INSULATED CONTAINER

Abstract

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.

Claims

1-18. (canceled)

19. An insulation assembly for installation inside of a cuboid container including six interior surfaces, the insulation assembly comprising: a first insulator pad comprising a first rectangular piece of natural fiber material forming a first plurality of panels; a second insulator pad comprising a second rectangular piece of natural fiber material forming a second plurality of panels, wherein the first insulator pad and the second insulator pad are provided in a folded position, where the first insulator pad and the second insulator pad are folded together to form a folded assembly, wherein the first insulator pad and the second insulator pad are further positionable in an unfolded position, where the first insulator pad and the second insulator pad have flat, rectangular shapes, and a partially folded insulating position, where the first insulator pad and the second insulator pad are configured to be positioned inside of the cuboid container such that the first plurality of panels and the second plurality of panels form a cuboid shape configured to line and insulate all of the six interior surfaces of the cuboid container; and a band secured around the folded assembly and holding the first insulator pad and the second insulator pad in the folded position, wherein the band is configured to be disconnected to permit the first insulator pad and the second insulator pad to be moved to the partially folded insulating position.

20. The insulation assembly of claim 19, wherein an outer profile of the folded assembly when the first insulator pad and the second insulator pad are in the folded position is smaller than the first insulator pad and the second insulator pad in the partially folded insulating position, such that the first insulator pad and the second insulator pad are expanded to move from the folded position to the partially folded insulating position.

21. The insulation assembly of claim 19, wherein the band completely encircles the first insulator pad and the second insulator pad in the folded position.

22. The insulation assembly of claim 19, wherein the band has a width which is less than 20 percent of a width of the folded assembly.

23. The insulation assembly of claim 19, wherein the first insulator pad, the second insulator pad, and the band are made from biodegradable materials.

24. The insulation assembly of claim 19, wherein the band further comprises a first end and a second end which overlap each other and are attached when the band is secured around the first insulator pad and the second insulator pad in the folded position.

25. The insulation assembly of claim 24, wherein the band is configured to be disconnected from the folded assembly by disconnecting the first end and the second end of the band.

26. The insulation assembly of claim 24, wherein the first end and the second end are attached by a connection selected from a group consisting of: adhesive, hook and loop fasteners, snaps, and buttons.

27. The insulation assembly of claim 19, wherein the band is configured to be disconnected from the folded assembly by severing the band and/or removing the band from the folded assembly.

28. The insulation assembly of claim 19, wherein the natural fiber material is a post-industrial, pre-consumer cotton waste comprising fiber material gleaned or trimmed as part of a cotton manufacturing and converting process.

29. The insulation assembly of claim 19, wherein the first plurality of panels and the second plurality of panels each comprise three panels, such that, in the partially folded insulating position, the first insulator pad and the second insulator pad each form a C-shape and are each configured to line and insulate three of the interior surfaces of the cuboid container.

30. The insulation assembly of claim 19, wherein the first insulator pad comprises a bottom panel configured to line and insulate a bottom interior surface of the cuboid container, a first side panel configured to line and insulate a first side interior surface of the cuboid container, and a top panel configured to line and insulate a top interior surface of the cuboid container, in the partially folded insulating position, and the second insulator pad comprises a second side panel configured to line and insulate a second side interior surface of the cuboid container, a third side panel configured to line and insulate a third side interior surface of the cuboid container, and a fourth side panel configured to line and insulate a fourth side interior surface of the cuboid container, in the partially folded insulating position, and wherein, in the folded position, the second insulator pad is folded and located between the bottom panel and the top panel of the first insulator pad.

31. A method for insulating a cuboid container including six interior surfaces defining a cavity, the method comprising: placing an insulation assembly in the cavity of the cuboid container in a folded position, the insulation assembly comprising a first insulator pad comprising a first rectangular piece of natural fiber material forming a first plurality of panels and a second insulator pad comprising a second rectangular piece of natural fiber material forming a second plurality of panels, wherein the first insulator pad and the second insulator pad are folded together in the folded position, and the first insulator pad and the second insulator pad are further positionable in an unfolded position, where the first insulator pad and the second insulator pad have flat, rectangular shapes, the insulation assembly further comprising a band secured around the first insulator pad and the second insulator pad and holding the first insulator pad and the second insulator pad in the folded position; disconnecting the band from the first insulator pad and the second insulator pad; and expanding the first insulator pad and the second insulator pad from the folded position to a partially folded insulating position within the cavity of the cuboid container, where the first plurality of panels and the second plurality of panels form a cuboid shape lining and insulating all of the six interior surfaces of the cuboid container and defining an insulated chamber.

