Biodegradable insulative shipping container

Abstract

A shipping container, particularly suited for shipping wine bottles within a shipping box, having a pair of container halves. Each container half includes an outer tray that is shaped to fit the shipping box, and an inner tray that is configured for securely holding one or more wine bottles. Both the outer tray and inner tray are made of readily recyclable pulp material, and have a void therebetween. A starch based biodegradable insulation material fills the void therebetween, such that the shipping container is made entirely of biodegradable material, yet is sturdy and has insulative properties.

Claims

1. A method of manufacturing a biodegradable insulative shipping container, the shipping container having two container halves, for each container half, the method comprising the steps of: providing a substantially rectangular prism shaped outer tray comprising a pulp material, the outer tray having side walls that extend substantially perpendicularly to each other and a bottom; providing an inner tray comprising a pulp material, the inner tray having a top, a peripheral edge at the top, the peripheral edge substantially rectangular and including four flaps extending outwardly therefrom and bendable to extend downwardly therefrom, and an irregular concave valley including a continuous surface that extends downwardly from the peripheral edge to define an interior volume that is adapted to receive shipping goods; creating a void between the concave valley and the bottom of the outer tray by aligning the peripheral edge of the inner tray with the side walls of the outer tray; filling the void with biodegradable insulative material by placing a prefabricated substantially solid insulation tray comprising a biodegradable insulative material in the void between the inner tray and outer tray; and sealing the inner tray to the outer tray by heat pressing the inner tray, insulative tray, and outer tray together.

2. The method of manufacturing a biodegradable insulative shipping container as recited in claim 1, wherein the step of sealing the inner tray to the outer tray further comprises: folding the flaps downwardly from the peripheral edge; coating the flaps with adhesive; and extending the flaps within the outer tray toward the bottom and against the side walls.

3. The method of manufacturing a biodegradable insulative shipping container as recited in claim 2, wherein the void formed between the irregular concave valley and the bottom of the outer tray is such that no portion of the inner tray contacts the bottom of the outer tray.

4. The method of manufacturing a biodegradable insulative shipping container as recited in claim 3, wherein the inner tray further comprises a plurality of ribs adapted to support a body of the shipping goods.

5. The method of manufacturing a biodegradable insulative shipping container as recited in claim 4, wherein the inner tray further comprises a neck hollow adapted to support a neck of the shipping goods, the plurality of ribs and the neck hollow defining the interior volume adapted to receive the shipping goods.

6. The method of manufacturing a biodegradable insulative shipping container as recited in claim 5, wherein the irregular concave valley includes a continuous recessed channel that spans the length of the irregular concave valley to the neck hollow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings, like elements are depicted by like reference numerals. The drawings are briefly described as follows.

(2) FIG. 1A is a diagrammatic perspective view, providing an outside view of a shipping container, wherein the shipping container halves are mated together to close the container.

(3) FIG. 1B is a diagrammatic perspective view, illustrating one of the halves of the shipping container. In the example illustrated, the container is configured for securely holding and shipping bottles of wine.

(4) FIG. 2A is a cross sectional view of one of the shipping container halves, illustrating a multi-layer construction made in accordance with the principles of the present disclosure, wherein an insulation tray is placed between the outer tray and inner tray.

(5) FIG. 2B is a cross sectional view, similar to FIG. 2A, illustrating fabrication of one of the container halves using expandable insulation pellets that are introduced into the void between the outer tray and inner tray.

(6) FIG. 3 is an exploded view, illustrating a further embodiment of the shipping container, wherein the inner tray and outer tray are being assembled.

(7) FIG. 4 is a diagrammatic perspective view, showing the embodiment of FIG. 3 wherein the inner tray and outer tray are assembled into the container half.

(8) FIG. 5A is a cross sectional view, illustrating the embodiment of FIG. 3.

(9) FIG. 5B is a cross sectional view, illustrating the embodiment of FIG. 3, in the position shown in FIG. 4, with the insulation not shown for clarity of illustration.

(10) The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, which show various example embodiments. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that the present disclosure is thorough, complete and fully conveys the scope of the present disclosure to those skilled in the art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(11) FIG. 1A illustrates a shipping container 10. The shipping container includes two shipping container halves 12, each having a mating edge 14. The shipping container 10 is substantially rectangular prism shaped, and are thereby sized and shaped to fit within a shipping box, such as a standard corrugated box. The shipping container halves 12 are substantially the same size and shape, and are substantially symmetrical with respect to the mating edge 14. When the shipping container is in a closed position, as illustrating, the mating edges 14 of the shipping container halves 12 are aligned and contact each other.

(12) Referring now to FIG. 1B, one of the shipping container halves 12 has been removed, revealing the interior of the shipping container 10. In particular each shipping container half 12 includes an outer tray 21 and an inner tray 22. The outer tray 21 is generally black and the inner tray 22 is generally white. Note that the outer tray 21 is generally shaped to conform to the rectangular shipping box in which it is placed during ordinary usage. The inner tray 22, however, is configured to accept, securely hold, and cushion the desired contents, namely shipping goods intended to be transported. Such shipping goods may include (but are not limited to) items such as wine bottles, as well as various food and medical items. In the example illustrated, wine bottles 40 are the shipping goods that the shipping container 10 is adapted to hold securely for shipment. Each wine bottle 40 has a body 42 and a neck 44.

