, the insulating layer 200 may comprise within the range
of about 1% to about 100% post-consumer recycled fibers. In some
embodiments, the insulating layer 200 may comprise about 1%, about
2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%,
about 9%, about 10%, about 11%, about 12%, about 13%, about 14%,
about 15%, about 16%, about 17%, about 18%, about 19%, about 20%,
about 21%, about 22%, about 23%, about 24%, about 25%, about 26%,
about 27%, about 28%, about 29%, about 30%, about 31%, about 32%,
about 33%, about 34%, about 35%, about 36%, about 37%, about 38%,
about 39%, about 40%, about 41%, about 42%, about 43%, about 44%,
about 45%, about 46%, about 47%, about 48%, about 49%, about 50%,
about 55%, about 60%, about 65%, about 70%, about 75%, about 80%,
about 85%, about 90%, about 95%, or about 100% post-consumer
recycled fibers.
[0107] In some embodiments, the insulating layer 200 may comprise
100% pre-consumer recycled fibers. Pre-consumer recycling refers to
materials of manufacturing that do not reach an end consumer prior
to being recycled. In some embodiments, the insulating layer 200
may comprise within the range of about 1% to about 100%
pre-consumer recycled fibers. In some embodiments, the insulating
layer 200 may comprise about 1%, about 2%, about 3%, about 4%,
about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about
11%, about 12%, about 13%, about 14%, about 15%, about 16%, about
17%, about 18%, about 19%, about 20%, about 21%, about 22%, about
23%, about 24%, about 25%, about 26%, about 27%, about 28%, about
29%, about 30%, about 31%, about 32%, about 33%, about 34%, about
35%, about 36%, about 37%, about 38%, about 39%, about 40%, about
41%, about 42%, about 43%, about 44%, about 45%, about 46%, about
47%, about 48%, about 49%, about 50%, about 55%, about 60%, about
65%, about 70%, about 75%, about 80%, about 85%, about 90%, about
95%, or about 100% pre-consumer recycled fibers.
[0108] In some embodiments, the insulating layer 200 may be
compostable. In some embodiments, about 1%, about 2%, about 3%,
about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about
10%, about 11%, about 12%, about 13%, about 14%, about 15%, about
16%, about 17%, about 18%, about 19%, about 20%, about 21%, about
22%, about 23%, about 24%, about 25%, about 26%, about 27%, about
28%, about 29%, about 30%, about 31%, about 32%, about 33%, about
34%, about 35%, about 36%, about 37%, about 38%, about 39%, about
40%, about 41%, about 42%, about 43%, about 44%, about 45%, about
46%, about 47%, about 48%, about 49%, about 50%, about 55%, about
60%, about 65%, about 70%, about 75%, about 80%, about 85%, about
90%, about 95%, or about 100% of the insulating layer 200 may
decompose within the range about 1 to about 50 weeks. In some
embodiments, the insulating layer 200 may decomposes within about 1
week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7 weeks, 8
weeks, 9 weeks, 10 weeks, 11 weeks, 12 weeks, 13 weeks, 14 weeks,
15 weeks, 16 weeks, 17 weeks, 18 weeks, 19 weeks, 20 weeks, 21
weeks, 22 weeks, 23 weeks, 24 weeks, 25 weeks, 26 weeks, 27 weeks,
28 weeks, 29 weeks, 30 weeks, 31 weeks, 32 weeks, 33 weeks, 34
weeks, 35 weeks, 36 weeks, 37 weeks, 38 weeks, 39 weeks, 40 weeks,
41 weeks, 42 weeks, 43 weeks, 44 weeks, 45 weeks, 46 weeks, 47
weeks, 48 weeks, 49 weeks, or about 50 weeks. In some embodiments,
the insulating layer 200 may decompose within at least 50 weeks. In
some embodiments, the insulating layer 200 may comprise a single
continuous insulating layer. In some embodiments, the insulating
layer 200 may comprise one or more segmented or discontinuous
layers. In some embodiments, the insulating layers may comprise at
least 1, at least 2, at least 3, at least 4, at least 5, at least
6, at least 7, at least 8, at least 9, at least 10, at least 11, at
least 12, at least 13, at least 14, at least 15, or at least 20
segmented or discontinuous layers.
Fibers
[0109] In some embodiments, the insulating layer 200 may comprise
fibrous materials. In some embodiments, the fibrous materials may
comprise natural fibers, such as animal, plant or mineral fibers.
In some embodiments, the insulating layer may comprise seed fibers.
In some embodiments, the fibrous materials may comprise a
regenerated fiber. In some embodiments, the fibrous materials may
comprise a semi-synthetic fiber. In some embodiments, the fibrous
materials may comprise a synthetic fiber, or a synthetic organic
polymer. Synthetic fiber may comprise recycled plastics such as PET
fibers. In some embodiments, polymer generally includes, but is not
limited to, homopolymers, copolymers, for example, block, graft,
random and alternating copolymers, terpolymers, etc., and blends
and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" also includes all possible
geometric configurations of the material. These configurations
include, but are not limited to, isotactic, syndiotactic, atactic
and random symmetries.
[0110] In some embodiments, the fibrous materials may comprise
mineral fibers. In some embodiments, the fibrous materials may
comprise natural fibers, synthetic fibers, or combinations
thereof.
[0111] In some embodiments, the fibrous materials may comprise a
bast fiber. In some embodiments, bast fibers may be plant fibers
collected from the phloem or bast surrounding the stem of certain
plants. In some embodiments, the fibrous materials may comprise but
are not limited to cotton fibers, flax fibers, wood fibers, silk
fibers, wool fibers, alpaca fibers, angora fibers, bison fibers,
cashmere fibers, mofiber fibers, sheep's wool fibers, qiviut
fibers, llama fibers, camel fibers, yak fibers, possum fibers,
horse fibers, dog fibers, chinchilla fibers, guanoaco fibers,
merino fibers, jute fibers, tag fibers, abaca fibers, slash pine
fibers, jack pine fibers, radiata pine fibers, loblolly pine
fibers, white spruce fibers, lodgepole pine fibers, redwood fibers,
Douglas fir. Oaks fibers, genus Quercus fibers, maples fibers,
genus Acer fibers, poplars fibers, genus Populus fibers, esparto
grass fibers, bagasse fibers, ramie fibers, kenaff fibers, sisal
fibers, hemp fibers, straw and other lignaceous and cellulosic
fiber sources, milkweed floss fibers, pineapple leaf fibers, woody
fibers, albardine fibers, wheat fibers, rice fibers, corn fibers,
sugar cane fibers, papyrus fibers, reed fibers, sabia fibers,
raphia fibers, bamboo fibers, sidal fibers, sunn fibers, lyocell
fibers, ramie fibers, nettle fibers, spanish broom fibers alone or
combinations thereof.
[0112] In some embodiments, the fibrous materials may be natural
non-plant sources, such as, down, feathers, or combinations
thereof.
[0113] In some embodiments, the fibrous materials may be treated or
otherwise modified mechanically or chemically to provide desired
characteristics or may be in a form that is generally similar to
the form in which they may be found in nature.
[0114] In some embodiments, the fibrous materials may comprise
viscose rayon fibers in all its varieties and other fibers derived
from viscose or chemically-modified cellulose, cupra-amrnonium
rayon, ethyl cellulose, cellulose acetate, cellulosic esters,
cellulosic ethers, cellulosic nitrates, cellulosic acetate
butyrates, regenerated celluloses, chemically modified cellulose
such as cross-linked cellulose fibers, highly purified cellulose
fibers such as Buckeye HPF polyamides alone or combinations
thereof.
[0115] In some embodiments, the fibrous materials may comprise
polyamides such as nylon, KEVLAR.RTM., and the like, TEFLON.RTM.,
polyesters, such as polyethylene terephthalate, poly(glycolic acid)
(PGA), poly(lactic acid) (PLA), poly(.beta.-malic acid) (PMLA),
poly(.epsilon.-caprolactone) (PCL), poly(.rho.-dioxanone) (PDS),
poly(3-hydroxybutyrate) (PHB), and the like, Dacron, acrylics,
Orlon, Acrilan, Dynel, polyolefins, such as, polyethylene,
polypropylene, polybutylene, and the like, (including atactic,
isotactic, syndiotactic and impact modified versions thereof) and
poly(4-methyl-1-pentene), polyethylene terephthalate (PET),
vinylidene chloride, saran, polyvinyl chloride, polyurethane,
neoprene or polychloroprene, recycled polyethylene terephthalate
(RPET), leather, canvas, bicomponent sheath-core fibers,
multi-component fibers, and the like, ethylene vinyl alcohol
copolymer fibers, carbon fibers, silicon nitride fibers, and the
like, alone or combinations thereof.
[0116] Polyester as used herein, encompasses both "homopolyesters"
and "copolyesters" and means a synthetic polymer prepared by the
polycondensation of difunctional carboxylic acids with a
difunctional hydroxyl compound. Typically, the difunctional
carboxylic acid may be a dicarboxylic acid and the difunctional
hydroxyl compound may be a dihydric alcohol such as, for example,
glycols and diols. Alternatively, the difunctional carboxylic acid
may be a hydroxy carboxylic acid such as, for example,
p-hydroxybenzoic acid. The difunctional hydroxyl compound may be an
aromatic nucleus bearing two hydroxy substituents such as, for
example, hydroquinone.
[0117] In some embodiments, a fibrous material can comprise a
polymer. In some embodiments, the fibrous materials may comprise
polymers such as ethylene-vinyl acetate (EVA), polystyrene, impact
modified polystyrene, ABS, styrenelbutadiene block copolymers and
hydrogenated derivatives thereof (SBS and SEBS), and thermoplastic
polyurethanes. In some embodiments, the fibrous materials may
comprise suitable styrenic polymers such as polystyrene, rubber
modified polystyrene (HIPS), styrene/acrylonitrile copolymers
(SAN), rubber modified SAN (ABS or AES), styrene maleic anhydride
copolymers alone or combinations thereof. In some embodiments, a
fibrous material can comprise a plastic. In some embodiments, a
fibrous material can comprise petroleum plastics.
[0118] In some embodiments, the synthetic fibers may be a single
component (e.g., single synthetic material or mixture makes up
entire fiber), bi-component (e.g., the fiber is divided into
regions, the regions including two or more different synthetic
materials or mixtures thereof and may include co-extruded fibers
and core and sheath fibers) or combinations thereof. Synthetic
fiber may comprise recycled plastics such as PET fibers.
[0119] In some embodiments, any or all of the synthetic fibers may
be treated before, during, or after manufacture to change any
desired properties of the fibers.
[0120] In some embodiments, the fibrous material may have various
cross-sectional shapes, including but not limited to round,
rectangular, oval, tri-lobal, or other cross-sectional shapes.
[0121] In some embodiments, the insulating layer 200 may comprise a
plurality of flame resistant fibers.
[0122] In some embodiments, the insulating layer 200 may further
comprise at least one or more additional fibrous materials. In some
embodiments, the additional fibrous materials may have a different
composition and/or configuration (e.g., length, minimum transverse
dimension, maximum transverse dimension, cross-sectional shape, or
combinations thereof) than the insulating layer 200 fibers and may
be of any type of fiber that is known in the art. In some
embodiments, the additional fibrous material may be natural, or
synthetic as disclosed herein. In some embodiments, the insulating
layer 200 may comprise additional fibers in an amount of at least
10, 15, 20, 25, 30, 40, or 60 weight percent of the insulating
layer 200 and/or not more than 99, 98, 95, 90, 85, 80, 70, 60, or
50 weight percent of the insulating layer 200. In some embodiments,
the insulating layer 200 may comprise additional fibers in an
amount of about 1 to about 99 weight percent of the insulating
layer 200.
Nonwoven
[0123] In some embodiments, the fibrous material may be
nonwoven.
[0124] In some embodiments, the nonwoven fibrous material may be
fabricated by methods such as, for example, bonded carded,
needling, spunbonding, melt blowing, wet laid, thermal bonding,
garnett processed, or combinations thereof.
[0125] In some embodiments, the fibers may be separated and then
carded, or "combed" into a web by passing through rotating
cylinders covered by wires with teeth. In some embodiments, the
unbonded web of fibers may be bonded using various techniques. In
some embodiments, carded refers to webs that are made from staple
fibers wherein the fibers are separated. Next, the fibers may be
sent through a combining or carding unit which further breaks apart
and aligns the staple fibers in the machine direction so as to form
a machine direction-oriented fibrous nonwoven web. Once the web has
been formed, it may be then bonded by one or more of several
bonding methods.
[0126] In some embodiments, the fibers may be bonded by inserting
barbed needles mechanically into the substrate, hooking tufts of
fibers and entangling them (needling). In some embodiments,
needling may refer to inserting and drawing a fiber-interlacing
tool such as needles into and from the base of loose fibers. The
mechanical interlocking may be achieved with a large number of
barbed needles that repeatedly punch through fibrous webs.
[0127] In some embodiments, spunbonding may refer to a process in
which small diameter of substantially continuous fibers are formed
by extruding a molten thermoplastic material from a plurality of
fine, usually circular, capillaries of a spinnerette with the
diameter of the extruded fibers then being rapidly reduced as by,
for example, educative drawing and/or other well-known spunbonding
mechanisms. The production of spun-bonded nonwoven fabric is
described and illustrated, for example, in U.S. Pat. No. 4,340,563
to Appel, et al., U.S. Pat. No. 3,692,618 to Dorschner, et al.,
U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat. No. 3,338,992
to Kinney, U.S. Pat. No. 3,341,394 to Kinney, U.S. Pat. No.
3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat.
No. 3,542,615 to Dobo, et al., and U.S. Pat. No. 5,382,400 to Pike,
et al., which are incorporated herein in their entirety by
reference thereto for all purposes. More information on the
spunbond process in general may be obtained from Wadsworth, L. C.
and Goswami, B. C., Nonwoven Fabrics: "Spunbonded and Melt Blown
Processes", Proceedings of the Eighth Annual Nonwovens Workshop,
Jul. 30 to Aug. 3, 1990, sponsored by TANDEC, University of
Tennessee at Knoxyille.
[0128] In some embodiments, garnett processed can refer to the use
of a fiber processing machine with a series of sawtooth wires that
are much coarser than found in a conventional carding system. In
some embodiments, garnett process can reduce textile waste, old
clothing and assorted natural fibers to a fibrous feed that can be
needlepunched.
[0129] In some embodiments, melt blowing may refer to fibers formed
by extruding a molten thermoplastic material through a plurality of
fine, usually circular, die capillaries as molten threads or
filaments into converging high velocity gas streams (for example,
airstreams) which attenuate the filaments of molten thermoplastic
material to reduce their diameter, which may be to microfiber
diameter. Such a process is disclosed, in various patents and
publications, including NRL Report 4364, "Manufacture of Super-Fine
Organic Fibers" by B. A. Wendt, E. L. Boone and D. D. Fluharty; NRL
Report 5265, "An Improved Device For The Formation of Super-Fine
Thermoplastic Fibers" by K. D. Lawrence, R. T. Lukas, J. A. Young;
and U.S. Pat. No. 3,849,241, issued Nov. 19, 1974, to Butin, et
al.
[0130] In some embodiments, the fibers may be bonded by laying a
slurry of the fibers on a screen followed by squeezing the web
between rolls and drying in an oven (wet laid). In some
embodiments, wet laid may refer to the process for making nonwoven
webs prepared by suspending fibers in a liquid medium, such as
water, applying the fibrous slurry to a forming wire or fabric,
removing the liquid from the fibers to form a continuous fibrous
web and drying the web. Wet laid webs are well known in the art. In
some embodiments, this process may produce a web in which fibers
are randomly oriented. In some embodiments, these webs may be then
superimposed on one another in a parallel fashion. Wet laid webs
are disclosed, for instance, in U.S. Pat. No. 3,879,257 to Gentile
et al., U.S. Pat. No. 5,399,412, issued to S. J. Sudall and S. A.
Engel on Mar. 21, 1995; and U.S. Pat. No. 5,672,248, issued to
Wendt et al. on Sep. 30, 1997 which are incorporated herein by
reference.
[0131] In some embodiments, the fibrous materials may be bonded
with heat and pressure from a calender (thermal bonding). In some
embodiments, thermal bonding may comprise hot calendering, belt
calendering, through-air thermal bonding, ultrasonic bonding,
radiant-heat bonding and methods known to one of skill in the art
or combinations thereof. In some embodiments, hot calendering
comprises area bonding, point bonding, embossing or combinations
thereof.
