THERMAL INSULATED SHIPPING CONTAINER

Abstract

A method and system of and for transporting items, including an improved container having thermal isolation and/or insulation characteristics to maintain a desired temperature within the container, the container being lightweight, sturdy, and able to keep its contents well insulated.

Claims

1. A shipping container comprising: a housing including: a bottom wall and four side walls defining an interior compartment, a set of inner folding flaps connected to a top portion of at least two of the four side walls, and a set of outer folding flaps connected to a top portion of the other of the at least four side walls; wherein an exterior surface of the housing is made via corrugated cardboard, wherein an internal surface of the housing includes an insulative layer, wherein the set of inner folding flaps are configured to completely close the interior of the shipping container, and wherein the set of outer folding flaps are configured to completely encase the set of inner folding flaps.

2. The shipping container of claim 1, further comprising at least one insulation insert having at least one side, the insulation insert configured to be placed within the interior of the housing.

3. The shipping container of claim 1, wherein the exterior surface of the housing includes a waterproof coating.

4. The shipping container of claim 1, wherein the set of inner folding flaps form an airtight seal within the interior of the shipping container and wherein edges of the set of inner folding flaps are fused together via adhesive, tape, glue, heat gun, and combinations thereof.

5. The shipping container of claim 1, wherein the shipping container is manufactured in various sizes and thickness.

6. The shipping container of claim 1, wherein the insulation insert is made of single- or double-sided bubble wrap.

7. The shipping container of claim 1, wherein the insulation insert has flaps that are able to fold into and out of the shipping container.

8. The shipping container of claim 1, wherein the set of outer folding flaps form an airtight seal within the interior of the shipping container.

9. The shipping container of claim 1, wherein the insulation insert is permanently affixed to the corrugated cardboard via the shock absorption material.

10. The shipping container of claim 1, wherein the set of inner folding flaps have edges that are configured to meet one another to fully enclose the interior of the housing.

11. The shipping container of claim 1, wherein the set of outer folding flaps have edges that are configured to meet one another.

12. The shipping container of claim 1, wherein the shipping container prevents heat transfer through the exterior of the shipping container.

13. A method for containing and transporting items, comprising: providing a shipping container according to claim 1; folding the inner folding flaps of the shipping container, so that the edges of the inner folding flaps touch and seal contents within an interior of the shipping container; and folding the outer folding flaps of the shipping container, so that the edges of the outer folding flaps touch one another to fully encase the inner folding flaps of the shipping container.

14. The method of claim 13, wherein the edges of the inner folding flaps and the outer folding flaps are fused together via adhesive, tape, glue, heat gun, and combinations thereof.

15. The method of claim 13, further comprising providing at least one insulation insert and folding the insulation insert within the interior of the housing.

16. A method for manufacturing the thermally insulated shipping container of claim 1, the method comprising the steps of: providing a structural material to be folded into a container shape; providing an insulating material for thermal isolation of the contents; manufacturing the structural material and the insulating material as one contiguous piece, which can be folded into the container shape.

17. The method of claim 16, further comprising providing a shock absorbing material and affixing the shock absorbing material to the inside surface of the container.

18. The method of claim 16, further comprising providing a supplemental insert and fitting the supplemental insert within the shipping container with flaps that can be folded.

19. The method of claim 16, wherein the structural material to be folded into the container shape is manufactured from waterproof material or with water proof material as the exterior surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 is a schematic diagram of an embodiment of the inventive system and method comprising a corrugated cardboard shipping box including an insulative layer and a shock absorption layer.

[0041] FIG. 2 is a schematic diagram of an embodiment of the inventive system and method comprising a corrugated cardboard shipping box including an insulative layer and a shock absorption layer and secondary corrugated cardboard shipping insert prior to installation.

[0042] FIG. 3 is a schematic diagram of FIG. 1 with the secondary thermally insulated corrugated cardboard shipping insert located within the shipping box.

[0043] FIG. 4 is a schematic diagram of FIG. 1 comprising the corrugated cardboard shipping box in a partially closed position.

[0044] FIG. 5 is a schematic diagram of FIG. 1 comprising the corrugated cardboard shipping box in a fully closed position.

[0045] FIG. 6 is a cross section diagram of FIG. 1 comprising the corrugated cardboard shipping box, the thermal insulation, and the shock absorbing bubble wrap.

DETAILED DESCRIPTION OF THE INVENTION

[0046] In the following description, numerous details are set forth for the purpose of explanation. However, one of ordinary skill in the art will realize that the invention may be practiced without the use of these specific details. For instance, the techniques described below are described in a specified order, but other embodiments may change the order of the operations while still embodying the current invention.