(13) The inner tray 22 is configured with several large cavities 24, each large cavity for holding the body 42 of one of the wine bottles 40. In addition a plurality of ribs 26 extend into each cavity to contact the body 42 of its associated wine bottle 40. By contacting only a portion of the bottle, the ribs 26 aid the insulative performance of the container 10. In addition, the inner tray 22 provides a neck hollow 28 for each wine bottle, for accommodating the neck thereof. The inner tray also has several protruding mating portions 29A and receding mating portions 29B, which protrude and recede from the plane of the mating edge 14, such that the protruding mating portions 29A are received within the receding mating portions 29B of the other container half 12, and vice versa.

(14) Note that in the example illustrated the inner tray 22 is configured for holding three wine bottles. It should be understood, however, that the inner tray 22 may be easily reconfigured or resized to hold a different number of wine bottles. In addition, the precise layout of the inner tray, and its topological features, may be varied while adhering to the principles described herein.

(15) Referring now to FIG. 2A, interior construction of the shipping container 10 is illustrated. In particular, generally between the inner tray 22 and outer tray 21 is a void 23. Note that the mating edge 14 may actually be layered—formed of portions of both the inner tray 22 and outer tray 21, such that the mating edge 14 actually becomes a sealing surface between the inner tray 22 and outer tray 21. In accordance with the principles of the present disclosure, it is desirable to fill the void 23 with a biodegradable, recyclable and sustainable, insulative material. Illustrated in FIG. 2A, the void is filled with an insulation tray 51, that is substantially solid and in a single, pre-shaped piece as fabricated, and shaped to fit the void 23. A suitable material for the insulation tray 51 is a starch and fiber based material sold under the tradename PAPERFOAM. To manufacture the shipping container according to this embodiment, the insulation tray 51 is placed between the inner tray 22 and outer tray 21. In the example illustrated, the three trays 21, 51, 22, are then heat-pressed together. Other techniques may be employed for joining the inner tray 22 and outer tray 21, as will be described further, hereinbelow.

(16) In the embodiment of FIG. 3 and FIG. 5A, the mating edge 14 includes four flaps 14A that extend from the inner tray 22 and are configured to fold and extend into the outer tray 21 and secure thereto. In particular, the inner tray has a top 22T and a substantially rectangular peripheral edge 22P located along the top 22T. The flaps 14A extend outwardly from the peripheral edge 22P and are foldable to extend downwardly therefrom (as shown). In addition, the outer tray 21 has four side walls 21S that are substantially perpendicular to each other and have a side wall top 21T. The outer tray 21 also has a bottom panel 21B, the side walls 21S extending upwardly from the bottom panel 21B by a sidewall height. The inner tray 22 includes an irregular concave valley 24A, the valley is a continuous surface that extends downwardly from the peripheral edge 22P and top 22T to define an interior volume that is adapted to accept shipping goods, and may include the large cavities 24 for holding wine bottles or other shipping goods, as described above with reference to FIG. 1B. The concave valley 24A only extends below but does not protrude above the top 22T. The concave valley 24A includes a recessed channel 25 spanning the longitudinal length of concave valley 24A to the neck hollow 28. The recessed channel 25 helps with air flow through the inner tray 22 when the shipping container is closed.

(17) Referring now to FIG. 5B, the flaps 14A are configured to fit within the outer tray 21, such that they extend within the side walls 21S toward the bottom panel 21B. The flaps may be coated with an adhesive such that as they extend against the side walls 21S they will bond securely thereto, to affect a tight seal between the inner tray 22 and outer tray 21. Once insulative material is placed in the void 23 between the inner tray 22 and outer tray 21, as described herein, they thereby form the completed shipping container half 12, shown in FIGS. 4 and 5B.

(18) FIG. 2B shows a further embodiment of the container, wherein the void 23 between the inner tray 22 and outer tray 21 is filled with expandable starch insulation pellets 52. The assembly of the outer tray 21 and inner tray 22 with the starch insulation pellets 52 is then heated within a pressurized oven. As the pellets are heated, they expand to fill up the void 23 between the outer tray 21 and inner tray 22. Once removed from the oven, the assembly is then heat pressed to seal the outer tray 21 and inner tray 22 together—trapping the now expanded insulation pellets 52 therebetween.

(19) It is understood that when an element is referred hereinabove as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

(20) Moreover, any components or materials can be formed from a same, structurally continuous piece or separately fabricated and connected.

(21) It is further understood that, although ordinal terms, such as, “first,” “second,” “third,” are used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer” or “section” discussed below could be termed a second element, component, region, layer or section without departing from the teachings herein.

(22) Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, are used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It is understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

(23) Example embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein, but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

(24) In conclusion, herein is presented a biodegradable insulative shipping container. The disclosure is illustrated by example in the drawing figures, and throughout the written description. It should be understood that numerous variations are possible, while adhering to the inventive concept. Such variations are contemplated as being a part of the present disclosure.