Abstract
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.
Claims
1. A thermal insulating transport container for the transportation of perishable goods, the thermal insulating transport container comprising: an inner lining comprising one or more side walls formed by bending a sheet material along preformed lines, 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 and wherein when assembled, the outer box layer is substantially waterproof, wherein a side wall of the outer box layer is connected to an adjacent side wall of the outer box layer by at least one locking tab, wherein the inner lining is adapted to be substantially received and retained within the outer box layer, and wherein the thermal insulation sheet material and/or the water resistant thermal insulation sheet material have sealed edges.
2. The thermal insulating transport container as claimed in claim 1, further comprising a lid, wherein the lid is fabricated from a water resistant thermal insulation sheet material.
3. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a material comprising two or more layers.
4. The thermal insulating transport container as claimed in claim 3, wherein one or more of the layers is a foam layer.
5. The thermal insulating transport container as claimed in claim 3, wherein one or more of the layers is a closed cell foam layer.
6. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between two or more layers of a reflective material.
7. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between two or more layers of an antimicrobial material.
8. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between one or more layers of a reflective material and one or more layers of an antimicrobial material.
9. The thermal insulating transport container as claimed in claim 7, wherein the antimicrobial material is a food grade antimicrobial material.
10. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a flexible, thermal insulation sheet material.
11. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a water-resistant thermal insulation sheet material.
12. The thermal insulating transport container as claimed in claim 1, wherein the outer box layer is fabricated from a material comprising two or more layers.
13. The thermal insulating transport container as claimed in claim 1, wherein the outer box layer is fabricated from a corrugated twin wall plastic sheet.
14. The thermal insulating transport container as claimed in claim 1, wherein at least one of the inner lining, the outer box layer, or the lid, comprise one or more monitoring devices.
15. The thermal insulating transport container as claimed in claim 14, wherein at least one monitoring device is used to track the location of the thermal insulating transport container, the inner lining thereof, the outer box layer thereof, or the lid thereof.
16. The thermal insulating transport container as claimed in claim 14, wherein data obtained from the one or more monitoring devices is written to a Blockchain.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0066] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:
[0067] FIG. 1 illustrates a perspective view of a thermal insulating container according to an embodiment of the invention without lid;
[0068] FIG. 2 illustrates a perspective view of an inner lining according to an embodiment of the invention;
[0069] FIG. 3 illustrates an inner lining according to an embodiment of the invention in a storage condition;
[0070] FIG. 4 illustrates a perspective view of a thermal insulating container according to an embodiment of the invention where the inner lining has not been sealed;
[0071] FIG. 5 illustrates a front view of a thermal insulating container according to an embodiment of the invention where the inner lining has not been sealed;
[0072] FIG. 6 illustrates a blank used to form an outer box layer according to an embodiment of the present invention;
[0073] FIG. 7 illustrates a blank used to form a lid for an outer box layer according to an embodiment of the present invention;
[0074] FIG. 8 illustrates a blank used to form an inner lining according to an embodiment of the present invention;
[0075] FIG. 9 illustrates a blank used to form an inner lining according to an embodiment of the present invention;
[0076] FIG. 10 illustrates a perspective view of an outer box layer according to an embodiment of the invention;
[0077] FIG. 11 illustrates a top view of a lid for an outer box layer according to an embodiment of the invention and shown in an inverted condition;
[0078] FIG. 12 shows a close up view of the side edges of an inner lining according to an embodiment of the invention;
[0079] FIG. 13 shows a front view of a lid according to an embodiment of the invention;
[0080] FIG. 14 shows a graph of temperature changes for an airfreight approved, expanded polystyrene box and the thermal insulating transport container according to an embodiment of the present invention;
[0081] FIG. 15 shows a graph of temperature changes for an airfreight approved, expanded polystyrene box and the thermal insulating transport container according to an embodiment of the present invention;