[0047] The invention is directed to a method and system of and for containing and transporting items which comprises a container having thermal isolation and/or insulation characteristics to maintain a desired temperature within the container.

[0048] In certain embodiments, the method and system are of and for containing and transporting items, the method and system including a container having thermal isolation and/or insulation characteristics to maintain a desired temperature within the container, the container being lightweight, sturdy, and able to keep its contents well insulated.

[0049] In certain embodiments, a shipping container having an insulative layer within the shipping container connected to the shipping container via a shock absorption layer is provided.

[0050] In certain embodiments, a shipping container has thermal isolation and/or insulation characteristics and capable of being flattened and/or folded for ease of transport and storage is provided.

[0051] In certain embodiments, a shipping container having thermal isolation and/or insulation characteristics and capable being used in and with automated packing and shipping systems is provided.

[0052] In certain embodiments of the invention, the insulative layer is made from a metallic material.

[0053] In certain embodiments of the invention, the shock absorption layer is bubble wrap or a material configured to and capable of absorbing shock.

[0054] In certain embodiments, the insulative layer prevents the transfer of heat across in insulative layer.

[0055] In certain embodiments, the air within the bubble wrap or material configured to and capable of absorbing shock is capable of having insulative properties and to prevent radiation from inside the container to outside the container.

[0056] In certain embodiments, the bubble wrap or material configured to and capable of absorbing shock controls heat transfer.

[0057] In certain embodiments, the insulative layer is configured to provide reflective insulation to able to keep heat in and reflect heat away.

[0058] In certain embodiments, the reflective insulation has the ability to control the transfer of radiant heat.

[0059] In certain embodiments, the reflective insulation has the ability to control radiation, conduction and convection.

[0060] In certain embodiments of the invention, the inside of the shipping container is completely covered by the shock absorption layer.

[0061] In certain embodiments of the invention, the shock absorption layer is completely covered by the insulative layer.

[0062] In certain embodiments of the invention, the shipping container includes two upper inner flap portions and two upper outer flap portions.

[0063] In certain embodiments of the invention, the two upper inner flap portions fold to have their edges meet one another to close the inner upper portion of the shipping container.

[0064] In certain embodiments of the invention, the two upper outer flap portions fold to have their edges meet one another to close the outer upper portion of the shipping container.

[0065] In certain embodiments of the invention, the closure of the two upper inner flap portions and the two upper outer flap portions provides an airtight seal to the shipping container.

[0066] In certain embodiments of the invention, the shipping container includes two lower inner flap portions and two lower outer flap portions.

[0067] In certain embodiments of the invention, the two lower inner flap portions fold to have their edges meet one another to close the inner lower portion of the shipping container.

[0068] In certain embodiments of the invention, the two lower outer flap portions fold to have their edges meet one another to close the lower portion of the shipping container.

[0069] In certain embodiments of the invention, the closure of the two lower inner flap portions and the two lower outer flap portions provides an airtight seal to the shipping container.

[0070] In certain embodiments of the invention, the shipping container provides the space advantages of a corrugated shipping box with the thermal advantages of a cooler.

[0071] In certain embodiments of the invention, the insulative layer has temperature transfer properties, such that heat is not able to easily pass through the insulative layer.

[0072] In certain embodiments of the invention, the shipping container further comprises a secondary insert, the secondary insert including an insulative layer and a shock absorption layer.

[0073] In certain embodiments of the invention, the secondary insert is configured to be placed within the shipping container.

[0074] In certain embodiments of the invention, the secondary insert provides additional support and insulation for the shipping container.

[0075] In certain embodiments of the invention, the insulative layer is affixed to the shock absorption layer via an adhesive. In certain embodiments, the adhesive is glue or another binding material. In certain embodiments, the insulative layer is affixed to the shock absorption layer via a heat gun.

[0076] In certain embodiments of the invention, the shock absorption layer is affixed to the inside of the shipping container via an adhesive.

[0077] In certain embodiments of the invention, the insulative layer is made from a metallic foil.

[0078] In certain embodiments, the insulative layer is made from a single bubble foil.

[0079] In certain embodiments, the insulative layer is made from a double bubble foil.

[0080] In certain embodiments, the double foil/foil insulation is constructed of a double layer of polyethylene bubble insulation bonded to two radiant barrier metalized sheets

[0081] In certain embodiments, the insulative layer is very thin - 5/16, but has a high reflectivity, 96%, and a low emissivity, 4%; whereby only 4% of radiant heat passes through the insulative layer.

