An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer or may be housed in a biodegradable plastic. The insulated layer may be manufactured in a capital T shape such that it may be folded for compact transportation prior to end use. The folded insulation layer may bound by a separable band. The separable band may be removed when folded insulation layer is placed in the rigid container. The insulation layer and the band may be biodegradable in an anaerobic environment.

A thermal insulation article for placement in a shipping container to hold an item includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container while leaving an interior space to receive the item. The thermally insulating pad includes a compostable panel that holds together as a single unit and is formed primarily of starch, and compostable or recyclable film forming a pocket and surrounding the panel to prevent water from reaching the panel within the pocket. The film is secured to the panel along a portion but not all of the opposite surfaces of the compostable panel.

In one aspect, a shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

A packaging assembly including an outer box including a plurality of side panels defining an interior cavity; and a wrap liner including an outer portion extending from a first panel to a second panel, the outer portion defining an outer hinge coupling the first panel to the second panel; a ledge portion extending across the first panel and the second panel, the ledge portion coupled to the outer portion by a first ledge hinge and a second ledge hinge; and an inner portion extending across the first panel and the second panel, a first inner hinge, and a second inner hinge each coupling the inner portion to the ledge portion; wherein the wrap liner is disposed within the interior cavity of the outer box.

Method and system are designed for storing and/or transporting temperature-sensitive materials. The system is designed to keep a payload within a desired temperature range of +2 C. to +8 C. for an extended time in a warm ambient environment. The system includes a thermally insulated container and first and second phase-change materials, each of the phase-change materials having a different solid/liquid phase-change temperature. Both phase-change materials are preconditioned to a solid state for pack-out. The first phase-change material has a solid/liquid phase-change temperature that is within the desired temperature range and that is at or below a hibernation temperature of about +5 C. to +6 C. The second phase-change material has a solid/liquid phase-change temperature that is above the hibernation temperature. When placed in the warm ambient environment, both phase-change materials move towards melting; however, when subsequently placed in hibernation, the second phase-change material reverses the direction of its phase change, becoming recharged.

A container includes an outer container including four sides and a bottom constructed from a self-reinforced composite material and/or self-reinforced polymer material. An inner container including a vacuum packed insulative material. The outer container comprising a single sheet of the self-reinforced composite material and/or self-reinforced polymer material with a plurality of tabs that overlap with a plurality of sides of the container. The outer container does not include any interior overlapping seams.

An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer or may be housed in a biodegradable plastic. The insulated layer may be manufactured in a capital T shape such that it may be folded for compact transportation prior to end use. The folded insulation layer may bound by a separable band. The separable band may be removed when folded insulation layer is placed in the rigid container. The insulation layer and the band may be biodegradable in an anaerobic environment.

An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may be characterized by a lack of any wrapping material. The insulation layer may be manufactured using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven material for providing consistent density throughout the insulation layer. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer. The insulation layer may be biodegradable in an anaerobic environment.

A thermal insulation article includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container. The pad includes a solid compostable panel formed primarily of starch and/or plant fiber pulp that holds together as a single unit, and a water-proof or water-resistant film forming a pocket enclosing the panel. The panel includes a first section, a second section, and a third section connecting the first section to the second section, the first and second section each having a central portion and two flaps that extend from the central portion beyond the third section, and wherein the panel is foldable into an open box.

A thermal insulation article for placement in a shipping container to hold an item includes a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container while leaving an interior space to receive the item. The thermally insulating pad includes a compostable panel that holds together as a single unit and is formed primarily of starch, and compostable or recyclable film forming a pocket and surrounding the panel to prevent water from reaching the panel within the pocket. The film is secured to the panel along a portion but not all of the opposite surfaces of the compostable panel.