[0132] In some embodiments, the fibrous materials may not be bonded
by a binder. In some embodiments, the fibrous material is not
bonded together by a bonding agent. In some embodiments, the
fibrous materials may be bonded by adding chemical binders
(chemical or resin bonding). In some embodiments, the fibrous
materials may be bonded by a powdered adhesive. In some
embodiments, the powdered adhesive may be distributed throughout
the web and then activated. In some embodiments, the powdered
adhesive may be activated by heating the web and adhesive with hot
air. In some embodiments, the fibrous materials in the web may be
bound together by a bonding agent. In some embodiments, the bonding
agent may consist of the same polymer as the fibrous materials, or
a different fibrous material. In some embodiments, the bond may be
a result of the combination of physical and chemical forces which
acts on the boundary layer between the two polymers.
[0133] In some embodiments, the bonding agent may be but not
limited to polyvinyl alcohol (PVA), polyvinyl chloride, polyvinyl
acetate, acrylic bonding agents or combinations thereof.
[0134] In some embodiments, the bonding agent may comprise
polyester, nylon, honey or sap. In some embodiments, a bonding
agent may be biodegradable. In some embodiments, a bonding agent
may be a polymer. In some embodiments, a bonding agent may be
polylactic acid. In some embodiments, a bonding agent comprise
polylactic acid. In some embodiments, a bonding agent may be a
polyhydroxyalkanoates. In some embodiments, a bonding agent may
comprise polyhydroxyalkanoates. In some embodiments, a bonding
agent may comprise a copolymer. In some embodiments, a bonding
agent may comprise a homopolymer. In some embodiments, a bonding
agent may comprise a heteropolymer. In some embodiments, a bonding
agent may be without limitation a biodegradable polymers of the
following types: polylactates (or PLA), polymalates (or PMA),
polyhydroxyalkanoates (or PHA), polycaprolactones (or PCL),
polyesteramides (PEA), aliphatic copolyesters (PBSA),
aliphatic-co-terephthalate copolyesters (PBAT), celluloses or
starches which are highly acetylated or rendered hydrophobic by
introduction of fixed fatty chains, taken alone or in combination,
in the form of homopolymers or heteropolymers, whether linear,
branched, crosslinked, dendritic or grafted.
[0135] In some embodiments, the bonding agent may comprise but is
not limited to a synthetic resin bonding agent and/or a phenolic
resin bonding agent. In some embodiments, the synthetic resin
bonding agent may be acrylic copolymers, copolymer latex, styrenic
copolymers, styrene-butadiene copolymers, vinyl copolymers,
polyurethanes, sulfopolyesters, or combinations thereof.
Sulfopolyester may include any polyester comprising a
sulfomonomer.
[0136] In some embodiments, the bonding agent may comprise but is
not limited to a resin bonding agent such as a starch, casein, a
cellulose derivative, a powder adhesive bonding agent, or
combinations thereof.
[0137] In some embodiments, the bonding agent may enhance one or
more properties of the insulating layer 200. In some embodiments,
the bonding agent may enhance dry tensile strength, wet tensile
strength, tear force. In some embodiments, the bonding agent may be
hydrophilic. In some embodiments, the bonding agent may be
hydrophobic. In some embodiments, the bonding agent may make up at
least about 0.1, 0.02. 0.5, 0.7, 0.9, 1, 2, 3, 4, 5, 7, 10, 12, 14,
16, 18, 20, 25, 30, or at least about 40 weight percent of the
insulating layer 200.
[0138] In some embodiments, fibrous materials may be produced by
total saturation of dry laid web of fibers in a suitable adhesive.
In some embodiments, the fibers may be immersed in a bath
containing adhesives, where the amount taken up by the web may be
controlled by the concentration of the adhesive in the bath and by
the degree of squeezing applied to the impegrated material. In some
embodiments, dry laid webs may be parallel laid, cross laid or
randomly laid.
[0139] In some embodiments, the fibrous materials may be bonded by
hydroentangling with water jets (spunlaced or hydroentangling).
[0140] In some embodiments, the fibrous materials may be bonded by
processing the webs through a hot air oven (airlaid or
thru-airbonded).
[0141] In some embodiments, the fibrous materials may be bonded by
stitched bonding.
[0142] In some embodiments, the one or more fibers may be bonded
into a nonwoven insulating layer 200.
Woven
[0143] In some embodiments, the fibrous materials of the insulating
layer 200 may be woven. There are literally hundreds of variations
of weave patterns commonly used in the textile industry, and those
of ordinary skill in the art are familiar with the patterns.
[0144] In some embodiments, the woven fabric may include, but is
not limited to, weaves such as plain weaves, basket weaves, rep or
rib weaves, twill weaves (e.g., straight twill, reverse twill,
herringbone twill), leno weave, a mock leno weave, satin weaves,
double weaves (e.g., double-width, tubular double weave, reversed
double weave) or combinations thereof.
[0145] The woven fabric material may be woven in any suitable
manner known by one of skill in the art. In some embodiments, the
fabric may be woven on, but not limited to a table loom, a floor
loom, a jacquard loom, a counterbalance loom, a jack loom, or an
upright loom, a floor loom or combinations thereof.
[0146] In some embodiments the woven fibers are bonded by methods
known by one of skill in the art. In some embodiments, the woven
fibers are treated or bonded by any method disclosed herein.
Heating
[0147] In some embodiments, after producing the insulating layer
200, the insulating layer 200 may undergo a heat setting step
comprising heating the insulating layer 200 to a temperature of at
least about 50, about 60, about 70, about 80, about 90, about 100,
about 110, or at least about 120.degree. C. In some embodiments,
the insulating layer 200 may be heated to least about 120, about
130, about 140, about 150, about 160, about 170, about 180, about
190, or at least about 200.degree. C. In some embodiments, after
adding an optional bonding agent, the insulating layer 200 may
undergo a heat setting step comprising heating the insulating layer
200 to a temperature of at least about 50, about 60, about 70,
about 80, about 90, about 100, about 110, or at least about
120.degree. C. In some embodiments, the insulating layer 200 may be
heated to least about 120, about 130, about 140, about 150, about
160, about 170, about 180, about 190, or at least about 200.degree.
C. In some embodiments, after adding an optional coating, the
insulating layer 200 may undergo a heat setting step comprising
heating the insulating layer 200 to a temperature of at least about
50, about 60, about 70, about 80, about 90, about 100, about 110,
or at least about 120.degree. C. In some embodiments, the
insulating layer 200 may be heated to least about 120, about 130,
about 140, 150, about 160, about 170, about 180, about 190, or at
least about 200.degree. C. In some embodiments, the heat setting
step may relax out internal fiber stresses and may aids in
producing a dimensionally stable insulating layer 200. In some
embodiments, an odor neutralizer may be dispersed through the
fibrous material during the heat treatment to reduce the presense
of undesirable odors. These odor neutralizing agents may comprise
organic, food safe substances and may be atmoized for effective
transportation through the hot air stream. To assist in the even
dispersion of the odor neutralizing agent through the material, a
pressure gradient may be formed within the oven by placing fans
above the material and vacuums underneath.
Insulating Layer Properties
[0148] In some embodiments, the insulating layer 200 may have a
thickness ranging from about 0.10 centimeter ("cm") to about 30 cm.
In some embodiments, the insulating layer 200 have a thickness of
about 0.10, about 0.15, about 0.20, about 0.25, about 0.30, about
0.40, about 0.50, about 0.60, about 0.70, about 0.80, about 0.90,
about 1.0, about 1.10, about 1.20, about 1.30, about 1.40, about
1.50, about 1.60, about 1.70, about 1.80, about 1.90, about 2.00,
about 2.50, about 3.00, about 3.50, about 4.00, about 5.0, about
6.0, about 7.0, about 8.0, about 9.0, about 10.0, about 11.0, about
11.5, about 12.0, about 12.5, about 13.0, about 13.5, about 14.0,
about 14.5, about 15.0, about 15.5, about 16.0, about 16.5, about
17.0, about 17.5, about 18.0, about 18.5, about 19.0, about 19.5,
about 20.0, about 21.0, about 22.0, about 23.0, about 24.0, about
25.0, about 26.0, about 27.0, about 28.0, about 29.0, or about 30.0
cm.
[0149] In some embodiments, the insulating layer 200 may have a
length ranging from about 12 cm to about 300 cm. In some
embodiments, the insulating layer 200 have a length of about 12,
about 15, about 20, about 25, about 30, about 35, about 40, about
45, about 50, about 55, about 60, about 65, about 70, about 75,
about 80, about 85, about 90, about 95, about 100, about 110, about
120, about 130, about 140, about 150, about 160, about 170, about
180, about 190, about 200, about 210, about 220, about 230, about
240, about 250, about 260, about 270, about 280, about 290, or
about 300 cm.
[0150] In some embodiments, the insulating layer 200 may have a
width ranging from about 12 cm to about 300 cm. In some
embodiments, the insulating layer 200 may have a width of about 12,
about 15, about 20, about 25, about 30, about 35, about 40, about
45, about 50, about 55, about 60, about 65, about 70, about 75,
about 80, about 85, about 90, about 95, about 100, about 110, about
120, about 130, about 140, about 150, about 160, about 170, about
180, about 190, about 200, about 210, about 220, about 230, about
240, about 250, about 260, about 270, about 280, about 290, or
about 300 cm. In some embodiments, the insulating layer 200 may be
to a specific length and width as needed.
[0151] In some embodiments, the insulating layer 200 may comprise a
density ranging from about 100 g/m.sup.2 to about 5000 g/m.sup.2.
In some embodiments, the insulating layer 200 may have a density of
about 100, about 110, about 120, about 130, about 140, about 150,
about 160, about 170, about 180, about 190, about 200, about 210,
about 220, about 230, about 240, about 250, about 260, about 270,
about 280, about 290, about 300, about 400, about 500, about 600,
about 700, about 800, about 900, about 1000, about 1100, about
1200, about 1300, about 1400, about 1500, about 1600, about 1700,
about 1800, about 1900, about 2000, about 2100, about 2200, about
2300, about 2400, about 2500, about 2600, about 2700, about 2800,
about 2900, about 3000, about 3500, about 4000, or about 5000
g/m.sup.2.
[0152] In some embodiments, the insulating layer 200 may further
comprise one or more additives. In some embodiments, the one or
more additives may be added in any one or more steps of producing
the insulating layer 200. In some embodiments, the additives may
include but are not limited to, starches, fillers, light and heat
stabilizers, antistatic agents, extrusion aids, dyes,
anticounterfeiting markers, slip agents, tougheners, adhesion
promoters, oxidative stabilizers, UV absorbers, colorants,
pigments, opacifiers (delustrants), optical brighteners, fillers,
nucleating agents, flame retardants, softeners, plasticizers,
viscosity modifiers, surface modifiers, antimicrobials, antifoams,
lubricants, thermostabilizers, emulsifiers, disinfectants, water
repellent, cold flow inhibitors, branching agents, oils, oil
extracts, waxes, cleaning agents, detergents, odor control agents
and catalysts.
[0153] In some embodiments, the oils may comprise one or more of
oils from thyme (thymol, carvacrol), oregano (carvacrol, terpenes),
lemon (limonene, terpinene, phellandrene, pinene, citral),
lemongrass (citral, methylheptenone, citronellal, geraniol), orange
flower (linalool, pinene, limonene), orange (limonene, citral),
anise (anethole, safrol), clove (eugenol, eugenyl acetate,
caryophyllene), rose (geraniol, citronellol), rosemary (borneol,
bornyl esters, camphor), geranium (geraniol, citronellol,
linalool), lavender (linalyl acetate, linalool), citronella
(geraniol, citronellol, citronellal, camphene), eucalyptus
(eucalyptol); peppermint (menthol, menthyl esters), spearmint
(carvone, limonene, pinene); wintergreen (methyl salicylate),
camphor (safrole, acetaldehyde, camphor), bay (eugenol, myrcene,
chavicol), cinnamon (cinnamaldehyde, cinnamyl acetate, eugenol),
tea tree (terpinen-4-ol, cineole), and cedar leaf (.alpha.-thujone,
.beta.-thujone, fenchone).
[0154] In some embodiments, an odor neutralizer may be dispersed
through the insulating layer to reduce the presence of undesirable
odors. These odor neutralizing agents may comprise organic, food
safe substances and may be atomized for effective transportation
through the hot air stream. To assist in the even dispersion of the
odor neutralizing agent through the material, a pressure gradient
may be formed within the oven by placing fans above the material
and vacuums underneath.
[0155] In some embodiments, oil extract may be oils dissolved in
one or more of ethyl alcohol, glycerol, propylene glycol, water, a
sweetening agent, a food color or combinations thereof.
[0156] In some embodiments, the insulating layer 200 may comprise
at least about 0.05 to about 70 weight percent of one or more
additives. In some embodiments, the insulating layer 200 may be at
least about 0.05, about 0.1, about 0.2, about 0.3, about 0.4, about
0.5, about 0.6, about 0.7, about 0.8, about 0.9, about 1.0, about
1.5, about 2.0, about 2.5, about 3.0, about 3.5, about 4.0, about
4.5, about 5.0, about 5.5, about 6.0, about 6.5, about 7.0, about
8.0, about 9.0, about 10, about 15, about 20, about 25, about 30,
about 35, about 40, about 45, about 50, about 60, or at least about
70 weight percent of one or more additives.
[0157] In some embodiments, an excised portion 104, 104a, 104b of
the insulating layer 200 may be removed. In some embodiments, the
excision may be made by any method known by one of skill in the
art. In some embodiments, the excision may be made by a die cut
(punch). In some embodiments, the excision may be made by a knife.
In some embodiments, the excision may be made by a scissor. In some
embodiments, the excision may be performed by hand. In some
embodiments, the excision may be performed by machine. In some
embodiments, the excised portion may be a polygonal box form. In
some embodiments, the excised portion 104, 104a, 104b may be
rectangular. In some embodiments, the excised portion may be a
square. In some embodiments, the die cut may be triangular. In some
embodiments, the excision may create a gusset design FIG. 1D. In
some embodiments, about 1 to about 50 excisions are made and
removed from the insulating layer 200. In some embodiments about 1
(104), about 2 (104a, 104b), about 3, about 4, about 5, about 6,
about 7, about 15, about 20, about 25, about 30, about 35, about
40, or about 50 excised portions may be removed. In some
embodiments, the excised portions may be of the same length and
width. In some embodiments, the excised portions have varying
length and width.
[0158] In some embodiments, the excised portion 104, 104a, 104b may
have a length ranging from about 5 cm to about 100 cm. In some
embodiments, the excised portion 104, 104a, 104b may have a length
of about 5, about 10, about 15, about 20, about 25, about 30, about
35, about 40, about 45, about 50, about 55, about 60, about 65,
about 70, about 75, about 80, about 85, about 90, about 95, or
about 100 cm.
[0159] In some embodiments, the excised portion 104, 104a, 104b may
have a width ranging from about 5 cm to about 100 cm. In some
embodiments, the excised portion 104, 104a, 104b may have a width
of about 5, about 10, about 15, about 20, about 25, about 30, about
35, about 40, about 45, about 50, about 55, about 60, about 65,
about 70, about 75, about 80, about 85, about 90, about 95, or
about 100 cm. In some embodiments, the excised portion 104, 104a,
104b may be to a specific length and width as needed.
[0160] In some embodiments, the excised portion may be added to the
bottom of the insulating layer. In some embodiments, about 1 to
about 50 excised portions may be added to the bottom of the
insulating layer. In some embodiments, about 1, about 2, about 3,
about 4, about 5, about 6, about 7, about 15, about 20, about 25,
about 30, about 35, about 40, or about 50 excised portions may be
added to the bottom of the insulating layer. In some embodiments,
adding the excised portion to the bottom of the insulating layer
may further mitigate conductive heat transfer.
Insulating Liner
[0161] FIG. 6 illustrates a collapsed thermal insulating liner 100.
The insulating layer enclosed in a transparent polyethylene barrier
114. The thermal insulating liner 100 may comprise a first side
portion, a second side portion 102, a middle portion 103, a first
side portion opposing first side flap and second side flap, and
second side portion opposing first side flap 106a and second side
flap 106b.
[0162] FIG. 7 illustrates a thermal insulating liner 100 placed in
a container 115. The thermal insulating liner 100 may comprise a
bottom, first side portion 101, second side portion 102, first side
portion opposing first side flap 105a and second side flap 105b,
and second side portion opposing first side flap 106a and second
side flap 106b, enclosed in a polyethylene barrier 114 in a
polygonal box form.