[0082] In certain embodiments of the invention, the insulative layer reflects radiant heat and works as a vapor barrier, preventing condensation which can cause mold.

[0083] In certain embodiments, the container is made of corrugated cardboard.

[0084] In certain embodiments, the insulative layer is affixed to the corrugated cardboard via an adhesive. In certain embodiments, the adhesive is glue or another binding material. In certain embodiments, the insulative layer is affixed to the shock absorption layer via a heat gun.

[0085] In certain embodiments, the corrugated cardboard has an outer coating that is waterproof or water resistant.

[0086] As depicted in FIG. 1, in an exemplary embodiment of the inventive thermal insulated packing and shipping container (100) comprising a corrugated cardboard shipping box (105) including an insulative layer (110) and a shock absorption layer (115).

[0087] FIG. 6 shows a cross section of the thermal insulated packing and shipping container (100) showing the cardboard shipping box (105) including an insulative layer (110) and a shock absorption layer (115). Additionally a waterproof film and coating (145) can be attached to the cardboard shipping box (105).

[0088] Corrugated cardboard may consist of layers of brown kraft (sulfate) paper made from wood pulp and pressed into layers. Most commonly, corrugated cardboard includes three affixed layers of paper with a middle layer being fluted or corrugated in various configurations to provide desired added rigidity and strength. Typically, finished corrugated cardboard is die-cut as required for producing boxes of various sizes and dimensions.

[0089] In certain embodiments, the corrugated cardboard may be of a white color or may have an insulative outer coating such that the shipping container is water proof. In certain embodiments, the external surface of the shipping container contains a waterproof layer or film that is manufactured with the corrugated cardboard and prevents water from entering the shipping container.

[0090] It is contemplated in some embodiments of the inventive method and system that the insulative and shock absorption layers (110, 115) may be permanently secured to corrugated cardboard as a part of the cardboard manufacturing and layering process itself, and prior to the assembled corrugated cardboard (105), shock absorption layer (115), and insulative layer (110) combination being die-cut to size.

[0091] It is contemplated in some embodiments of the inventive method and system that the insulative and shock absorption layers (110, 115) may be permanently secured to corrugated cardboard after the cardboard manufacturing and layering process; that is, the shock absorption layer (115) and insulative layer (110) may be affixed to finished corrugated cardboard from another manufacturing source and then be die-cut to size.

[0092] As depicted in FIG. 2, in an exemplary embodiment the inventive thermal insulated packing and shipping container (100) includes a secondary insert (120) comprising corrugated cardboard (105) an insulative layer (110) and a shock absorption layer (115) configured to be placed within the shipping container (100). It is contemplated that the secondary insert (120) may be of identical material as the inventive thermal insulated packing and shipping container (100). In certain embodiments, the secondary insert (120) includes the identical material as the inventive thermal insulated packing and shipping container (100), but for a waterproof outer film.

[0093] As depicted in FIG. 3-5, in an exemplary embodiment the inventive thermal insulated packing and shipping container (100) a secondary insert (120) comprising corrugated cardboard (105) an insulative layer (110) and a shock absorption layer (115) configured is placed within the shipping container (100) to provide additional and equal insulation and shock absorption once lower inner and outer portions, and upper inner portion (125) and upper outer portion (130) are closed and secured.

[0094] In FIG. 4, the shipping container (100) is shown having upper inner flaps (125) closed so the shipping container is in a partially closed position. The unclosed upper outer flaps (130) are shown and the embodiment with an adhesive lining the inner edge (135) of the upper outer flap is shown. In FIG. 5, the shipping container is shown having two upper outer flap portions (130) in a closed position.

[0095] Having the upper inner flaps (125) and upper outer flaps (130) shown having their edges touch one another is advantageous as this creates an airtight seal within the shipping container and maintains the insulative properties of the shipping container.

[0096] Additionally, in certain embodiments, adhesive or a tape material can be provided on the top of the upper inner flaps (125) such that when the two upper outer flap portions (130) are in a closed position, they are secured to the top of the upper inner flaps (125).

[0097] Having thus described several embodiments for practicing the inventive method, its advantages and objectives can be easily understood. Variations from the description above may and can be made by one skilled in the art without departing from the scope of the invention.

[0098] Accordingly, this invention is not to be limited by the embodiments as described, which are given by way of example only and not by way of limitation.