[0082] FIG. 16 shows a top perspective view of a thermal insulating transport container according to an embodiment of the invention without lid;
[0083] FIG. 17 shows a top perspective view of an inner lining according to an embodiment of the invention;
[0084] FIG. 18 shows a perspective view of a thermal insulating transport container according to an embodiment of the invention;
[0085] FIG. 19 illustrates a thermal insulating transport container according to an embodiment of the invention in use;
[0086] FIG. 20 illustrates a thermal insulating transport container according to an embodiment of the invention;
[0087] FIG. 21 illustrates a thermal insulating transport container according to an embodiment of the invention in use;
[0088] FIG. 22 illustrates a thermal insulating transport container according to an embodiment of the invention in use;
[0089] FIG. 23 shows a graph of temperature and humidity over 1.2 day time period during transport testing of an airfreight approved corrugated cardboard container;
[0090] FIG. 24 shows a graph of temperature and humidity over 1.2 day time period during transport testing of a transport container manufactured from plastic corrugated twin wall sheets; and
[0091] FIG. 25 shows a graph of temperature and humidity over 1.2 day time period during transport testing of a thermal insulating transport container according to an embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
[0092] In FIG. 1, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated. The thermal insulating transport container (100) comprises an inner lining (1) and an outer box layer (2). A lid (not shown) for the outer box layer (3) may be provided. Outer box layer (2) may comprise one or more apertures (10a, 11a, 13a) which substantially align with monitoring devices (10, 11, 13) located on the inner lining (1). Apertures (10a, 11a, 13a) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the outer box layer (2). Outer box layer (2) may comprise one or more monitoring devices (9), such as a NFC tag, which may track the location of the outer box layer or passively monitor and log the temperature. A side wall of the outer box layer (2) may be connected to an adjacent end wall by at least one male locking tab (4) which fits into a corresponding female locking pocket (not shown).
[0093] In FIG. 2, the inner lining (1) of a thermal insulating transport container (100) according to an embodiment of the invention is illustrated. In FIG. 3, the inner lining (1) of a thermal insulating transport container according to an embodiment of the invention is illustrated in a storage condition. In FIG. 4, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated in use wherein inner lining (1) in a partially assembled state is substantially received in outer box layer (2).
[0094] In FIGS. 2 to 4, inner lining (1) comprises an outer facing fabricated from a metallised reflective layer and an inner facing fabricated from a food grade antimicrobial layer. An NFC tag (13) is located on the outer facing of the inner lining (1). In a fully assembled state, it is envisaged that an end of the inner lining (1) may be folded over on a thermally induced fold lines (17) in the inner lining (1) and sealed by compression (18) to close the inner lining (1). (Tape (12) to hold inner lining closed is used for display purposes only. Weights (25) to hold the inner lining flat are used for display purposes only.)
[0095] In FIG. 5, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated in use wherein inner lining (1) in a partially assembled state is partially received in outer box layer (2). In an assembled state, side locking flaps (7) on a side wall of the outer box layer (2) are folded over such that they extend at least partially across side locking tabs (6) and into the cavity of the outer box layer (2). In this way, it is envisaged that the side locking flaps (7) substantially retain the end wall and side wall of outer box layer (2) in an erected condition. In an assembled state, male locking tabs (4) which fit into corresponding female locking pockets (5) when the outer box layer (2) and substantially retain the end wall and the side wall of the outer box layer (2) in an erected condition.
[0096] In FIG. 6, a blank for forming an outer box layer (2) according to an embodiment of the invention is illustrated. The outer box layer (2) comprises male locking tabs (4) which fit into corresponding female locking pockets (5) and side locking flaps (7) which fit into corresponding locking pockets (6) on an end wall of the outer box layer.
[0097] In FIG. 7, a blank for forming a lid (3) for an outer box layer (2) according to an embodiment of the invention is illustrated. Lid (3) comprises end locking tabs (19) located on the edge of the end walls and side walls of the lid (3) and end locking flaps (20) hingedly attached at each end wall of lid (3). Lid (3) further comprises male locking tabs (21) which, fit into corresponding female locking pockets (22). Indica (200) may be provided on an outer surface of the lid (3).