32. The method of claim 31, wherein the first insulator pad, the second insulator pad, and the band are made from biodegradable materials.

33. The method of claim 31, wherein the natural fiber material is a post-industrial, pre-consumer cotton waste comprising fiber material gleaned or trimmed as part of a cotton manufacturing and converting process.

34. The method of claim 31, wherein the first plurality of panels and the second plurality of panels each comprise three panels, such that, in the partially folded insulating position, the first insulator pad and the second insulator pad each form a C-shape and each line and insulate three of the interior surfaces of the cuboid container.

35. The method of claim 31, wherein the first insulator pad comprises a bottom panel lining and insulating a bottom interior surface of the cuboid container, a first side panel lining and insulating a first side interior surface of the cuboid container, and a top panel lining and insulating a top interior surface of the cuboid container, in the partially folded insulating position, and the second insulator pad comprises a second side panel lining and insulating a second side interior surface of the cuboid container, a third side panel lining and insulating a third side interior surface of the cuboid container, and a fourth side panel lining and insulating a fourth side interior surface of the cuboid container, in the partially folded insulating position, and wherein, in the folded position, the second insulator pad is folded and located between the bottom panel and the top panel of the first insulator pad.

36. The method of claim 35, wherein the insulation assembly is placed in the cavity of the cuboid container in the folded position such that the bottom panel is placed against the bottom interior surface, and wherein expanding the first insulator pad and the second insulator pad from the folded position to the partially folded insulating position comprises: lifting the top panel of the first insulator pad; unfolding the second insulator pad and placing the second insulator pad such that the second side panel, the third side panel, and the fourth side panel line and insulate the second side interior surface, the third side interior surface, and the fourth side interior surface, respectively; arranging the first insulator pad such that the first side panel lines and insulates the first side interior surface; and folding the top panel of the first insulator pad downward to form a top of the insulated chamber.

37. The method of claim 31, further comprising placing an article to be insulated in the insulated chamber, such that the first insulator pad and the second insulator pad surround and insulate the article.

38. The method of claim 37, further comprising sealing the cuboid container for shipping.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Features, aspects and advantages of the present invention are understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

[0043] FIG. 1 is an exploded view of the insulated container in a partially assembled state;

[0044] FIG. 2 is an exploded view of the insulated container in a partially assembled state;

[0045] FIG. 3 is an exploded view of the insulated container in an unassembled state;

[0046] FIG. 4 is an exploded view of the insulated container in a partially assembled state;

[0047] FIG. 5 is an exploded view of the insulated container in a partially assembled state;

[0048] FIG. 6 is an exploded view of the insulated container in a partially assembled state;

[0049] FIG. 7 is an exploded view of the insulated container in a partially assembled state;

[0050] FIG. 8 is an exploded view of the insulated container in a partially assembled state;

[0051] FIG. 9 is a perspective view of the insulated container in an assembled state;

[0052] FIG. 10 is a perspective view of the insulated container in an assembled state;

[0053] FIG. 10A is sectional view of the insulated container:

[0054] FIG. 11 is an exploded view of the insulated container in a partially assembled state and where the insulation layer does not include the natural fiber lamination;

[0055] FIG. 12 is a heat stress chart;

[0056] FIG. 13 is a heat stress chart;

[0057] FIG. 14 is a cold stress chart:

[0058] FIG. 15A is a perspective view of an embodiment of the insulated container in an unfolded position;

[0059] FIG. 15B is a perspective view of an embodiment of the insulated container in the unfolded position;

[0060] FIG. 15C is a perspective view of an embodiment of the insulated container in the unfolded position;

[0061] FIG. 16 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in a process of folding from the unfolded position to a folded position;

[0062] FIG. 17 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the process of folding from the unfolded position to the folded position:

[0063] FIG. 18 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the process of folding from the unfolded position to the folded position;

[0064] FIG. 19 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the process of folding from the unfolded position to the folded position;

[0065] FIG. 20 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation;

[0066] FIG. 21 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation;

[0067] FIG. 22 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation;