[0163] In some embodiments, the polygonal box form may be
triangular, a quadrilateral, pentagon, hexagon, heptagon, octagon,
nonagon, or decagon. In some embodiments, the polygonal box form
may be a concave polygon, a cyclic polygon, a regular polygon, a
star polygon, a monoform polygon, polyform polygon or combinations
thereof.
[0164] In some embodiments, the polygonal box form may comprise
about 5 to about 30 sides. In some embodiments, the polygonal box
form has about 5, about 6, about 7, about 8, about 9, or about 10
sides.
[0165] In some embodiments, the insulating layer 200 may be folded
about its length or width and sealed at the edges to form a
pouch.
[0166] In some embodiments, the open mouth substantially polygonal
box form may be transformed into a closed structure by folding the
top portion of the first side portion and the second side portion
towards the center of the substantially polygonal box form and onto
the opposing first and second side flaps. In some embodiments,
during this maneuver, the first and second side flaps may also be
folded toward the center of the substantially polygonal box
form.
[0167] In some embodiments, the thermal insulating liner 100 may
have a thermal conductivity ranging from about 0.001 W/mK (watts
per meter kelvin) to about 4 W/mK. In some embodiments, the thermal
insulating liner 100 may have a thermal conductivity of about
0.001, 0.002, 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009,
0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018,
0.019, 0.02, 0.021, 0.022, 0.023, 0.024, 0.025, 0.026, 0.027,
0.028, 0.029, 0.030, 0.031, 0.032, 0.033, 0.034, 0.035, 0.036,
0.037, 0.038, 0.039, 0.04, 0.041, 0.042, 0.043, 0.044, 0.045,
0.046, 0.047, 0.048, 0.049, 0.05, 0.051, 0.052, 0.053, 0.056,
0.057, 0.058, 0.059, 0.6, 0.061, 0.062, 0.063, 0.064, 0.065, 0.066,
0.067, 0.068, 0.069, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14,
0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5,
0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.95, 1, 1.01, 1.1, 1.2, 1.3, 1.4,
1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7,
2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or
about 4 W/mK.
[0168] In some embodiments, the thermal insulating liner 100 may
include one or more insulating layers 200. In some embodiments, the
thermal insulating liner 100 may comprise about 1 to about 50
insulating layers 200. In some embodiments, the thermal insulating
liner 100 comprises about 1, about 2, about 3, about 4, about 5,
about 6, about 7, about 8, about 9, about 10, about 11, about 12,
about 13, about 14, about 15, about 20, about 25, about 30, about
35, about 40, or about 50 insulating layers 200. In some
embodiments, the additional insulating layers 200 may serve as
strength reinforcement. In some embodiments, the additional
insulating layers 200 may serve as an aid for bonding. In some
embodiments, the additional insulating layers 200 may include woven
or non-woven, natural or synthetic, components or fibers. In some
embodiments, the additional insulating layers 200 may provide
enhanced dimensional stability to the thermal insulating liner 100
structure. In some embodiments, one or more insulating layers 200
may be stacked together. In some embodiments, portions of the
insulating layers 200 may be stacked together.
[0169] In some embodiments, the thermal insulating liner may be
used as a temperature regulating apparatus, for example a cooler.
In some embodiments, the thermal insulating liner may comprise a
lid and may be a temperature regulating apparatus. In some
embodiments, the thermal insulating liner may comprise a lid and
may be a cooler. In some embodiments, the lid may be attached to
the thermal insulating liner. In some embodiments, the lid may be a
portion of the insulating layer. The lid may be movable from a
closed state to an open state. The lid may be movable form an open
state to a close state. The lid may comprise nonwoven and/or woven
fibers. The lid may be flexible or rigid. The lid may comprise
natural fibers such as jute fibers. The lid may comprise synthetic
fibers. The lid may comprise recycled fibers such as post-consumer
and/or pre-consumer recycled fibers. The lid may be attached to the
thermal insulating liner by adhesive, pressure sensitive adhesive,
tapes, zippers, zip-lock, hooks, buttons, friction, solder, pins,
clips, VELCRO.RTM., among others. The lid may be woven or nonwoven
into the thermal insulating liner by any method disclosed here in.
The lid may be closed from an open state by adhesive, pressure
sensitive adhesive, tapes, zippers, zip-lock, hooks, buttons,
friction, solder, pins, clips, VELCRO.RTM., among others. The lid
may be manufactured in a process similar to that of the insulating
layer disclosed herein. The lid may share the properties of the
insulating layer as disclosed herein. In some embodiments, the lid
may be covered by a barrier.
[0170] In some embodiments, a thermal insulating liner may comprise
a backing 504. In some embodiment, a backing may be rigid or
flexible. In some embodiments, a backing may comprise any one or
more materials disclosed herein. In embodiments, the backing may
comprise the same and or similar properties as a barrier, an
insulating layer, a container or a thermal insulating liner. In
embodiments, the backing may comprise the same and or similar
materials as a barrier, an insulating layer, a container or a
thermal insulating liner. In some embodiments, the backing may
comprise a corrugated material, for example cardboard. In some
embodiments, the backing may comprise one or more fibrous materials
disclosed herein. In some embodiments, the backing may be attached
to a barrier, an insulating layer and or a coating of an thermal
insulating liner by any method disclosed herein, for example
adhesive, pressure sensitive adhesive, tapes, zippers, zip-lock,
hooks, buttons, friction, solder, pins, clips, VELCRO.RTM., among
others. In some embodiments, the backing may be on all sides of a
thermal insulating liner. In some embodiments, a backing may be on
an external surface of a thermal insulating liner. In some
embodiments, a backing may be on an internal surface of a thermal
insulating liner. In some embodiments, a backing is not on all
sides of a thermal insulating liner. In some embodiments, a backing
is on 1, 2, 3, 4, 5, 6, 7 or more sides of a thermal insulating
liner. In some embodiments, a thermal insulating liner may have 1,
2, 3, 4, 5, 6, 7 or more backings. In some embodiments, a backing
may mirror the dimensions of a side or a portion of a thermal
insulating liner. In some embodiments, a backing may mirror the
shape or a side or a portion of a thermal insulating liner. In some
embodiments, the backing may be pliable, bendable, or gives way
easily under pressure. In some embodiments, the backing may be one
that is capable of being bent or flexed repeatedly without
significant damage. In some embodiments, the backing may be
hydrophilic, hydrophobic, hygroscopic, and or electrically
conductive. In some embodiments, a backing may be moisture
resistant. In some embodiments, a backing may be oxygen
impermeable. In some embodiments, a backing may be compostable,
recyclable, and/or biodegradable. In some embodiments, a backing
comprises recycled materials.
[0171] In some embodiments, a thermal insulating liner 100 may be
compostable. In some embodiments, about 1%, about 2%, about 3%,
about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about
10%, about 11%, about 12%, about 13%, about 14%, about 15%, about
16%, about 17%, about 18%, about 19%, about 20%, about 21%, about
22%, about 23%, about 24%, about 25%, about 26%, about 27%, about
28%, about 29%, about 30%, about 31%, about 32%, about 33%, about
34%, about 35%, about 36%, about 37%, about 38%, about 39%, about
40%, about 41%, about 42%, about 43%, about 44%, about 45%, about
46%, about 47%, about 48%, about 49%, about 50%, about 55%, about
60%, about 65%, about 70%, about 75%, about 80%, about 85%, about
90%, about 95%, or about 100% of the thermal insulating liner 100
may decompose within the range about 1 to about 50 weeks. In some
embodiments, the thermal insulating liner 100 may decomposes within
about 1 week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7 weeks,
8 weeks, 9 weeks, 10 weeks, 11 weeks, 12 weeks, 13 weeks, 14 weeks,
15 weeks, 16 weeks, 17 weeks, 18 weeks, 19 weeks, 20 weeks, 21
weeks, 22 weeks, 23 weeks, 24 weeks, 25 weeks, 26 weeks, 27 weeks,
28 weeks, 29 weeks, 30 weeks, 31 weeks, 32 weeks, 33 weeks, 34
weeks, 35 weeks, 36 weeks, 37 weeks, 38 weeks, 39 weeks, 40 weeks,
41 weeks, 42 weeks, 43 weeks, 44 weeks, 45 weeks, 46 weeks, 47
weeks, 48 weeks, 49 weeks, or about 50 weeks. In some embodiments,
the thermal insulating liner 100 may decompose within at least 50
weeks.
Barriers
[0172] In some embodiments, the insulating layer 200 may not be
enclosed in a barrier 114. In some embodiments, the insulating
layer 200 may be enclosed in a barrier 114 thus forming the thermal
insulating liner 100. In some embodiments, a portion of the
insulating layer 200 may be covered by a barrier 114. In some
embodiments, the inner surface of the insulating layer 200 may be
covered by a barrier 114. In some embodiments, the insulating layer
200 may be partially enclosed in a barrier 114. In some
embodiments, the insulating layer 200 may be fully enclosed in a
barrier 114. In some embodiments, enclosing or covering the
insulating layer 200 may be accomplished with a sealer. In some
embodiments, a sealer may seal the barrier 114 around the
insulating layer 200.
[0173] In some embodiments, the barrier 114 may contain at least
one seal. In some embodiments, the barrier 114 may contain at least
about 1 to at least about 50 seals. In some embodiments, the
barrier 114 contains at least about 1, about 2, about 3, about 4,
about 5, about 6, about 7, about 8, about 9, about 10, about 11,
about 12, about 13, about 14, about 15, about 16, about 17, about
18, about 19, about 20, about 21, about 22, about 23, about 24,
about 25, about 26, about 27, about 28, about 29, about 30, about
31, about 32, about 33, about 34, about 35, about 36, about 37,
about 38, about 39, about 40, about 41, about 42, about 43, about
44, about 45, about 46, about 47, about 48, about 49, or at least
about 50 seals.
[0174] In some embodiments, the sealer may be a vacuum valve
sealer, heat sealer or radiofrequency welder, tape, adhesives,
sealants, zip-locks, zippers, mechanical closure or any combination
thereof. In some embodiments, the sealer may be a fastening
mechanism. In some embodiments, the barrier 114 may comprise a
rigid or semi-rigid material.
[0175] In some embodiments, the barrier 114 may loosely enclose the
insulating layer 200. In some embodiments, the barrier 114 may
tightly enclose the insulating layer 200. In some embodiments, the
barrier 114 may be flexible. In some embodiments, the barrier 114
may be pliable, bendable, or gives way easily under pressure. In
some embodiments, the barrier 114 may be one that is capable of
being bent or flexed repeatedly without significant damage. In some
embodiments, the barrier 114 may be hydrophilic, hydrophobic,
hygroscopic, and or electrically conductive.
[0176] In some embodiments, the barrier 114 may be a coating. In
some embodiments, the barrier 114 may be a polymer coating. In some
embodiments, the insulating layer 200 may be subjected to drying,
and the barrier 114 coating may be applied to the insulating layer
200. In some embodiments, the barrier 114 coating is applied to the
insulating layer 200 and thereafter dried.
[0177] In some embodiments, the barrier 114 may comprise a
decorative coating, a printing ink, an adhesive coating, and/or a
heat seal coating. In some embodiments, the coating may comprise a
liquid impermeable substance and/or a microbial substance. In some
embodiments, the microbial substance may be an antimicrobial,
antibiotic, antiviral, antiparasitic, antiamoebic, antifungal, or
antiprotozoal materials and/or compounds.
[0178] In some embodiments, the barrier 114 may be paper. In some
embodiments, the barrier 114 may be Kraft paper. Kraft paper is a
paper made by a Kraft pulping process wherein the paper consists of
a web of pulp fibers (normally from wood or other plant fibers),
and may be formed from an aqueous slurry on a wire or screen, and
may be held together by hydrogen bonding. Kraft paper may also
contain a variety of additives and fillers. See, for example,
Handbook of Pulping and Papermaking, Christopher Bierman, Academic
Press, 1996. In some embodiments, the Kraft paper barrier can be
coated with petroleum plastics. In some embodiments, the Kraft
paper barrier can be coated with biodegradable polymers that behave
like plastics. In some embodiments, the Kraft paper barrier can be
coated with PHA Latex. In some embodiments, the Kraft paper barrier
can be coated with resins derived from sugarcane. In some
embodiments, the Kraft paper barrier can be coated with resins
derived from cornstarch. In some embodiments, the Kraft paper
barrier can be coated with resins derived from any resins that is
derived from a biological material that is known in the art.
[0179] In some embodiments, the barrier 114 may comprise fluted
paper laminated between higher density paperboard components. In
some embodiments, the barrier 114 may mirror the container 115 in
color. In some embodiments, the barrier 114 may mirror the
container 115 in physical strength. In some embodiments, the
barrier 114 may mirror the container 115 in rigidity. In some
embodiments, the barrier 114 may mirror the container 115 in
thickness.
[0180] In some embodiments, the barrier 114 may comprise one or
more materials that may reflect radiant heat. In some embodiments,
the barrier 114 may comprise one or more materials that may be tear
resistant. In some embodiments, the barrier 114 may comprise one or
more materials that may be non-porous. In some embodiments, the
barrier 114 may comprise one or more materials that may be leak
proof. In some embodiments, the barrier can be a moisture resistant
barrier. In some embodiments, the barrier 114 may comprise one or
more materials that may be heat sealed. In some embodiments, the
barrier 114 may comprise one or more materials that may be welded.
In some embodiments, the barrier 114 may comprise one or more
materials that may be sealed with a sterile polyethylene pouch
material. In some embodiments, the barrier 114 may comprise one or
more materials that may be compatible with conventional printing
techniques. In some embodiments, the barrier may comprise but is
not limited to, thermoplastic polymers, such as metallic
polyethylene terephthalate (METPET), and various reflective or
metallic foils. In some embodiments, the barrier 114 may comprise
films derived from hydrocarbons or other materials. In some
embodiments, the barrier 114 may be printed with advertising
information, artwork or any other indicia as desired. In some
embodiments, advertising information, artwork or any other indicia
may be printed as a mirror image or reversed image. In some
embodiments, the barrier may be printed with mirror imaged
advertising information, artwork or any other indicia and may be
flipped to be read in the correct sense. In some embodiment,
advertising information, artwork or any other indicia may be
printed in the correct sense. In some embodiments, the barrier 114
may comprise a fibrous material. In some embodiments, the barrier
114 may comprise any one or more fibers disclosed herein. In some
embodiments, the barrier 114 may comprise fibers consolidated or
bonded by any method known to one of skill in the art. In some
embodiments, the barrier 114 may comprise woven, nonwoven, weaved,
knitted, laced, felted, braided, plaited fibers or combinations
thereof.
[0181] In some embodiments, the barrier 114 may comprise virgin
material. In some embodiments, the barrier 114 may comprise about
1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%,
about 8%, about 9%, about 10%, about 11%, about 12%, about 13%,
about 14%, about 15%, about 16%, about 17%, about 18%, about 19%,
about 20%, about 21%, about 22%, about 23%, about 24%, about 25%,
about 26%, about 27%, about 28%, about 29%, about 30%, about 31%,
about 32%, about 33%, about 34%, about 35%, about 36%, about 37%,
about 38%, about 39%, about 40%, about 41%, about 42%, about 43%,
about 44%, about 45%, about 46%, about 47%, about 48%, about 49%,
about 50%, about 55%, about 60%, about 65%, about 70%, about 75%,
about 80%, about 85%, about 90%, about 95%, or about 100% virgin
material.
[0182] In some embodiments, the barrier 114 may be transparent. In
some embodiments, the barrier 114 may be substantially transparent.
In some embodiments, the barrier 114 may not be transparent. In
some embodiment the barrier 114 may comprise pre-consumer recycled
materials.
[0183] In some embodiments, the barrier 114 may comprise within the
range of about 0% to about 100% pre-consumer recycled materials. In
some embodiments, the barrier may comprise about 0, about 1, about
2, about 3, about 4, about 5, about 6, about 7, about 8, about 9,
about 10, about 11, about 12, about 13, about 14, about 15, about
16, about 17, about 18, about 19, about 20, about 21, about 22,
about 23, about 24, about 25, about 26, about 27, about 28, about
29, about 30, about 31, about 32, about 33, about 34, about 35,
about 36, about 37, about 38, about 39, about 40, about 41, about
42, about 43, about 44, about 45, about 46, about 47, about 48,
about 49, about 50, about 55, about 60, about 65, about 70, about
75, about 80, about 85, about 90, about 95, or about 100%
pre-consumer recycled materials.