[0098] In FIGS. 8 and 9, a blank for forming an inner lining (1) according to an embodiment of the invention is illustrated. The inner lining (1) comprises thermally induced formed fold lines (17) and one or more monitoring devices (13,11), such as NFC tags, which may track the location of the outer box layer or passively monitor and log the temperature. At least a portion of inner lining (1) comprises sealed edges (23). Inner lining (1) comprises an outer facing fabricated from a metallised reflective layer, the periphery of which extends beyond the periphery of an inner facing at (overlapping material, 24). It is envisaged that when the inner lining is assembled, overlapping material (24) on one portion of the inner lining (1) may abut overlapping material (24) on second portion of the inner lining (1). The abutting, overlapping material (24) may be sealed to provide a water-resistant barrier.
[0099] In FIG. 10, lid (3) in the form of an open box structure may be fitted over the outer box layer (2) such that the side panels of the lid extend substantially over the side panels of the outer box layer (2). Lid (3) comprises male locking tabs (21) which fit into corresponding female locking pockets (22). Lid (3) may be provided with one or more monitoring devices (8) which may track the location of the outer box layer or passively monitor and log the temperature. Lid (3) may also be provided with apertures (16) which substantially align with monitoring devices (10, 11 and 13) located on the inner lining (1). Apertures (16) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the lid (3). Lid (3) may comprise one or more monitoring devices (8), such as an NFC tag, which may track the location of the outer box layer or passively monitor and log the temperature.
[0100] In FIG. 11, a top view of a lid for an outer box layer in an inverted condition is shown. Locking flaps (20) on an end wall of the lid (3) are folded over such that the folded locking flaps at least partially extend across locking tabs (19) located on adjacent end and side walls of lid (3) and into the cavity of the lid (3). In this way, it is envisaged that the end locking flaps (20) substantially retain the end and side walls of the lid (3) in an erected condition. In an assembled state, the lid (3) comprises male locking tabs (21) which fit into corresponding female locking pockets (22) substantially retain the end wall and side wall of lid (3) in an erected condition.
[0101] In FIG. 12, a close up view of the side edges of an inner lining (1) according to an embodiment of the invention are shown. Inner lining (1) comprises thermally induced fold lines (17) and sealed edges (23).
[0102] In FIG. 13, a front view of a lid (3) according to an embodiment of the invention is illustrated. Lid (3) is provided with a metallised oriented polypropylene film (29) for improved thermal performance. The metallised oriented polypropylene film (29) may be provided with apertures (16) which substantially align with monitoring devices (10, 11 and 13) located on the outer box layer and/or the inner lining (not shown). Apertures (16) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the lid (3). The lid (3) may comprise one or more monitoring devices (8), such as an NFC tag, which may track the location of the lid or passively monitor and log the temperature.
[0103] In FIG. 14, the results of a trial assessing the internal temperature changes of an airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention is shown (see Example 2). Surprisingly, the thermal insulating transport container of the present invention has a higher thermal resistance than an expanded polystyrene box, exhibiting a slower increase in temperature than the current airfreight approved expanded polystyrene box.
[0104] In FIG. 15, a graph of temperature changes for an airfreight approved, expanded polystyrene box and embodiments of the thermal insulating transport container of the present invention is shown (see Example 3). Surprisingly, the thermal insulating transport container of the present invention has a higher thermal resistance than an expanded polystyrene box, exhibiting a slower increase in temperature than the current airfreight approved expanded polystyrene box. The experiment also demonstrates that providing the thermal insulating transport container with an additional reflective layer on an outside surface of the lid (Box 1 and Box 2, Silver KoolPak, versus Box 3, White KoolPak) improves the thermal performance of the thermal insulating transport container.
[0105] In FIG. 16, a thermal insulating transport container (300) according to an embodiment of the invention is illustrated. Thermal insulating transport container (300) comprises an inner lining (301) and an outer box layer (302). Outer box layer (302) and inner lining (301) are shown in a substantially rectangular prism configuration which may be used for the transportation of whole fish.