[0068] FIG. 23 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation;

[0069] FIG. 24 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation and being placed in a rigid container;

[0070] FIG. 25 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation and placed in the rigid container;

[0071] FIG. 26 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the folded orientation, placed in the rigid container, and being opened;

[0072] FIG. 27 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in a partially-unfolded position within the rigid container;

[0073] FIG. 28 is a perspective view of the embodiment of the insulated container of FIGS. 15A-C in the partially-unfolded position within the rigid container and having contents placed therein;

[0074] FIG. 29A is a perspective view of an embodiment of the insulated container in an unfolded orientation;

[0075] FIG. 29B is a perspective view of an embodiment of the insulated container in an unfolded orientation;

[0076] FIG. 29C is a perspective view of an embodiment of the insulated container in an unfolded orientation;

[0077] FIG. 30 is a perspective view of an embodiment of the insulated container in a partially folded orientation;

[0078] FIG. 31 is a perspective view of an embodiment of the insulated container in a partially folded orientation;

[0079] FIG. 32 is a perspective view of an embodiment of the insulated container in a folded orientation;

[0080] FIG. 33 is a perspective view of an embodiment of the insulated container in a folded orientation:

[0081] FIG. 34 is a perspective view of an embodiment of the insulated container in a folded orientation:

[0082] FIG. 35 is a perspective view of an embodiment of the insulated container in a partially folded orientation and being placed in a rigid container;

[0083] FIG. 36 is a perspective view of an embodiment of the insulated container in a folded orientation and placed in a rigid container;

[0084] FIG. 37 is a perspective view of an embodiment of the insulated container in a folded orientation, placed in a rigid container, and being opened;

[0085] FIG. 38 is a perspective view of an embodiment of the insulated container in an open position within the rigid container; and

[0086] FIG. 39 is a perspective view of an embodiment of the insulated container in an open position within the rigid container and having contents placed therein.

DETAILED DESCRIPTION OF THE INVENTION

[0087] Generally. FIGS. 1 through 8, show embodiments of the invention with insulation layer 20 having a natural fiber lamination layer 26 applied to contact surfaces. The contact surfaces are surfaces which may come into contact with contents of the container. Generally, FIG. 11 shows an alternate embodiment of the invention where there is no natural fiber lamination layer and the fibers of the insulation layer 20 are exposed to the contents of the container. The embodiment utilizing the natural lamination layer 26 may be preferred to the embodiment of FIG. 11 when a shipper desires that the contents not come into contact with the insulation layer, such as when shipping raw, unwrapped produce. The natural fiber lamination layer 26 is sustainable and is biodegradable. The natural fiber lamination layer 26 thus provides a helpful option to companies seeking a smoother, more consistent surface. The natural fiber lamination layer 26 may be made from a coffee filter paper, kraft paper, and the like. Text and images (not shown) may be printed on the lamination layer 26.

[0088] Referring to FIG. 1, an insulated container 10 is shown in a partially assembled state. The insulated container 10 includes rigid container 50 and insulation layer 20. The rigid container 50 may be a cardboard box as shown. The insulation layer 20 is made from cotton waste. The cotton waste is processed into a sheet formed using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven sheet. The insulation layer 20 is formed to maintain uniform density and of a thickness optimized for particular applications.

[0089] The sheet may then be cut into rectangles which may be bent into a pair of C-shaped members, 22, 24. The first C-shaped member, referred to as an A pad 22 forms lid portion 30 which is connected to back side portion 32 via first hinge portion 31. Bottom portion 34 is connected to back portion 32 via second hinge portion 33.

[0090] Similarly, the second C-shaped member, referred to as a B pad 24 forms first side portion 40 which is connected to front side portion 24 via hinge 41. Second side portion 44 is connected to front side portion 24 via hinge portion 43.

[0091] When assembled, as shown in FIG. 2, second C-shaped member 24 fits into a cavity formed by first C-shaped member 22 to form the interlocking C-shapes of the insulation layer 20. As shown in FIGS. 3-8, the insulation layer 20 of the insulated container 10 may be assembled by folding respective C-shaped members 22, 24. As shown in FIG. 3, the C-shaped members 22, 24 may have in unfolded state that is a flat rectangular shape. As shown in FIGS. 4-7, hinges 31, 33 and 41, 43 may be formed by folding. These folds separate the portions 30, 32, 34, 40, 42, 44 of each C-shaped member 22, 24.

