A process for forming a container from a blank, the process comprising the steps of: thermally inducing one or more fold lines on at least one surface of a container blank fabricated from a thermal insulation sheet material, wherein the blank comprises: a first panel portion; a second panel portion located adjacent the first panel portion and sharing a first common edge therewith; and a third panel portion located adjacent the second panel portion and sharing a second common edge therewith, the second common edge being substantially parallel to the first common edge, wherein the first panel portion and the third panel portion are each associated with a pair of flap members adapted for folding movement relative to the respective first and third panel portions such that, when assembled, each of the flap members overlies an edge of the second panel portion substantially perpendicular to the first common edge and the second common edge, folding the first panel portion of the container blank along a first fold line, wherein when folded, the first panel portion is substantially perpendicular to the second panel portion of the container blank; folding the third panel portion of the container blank along a second fold line, wherein when folded, the third panel portion is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion; sealing a portion of each of the pair of flap members of the first panel portion to a portion of each of the pair of flap members of the third panel portion to form a side seam joint; and sealing a portion of the first panel portion adjacent the side seam joint and a portion of the third panel portion adjacent the side seam joint to an edge of the second panel portion to form a bottom seam joint.

A blank made of a polymeric material is provided and used to form at least a portion of a container. The blank is folded to establish a base and a side wall included in the container.

A novel modular thermal insulator is disclosed. The insulator comprises a pliable, thermally insulated container and a one-piece, self-standing, pliable shell. The container includes a front wall, rear wall, left wall, right wall, and bottom wall defining an interior compartment preferably lined with a thermoplastic polyurethane coated nylon. The container also includes a top cover pivotally connected to the rear wall. Each wall and top cover of the container is preferably thermally insulated using high-density open-cell foam insulation. Each wall of the shell defines a form-fitting receptacle for frictionally receiving the container. The shell is preferably comprised of a fabric material capable of being embroidered with, for example, a logo, name, or other indicia. The front wall, rear wall, left wall, right wall, and bottom wall of the container are slid into the receptacle of the shell and held in place by frictional engagement. Thus, with this invention, a user may have multiple, personalized shells, and choose which shell to use depending on the occasion. The result is a high-performance, soft-shelled, customizable thermal insulator with different looks.

Foldable insulation systems may comprise recyclable materials fabricated for ease of insertion into a typical box. Disclosed embodiments include the use of polyester fill encased or covered with a clear membrane or other surface material. Disclosed embodiments eschew the current trend of using biodegradable materials. The use of biodegradable materials represents a new found shortfall in the art as few useful insulation materials are biodegradable within a reasonable period of time. The disclosed insulation systems overcome shortfalls in the art by using polyester type materials that often achieve a number “1” value for recycling. Disclosed embodiments may be comprised of virgin resin or more common material such as recycled bottles and other recycled polymers, polyesters, polypropylenes and similar materials. Disclosed systems include a relatively flat insulation member that may be disposed or attached to the top of a box or other container.

A thermal insulating transport container comprising an inner lining, wherein the inner lining is fabricated from a thermal insulation sheet material; and an outer box layer, wherein the outer box layer is fabricated from a water resistant thermal insulation sheet material, wherein a side wall of the outer thermal insulation box layer is connected to an adjacent side wall of the outer thermal insulation box layer by at least one locking tab.

Molded foam articles are provided. The molded foam articles have at least one surface having at least a portion that has been skin-formed for improving the thermal and mechanical properties of the molded foam articles without the need for material, density, or foam particle size changes.

Foldable insulation systems may comprise recyclable materials fabricated for ease of insertion into a typical box. Disclosed embodiments include the use of polyester fill encased or covered with a clear membrane or other surface material. Disclosed embodiments eschew the current trend of using biodegradable materials. The use of biodegradable materials represents a new found shortfall in the art as few useful insulation materials are biodegradable within a reasonable period of time. The disclosed insulation systems overcome shortfalls in the art by using polyester type materials that often achieve a number 1 value for recycling. Disclosed embodiments may be comprised of virgin resin or more common material such as recycled bottles and other recycled polymers, polyesters, polypropylenes and similar materials. Disclosed systems include a relatively flat insulation member that may be disposed or attached to the top of a box or other container.

A process for forming a container from a blank, the process comprising the steps of: thermally inducing one or more fold lines on at least one surface of a container blank fabricated from a thermal insulation sheet material, wherein the blank comprises: a first panel portion; a second panel portion located adjacent the first panel portion and sharing a first common edge therewith; and a third panel portion located adjacent the second panel portion and sharing a second common edge therewith, the second common edge being substantially parallel to the first common edge, wherein the first panel portion and the third panel portion are each associated with a pair of flap members adapted for folding movement relative to the respective first and third panel portions such that, when assembled, each of the flap members overlies an edge of the second panel portion substantially perpendicular to the first common edge and the second common edge, folding the first panel portion of the container blank along a first fold line, wherein when folded, the first panel portion is substantially perpendicular to the second panel portion of the container blank; folding the third panel portion of the container blank along a second fold line, wherein when folded, the third panel portion is substantially perpendicular to the second panel portion and substantially parallel to the first panel portion; sealing a portion of each of the pair of flap members of the first panel portion to a portion of each of the pair of flap members of the third panel portion to form a side seam joint; and sealing a portion of the first panel portion adjacent the side seam joint and a portion of the third panel portion adjacent the side seam joint to an edge of the second panel portion to form a bottom seam joint.