[0106] In FIG. 17, the inner lining (301) of the thermal insulating transport container (300) is shown in a partially assembled state. Inner lining (301) is fabricated from a thermal insulation sheet layer comprising a foam layer encapsulated between an upper and lower reflective layer. Edges (305) of the inner lining have been sealed to improve the thermal insulating capacity of the material and to assist with food grade status approval. In use, it is envisaged that side walls (303) of the inner lining may be formed by bending a flexible sheet of material along preformed lines (306) and longitudinally closing the ends (304) using an aluminium tape (307).
[0107] In FIG. 18, the outer box layer (302) of the thermal insulating transport container (300) is shown. Outer box layer (302) is fabricated from a water-resistant thermal insulation sheet layer in the form a pair of sheets separated by a plurality of ribs. The outer box layer may have sealed edges (not shown) to improve the thermal insulating capacity of the material and assist with food grade status approval. In use, it is envisaged that the outer box layer (302) may be formed by folding a box blank along preformed lines to form a base (not shown), side walls (313) and end walls (314). A side wall (313) may be connected to an adjacent end wall (314) by at least one male locking tab (318) which fits into a corresponding female locking pocket (not shown). A lid (319) may be formed by bending a side wall (313) along a preformed line and securing abutting edges of side wall (313) and lid (319) with adhesive tape.
[0108] In FIGS. 19 and 20 a thermal insulating transport container (300) in a cardboard box (320) is shown. Optionally, straps (321) may be provided to secure lid (319) to outer box layer (302). In use, it is envisaged, that straps (321) may assist in moving and lifting the thermal insulating transport container (300).
[0109] In FIG. 21, a thermal insulating transport container according to an embodiment of the invention is shown in use. The inner lining (1) comprising an inner facing fabricated from a food grade antimicrobial layer (26) has been packed with fresh fish fillets (28) and frozen gel packs (27). FIG. 21 in an empty state is the container used in a transport trial (Example 3, Box 2 Silver KoolPak).
[0110] In FIG. 22, a thermal insulating transport container according to an embodiment of the invention used in a transport trial (see Example 1) is shown. The inner lining (301) comprising an inner facing fabricated from a reflective layer and sealed with aluminium tape (307) has been packed with fish fillets (28) inside a plastic bag.
[0111] FIGS. 23 to 25 illustrate the change in temperature and humidity over 1.2 day time period during transport testing of an airfreight approved, corrugated cardboard container (FIG. 23), a transport container fabricated from plastic corrugated twin wall sheets (FIG. 24) and a thermal insulating transport container according to an embodiment of the invention (FIG. 25) as explained in Example 1. Surprisingly, the thermal insulating transport container of the present invention is more effective at maintaining a stable humidity and temperature than the current airfreight approved packaging options.
EXAMPLE 1: TEMPERATURE AND HUMIDITY MONITORING USING DIFFERENT TRANSPORT CONTAINERS
[0112] A data logger was placed in with the whole fish inside a 100 micron polyethylene bag and goose neck cable tied closed. This package resided inside a second 100 micron polyethylene bag that contained the cooling gel packs, it was also goose neck cable tied closed (maintaining separation of fish and gel packs). Both fish and gel packs resided inside the thermal lining which was fitted inside the test transport containers (see FIG. 22). The test transport containers included an airfreight approved, corrugated cardboard container, a transport container fabricated from plastic corrugated twin wall sheets (“Fluted PP transport container”) and the thermal insulating transport container of the present invention. The Fluted PP transport container and the thermal insulating container of the present invention were placed inside an airfreight approved, corrugated cardboard container for transport in order to comply with the appropriate regulations.
[0113] The humidity and temperature of the interior of each box was monitored over a time period of 1.2 days every 15 minutes.
[0114] The results for the airfreight approved, corrugated cardboard container may be found in FIG. 23.