[0092] FIG. 9 shows the fully assembled insulated container 10 with the lid of the rigid container 50 open. FIG. 10 visualizes the cross-section A-A which is shown in FIG. 10A. In particular, the cross section A-A shows the insulation layer 20 inside the rigid container 50. The natural fiber lamentation layer 26 is shown on the contact surfaces. Importantly, there is no plastic or non-biodegradable layer between the insulation layer 20 and the rigid container 50 as is present in the prior art of FIG. 2. That is, there is no additional plastic housing surrounding the insulation layer 20. Both to the rigid container 50 and the internal cavity of the insulate container.

[0093] FIG. 11 shows the insulated container 10 of FIGS. 1-10A but where the natural fiber insulation layer has not been added during the manufacturing process. Accordingly, the cotton waste of the insulation layer 20 is exposed.

[0094] An embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where three 500 ML and two 250 ML IV bags are cooled by four 24 oz frozen ice packs. The ice packs are placed at the top and bottom below the payload. FIG. 12 shows heat stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV bags. The top line shows the ambient temperature outside the insulated container. The other lines show wrapped white cotton molded 1.5 inch foam and unwrapped white cotton.

[0095] Another embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where six 600 ML IV bags are cooled by four 24 oz frozen ice packs. The ice packs are placed at the top and bottom below the payload. FIG. 13 shows heat stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV gabs. The top line shows the ambient temperature outside the insulated container. The lower line shows the internal temperature.

[0096] Another embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where six 600 ML IV bags are cooled by two 24 oz frozen ice packs and two 24 oz ambient ice packs. The ice packs are placed at the top and bottom below the payload. FIG. 14 shows cold stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV gabs. The top line shows the ambient temperature outside the insulated container. The lower line shows the internal temperature.

[0097] Another embodiment may be created where the insulated container 10 complies with test scope protocol ISTA 7D such that it maintains temperature above 2 C. and below 8 C., without freezing, in simulated summer/heat stress conditions for a 48 hour distribution cycle. According to the ISTA 7D test, six 24 oz gel ice packs were added to the insulated container 10 with a payload of six 500 mL IV bags (Lactated Ringer's Solution USP), conditioned to 3 C.

[0098] Another embodiment may be created where the insulated container 10 complies with test scope protocol ISTA 7D such that it maintains temperature above 2 C. and below 8 C., without freezing, in simulated winter/cold stress conditions for a 48 hour distribution cycle. According to the ISTA 7D test, four 24 oz gel ice packs were added to the insulated container 10 with a payload of ten 500 mL IV bags (Lactated Ringer's Solution USP), condition to 3 C.

[0099] Referring to FIG. 15A through FIG. 28, another embodiment of the invention may include an insulated container 100 which is formed in a capital 1T shape. The T shape may be formed from natural fibers such as cotton. The fibers may be postindustrial, pre-consumer recycled cotton. As shown in FIG. 15A, the fibers may be enclosed in a wrapping. The wrapping may serve to protect contents of the container and may also allow smaller fibers to be used which are contained in the wrapping. The wrapping may be a plastic bag. The plastic bag may be biodegradable.

[0100] As shown in FIG. 15B, rather than the wrapping of FIG. 15A, the natural fibers 102 are exposed. Large pads of natural fibers may be created and the T shape cut from the natural fibers. Multiple T shapes may be cut from a single pad. Any waste material from the pads may be further recycled to form additional pads or may be recycled for other purposes.

[0101] As shown in FIG. 15C, a natural fiber lamination layer 126 has been applied to the fibers 103. The natural fiber lamination layer 126 may be paper and may have markings or other indicia applied. As with the embodiment of FIG. 15A, pads may be prepared and the T shape may be cut from the pad. Multiple T shapes may be cut from a single pad. Any waste material from the pads may be further recycled to form additional pads or may be recycled for other purposes.

[0102] FIGS. 16 through 23 show how the insulated container 100 having the T shape may be folded into a compact form for shipment according to an aspect of the present invention. Though these figures show the T shape embodiment of FIG. 15A, one of skill in the art will understand that the same method of folding may be realized with the embodiments of 15A, 15B, or 15C.