[0184] In some embodiments, the barrier 114 may comprise
post-consumer recycled materials. In some embodiments, the barrier
114 may comprise within the range of about 0% to about 100%
post-consumer recycled materials. In some embodiments, the barrier
may comprise about 0, about 1, about 2, about 3, about 4, about 5,
about 6, about 7, about 8, about 9, about 10, about 11, about 12,
about 13, about 14, about 15, about 16, about 17, about 18, about
19, about 20, about 21, about 22, about 23, about 24, about 25,
about 26, about 27, about 28, about 29, about 30, about 31, about
32, about 33, about 34, about 35, about 36, about 37, about 38,
about 39, about 40, about 41, about 42, about 43, about 44, about
45, about 46, about 47, about 48, about 49, about 50, about 55,
about 60, about 65, about 70, about 75, about 80, about 85, about
90, about 95, or about 100% pre-consumer recycled materials.
[0185] In some embodiments, the barrier 114 may be biodegradable.
In some embodiments, a barrier may degrade upon exposure to the
conditions of temperature and humidity commonly encountered in
municipal compost. In some embodiments, an insulating layer may
degrade upon exposure to the conditions of temperature and humidity
commonly encountered in household compost. In some embodiments, the
barrier 114 may be about 1%, about 2%, about 3%, about 4%, about
5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%,
about 12%, about 13%, about 14%, about 15%, about 16%, about 17%,
about 18%, about 19%, about 20%, about 21%, about 22%, about 23%,
about 24%, about 25%, about 26%, about 27%, about 28%, about 29%,
about 30%, about 31%, about 32%, about 33%, about 34%, about 35%,
about 36%, about 37%, about 38%, about 39%, about 40%, about 41%,
about 42%, about 43%, about 44%, about 45%, about 46%, about 47%,
about 48%, about 49%, about 50%, about 55%, about 60%, about 65%,
about 70%, about 75%, about 80%, about 85%, about 90%, about 95%,
or about 100% biodegradable under municipal or household compost
conditions.
[0186] In some embodiments, the barrier 114 may be about 1%, about
2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%,
about 9%, about 10%, about 11%, about 12%, about 13%, about 14%,
about 15%, about 16%, about 17%, about 18%, about 19%, about 20%,
about 21%, about 22%, about 23%, about 24%, about 25%, about 26%,
about 27%, about 28%, about 29%, about 30%, about 31%, about 32%,
about 33%, about 34%, about 35%, about 36%, about 37%, about 38%,
about 39%, about 40%, about 41%, about 42%, about 43%, about 44%,
about 45%, about 46%, about 47%, about 48%, about 49%, about 50%,
about 55%, about 60%, about 65%, about 70%, about 75%, about 80%,
about 85%, about 90%, about 95%, or about 100% biodegradable.
[0187] In some embodiments, the barrier 114 may be compostable. In
some embodiments, about 1%, about 2%, about 3%, about 4%, about 5%,
about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about
12%, about 13%, about 14%, about 15%, about 16%, about 17%, about
18%, about 19%, about 20%, about 21%, about 22%, about 23%, about
24%, about 25%, about 26%, about 27%, about 28%, about 29%, about
30%, about 31%, about 32%, about 33%, about 34%, about 35%, about
36%, about 37%, about 38%, about 39%, about 40%, about 41%, about
42%, about 43%, about 44%, about 45%, about 46%, about 47%, about
48%, about 49%, about 50%, about 55%, about 60%, about 65%, about
70%, about 75%, about 80%, about 85%, about 90%, about 95%, or
about 100% of the barrier 114 may decompose within the range about
1 to about 50 weeks. In some embodiments, the barrier 114 may
decomposes within about 1 week, 2 weeks, 3 weeks, 4 weeks, 5 weeks,
6 weeks, 7 weeks, 8 weeks, 9 weeks, 10 weeks, 11 weeks, 12 weeks,
13 weeks, 14 weeks, 15 weeks, 16 weeks, 17 weeks, 18 weeks, 19
weeks, 20 weeks, 21 weeks, 22 weeks, 23 weeks, 24 weeks, 25 weeks,
26 weeks, 27 weeks, 28 weeks, 29 weeks, 30 weeks, 31 weeks, 32
weeks, 33 weeks, 34 weeks, 35 weeks, 36 weeks, 37 weeks, 38 weeks,
39 weeks, 40 weeks, 41 weeks, 42 weeks, 43 weeks, 44 weeks, 45
weeks, 46 weeks, 47 weeks, 48 weeks, 49 weeks, or about 50 weeks.
In some embodiments, the barrier 114 may decompose within at least
50 weeks.
[0188] In some embodiments, the barrier 114 may comprise within the
range of about 1 to about 99 weight percent of the thermal
insulating liner 100. In some embodiments, the barrier may be about
1, about 2, about 3, about 4, about 5, about 6, about 7, about 8,
about 9, about 10, about 11, about 12, about 13, about 14, about
15, about 16, about 17, about 18, about 19, about 20, about 21,
about 22, about 23, about 24, about 25, about 26, about 27, about
28, about 29, about 30, about 31, about 32, about 33, about 34,
about 35, about 36, about 37, about 38, about 39, about 40, about
41, about 42, about 43, about 44, about 45, about 46, about 47,
about 48, about 49, about 50, about 55, about 60, about 65, about
70, about 75, about 80, about 85, about 90, about 95, or about 100
weight percent of the thermal insulating liner 100.
[0189] In some embodiments, the barrier 114 may be the same shape
as the insulating layer 200. In some embodiments, the barrier 114
may be substantially the same shape as the insulating layer 200. In
some embodiments, the barrier 114 may not be substantially the same
shape as the layer 200. In some embodiments, the barrier 114 may be
a polygonal box form.
[0190] MIL is one thousandth of an inch and measures the thickness.
In some embodiments, the barrier 114 may have a thickness ranging
from about 0.5 MIL to about 10 MIL. In some embodiments, the
barrier 114 may have a thickness of about 0.5, about 0.6, about
0.7, about 0.8, about 0.9, about 1.0, about 1.1, about 1.2, about
1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about
1.9, about 2.0, about 2.1, about 2.2, about 2.3, about 2.4, about
2.5, about 2.6, about 2.7, about 2.8, about 2.9, about 3.0, about
3.1, about 3.2, about 3.3, about 3.4, about 3.5, about 3.6, about
3.7, about 3.8, about 3.9, about 4.0, about 4.1, about 4.2, about
4.3, about 4.4, about 4.5, about 4.6, about 4.7, about 4.8, about
4.9, about 5, about 6, about 7, about 8, about 9, or about 10 MIL.
In some embodiments, the barrier 114 may have a thickness of at
least 10, 20, 30, 40, 50, or at least 60 MIL.
[0191] In some embodiments the insulating layer 200 may comprise a
barrier 114, wherein the barrier may cover an inner surface of the
insulating layer 100. In some embodiments, the barrier 114 may
cover an outer surface of the insulating layer 200.
[0192] In some embodiments, the barrier 114 may comprise renewable,
biobased, biodegradable latex. In some embodiments, the barrier 114
may comprise a polymer. In some embodiments, the polymer may be a
biodegradable polymer. In some embodiments, the biodegradable
polymer may include a polymer that may be obtained from renewable
monomers, polymers which may be obtained from renewable natural
sources (e.g., starch, sugars, lipids, corn, sugar beet, wheat,
sugarcane, castor oil plant, rapeseed, wood, or other starch-rich
products etc.). In some embodiments, the biodegradable polymer may
include plant resins. The present invention is not limited to any
particular plant resin. Indeed, a variety of plant resins are
contemplated, the resins can be obtained from a plant including but
not limited to a flowering plant, a vegetable plant, a crop plant,
an herb plant, a shrub plant, and a tree plant. In some
embodiments, the plant can be selected from the group of a Brassica
carinata, Crambe abyssinica, corn (Zea mays), canola (Brassica
napus), alfalfa (Medicago sativa), rice (Oryza sativa), rye (Secale
cereale), sorghum (Sorghum bicolor), millet (Pennisetum glaucum),
sunflower (Helianthus annuus), safflower (Carthamus tinctorius),
wheat (Triticum aestivum), soybean (Glycine max), tobacco
(Nicotiana tabacum), potato (Solanum tuberosum), peanuts (Arachis
hypogaea), cotton (Gossypium hirsutum), sweet potato (Ipomoea
batatus), cassava (Manihot esculenta), coffee (Coffea spp.),
bamboo, coconut (Cocos nucifera), pineapple (Ananas comosus),
citrus (Citrus spp.), cocoa (Theobroma cacao), tea (Camellia
sinensis), banana (Musa spp.), avocado (Persea americana), fig
(Ficus casica), guava (Psidium guajava), mango (Mangifera indica),
olive (Olea europaea), papaya (Carica papaya), cashew (Anacardium
occidentale), macadamia (Macadamia integrifolia), almond (Prunus
amygdalus), sugar beets (Beta vulgaris), sugarcane (Saccharum
spp.), oats, barley, Cork Oak (Quercus suber), Aspen (Populus
tremula), Loblolly pine (Pinus taeda). In some embodiments, the
plant can be selected from the group of a Brassicaceae species,
Nicotiana species, a Solanum species, a Gossypium species, or a
Botryococcus species. In some embodiments, the crop plant can be
selected from the group of a mustard, tobacco, potato, cotton,
sunflower, corn, safflower, rice, or algae. In some embodiments,
the flowering plant can be an Arabidopsis sp. plant.
[0193] Examples of plant resins include but are not limited to
amber, Balm of Gilead, balsam, Canada balsam, Boswellia, copal from
trees of Protium copal and Hymenaea courbaril, dammar gum from
trees of the family Dipterocarpaceae, Dragon's blood from the
dragon trees (Dracaena species), elemi, frankincense from Boswellia
sacra, galbanum from Ferula gummosa, gum guaiacum from the lignum
vitae trees of the genus Guaiacum, kauri gum from trees of Agathis
australis, labdanum from mediterranean species of Cistus, mastic
(plant resin) from the mastic tree Pistacia lentiscus, myrrh from
shrubs of Commiphora, sandarac resin from Tetraclinis articulata,
styrax (a Benzoin resin from various Styrax species), Spinifex
resin from Australian Spinifex grasses, and turpentine, distilled
from pine resin.
[0194] In some embodiments, the biodegradable polymer may be
polylactic acid. In some embodiments, the biodegradable polymer
comprise polylactic acid. In some embodiments, the biodegradable
polymer may be polyhydroxyalkanoates. In some embodiments, the
biodegradable polymer may comprise polyhydroxyalkanoates. In some
embodiments, the barrier 114 may comprise a copolymer. In some
embodiments, the barrier 114 may comprise a homopolymer. In some
embodiments, the barrier 114 may comprise a heteropolymer.
[0195] In some embodiments, the biodegradable polymer may be
without limitation a biodegradable polymers of the following types:
polylactates (or PLA), polymalates (or PMA), polyhydroxyalkanoates
(or PHA), polycaprolactones (or PCL), polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters (PBAT), celluloses or starches which are highly
acetylated or rendered hydrophobic by introduction of fixed fatty
chains, taken alone or in combination, in the form of homopolymers
or heteropolymers, whether linear, branched, crosslinked, dendritic
or grafted.
[0196] Polyhydroxyalkanoates are biopolyesters with various side
chains and fatty acids with hydroxyl groups at the 4- or
5-position. They consist of (R)-3-hydroxy fatty acids. In some
embodiments the polyhydroxyalkanoates may be a short chain length
hydroxyalkanoic acids (PHAscL) with an alkyl side chain. PHAscL
contain 3-5 carbon atoms, for example poly-3-hydroxybutyrate
(P3HB), poly-4-hydroxybutyrate (P4HB). In some embodiments, the
polyhydroxyalkanotes may be medium chain length hydroxyalkanoic
acids (PHAMCL) with alkyl side chains. PHAMCL contain 6-14 carbon
atoms. In some embodiments, the polyhydroxyalkanotes may be long
chain length (PHALCL) obtained from long chain fatty acids, which
contain more than 14 carbon atoms. The monomer composition,
macromolecular structure and physical chemical properties of PHAs
vary. More than 150 different monomers may be combined within this
family to give materials with extremely different properties. In
some embodiments, the monomers may be 3-hydroxybutyrate (3HBA). In
some embodiments, the monomers may be 3-hydroxyvalerate (3HVA). In
some embodiments, the PHA may be a copolymer. In some embodiments,
the copolymer may be Poly(3-hydroxybutyrate-co-3-hydroxyvalerate),
commonly known as PHBV.
[0197] In some embodiments, the polyhdyroxyalkanoates may comprise
high molecular weights (for example, about 300,000 to about 800,000
Daltons (e.g., 350,000 Daltons; 400,000 Daltons; 450,000 Daltons;
500,000 Daltons; 550,000 Daltons; 600,000 Daltons; 650,000 Daltons;
or 700,000 Daltons; 750,000 Daltons) with high melt temperatures of
about 160.degree. C. to about 170.degree. C.). U.S. Pat. Nos.
6,201,083 and 9,085,688 are incorporated herein in their entirety
by reference thereto for all purposes.
[0198] In some embodiments, an aqueous polyhydroxyalkanoate (PHA)
emulsion from a biobased, biodegradable PHA polymer, copolymer or
blend thereof can be produced by, melting the PHA polymer,
copolymer or blend thereof to form a molten PHA polymer, copolymer
or blend thereof; lowering the temperature of the molten PHA
polymer, copolymer or blend thereof to about 20.degree. C. to about
50.degree. C. below the melting temperature of the highest melting
polymer component of the PHA polymer, copolymer or blend thereof to
obtain a lower-temperature PHA polymer, copolymer or blend thereof;
combining the lower-temperature PHA polymer, copolymer or blend
thereof and an aqueous colloid stabilizer solution heated to about
60.degree. C. to about 90.degree. C. under high distributive mixing
thereby forming a water-in-PHA emulsion; lowering the temperature
of the water-in-PHA emulsion by about 20.degree. C. to about
50.degree. C.; and adding water and optionally one or more
polymeric dispersants or surfactants producing an aqueous PHA
emulsion having a ratio of colloid stabilizer to PHA polymer of 0.1
to 8 parts to 100 parts by dry weight PHA polymer.
[0199] In some embodiments, latexes can be produced from biobased,
biodegradable polyhydroxyalkanoate (PHA) polyester for example by
forming a PHA suspension from biomass containing the PHA using an
aqueous recovery process involving cell digestion, washing with
surfactant/peroxide followed by microfluidization, centrifugation
and re-suspension of the PHA particles in water and producing an
amorphous PHA latex by heating the suspension under pressure to
190.degree. C.-200.degree. C. (25.degree. C. above melt temperature
of PHA) followed by rapid cooling.
[0200] In some embodiments, a biobased, biodegradable
polyhydroxyalkanoate (PHA) latex can be produced initially by
melting at least one PHA polymer or copolymer at a temperature
above its highest melting temperature e.g., at about 160.degree. C.
to about 170.degree. C., producing a melt which has a viscosity of
about 800 Pas to 2500 Pas, and then optionally adding other polymer
materials, plasticizers, emulsification additives or fillers
producing a homogeneous molten composition; the temperature of the
molten mass is then lowered, with continuous mixing, to a
temperature about 20.degree. C. to about 50.degree. C. below the
melting temperature of the highest melting polymer component e.g.,
about 120.degree. C. to about 140.degree. C. and then an aqueous
solution containing colloid stabilizers can be added into the
molten PHA which then undergoes a high shear or high distributive
mixing event to produce a water-in-PHA dispersion; a second aqueous
solution containing only water or pH adjusting aids and optionally
more colloid stabilizers (same or different from the first step
aqueous addition) can then be added to the water-in-PHA emulsion
which then undergoes another high shear or high distributive mixing
event producing a PHA-in-water emulsion; the temperature of the
dispersion can be lowered to about 80.degree. C. and finally
dispensing the formed latex (aqueous PHA emulsion) below about
40.degree. C.
[0201] Polylactates (PLA) is a common biodegradable polymer derived
from lactate. In some embodiments, the polylactate may comprise the
monomers lactic acid. In some embodiments, the polylactate may
comprise the cyclic di-ester, lactide.
[0202] In some embodiments, the biodegradable polymer may be
heteropolymers. In some embodiments, the biodegradable polymers may
be di-, tri- or tetrapolymers. In some embodiments, the monomers of
which may be diols, caprolactones or acids and hydroxy acids, for
example but not limited to D-lactic, L-lactic, glycolic,
tetramethylglycolic, malic, (3-propiolactic, butyric, valeric,
phthalic, terephthalic, succinic, adipic, sebacic, hexanoic,
octanoic, decanoic, dodecanoic, tetradecanoic, hexadecanoic or
octadecanoic acids. In some embodiments, the biodegradable polymers
may be random, alternating, sequential or block heteropolymers.