[0115] The humidity and temperature in the cardboard container varied considerably. The temperature varies between 18.6° C. and 2.5° C. with an average of 6.9° C. and represented an “out of cold chain” transport situation 3 times for varying duration. Temperature and humidity stabilised only after re-entry in the cold chain at time point approximately 20:53.
[0116] This clearly shows that the airfreight approved, corrugated cardboard container is not efficient at maintaining the required temperature and humidity to ensure the quality of the product and therefore not suitable as a standalone “out of cold chain” transport container.
[0117] The results for the Fluted PP transport container may be found in FIG. 24.
[0118] Both the humidity and temperature varied although the insulation qualities of the Fluted PP transport container reduced that somewhat. The temperature varies between 15.9° C. and 3.2° C. with an average of 3.6° C. The humidity varies between 85.2% to 68.9% with an average of 82.1%. Temperature and humidity stabilised only after re-entry in the cold chain at time point approximately 20:53.
[0119] This clearly shows that a transport container fabricated from plastic corrugated twin wall sheets is not efficient at maintaining the required temperature and humidity to ensure the quality of the product and therefore not suitable as a standalone “out of cold chain” transport container.
[0120] The results for the thermal insulating transport container of the present invention may be found in FIG. 25.
[0121] Both the humidity and temperature are relatively constant and only varied during activation and placement in the consignment. The temperature varies between 15.1° C. and −0.6° C. with an average of 0.2° C. But once stabilised at time point approximately 06:08 the variation is negligible. The humidity varied between 93.1% to 68.2% with an average of 90.6%. But once stabilised at time point approximately 06:08 the variation is negligible.
[0122] This shows that the thermal insulating transport container of the present invention is efficient at maintaining the required temperature and humidity to ensure the quality of the product.
EXAMPLE 2: MEASURING THE THERMAL RESISTANCE OF AN EXPANDED POLYSTYRENE BOX AND A THERMAL INSULATING TRANSPORT CONTAINER OF THE PRESENT INVENTION
[0123] An airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention were provided with data loggers and sealed. The boxes were placed in an environment having a temperature of 4° C. and when equilibrated were transferred to a second environment having a temperature of 30° C. The temperature of the interior of the empty boxes was monitored over a time period of approximately 90 minutes at one minute intervals. The results are shown in FIG. 14.
[0124] The internal temperature of the polystyrene box reached 25° C. after 30 minutes and 30° C. after approximately 65 minutes. In contrast, the container of the present invention required approximately 43 and 83 minutes respectively to reach the same temperatures.
[0125] This result clearly shows that the container of the present invention has a higher thermal resistance than an expanded polystyrene box.
EXAMPLE 3: MEASURING THE THERMAL RESISTANCE OF DIFFERENT TRANSPORT CONTAINERS
[0126] An airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention were provided with data loggers and sealed. Two of the thermal insulating transport containers were provided with a metallised oriented polypropylene film on the outside surfaces of the lid.
[0127] The boxes were placed in an environment having a temperature of 4° C. and when equilibrated were transferred outdoors having an environmental temperature of 33° C. and exposed to sunlight. The temperature of the interior of the empty boxes was monitored over a time period of approximately 90 minutes at one minute intervals. The results are shown in FIG. 15.
[0128] The internal temperature of the polystyrene box reached 25° C. after 20 minutes and exceeded the environmental temperature (33° C.) after approximately 25 minutes. The transport container of the present invention (without metallised oriented polypropylene film) required approximately 30 and 40 minutes respectively to reach the same temperatures. The transport container of the present invention (with metallised oriented polypropylene film) required approximately 30 and 50 minutes respectively to reach the same temperatures.
[0129] This result clearly shows that the container of the present invention has a higher thermal resistance than polystyrene. This result also shows that providing the transport container of the present invention with an additional reflective layer on the outside of the lid improves the thermal performance of the transport container when exposed to sunlight.
[0130] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.
[0131] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
[0132] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.