[0103] As shown in FIGS. 16-18, the rear panel 110, left panel 112, and right panel 114 are folded up together and down onto bottom panel 116. As shown in FIG. 19, the front panel 118 is folded over up and, in FIG. 20, is folded over the rear panel 110. The top panel 120 (or lid) is then folded over the front panel 118.

[0104] As shown in FIG. 21, a band 122 may be wrapped around the folded container 100 for transport. The band 122 may keep the folded container 100 in a compact folded condition for transport. The band 122 may be made of paper, plastic, natural fibers, or other biodegradable material. Alternatively, the band may be made of a reusable material. The band 122 is designed to be easily connected when the container 100 is folded and is also designed to be easily disconnected as shown in FIG. 26. The band 122 may be connected by way of an adhesive, hook and loop fasteners, snaps, buttons, and the like. The band 122 may also be disconnected and unwrapped from the folded container 100 by tearing, cutting, pulling the band 100. The band 122 may have a perforation which aids in removal. The band 122 may feature a tab and tongue system where a tab is pealed from the band 122 to allow an adhesive to attach the respective ends of the band 122. According to another embodiment, the band 122 may be attached, detached, and reattached at a same or different location along the band such that the attachment point additionally serves the function of a closure of the top 120 of the container 100 in the unfolded state of FIG. 28.

[0105] Once the band 122 is in place, the folded container is ready for shipment form the manufacturer to a packager. As shown in FIGS. 24 and 25, once the packager receives the folded container 100, the packager may place the folded container 100 into a rigid container 150. The rigid container 150 may be a box and it may be mad of cardboard. Once the folded container 100 is in the rigid container 150, the packager may remove the band 122 as shown in FIG. 26. The packager may then partially unfold the panels of the container 100 as shown in FIG. 27 to form an inner void which can contain products as shown in FIG. 28.

[0106] FIGS. 29A, 29B, and 29C show a further embodiment of the insulated container 200 which utilizes a pair of pads. These pads are similar to the pads of FIG. 1 in that they ultimate form an interlocking C shape inside a rigid container. However, the embodiments of FIGS. 30-34 show how the pair of pads may be folded for compact transport.

[0107] Additionally, the embodiments of FIGS. 29A, 29B, and 29C may be formed from natural fibers such as cotton. The fibers may be postindustrial, pre-consumer recycled cotton. As shown in FIG. 29A, the fibers may the natural fibers 200 may be covered with a lamination layer 226. As shown, a natural fiber lamination layer 226 has been applied to the fibers 200. The natural fiber lamination layer 226 may be paper and may have markings or other indicia applied. Large pads of natural fibers may be created and the smaller pads cut from the natural fibers. Multiple pads 200 may be cut from a single pad. Any waste material from the pads may be further recycled to form additional pads or may be recycled for other purposes. Any waste material from the pads may be further recycled to form additional pads or may be recycled for other purposes.

[0108] As shown in FIG. 29B, according to one embodiment the pads 202 do not have a lamination layer. As show in FIG. 29C, according to another embodiment, the pads 203 may be enclosed in a wrapping. The wrapping may serve to protect contents of the container and may also allow smaller fibers to be used which are contained in the wrapping. The wrapping may be a plastic bag. The plastic bag may be biodegradable.

[0109] As shown in FIG. 30-34, the pair of pads 200 may be folded for compact transport. As shown in FIG. 30, the rear panel 210, the left panel 212, and the right panel 214 which are part of pad A 211 are folded and placed upon the bottom panel 216 of pad B As shown in FIGS. 31 and 32, the front panel 218 of pad B is folded up and over the rear panel 210 of pad A. The top panel 220 (or lid) is then folded over the front panel 218.

[0110] As shown in FIGS. 32 through 34, a band 222 may secure the folded pads 200 in a folded compact form for transportation from a manufacturer to a packager. As shown in FIGS. 35 and 36, the packager may place the folded pads 200 into a rigid container 250. As shown in FIG. 37, the packager may separate or otherwise remove the band 222 so that the insulated pads can be partially unfolded within the rigid container as shown in FIG. 3838. As shown in FIG. 39, products may be placed inside the container 200 for shipment.

[0111] An insulated container 10, 100, 200 according to the invention has been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. It is envisioned that other embodiments may perform similar functions and/or achieve similar results. Any and all such equivalent embodiments and examples are within the scope of the present invention and are intended to be covered by the appended claims.