[0203] In some embodiments, the barrier 114 may be applied by a
powder coating approach, casting, spraying, dipping or immersing,
by the use of brushes, rollers, blocks or other instruments. In
some embodiments, the barrier 114 may be applied by air knife
coating, blade coating, metering roll coating, gravure coating, rod
coating, curtain coating, bath coating.
[0204] In some embodiments, the barrier 114 may comprise wax, or
polyethylene film. In some embodiments, wax may be used to improve
moisture resistance properties of the barrier 114. In some
embodiments, wax may be used to reduce the barrier's 114
coefficient of friction, and/or to reduce brittleness of the
barrier 114. In some embodiments, the wax may be, without
limitation, for example, carnauba, candelilla, beeswax, or
paraffin.
[0205] In some embodiments, the barrier 114 may be applied in at
least about 1, 2, 3, 4, 5, 6, 7, 8, 9, or at least about 10 steps.
In some embodiments, the barrier 114 may comprise one or more
layers. In some embodiments, the barrier 114 may comprise at least
1, 2, 3, 4, 5, 6, 7, 8, 9, or at least 10 layers. In some
embodiments, a first barrier layer may comprise a different
composition compare to a second barrier layer. In some embodiments,
a first barrier layer may comprise the same composition as a second
barrier layer.
[0206] In some embodiments, the barrier 114 may comprise a polymer
selected from the group comprising, without limitation acrylic
polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol,
poly-ethylene vinyl acetate, poly-ethylene vinyl chloride, styrene
butadiene copolymers, polyvinylidiene chloride, or starch.
[0207] In some embodiments, the barrier 114 disclosed herein may
comprise a polymer blend. In some embodiments, the polymer blend
may be a first polymer blended with another polymer to form a
latex. In some embodiments, the polymer blend may comprise one or
more biodegradable polymer. In some embodiments, the polymer blend
may comprise use of a melt blending process. In some embodiments,
the melt blend may comprise polycaprolactone having a molecular
weight from about 1000 to 1,000,000 Daltons. In some embodiments,
the melt blend may comprise aliphatic polyesters derived from a
diol and diacid comprising at least one diol selected from ethylene
glycol, polyethylene glycol, butane diol, 1,2-hexane diol,
1,3-propylene glycol and at least one diacid selected from adipic
acid, succinic acid, terephthalic acid or furan dicarboxylic acid.
In some embodiments, the melt blend may comprise one or more
polymers disclosed herein. In some embodiments, the blend may
comprise one or more polymers disclosed herein. In some
embodiments, the aforementioned polymers may be combined with other
materials to impart specific characteristics to the barrier
114.
Barrier Coating
[0208] In some embodiments, the barrier 114 can be coated. In some
embodiments, a portion of a barrier 114 may be coated. In some
embodiments, the inner surface of the barrier 114 can be coated. In
some embodiments, the barrier 114 may be partially coated. In some
embodiments, the barrier 114 may be fully coated. The barrier may
be coated by any method disclosed herein.
[0209] In some embodiments, the coating may be a polymer coating.
In some embodiments, the coating may comprise a rigid or semi-rigid
material. In some embodiments, the coating may be flexible. In some
embodiments, the coating may be pliable, bendable, or gives way
easily under pressure. In some embodiments, the coating may be one
that is capable of being bent or flexed repeatedly without
significant damage. In some embodiments, the coating may be
hydrophilic, hydrophobic, hygroscopic, and or electrically
conductive.
[0210] In some embodiments, the coating may comprise a decorative
coating, a printing ink, an adhesive coating, and/or a heat seal
coating. In some embodiments, the coating may comprise a liquid
impermeable substance and/or a microbial substance. In some
embodiments, the microbial substance may be an antimicrobial,
antibiotic, antiviral, antiparasitic, antiamoebic, antifungal, or
antiprotozoal materials and/or compounds.
[0211] In some embodiments, the coating may be paper. In some
embodiments, the coating may mirror the container 115 in color. In
some embodiments, the coating may mirror the container 115 in
physical strength. In some embodiments, the coating may mirror the
container 115 in rigidity. In some embodiments, the coating may
mirror the container 115 in thickness.
[0212] In some embodiments, the coating may comprise one or more
materials that may reflect radiant heat. In some embodiments, the
coating may comprise one or more materials that may be tear
resistant. In some embodiments, the coating comprise one or more
materials that may be non-porous. In some embodiments, the coating
may comprise one or more materials that may be leak proof. In some
embodiments, the coating can be a moisture resistant coating. In
some embodiments, the coating may comprise one or more materials
that may be heat sealed. In some embodiments, the coating may
comprise one or more materials that may be welded. In some
embodiments, the coating may comprise one or more materials that
may be sealed with a sterile polyethylene pouch material. In some
embodiments, the coating may comprise one or more materials that
may be compatible with conventional printing techniques. In some
embodiments, the coating may comprise but is not limited to,
thermoplastic polymers, such as metallic polyethylene terephthalate
(METPET), and various reflective or metallic foils. In some
embodiments, the coating may comprise films derived from
hydrocarbons or other materials. In some embodiments, the coating
may be printed with advertising information, artwork or any other
indicia as desired. In some embodiments, advertising information,
artwork or any other indicia may be printed as a mirror image or
reversed image. In some embodiments, the coating may be printed
with mirror imaged advertising information, artwork or any other
indicia and may be flipped to be read in the correct sense. In some
embodiment, advertising information, artwork or any other indicia
may be printed in the correct sense. In some embodiments, the
coating may comprise a fibrous material. In some embodiments, the
coating may comprise any one or more fibers disclosed herein. In
some embodiments, the coating may comprise fibers consolidated or
bonded by any method known to one of skill in the art. In some
embodiments, the coating may comprise woven, nonwoven, weaved,
knitted, laced, felted, braided, plaited fibers or combinations
thereof.
[0213] In some embodiments, the coating may comprise virgin
material. In some embodiments, the coating may comprise about 1%,
about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about
8%, about 9%, about 10%, about 11%, about 12%, about 13%, about
14%, about 15%, about 16%, about 17%, about 18%, about 19%, about
20%, about 21%, about 22%, about 23%, about 24%, about 25%, about
26%, about 27%, about 28%, about 29%, about 30%, about 31%, about
32%, about 33%, about 34%, about 35%, about 36%, about 37%, about
38%, about 39%, about 40%, about 41%, about 42%, about 43%, about
44%, about 45%, about 46%, about 47%, about 48%, about 49%, about
50%, about 55%, about 60%, about 65%, about 70%, about 75%, about
80%, about 85%, about 90%, about 95%, or about 100% virgin
material.
[0214] In some embodiments, the barrier can be coated with
petroleum plastics. In some embodiments, the barrier can be coated
with biodegradable polymers that behave like plastics. In some
embodiments, the barrier can be coated with PHA Latex. In some
embodiments, the barrier can be coated with resins derived from
sugarcane. In some embodiments, the barrier can be coated with
resins derived from cornstarch. In some embodiments, the barrier
can be coated with resins derived from any resins that is derived
from a biological material that is known in the art.
[0215] In some embodiments, the coating may be transparent. In some
embodiments, the coating may be substantially transparent. In some
embodiments, the coating may not be transparent. In some embodiment
the coating may comprise pre-consumer recycled materials.
[0216] In some embodiments, the coating may comprise within the
range of about 0% to about 100% pre-consumer recycled materials. In
some embodiments, the coating may comprise about 0, about 1, about
2, about 3, about 4, about 5, about 6, about 7, about 8, about 9,
about 10, about 11, about 12, about 13, about 14, about 15, about
16, about 17, about 18, about 19, about 20, about 21, about 22,
about 23, about 24, about 25, about 26, about 27, about 28, about
29, about 30, about 31, about 32, about 33, about 34, about 35,
about 36, about 37, about 38, about 39, about 40, about 41, about
42, about 43, about 44, about 45, about 46, about 47, about 48,
about 49, about 50, about 55, about 60, about 65, about 70, about
75, about 80, about 85, about 90, about 95, or about 100%
pre-consumer recycled materials.
[0217] In some embodiments, the coating may comprise post-consumer
recycled materials. In some embodiments, the coating may comprise
within the range of about 0% to about 100% post-consumer recycled
materials. In some embodiments, the coating may comprise about 0,
about 1, about 2, about 3, about 4, about 5, about 6, about 7,
about 8, about 9, about 10, about 11, about 12, about 13, about 14,
about 15, about 16, about 17, about 18, about 19, about 20, about
21, about 22, about 23, about 24, about 25, about 26, about 27,
about 28, about 29, about 30, about 31, about 32, about 33, about
34, about 35, about 36, about 37, about 38, about 39, about 40,
about 41, about 42, about 43, about 44, about 45, about 46, about
47, about 48, about 49, about 50, about 55, about 60, about 65,
about 70, about 75, about 80, about 85, about 90, about 95, or
about 100% pre-consumer recycled materials.
[0218] In some embodiments, the coating may be compostable. In some
embodiments, about 1%, about 2%, about 3%, about 4%, about 5%,
about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about
12%, about 13%, about 14%, about 15%, about 16%, about 17%, about
18%, about 19%, about 20%, about 21%, about 22%, about 23%, about
24%, about 25%, about 26%, about 27%, about 28%, about 29%, about
30%, about 31%, about 32%, about 33%, about 34%, about 35%, about
36%, about 37%, about 38%, about 39%, about 40%, about 41%, about
42%, about 43%, about 44%, about 45%, about 46%, about 47%, about
48%, about 49%, about 50%, about 55%, about 60%, about 65%, about
70%, about 75%, about 80%, about 85%, about 90%, about 95%, or
about 100% of the coating may decompose within the range about 1 to
about 50 weeks. In some embodiments, the coating may decomposes
within about 1 week, 2 weeks, 3 weeks, 4 weeks, 5 weeks, 6 weeks, 7
weeks, 8 weeks, 9 weeks, 10 weeks, 11 weeks, 12 weeks, 13 weeks, 14
weeks, 15 weeks, 16 weeks, 17 weeks, 18 weeks, 19 weeks, 20 weeks,
21 weeks, 22 weeks, 23 weeks, 24 weeks, 25 weeks, 26 weeks, 27
weeks, 28 weeks, 29 weeks, 30 weeks, 31 weeks, 32 weeks, 33 weeks,
34 weeks, 35 weeks, 36 weeks, 37 weeks, 38 weeks, 39 weeks, 40
weeks, 41 weeks, 42 weeks, 43 weeks, 44 weeks, 45 weeks, 46 weeks,
47 weeks, 48 weeks, 49 weeks, or about 50 weeks. In some
embodiments, the coating may decompose within at least 50
weeks.
[0219] In some embodiments, the coating may comprise within the
range of about 1 to about 99 weight percent of the thermal
insulating liner 100. In some embodiments, the coating may be about
1, about 2, about 3, about 4, about 5, about 6, about 7, about 8,
about 9, about 10, about 11, about 12, about 13, about 14, about
15, about 16, about 17, about 18, about 19, about 20, about 21,
about 22, about 23, about 24, about 25, about 26, about 27, about
28, about 29, about 30, about 31, about 32, about 33, about 34,
about 35, about 36, about 37, about 38, about 39, about 40, about
41, about 42, about 43, about 44, about 45, about 46, about 47,
about 48, about 49, about 50, about 55, about 60, about 65, about
70, about 75, about 80, about 85, about 90, about 95, or about 100
weight percent of the thermal insulating liner 100.
[0220] In some embodiments, the coating may be the same shape as
the insulating layer 200. In some embodiments, the coating may be
substantially the same shape as the insulating layer 200. In some
embodiments, the coating may not be substantially the same shape as
the insulating layer 200.
[0221] In some embodiments, the coating may have a thickness
ranging from about 0.5 MIL to about 10 MIL. In some embodiments,
the coating may have a thickness of about 0.5, about 0.6, about
0.7, about 0.8, about 0.9, about 1.0, about 1.1, about 1.2, about
1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about
1.9, about 2.0, about 2.1, about 2.2, about 2.3, about 2.4, about
2.5, about 2.6, about 2.7, about 2.8, about 2.9, about 3.0, about
3.1, about 3.2, about 3.3, about 3.4, about 3.5, about 3.6, about
3.7, about 3.8, about 3.9, about 4.0, about 4.1, about 4.2, about
4.3, about 4.4, about 4.5, about 4.6, about 4.7, about 4.8, about
4.9, about 5, about 6, about 7, about 8, about 9, or about 10 MIL.
In some embodiments, the coating may have a thickness of at least
10, 20, 30, 40, 50, or at least 60 MIL.
[0222] In some embodiments the barrier 114 may comprise a coating,
wherein the coating may cover an inner surface of the barrier 114.
In some embodiments, the coating may cover an outer surface of the
barrier 114.
[0223] In some embodiments, the coating may comprise renewable,
biobased, biodegradable latex. In some embodiments, the coating can
comprise a plastic. In some embodiments, the plastic can comprise
petroleum plastics. In some embodiments, the coating may comprise a
polymer. In some embodiments, the polymer may be a biodegradable
polymer. In some embodiments, the biodegradable polymer may include
a polymer that may be obtained from renewable monomers, polymers
which may be obtained from renewable natural sources (e.g., starch,
sugars, lipids, corn, sugar beet, wheat, castor oil plant,
rapeseed, wood, or other starch-rich products etc.). In some
embodiments, the biodegradable polymer may include plant resins.
The present invention is not limited to any particular plant resin.
Indeed, a variety of plant resins are contemplated, the resins can
be obtained from a plant including but not limited to a flowering
plant, a vegetable plant, a crop plant, an herb plant, a shrub
plant, and a tree plant. In some embodiments, the plant can be
selected from the group of a Brassica carinata, Crambe abyssinica,
corn (Zea mays), canola (Brassica napus), alfalfa (Medicago
sativa), rice (Oryza sativa), rye (Secale cereale), sorghum
(Sorghum bicolor), millet (Pennisetum glaucum), sunflower
(Helianthus annuus), safflower (Carthamus tinctorius), wheat
(Triticum aestivum), soybean (Glycine max), tobacco (Nicotiana
tabacum), potato (Solanum tuberosum), peanuts (Arachis hypogaea),
cotton (Gossypium hirsutum), sweet potato (Ipomoea batatus),
cassava (Manihot esculenta), coffee (Coffea spp.), bamboo, coconut
(Cocos nucifera), pineapple (Ananas comosus), citrus (Citrus spp.),
cocoa (Theobroma cacao), tea (Camellia sinensis), banana (Musa
spp.), avocado (Persea americana), fig (Ficus casica), guava
(Psidium guajava), mango (Mangifera indica), olive (Olea europaea),
papaya (Carica papaya), cashew (Anacardium occidentale), macadamia
(Macadamia integrifolia), almond (Prunus amygdalus), sugar beets
(Beta vulgaris), sugarcane (Saccharum spp.), oats, barley, Cork Oak
(Quercus suber), Aspen (Populus tremula), Loblolly pine (Pinus
taeda). In some embodiments, the plant can be selected from the
group of a Brassicaceae species, Nicotiana species, a Solanum
species, a Gossypium species, or a Botryococcus species. In some
embodiments, the crop plant can be selected from the group of a
mustard, tobacco, potato, cotton, sunflower, corn, safflower, rice,
or algae. In some embodiments, the flowering plant can be an
Arabidopsis sp. plant.
[0224] Examples of plant resins include but are not limited to
amber, Balm of Gilead, balsam, Canada balsam, Boswellia, copal from
trees of Protium copal and Hymenaea courbaril, dammar gum from
trees of the family Dipterocarpaceae, Dragon's blood from the
dragon trees (Dracaena species), elemi, frankincense from Boswellia
sacra, galbanum from Ferula gummosa, gum guaiacum from the lignum
vitae trees of the genus Guaiacum, kauri gum from trees of Agathis
australis, labdanum from mediterranean species of Cistus, mastic
(plant resin) from the mastic tree Pistacia lentiscus, myrrh from
shrubs of Commiphora, sandarac resin from Tetraclinis articulata,
styrax (a Benzoin resin from various Styrax species), Spinifex
resin from Australian Spinifex grasses, and turpentine, distilled
from pine resin.
[0225] In some embodiments, the biodegradable polymer may be
polylactic acid. In some embodiments, the biodegradable polymer
comprise polylactic acid. In some embodiments, the biodegradable
polymer may be polyhydroxyalkanoates. In some embodiments, the
biodegradable polymer may comprise polyhydroxyalkanoates. In some
embodiments, the coating may comprise a copolymer. In some
embodiments, the coating may comprise a homopolymer. In some
embodiments, the coating may comprise a heteropolymer.
[0226] Examples of biobased polymers include polyethylene (PE)
produced from sugarcane ethanol (Braskem's Green Polyethylene),
polylactic acid (PLA) made from corn sugar (Nature Works Ingeo.TM.
PLA) and polyhydroxyalkanoates (PHA's) produced by the fermentation
of glucose (U.S. Pat. Nos. 6,593,116 and 6,913,911, US Patent Pub.
No. 2010/0168481), which is herein incorporated by reference in the
entirety.
[0227] In some embodiments, the biodegradable polymer may be
without limitation a biodegradable polymers of the following types:
polylactates (or PLA), polymalates (or PMA), polyhydroxyalkanoates
(or PHA), polycaprolactones (or PCL), polyesteramides (PEA),
aliphatic copolyesters (PBSA), aliphatic-co-terephthalate
copolyesters (PBAT), celluloses or starches which are highly
acetylated or rendered hydrophobic by introduction of fixed fatty
chains, taken alone or in combination, in the form of homopolymers
or heteropolymers, whether linear, branched, crosslinked, dendritic
or grafted.
[0228] In some embodiments, the coating may be applied by a powder
coating approach, casting, spraying, dipping or immersing, by the
use of brushes, rollers, blocks or other instruments. In some
embodiments, the coating may be applied by air knife coating, blade
coating, metering roll coating, gravure coating, rod coating,
curtain coating, bath coating.
[0229] In some embodiments, the coating may comprise wax, or
polyethylene film. In some embodiments, the coating may be applied
in at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, or at least about 10
steps. In some embodiments, the coating may comprise one or more
layers. In some embodiments, the coating may comprise at least 1,
2, 3, 4, 5, 6, 7, 8, 9, or at least 10 layers. In some embodiments,
a first coating layer may comprise a different composition compare
to a second coating layer. In some embodiments, a first coating
layer may comprise the same composition as a second coating
layer.
[0230] In some embodiments, the coating may comprise a polymer
selected from the group comprising, without limitation acrylic
polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol,
poly-ethylene vinyl acetate, poly-ethylene vinyl chloride, styrene
butadiene copolymers, polyvinylidiene chloride, or starch.
[0231] In some embodiments, the coating disclosed herein may
comprise a polymer blend. In some embodiments, the polymer blend
may be a first polymer blended with another polymer to form a
latex. In some embodiments, the polymer blend may comprise one or
more biodegradable polymer. In some embodiments, the polymer blend
may comprise use of a melt blending process. In some embodiments,
the melt blend may comprise polycaprolactone having a molecular
weight from about 1000 to 1,000,000 Daltons. In some embodiments,
the melt blend may comprise aliphatic polyesters derived from a
diol and diacid comprising at least one diol selected from ethylene
glycol, polyethylene glycol, butane diol, 1,2-hexane diol,
1,3-propylene glycol and at least one diacid selected from adipic
acid, succinic acid, terephthalic acid or furan dicarboxylic acid.
In some embodiments, the melt blend may comprise one or more
polymers disclosed herein. In some embodiments, the blend may
comprise one or more polymers disclosed herein. In some
embodiments, the aforementioned polymers may be combined with other
materials to impart specific characteristics to the coating.
Thermal Insulating Layer and Barrier
[0232] In some embodiments, the insulating layer 200 may be
otherwise unattached to the barrier 114.
[0233] In some embodiments, the insulating layer 200 may be joined
to the barrier 114 by various methods known in the art. In some
embodiments, the insulating layer 200 may be joined to the barrier
114 by lamination. Lamination is the technique of manufacturing a
material in multiple layers, so that the composite material
achieves improved strength, stability, sound insulation, appearance
or other properties from the use of differing materials. In some
embodiments, the laminate may be permanently assembled by heat,
pressure, welding, or adhesives. In some embodiments, the
insulating layer 200 may be joined to the barrier 114 by uniting
layers of material by an adhesive or other techniques disclosed
herein.
[0234] In some embodiments, the adhesive may be applied in various
ways. In some embodiments, the adhesive may be applied in a
pattern-application or spray application, or through the use of an
adhesive layer, e.g., a thermoplastic adhesive scrim, which may be
a web-like layer of adhesive. In some embodiments, the use of
pattern-application adhesive or an adhesive scrim may achieve a
similar effect within the multilayer liner of the invention
herein.
[0235] In some embodiments, insulating layer 200 may be joined to
the barrier 114 by pinpoint embossing, needling and quilting, among
others known to those of skill in the art.
[0236] In some embodiments, the insulating layer 200 may be joined
to the barrier 114 by sealing such as with a hot knife, at its
edges so that fluid cannot penetrate the edges. In some
embodiments, the insulating layer 200 may be joined to the barrier
by any one or more methods described herein.
[0237] In some embodiments, an additive may be added to the
insulating layer 200 before the barrier 114 is sealed. In some
embodiments, an additive may be added between the insulating layer
200 and the barrier 114. In some embodiments, the additive may be
one or more additives disclosed herein. In some embodiments, one or
more coffee beans may be placed between the insulating layer 200
and the barrier 114. In some embodiments, one or more mint leaves
may be placed between the insulating layer 200 and the barrier 114.
In some embodiments, one or more oils may be placed between the
insulating layer 200 and the barrier 114. In some embodiments, one
or more oil extracts may be placed between the insulating layer 200
and the barrier 114. In some embodiments, one or more detergents
may be placed between the insulating layer 200 and the barrier 114.
In some embodiments, detergents may be a surfactant or a mixture of
one or more surfactants. In some embodiments the detergent may be
in a solid, liquid or power form. In some embodiments, the
detergent may be anionic, cationic, non-ionic or zwitterionic. A
number of other detergents may be used, including those disclosed
in WO2011/073062 and WO2012/041774.
[0238] In some embodiments, one or more cleaning agents may be
placed between the insulating layer 200 and the barrier 114. In
some embodiments, the cleaning agent may be a liquid, powder,
spray, granules or a combination there of. In some embodiments, the
cleaning agent may remove dirt, dust, stains, odor, and clutter on
surfaces. In some embodiments, the cleaning agent may be acidic,
alkaline or neutral. In some embodiments, the cleaning agent may
comprise carbon tetrachloride, ammonia, borax, sodium bicarbonate,
carbon dioxide, calcium hypochlorite, cyanuric acid, chromic acid,
ethanol, methanol, chlorine, acetic acid, trisodium phosphate,
sodium percarbonate, sodium perborate or combinations thereof. In
some embodiments, the cleaning agent may be LYSOL.RTM.
[0239] In some embodiments, one or more odor control agents may be
placed between the insulating layer 200 and the barrier 114. In
some embodiments, the odor control agent may be in a solid or
liquid form. In some embodiments, the odor control agent may be an
acrylic ester such as lauryl methacrylate, (sold under trade name
METAZENE.RTM. by Pestco Company), sodium bicarbonate, benzalkonium
chloride, bisulfite complexes of aldehydes and ketones, boric acid,
borax, menthol, camphor, sodium bisulfate, lemon oil, and pine oil.
In some embodiments, the odor control agent may be a powdered
compounds such as magnesium silicates (talc), inorganic silicone
and magnesium powders, sodium bicarbonate, chlorophyll, sodium
dihydrogen phosphate, potassium acid phthalates, or other powdered
odor control agents known to those skilled in the art, or
combinations thereof. A number of other odor control agents and
cleaning agents may be used, including those disclosed in U.S. Pat.
No. 4,898,727 to Osada et al., U.S. Pat. No. 6,495,097 to Streit et
al., and U.S. Pat. No. 6,253,710 to Ward et al.
Goods, Foodstuffs, Samples and Medical Items
[0240] FIG. 8 illustrates a thermal insulating liner 100 placed in
a container 115 with goods, foodstuffs, samples, and medical items.
The thermal insulating liner 100 may comprise a first side portion,
a second side portion 102, a first side portion opposing first side
flap 105a and second side flap 105b, and second side portion
opposing first side flap 106a and second side flap enclosed in a
polyethylene barrier 114 in a polygonal box form, with goods,
foodstuffs, samples, and medical items placed in the cavity of the
thermal insulating liner and placed in a container 115.
[0241] FIG. 9 illustrates a covered thermal insulating liner placed
in a container with goods, foodstuffs, samples, and medical items.
The thermal insulating liner 100 may comprise a first side portion
101, a second side portion 102, a first side portion opposing first
side flap 105a and second side flap, and second side portion
opposing first side flap and second side flap enclosed in a
polyethylene barrier 114 in a polygonal box form. Goods,
foodstuffs, samples, and medical items may be placed in the cavity
of the thermal insulating liner and placed in a container 115, with
a portion of the first side portion 101, second side portion 102,
the first side portion opposing first side flap 105a and second
side flap, second side portion opposing first side flap and second
side flap folded about to cover the goods, foodstuffs, samples, and
medical items from the ambient environment.
[0242] In some embodiments, the insulating layer 200 may be
configured to form a pouch, bag or box for enclosing goods,
foodstuffs, samples and/or medical items. In some embodiments,
pouches, bags, or boxes may be manufactured according to any
well-known method. One skilled in the art can recognize that a
"pouch" means an enclosure sealed on at least two of four sides,
though generally sealed on three of four sides with the fourth side
being an opening. A "bag" may be a pouch, but can also include a
"stand-up pouch", comprising four sides and a rectangular bottom
opposite an opening. In some embodiments, the thermal insulating
liner 100 has an open mouth 107. In some embodiments, a bag may
comprise a gusset.
[0243] In some embodiments, after inserting the goods, foodstuffs,
samples and medical items into the thermal insulating liner 100
pouch, bag or box of the invention herein, the pouch, bag or box
may be sealed or closed in various ways known to those of skill in
the art. The closing may be mechanical, such as the thermal
insulating liner 100 flaps 105a, 105b, 106a, 106b or side portions
101, 102 may be folded over and/or tucked in; and/or adhesive, such
as pressure sensitive adhesive, zippers, among others. In some
embodiments, the closing may be by any method disclosed herein.
[0244] In some embodiments, the goods, foodstuffs, samples and
medical items may comprise perishable goods. In some embodiments,
the goods, foodstuffs, samples and medical items may comprise
nonperishable goods. In some embodiments, the goods, foodstuffs,
samples and medical items may comprise temperature sensitive goods.
In some embodiments, the goods, foodstuffs, samples and medical
items may comprise non temperature sensitive goods.
[0245] In some embodiments, as will be appreciated by those of
skill in the art, the goods, foodstuffs, samples and medical items
may comprise any number of things, including, but not limited to,
bodily fluids including, but not limited to, blood, nasopharyngeal
secretions, urine, serum, lymph, saliva, milk, anal and vaginal
secretions, and semen of any organism. In some embodiments, the
goods, foodstuffs, samples and medical items may comprise mammalian
samples taken from, including, but not limited to sheep, cow,
horse, pig, goat, lama, emu, ostrich or donkey, chicken, turkey,
goose, duck, game bird, human, fish, rabbit, guinea pig, rat or
mouse, dog, and/or cat. In some embodiments, the goods, foodstuffs,
samples and medical items may comprise environmental samples
including, but not limited to, air, agricultural, water and soil
samples. In some embodiments, the goods, foodstuffs, samples and
medical items may comprise biological warfare agent samples,
research samples, purified samples, such as purified genomic DNA,
RNA, proteins, etc.; and raw samples (bacteria, virus, genomic DNA,
etc.).
[0246] In some embodiments, the goods, foodstuffs, samples and
medical items may comprise food products. In some embodiments, the
disclosure provides a sample comprising raw food products, fresh
food products, cooled or frozen food products, or products that are
generally heated prior to consumption. In some embodiments, the
food product could be partially cooked. In some embodiments, the
food product could be cooked but may require additional heating
prior to consumption. In some embodiments, the food product may
comprise meats, poultry, fish, seafood, fruits, and vegetables. In
some embodiments the food product may include meats (beef, pork,
lamb, rabbit and/or goat), poultry, wild game (pheasant, partridge,
boar and/or bison), fish, vegetables (veggie-patties, veggie
hamburgers), combinations of vegetables and meat, egg products
(quiches, custards, cheesecakes) and/or baked goods (batters,
doughs, cakes, breads, muffins, biscuits, cupcakes, pancakes and
the like whether baked, raw or partially baked).
[0247] In some embodiments, the goods, foodstuffs, samples and
medical items may be less than or equal to about 25 kilograms (kg)
by weight. In some aspects, the goods, foodstuffs, samples and
medical items is about 0.1, about 0.2, about 0.3, about 0.4, about
0.5, about 0.6, about 0.7, about 0.8, about 0.9, 1, about 2, about
3, about 4, about 5, about 6, about 7, about 8, about 9, about 10,
about 11, about 12, about 13, about 14, about 15, about 16 s, about
17, about 18, about 19, about 20, about 21, about 22, about 23,
about 24, or about 25 kg. In some embodiments, the goods,
foodstuffs, samples and medical items may be less than 1 kg
[0248] In some embodiments, the goods, foodstuffs, samples and
medical items may be greater than or equal to about 25 kg by
weight. In some embodiments the goods, foodstuffs, samples and
medical items is about 26, about 27, about 28, about 29, about 30,
about 31, about 32, about 33, about 34, about 35, about 36, about
37, about 38, about 39, about 40, about 41, about 42, about 43,
about 44, about 45, about 46, about 47, about 48, about 49, about
50, about 51, about 52, about 53, about 54, or about 55 kg. In some
aspects, the sample is greater than 55 kg by weight.
Container
[0249] In some embodiments, the thermal insulating liner 100 may
not be placed in a container 115. In some embodiments, the thermal
insulating liner 100 may be placed in a container 115. In some
embodiments, the thermal insulating liner 100 may be the same size
as the container 115 it will be placed in. In some embodiments, the
thermal insulating liner 100 may be the same shape as the container
115 it will be placed in. In some embodiments, the thermal
insulating liner 100 may be larger than the container 115 it will
be placed in. In some embodiments, the thermal insulating liner 100
may be a different shape than the container 115 it will be placed
in. In some embodiments, the thermal insulating liner 100 fits in a
portion of the container 115 it will be placed in. In some
embodiments, the thermal insulating liner 100 fits completely in
the container 115 it will be placed in.
[0250] In some embodiments, the container 115 may be reusable. In
some embodiments, the container 115 may be single use. In some
embodiments, the container 115 may comprise steel. In some
embodiments, the container 115 may be a corrugated box. In some
embodiments, the container 115 may comprise wood. In some
embodiments, the container 115 may be a crate. In some embodiments,
the container 115 may comprise a plastic. In some embodiments, the
container 115 may comprise a composite. In some embodiments, the
container 115 may comprise stainless steel. In some embodiments,
the container 115 may comprise a fibrous material. In some
embodiments, the container 115 may be made of any one or more
fibers disclosed here in. In some embodiments, the container 115
may be flexible. In some embodiments, the container 115 may be
collapsible. In some embodiments, the container 115 may be rigid.
In some embodiments, the container 115 may be substantially
rigid.
[0251] In some embodiments, the container 115 may include one or
more openings for storage.
[0252] In some embodiments, the container 115 may be secured to the
thermal insulating liner 100 by stitches, snaps, clips, or any
method disclosed herein or may remain removable and unsecured to
the thermal insulating liner 100.
[0253] In some embodiments, the flexible nature of the thermal
insulating liner 100 may enable the thermal insulating liner 100 to
conform to the inner dimensions of the container 115. In some
embodiments, the thermal insulating liner 100 may extend along
corresponding sides the container 115. In some embodiments, the
goods, foodstuffs, samples and medical items may be inserted into
the thermal insulating liner 100 after the thermal insulating liner
100 is placed in a container 115. In some embodiments, the goods,
foodstuffs, samples and medical items may be inserted into the
thermal insulating liner 100 prior to the thermal insulating liner
100 being placed in a container 115. In some embodiments, the
thermal insulating liner 100 may be closed. In some embodiments,
the thermal insulating liner 100 side portions 105a, 105b, 106a,
106b may be folded. In some embodiments, the closing may be by
adhesive, pressure sensitive adhesive, tapes, zippers, zip-lock,
hooks, buttons, friction, solder, pins, clips, VELCRO.RTM., among
others. The closing may be by any method disclosed herein. In some
embodiments, an adhesive described herein may be biodegradable. In
some embodiments, an adhesive described herein may comprise
polymers. In some embodiments, a polymer may comprise at least one
of a polylactate, polymalate, polyhydroxyalkanoate,
polycaprolactone, polyesteramide, aliphatic copolyester,
aliphatic-co-terephthalate copolyester, cellulose or starch. In
some embodiments, an adhesive comprise cornstarch. In some
embodiments, an adhesive comprise a resin. In some embodiments, an
adhesive is water proof and can be a sealant when heated. In some
embodiments, an adhesive may be waterproof. In some embodiments, an
adhesive may be a sealant when heated or chilled.
[0254] In some embodiments, when the container 115 is open, the
thermal insulating liner 100 may extend above the top of the
container 115. In some embodiments, when the container 115 is open,
the thermal insulating liner 100 may extend below the top of the
container 115.
Temperature Regulation
[0255] In some embodiments, a cooling or heating agent may be
enclosed in the thermal insulating liner 100. In some embodiments,
a thermal insulating liner can comprise one or more compartments
for storing a cooling or heating agent. In some embodiments, the
compartment is on the interior of a thermal insulating liner. In
some embodiments, the compartment is on the exterior of a thermal
insulating liner. In some embodiments, the cooling or heating agent
may be single use. In some embodiments, the cooling or heating
agent may be reusable. In some embodiments, the cooling or heating
agent may comprise wet ice, dry ice, ice packs, ice tubes, ice gel,
BLUE ICE.RTM., frozen gel, water, frozen substances, warm
substances, gel packs, reusable gel packs, and/or removable gel
packs, or any other phase change material pack. In some
embodiments, the cooling or heating agents may be placed within the
thermal insulating liner 100 and or the container 115 wherein which
the thermal insulating liner 100 may be place to keep the interior
cold or warm.
[0256] In some embodiments, the gel packs may be hot gel packs. In
some embodiments, the gel packs may be cold gel packs. In some
embodiments, the gel packs may be cooled or heated and then
inserted within the thermal insulating liner 100 for keeping the
object within the container 115 cold or hot. In some embodiments,
the cold gel packs may be plastic. In some embodiments, the cold
gel packs may contain a chemical gel therein. In some embodiments,
the chemical gel may be quickly and easily frozen and remain in a
frozen state for an extended period of time. In some embodiments,
the hot gel packs may be metal. In some embodiments, the hot gel
packs may be filled with a chemical gel. In some embodiments the
chemical gel may be easily preheated and used for keeping an object
warm for an extended period of time.
[0257] In some embodiments, the thermal insulating liner 100 may
regulate and keep the temperature of goods, foodstuffs, samples,
and medical items constant for at least about 1 to about 500 hours
("hrs."). In some embodiments, the thermal insulating liner 100
regulates and keep the temperature of an object constant for at
least about 1, about 2, about 3, about 4, about 5, about 6, about
7, about 8, about 9, about 10, about 11, about 12, about 13, about
14, about 15, about 16, about 17, about 18, about 19, about 20,
about 21, about 22, about 23, about 24, about 25, about 26, about
27, about 28, about 29, about 30, about 31, about 32, about 33,
about 34, about 35, about 36, about 37, about 38, about 39, about
40, about 41, about 42, about 43, about 44, about 45, about 46,
about 47, about 48, about 49, about 70, about 51, about 52, about
53, about 54, about 55, about 56, about 57, about 58, about 59,
about 60, about 70, about 72, about 75, about 80, about 90, about
100, about 110, about 120, about 130, about 140, about 150, about
200, or at least about 500 hrs.
[0258] In some embodiments, an insulating liner may regulate and
keep the temperature of goods, foodstuffs, samples, and medical
items at a temperature of about -80.degree. C. to about 150.degree.
C. for a period of time. In some embodiments, an insulating liner
may regulate and keep the temperature of goods, foodstuffs,
samples, and medical items at a temperature of about -100, about
-90, about -80, about -79, about -78, about -77, about -76, about
-75, about -70, about -60, about -50, about -40, about -30, about
-20, about -10, about -5, about -4, about -3, about -2, about -1,
about 0, about 1, about 0.5, about 1, about 1.5, about 2, about
2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5,
about 6, about 6.5, about 7, about 7.5, about 8, about 8.5, about
9, about 9.5, about 10, about 10.5, about 11, about 11.5, about 12,
about 12.5, about 13, about 13.5, about 14, about 14.5, about 15,
about 15.5, about 16, about 16.5, about 17, about 17.5, about 18,
about 18.5, about 19, about 19.5, about 20, about 21, about 22,
about 23, about 24, about 25, about 26, about 27, about 28, about
29, about 30, about 31, about 32, about 33, about 34, about 35,
about 36, about 37, about 38, about 39, about 40, about 41, about
42, about 43, about 44, about 45, about 46, about 47, about 48,
about 49, about 50, about 52, about 53, about 54, about 55, about
56, about 57, about 58, about 59, about 60, about 61, about 62,
about 63, about 64, about 65, about 66, about 67, about 68, about
69, about 70, about 71, about 72, about 73, about 74, about 75,
about 76, about 77, about 78, about 79, about 80, about 90, about
100, about 120, about 140, about 150, about 160, about 170, about
180, or about 190.degree. C.
[0259] In some embodiments, the thermal insulating liner 100 may
regulate and keep the temperature of an object with in a
temperature range for about at least about 1 to about 500 hrs. In
some embodiments, the thermal insulating liner 100 may regulate and
keep the temperature of an object with in a temperature range for
about at least about 1, about 2, about 3, about 4, about 5, about
6, about 7, about 8, about 9, about 10, about 11, about 12, about
13, about 14, about 15, about 16, about 17, about 18, about 19,
about 20, about 21, about 22, about 23, about 24, about 25, about
26, about 27, about 28, about 29, about 30, about 31, about 32,
about 33, about 34, about 35, about 36, about 37, about 38, about
39, about 40, about 41, about 42, about 43, about 44, about 45,
about 46, about 47, about 48, about 49, about 70, about 51, about
52, about 53, about 54, about 55, about 56, about 57, about 58,
about 59, about 60, about 70, about 72, about 75, about 80, about
90, about 100, about 110, about 120, about 130, about 140, about
150, about 200, or at least about 500 hrs.
[0260] In some embodiments, the temperature range may be within the
range of about 0.1 to about 50.degree. C. In some embodiments, the
temperature range is within about 0.1, about 0.5, about 1, about
1.5, about 2, about 2.5, about 3, about 3.5, about 4, about 4.5,
about 5, about 5.5, about 6, about 6.5, about 7, about 7.5, about
8, about 8.5, about 9, about 9.5, about 10, about 10.5, about 11,
about 11.5, about 12, about 12.5, about 13, about 13.5, about 14,
about 14.5, about 15, about 15.5, about 16, about 16.5, about 17,
about 17.5, about 18, about 18.5, about 19, about 19.5, about 20,
about 21, about 22, about 23, about 24, about 25, about 26, about
27, about 28, about 29, about 30, about 31, about 32, about 33,
about 34, about 35, about 36, about 37, about 38, about 39, about
40, about 41, about 42, about 43, about 44, about 45, about 46,
about 47, about 48, about 49, or about 50.degree. C.
[0261] Although described with reference to preferred embodiments
of the invention, it should be readily understood that various
changes and/or modifications may be made to the invention without
departing from the spirit thereof.
EXAMPLES
Example 1. Thermal Insulating Liner Production
[0262] Recycled jute fibers were sourced from secondary fiber
markets. The recycled jute fibers were previously used as inputs
for the production of woven burlap bags used for the transportation
of coffee and cacao beans. The jute fibers were received in the
form of bales. The bales were tightly packed and range in weight
from 100 lbs. (45.359 kg). to over 500 lbs. (226.796 kg). Baled
fibers were unpacked and loaded onto a moving conveyor in the form
of loose chunks of densely packed jute fibers.
[0263] The loose jute fibers were escalated up a vertical conveyor
wall about 15 to 20 feet in height. Protrusions (spikes) lift the
jute fibers up the wall and served the function of opening the jute
fibers. In this sense, opening refers to the breaking down of
higher density, packed chunks of the jute fibers into lower
density, evenly distributed individual jute fibers. The jute fibers
were subsequently dropped into a vacuum shoot, which facilitated
transport to the next process.
[0264] The jute fibers were moved by way of air pressure onto the
secondary conveyor belt and passed underneath a guiding jig that
had a variable height. The height of the jig sets and controls the
height of the stack of jute fibers (usually 0.2'' to 6.0'' at this
stage).
[0265] The loosely packed jute fibers were subjected to a needling
process where rapid movements of thin needles into and out of the
fiber bed led to entanglement and the production of an insulating
layer 200.
[0266] A rotary blade was installed on the conveyor belt and the
rotary blade made incisions parallel to the direction of the
movement of the newly formed insulating layer 200. The rotary blade
can be adjusted across the width of the insulating layer 200 to
alter and fix the width of the insulating layer 200.
[0267] Another blade was set to cut across the insulating layer 200
(perpendicular to the movement of the conveyor) allowing for a
predetermined insulating layer 200 length to be implemented. The
result was rectangular strips of insulating layers 200.
[0268] The rectangular strips of insulating layers 200 were stacked
on pallets. The pallets were left open to allow for airflow through
the insulating layers 200. The airflow reduced the moisture content
of the insulating layer 200, thus reducing the risk of odor
generation.
[0269] Individual insulating layers 200 were folded along their
lengths (FIG. 5A), thereby having a first side portion 101, a
second side portion 102, and a middle portion 103. An excised
portion 104 of the folded insulating layer 200 was removed by a die
punch (FIG. 5C). The excised portion 104 had a length approximately
equal to the width of the intended container 115 and a width
approximately equal to half the width of the container 115.
Intended container refers to the container 115 the completed
thermal insulating liner 100 will be placed in.
[0270] A large bottom sealed polyethylene barrier 114, 1 MIL to 2
MIL in thickness, was turned inside out, and then partially
inverted back. The insulating layer 200 was folded and placed into
the halfway inverted polyethylene barrier 114 in a fashion such
that the inverted section of the polyethylene barrier 114 rested
between the two layers of the folded insulation insulating layer
200. The cross section view was as follows: polyethylene
barrier|insulating layer|polyethylene barrier|polyethylene
barrier|insulating layer|polyethylene barrier.
[0271] The edges of the inverted polyethylene barrier 114
containing the insulating layer 200 were heat sealed together for
the purpose of securing the insulating layer 200 within the
polyethylene barrier 114, thus forming the thermal insulating liner
100.
[0272] A mechanical, handheld rotary micro-perforator was used to
produce small holes across the thermal insulating liner 100.
Example 2. Thermal Insulating Liner Production
[0273] Rectangular strips of insulating layer 200 as described in
example 1 were folded along its width (FIG. 1A) and a die punch was
used to remove excised portions 104a, 104b. A large bottom sealed
polyethylene barrier 114, 1 MIL to 2 MIL in thickness, were turned
inside out, and then partially inverted back. The insulating layer
200 was folded and placed into the halfway inverted polyethylene
barrier 114 in a fashion such that the inverted section of the
polyethylene barrier 114 rested between the two layers of the
folded insulation insulating layer 200. The cross section view was
as follows: polyethylene barrier|insulating layer|polyethylene
barrier|polyethylene barrier|insulating layer|polyethylene
barrier.
[0274] The edges of the inverted polyethylene barrier 114
containing the insulating layer 200 were heat sealed together for
the purpose of securing the insulating layer 200 within the
polyethylene barrier 114, thus forming the thermal insulating liner
100.
[0275] A mechanical, handheld rotary micro-perforator was used to
produce small holes across the thermal insulating liner 100.
Example 3. Thermal Insulating Liner Production
[0276] Thermal insulating liners 100 as described in example 1 or
2, were refolded into a polygonal box form. The polygonal box form
comprising an opening 107, a first side portion 101 and second a
side portion 102 defining opposing sides of the polygonal box form,
the middle portion 103 defining a bottom of the polygonal box form,
a first side portion opposing first side flap 105a and second side
flap 105b, and second side portion opposing first side flap 106a
and second side flap enclosed in a polyethylene barrier 114.
Example 4. Non-Gusseted Design
[0277] The manufacturing process were the same or similar to those
described herein (example 3), however with the exception of the
creation of the gussets by removing excised portions 104, 104a,
104b of the insulating layer 200. In this design, thermal
insulation liners were produced by folding a rectangular insulating
layer along its width or along its length. The folded insulating
layer was encapsulated and heat sealed within a polyethylene
barrier. The polyethylene barrier was 1.5 MIL in thickness. The
thermal insulating liner was inserted into a container. The thermal
insulating liner was placed in a container such that the base width
of the thermal insulating liner rests diagonally in the
container.
Example 5. Non-Gusseted A|B Design
[0278] The manufacturing process was the same or similar to those
described herein, however the thermal insulating liner comprised
two or more pieces. The thermal insulating liner took the form of
two flexible rectangular strips that, when placed into a container,
cover all six internal walls including the lid of a six sided
container. In this configuration, a first component, was denoted as
"part A", and was placed into a container such that it covered the
bottom surface 403, a first side portion 401, and the remaining
material was used as a flap that acts as the lid when folded 402.
In this configuration, a second component was denoted as "part B"
400b, was subsequently placed into the container and it covered the
three remaining sides of the six sided container. FIG. 31.
Example 6. Rigid Corrugated Paper Design
[0279] The thermal insulating liner may be manufactured as
described herein to be rigid. The rigid thermal insulating liner
may be folded into a three-dimensional box liner. The rigid thermal
insulating liner may be transported and stored flat prior to use.
Furthermore, the thermal insulating liner may be enclosed in a
rigid barrier. The rigid barrier may be corrugated paperboard. The
rigid barrier may comprise a compartment for holding the thermal
insulating liner. The compartment for holding the thermal
insulating liner may secure the thermal insulating liner in such a
manner that the walls maintain geometry and structure integrity of
the thermal insulating liner.
Example 7. The Concept of a Partially Insulated Container
[0280] The thermal insulating liner of the present invention may
partially insulate a container. The thermal insulating liner may be
a partial liner wherein the goods, foodstuffs, samples and medical
items placed in or on the thermal insulating liner may be a mixture
of both temperature sensitive and non-temperature sensitive
objects. In this configuration, the container may be
compartmentalized such that only objects requiring insulation is
insulated.
Performance Tests
[0281] Examples 8-24 were performed according to the following.
Tests were performed to analyze the performance of the present
invention compared to other assorted thermal insulating liners
under various conditions for fresh food products. 48 oz. or 32 oz.
gel packs were frozen for at least 72 hours prior to testing. In
each test, temperature loggers recorded and save temperature
readings every two minutes.
Example 8. Thermal Insulating Liner, Polyurethane A|B Liner
Test
[0282] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2 and about 700 g/m.sup.2. The thermal insulating liners
were placed inside corrugated box containers according to example
4. The exterior dimensions of the corrugated box containers were
12''.times.12''.times.8''. ('') inch. Gel packs were added to the
cavity of the thermal insulating liners. Total gel pack weight was
2.times.48 oz. per thermal insulating liner. The thermal insulating
liners were folded at the opening created by the first side portion
and the second side portion. The corrugated box containers were
then closed. The polyurethane ("PUR") foam insulating liner was 1.0
inch thick, and was packaged in a similar manner as the thermal
insulating liners. FIG. 10.
Example 9. Thermal Insulating Liner, Polyurethane A|B Liner, Bubble
Foil Test
[0283] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2 and about 700 g/m.sup.2. The thermal insulating liners
were placed inside corrugated box containers according to example
4. The exterior dimensions of the corrugated box containers were
12''.times.12''.times.8''. Gel packs were added to the cavity of
the thermal insulating liners. Total gel pack weight was 1.times.32
oz. per thermal insulating liner. The thermal insulating liners
were folded at the opening created by the first side portion and
the second side portion. The corrugated box containers were then
closed. The PUR foam insulating liner was 1.0'' thick. The Bubble
foil insulating liner comprised a bag formed from bubble wrap. PUR
foam and bubble foil insulating liners were packaged in a similar
manner as the thermal insulating liners. FIG. 11.
Example 10. Thermal Insulating Liner, Bubble Foil Test
[0284] A 0.25 inch thick jute thermal insulating liner was
manufactured according to example 4. In this illustration, the
insulating layer was manufactured at a density of about 450
g/m.sup.2. The thermal insulating liner was placed inside a
corrugated box container according to example 4. The exterior
dimensions of the corrugated box container were
12''.times.12''.times.8''. Gel packs were added to the cavity of
the thermal insulating liner. Total gel pack weight was 2.times.32
oz. The thermal insulating liner was folded at the opening created
by the first side portion and the second side portion. The
corrugated box container was then closed. Bubble foil insulating
liner comprised an enclosure formed from bubble wrap (InsuLTote
bubble wrap bag), and was packaged in a similar manner as the
thermal insulating liner. FIG. 12.
Example 11. Thermal Insulating Liner, EPS Foam Cooler Test
[0285] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2 and about 700 g/m.sup.2. The thermal insulating liners
were placed inside corrugated box containers according to example
4. The exterior dimensions of the corrugated box containers were
16''.times.13''.times.9''. Gel packs were added to the cavity of
the thermal insulating liners. Total gel pack weight was 2.times.48
oz. per thermal insulating liner. The thermal insulating liners
were folded at the opening created by the first side portion and
the second side portion. The corrugated box containers were then
closed. The EPS foam cooler was 1.0 inch thick, and was packaged in
a similar manner as the thermal insulating liners. FIG. 13.
FIG. 12. Thermal Insulating Liner Density Test
[0286] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2 and about 700 g/m.sup.2. The thermal insulating liners
were placed inside corrugated box containers according to example
4. The exterior dimensions of the corrugated box containers were
16''.times.13''.times.9''. Gel packs were added to the cavity of
the thermal insulating liners. Total gel pack weight was 2.times.48
oz. per insulating liner. The thermal insulating liners were folded
at the opening created by the first side portion and the second
side portion. The corrugated box containers were then covered. FIG.
14.
Example 13. Thermal Insulating Liner Composition Test
[0287] In this illustration, all insulating liners were 1.0 inch
thick. "2 pc" refers to thermal insulating liners that were
manufactured according to example 5 and refers to the A|B design
wherein the thermal insulating liners are placed independently into
a six sided container to cover all six internal walls. "kraft"
refers to thermal insulating liners manufactured with a kraft paper
barrier. "Jute 30% wool" refers to an insulating layer manufactured
to comprise a composite of 70% jute and 30% wool. In this
illustration, jute insulating layers were manufactured at a density
of about 1535 g/m.sup.2 and 2185 g/m.sup.2. Each thermal insulating
liner was placed inside a corrugated box container according to
example 4. The exterior dimensions of the corrugated box containers
were 12''.times.12''.times.12''. Dry ice was added to the cavity of
the thermal insulating liners. Total ice was 3.2 kg per thermal
insulating liner. Thermal insulating liners were folded at the
opening created by the first side portion and the second side
portion. The corrugated box containers were then closed. FIG.
15.
Example 14. Thermal Insulating Liner, Bubble Foil Test
[0288] 0.5 and 0.25 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration, 0.5 inch
thick insulating layers were manufactured at a density of about
1100 g/m.sup.2 and 700 g/m.sup.2. In this illustration, 0.25 inch
thick insulating layers were manufactured at a density of about 430
g/m.sup.2. The thermal insulating liners were placed inside
corrugated box containers according to example 4. The exterior
dimensions of the corrugated box containers were
16''.times.10''.times.10''. Gel packs were added to the cavity of
the thermal insulating liners. Total gel pack weight was 2.times.48
oz. per thermal insulating liner. The thermal insulating liners
were folded at the opening created by the first side portion and
the second side portion. The corrugated box containers were then
closed. The bubble foil insulating liner comprised an enclosure
formed from bubble wrap, and was packaged in a similar manner as
the thermal insulating liners. FIG. 16.
Example 15. Thermal Insulating Liner, Polyurethane A|B Liner
Test
[0289] 1.0 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1275
g/m.sup.2 and about 700 g/m.sup.2. Two 700 g/m.sup.2 insulating
layers were stacked together for this test. Each thermal insulating
liner was placed inside a corrugated box container according to
example 4. The exterior dimensions of the corrugated box containers
were 16''.times.10''.times.10''. Gel packs were added to the cavity
of the thermal insulating liners. Total gel pack weight was
2.times.48 oz. per thermal insulating liner. The thermal insulating
liners were folded at the opening created by the first side portion
and the second side portion. The corrugated box containers were
then covered. The PUR foam insulating liner was 1.0 inch thick, and
was packaged in a similar manner as the thermal insulating liners.
FIG. 17.
Example 16. Thermal Insulating Liner, EPS Foam Test
[0290] A 1.0 inch thick jute thermal insulating liner was
manufactured according to example 4. In this illustration, the
insulating layer was manufactured at a density of about 1500
g/m.sup.2. The thermal insulating liner was placed inside a
corrugated box container according to example 4. The exterior
dimensions of the corrugated box container were
16''.times.13''.times.9''. Dry ice was added to the cavity of the
thermal insulating liner. Total dry ice weight was 3.2 kg. The
thermal insulating liner was folded at the opening created by the
first side portion and the second side portion and the corrugated
box container was closed. The EPS foam insulating liner was 1.0
inch thick, and was packaged in a similar manner as the thermal
insulating liner. FIG. 18.
Example 17. Thermal Insulating Liner, Polyurethane A|B Liner
Test
[0291] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2. Each thermal insulating liner was placed inside a
corrugated box container according to example 4. The exterior
dimensions of the corrugated box containers were
22''.times.15''.times.12''. Gel packs were added to the cavity of
the thermal insulating liner. Total gel pack weight was 2.times.48
oz.+32 oz. per thermal insulating liner. The thermal insulating
liners were folded at the opening created by the first side portion
and the second side portion. The corrugated box containers were
thereafter closed. The PUR foam insulating liner was 1.0 inch
thick, and was packaged in a similar manner as the thermal
insulating liner. FIG. 19.
Example 18. Thermal Insulating Liner, Polyurethane A|B Liner
Adhesive Test
[0292] This test was performed according to Example 19. However, in
this test, thermal insulating liners were fitted with adhesive
strips, "stick and peel". These adhesives strips were used to aid
the closing of each thermal insulating liner. FIG. 20.
Example 19. Gusset/Non-Gusset Test
[0293] 1.0 inch jute thermal insulating liners were manufactured
according to example 4. Gusseted jute thermal insulating liners
were manufactured according to example 3. In this illustration,
insulating layers were manufactured at a density of about 1200
g/m.sup.2. Each thermal insulating liner was placed inside a
corrugated box container. The exterior dimensions of the corrugated
box containers were 15''.times.10.5''.times.10.5''. Gel packs were
added to the cavity of the thermal insulating liner. Total gel pack
weight was 1.times.32 oz. per thermal insulating liner. The thermal
insulating liners were folded at the opening created by the first
side portion and the second side portion and the corrugated box
container was closed thereafter. FIG. 21.
Example 20. Adhesive/Non Adhesive Test
[0294] 1.0 inch jute thermal insulating liners were manufactured
according to example 3. In this illustration, insulating layers
were manufactured at a density of about 1100 g/m.sup.2. In this
illustration, a first thermal insulating liner was fitted with an
adhesive strip to aid in closing the liner. A second thermal
insulating liner was not fitted with said adhesive strip. Each
thermal insulating liner was placed inside a corrugated box
container. The exterior dimensions of the corrugated box containers
were 16''.times.13''.times.9''. Gel packs were added to the cavity
of the thermal insulating liners. Total gel pack weight was
2.times.48 oz. per thermal insulating liner. The thermal insulating
liners were folded at the opening created by the first side portion
and the second side portion and the corrugated box container was
thereafter closed. The EPS foam insulating liner was 1.0 inch
thick, and was packaged in a similar manner as the thermal
insulating liners. FIG. 22.
Example 21. 0.5 Inch Thermal Insulating Liner, 1.0 Inch
Polyurethane A|B Liner Test
[0295] 0.5 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1100
g/m.sup.2 and about 1300 g/m.sup.2. Each thermal insulating liner
was placed inside a corrugated box container according to example
4. The exterior dimensions of the corrugated box containers were
16''.times.13''.times.12''. Gel packs were added to the cavity of
the thermal insulating liner. Total gel pack weight was 2.times.48
oz. per thermal insulating liner. The thermal insulating liners
were folded at the opening created by the first side portion and
the second side portion and the corrugated box containers were
thereafter closed. The PUR foam insulating liner was 1.0 inch
thick, and was packaged in a similar manner as the thermal
insulating liners. FIG. 23.
Example 22. Thermal Insulating Liners, Polyurethane A|B Liner Food
Test
[0296] 1.0 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of about 1270
g/m.sup.2. 2 layers indicate that insulating layers were stacked
together for this test. 2 layer thermal insulating liners had a
final thickness of about 1.85-about 2.0 inches. Each thermal
insulating liner was placed inside a corrugated box container
according to example 4. The exterior dimensions of the corrugated
box containers were 16''.times.13''.times.9''. Gel packs were added
to the cavity of the thermal insulating liners. Total gel pack
weight added to the PUR Foam, Jute, Jute, Jute, Jute 2 layers, and
the Jute 2 layers thermal insulating liner were 6 lbs (2.722 kg), 6
lbs (2.722 kg), 9 lbs (4.082 kg), 12 lbs (5.443 kg), 9 lbs (4.082
kg), and 12 lbs. (5.443 kg) respectively. Food products were also
added to the cavity of the thermal insulating liners. Food products
totaled 6 lbs (2.722 kg). per thermal insulating liner. The thermal
insulating liners were folded at the opening created by the first
side portion and the second side portion and the corrugated box
container were thereafter closed. The PUR foam insulating liner was
1.0 inch thick and was packaged in a similar manner as the thermal
insulating liners. FIG. 24.
Example 23. Thermal Insulating Liners Food Test
[0297] 1.0 inch thick jute thermal insulating liners were
manufactured according to example 4. In this illustration,
insulating layers were manufactured at a density of 1275 g/m.sup.2.
2 layers indicate that insulating layers were stacked together for
this test. 2 layer thermal insulating liners had a final thickness
of about 1.85-about 2.0 inches. Each thermal insulating liner was
placed inside a corrugated box container according to example 4.
The exterior dimensions of the corrugated box container were
16''.times.10''.times.10''. Gel packs were added to the cavity of
the thermal insulating liners. Total gel pack weight was 12 lbs.
(5.443 kg). per thermal insulating liner. Food products were also
added to the cavity of the thermal insulating liners. Food products
totaled 6 lbs (2.722 kg). per thermal insulating liner. Thermal
insulating liners were folded at the opening created by the first
side portion and the second side portion and the corrugated box
container was thereafter closed. FIG. 25.
Example 24. LP Summer, LP Winter, Wool Liner Test
[0298] LP Summer refers to a 1.85-2.0 inch thick jute thermal
insulating liner according to example 4, comprising 2 layers of
insulating layers manufactured each at a density of about 1275
g/m.sup.2. LP Winter refers to a 1 inch thick jute thermal
insulating liner according to example 4, comprising 1 layer of an
insulating layer manufactured at a density of about of 1275
g/m.sup.2. Each thermal insulating liner was placed inside a
corrugated box container according to example 4. The exterior
dimensions of the corrugated box container were
14''.times.12''.times.10''. Ice was added to the cavity of the
thermal insulating liners. Total ice for the first LP Summer was
2,000 ml. Total ice for the Wool liner was 1,000 ml. Total ice for
the second LP Summer was 1,000 ml. Total ice for the LP winter was
1,000 ml. Thermal insulating liners were folded at the opening
created by the first side portion and the second side portion and
the corrugated box containers thereafter closed. The Wool liner
insulating liner was about 1.0 inch thick, and was packaged in a
similar manner as the thermal insulating liners. FIG. 26.
[0299] While preferred embodiments have been shown and described
herein, it will be obvious to those skilled in the art that such
embodiments are provided by way of example only. Numerous
variations, changes, and substitutions will now occur to those
skilled in the art. It should be understood that various
alternatives to the embodiments of the invention described herein
may be employed. It is intended that the following claims define
the scope of the invention and that methods and structures within
the scope of these claims and their equivalents be covered
thereby.
Example 25. Once Piece Box Liner from Paper Strip Loaded with
Pre-Cut Insulating Layer
[0300] A rectangular strip of insulating layer as described herein
was die punched to form an insulating layer having a shape similar
to " ". The cut out material was placed in the center of the die
cut insulating layer. The die cut insulating layer was inserted
into a continuous half folded line of kraft paper. FIG. 27. The
kraft paper was sealed with a band sealer on the edges opposite the
fold. The kraft paper was cut along the width, perpendicular to the
length on the top and bottom of the length. The newly cut edges
were sealed with a clamp sealer (impulse or direct heat sealer)
thus enclosing the insulating layer. The kraft paper enclosing the
insulating layer is thereafter folded in half along the centerline
connecting one side length to the other side length. The edges
formed by the fold were taped together with kraft tape 300.
Optionally, the edges can be sewn together or fastened by other
mechanical means. FIG. 28-30. Optionally, a gusset can be formed
and taped 300 into place to give the part a 3D attribute. FIG. 29.
The resulting one piece box liner (thermal insulating liner) is
shown in FIG. 30.
Example 26. Non-Gusseted A|B Design with Ridged Backing
[0301] The manufacturing process was the same or similar to those
described herein, however the thermal insulating liner comprised
two or more pieces. The thermal insulating liner took the form of
two rectangular strips with kraft barrier having corrugated backing
504 that, when placed into a container such as a grocery bag 500c,
cover all five sides of a five sided container, the lid exposed
502. In this configuration, the corrugated backing 504 provides
rigidity. In this configuration, a first component, was denoted as
"part A", and was placed into a container such that it covered the
bottom surface 503, a first side portion 501, and the remaining
material was used as a flap that acts as the lid when folded 502.
In this configuration, a second component was denoted as "part B"
500b, was subsequently placed into the container 500c and it
covered the three remaining sides of the five sided container. This
non-gusseted A|B design fits into a container such as a grocery bag
to form a rigid, portable cooler. FIG. 32.
Example 27. Non-Gusseted A|B Design Production
[0302] All insulating materials disclosed herein may be used in
this process. In this instance, the barrier comprised kraft paper
600a. A kraft paper 600a roll, was mounted vertically on a roll
holder. The roll was positioned vertically to allow for the paper
to folds on itself by gravity during unwinding. The kraft roll can
be adjusted in height. The kraft paper had a heat-sealable coating
on its interior facing the insulating layer. The production line
spanned about 60 ft. and the distance between two production lines
was about 10 ft. A band sealer 600b, paper trimer 600c, and foot
sealer 600d were positioned along the production line.
[0303] An insulating layer 200 was loaded at the front of the line
and sandwiched between the conformed kraft paper 600a. The band
sealer 600b had traction wheels and pulled the kraft paper 600a
(thus unwinding the roll) while simultaneously sealing the
longitudinal edge. The band sealer 600b had a variable speed and
temperature control, which dictated the production speed and
sealing parameters. Once the unsealed-folded kraft ran through the
band sealer 600b, the outcome is a sealed kraft tube with discrete
pieces of an insulating layer inside.
[0304] The edge 602-604 had the folded edge from the kraft paper
600a roll. The encapsulated insulation layer (now had edge 601-603
sealed) then traveled to the paper trimmer 600c. The paper trimmer
600c had an auto-sharpening blade that was used to cut between two
insulating layers. The result was a tube with a longitudinal seal
on the length 601-603, and two open sides at the extremities,
601-602 and 603-604. The tube then traveled to a foot sealer 600d
to seal edge 603-604. In this instance the foot sealer 600d was an
automatic constant foot-operated heat-sealer. The unfinished
thermal insulating liner was then rotated 180 degrees to trim the
excess kraft on edge 601-602 using a paper trimer 600c. The
unfinished thermal insulating liner edge 601-602 was sealed using a
foot sealer 600d. During this sealing process, the unfinished
thermal insulating liner may be offset to leave a small about 1.0''
ventilation hole unsealed for the air to escape in order to
increase packing efficiency. The individual thermal insulating
liner pieces 600e were thereafter inspected and packed into
gaylords. The number of units of thermal insulating liner pieces
per gaylord was a function of the dimensions of the liners. In some
instances, 150-650 thermal insulating liners can fit into a
40''.times.48''.times.48'' gaylord box. Once filled, the gaylord
box may be closed. In some instances, once filled, the gaylord box
may be taped, labeled and shrink wrapped. FIG. 33-FIG. 38.
* * * * *