NATURAL FIBER-BASED INSULATED PANEL AND TEMPERATURE CONTROLLED SHIPPING SYSTEM

Abstract

A natural fiber-based insulating panel system to facilitate shipping. One or more natural fiber-based panels are inserted into the interior of a shipping container to encapsulate the payload, or on the exterior of the shipping container to encapsulate the shipping container and payload. A film or membrane may encapsulate one or more of the insulating panels. Micro perforations may be present in the membrane to facilitate the capture of moisture from the interior.

Claims

1. A system for maintaining temperature during shipment and/or storage, the system comprising: a container comprising a top, a bottom, and a plurality of sides, wherein each of the top, bottom, and plurality of sides of the container comprises an interior surface which collectively define an interior of the container; a payload disposed in the interior of the container; a phase change material disposed in the interior of the container; a plurality of flexible insulating panels located in the interior of the container, wherein each flexible insulating panel is comprised of an insulating composition comprising natural fiber and a binder wherein each flexible insulating panel comprises an interior surface facing the payload and the phase change material and an exterior surface facing the interior surface of the top, bottom or plurality of sides of the container, wherein the plurality of flexible insulating panels collectively extend about the interior surfaces of the top, bottom, and plurality of sides of the container, wherein the plurality of flexible insulating panels collectively are located between the payload and the interior surfaces of the top, bottom, and plurality of sides of the container, and further wherein the plurality of flexible insulating panels collectively are located between the phase change material and the interior surfaces of the top, bottom, and plurality of sides of the container.

2. The system of claim 1 wherein the natural fiber in each flexible insulating panel comprises hemp fiber.

3. The system of claim 2 wherein each flexible insulating panel is the form of a compressed mat comprising hemp fiber bound together by the binder.

4. The system of claim 3 wherein each compressed mat is formed by heating a mixture of the hemp fiber and the binder, and then compressing the heated mixture to form the mat.

5. The system of claim 3 wherein each compressed mat is shape-stable and configured to bend at least 90 degrees without breaking.

6. The system of claim 2 wherein the flexible insulating panels comprise substantially more hemp fiber than binder by volume.

7. The system of claim 6 wherein the flexible insulating panels comprise at least 40% hemp fiber by volume.

8. The system of claim 2 wherein the insulating composition consists essentially of hemp fiber and binder.

9. The system of claim 2 wherein the binder comprises polylactic acid.

10. The system of claim 2 wherein each of the flexible insulating panels is rectangular in shape, wherein the interior surfaces of the flexible insulating panels collectively define a rectangular cavity, and further wherein the payload and the phase change material are located in the rectangular cavity.

11. The system of claim 10 wherein each of the flexible insulating panels has a flat interior surface, a flat exterior surface and a thickness of from about 0.5 to about 2 inches.

12. The system of claim 11 wherein at least one of the flexible insulating panels extends along a top of the payload, at least one of the flexible insulating panel extends along a bottom of the payload, and further wherein at least four of the flexible insulating panels extend about one or more sides of the payload.

13. The system of claim 12 wherein the container is comprised of cardboard.

14. The system of claim 13 wherein the container is rectangular in shape.

15. The system of claim 14 wherein the flexible insulating panels comprise a first mat folded in a c-shaped manner and extending around the interior surfaces of the top, bottom and one side of the container, and a second mat folded in a c-shaped manner extending around the interior surfaces of three sides of the container.

16. The system of claim 10 wherein at least one of the flexible insulating panels is attached to at least one other flexible insulating panel.

17. The system of claim 10 wherein the plurality of flexible insulating panels collectively line the interior surfaces of the top, bottom, and plurality of sides of the container.

18. The system of claim 2 wherein each flexible insulating panel is configured to absorb moisture.

19. The system of claim 2 wherein each insulating panel comprises a film encapsulating the insulating composition.

20. The system of claim 19 wherein, for each flexible insulating panel, the film comprises a plurality of perforations extending along at least one side of the respective flexible insulating panel.

21. The system of claim 20 wherein the film is comprised of plastic.

22. The system of claim 20 wherein the film is comprised of kraft paper.

23. The system of claim 1 wherein the phase change material comprises a plurality of gel packs.

24. The system of claim 1 wherein the phase change material is located between the payload and the interior surfaces of the flexible insulating panels.

25. The system of claim 1 wherein each flexible insulating panel is in the form of a shape-stable mat configured to bend at least 90 degrees without breaking.

26. A system for maintaining temperature during shipment and/or storage, the system comprising: a rectangular cardboard box comprising a top, a bottom, and four sides, each of the top, bottom, and four sides comprising an interior surface that collectively define an interior of the box; a payload disposed in the interior of the box; a phase change material disposed in the interior of the box; a plurality of flexible, rectangular insulating panels located in the interior of the box, the plurality of flexible, rectangular insulating panels comprising: i) a top flexible, rectangular insulating panel extending about a top of the payload and the box top and comprising a bottom surface facing the payload and a top surface facing the box top, ii) a bottom flexible, rectangular insulating panel extending about a bottom of the payload and the box bottom and comprising a bottom surface facing the box bottom and a top surface facing the payload, and iii) four flexible, rectangular insulating side panels collectively extending about one or more sides of the payload and the four sides of the box, each of the four flexible, rectangular insulating side panels comprising an interior surface facing the payload and an exterior surface facing a side of the box, wherein each flexible insulating panel is comprised of an insulating composition comprising natural fiber and a binder, wherein the interior surfaces of the flexible, rectangular insulating panels collectively define a rectangular cavity, and further wherein the payload and the phase change material are located in the rectangular cavity.

27. The system of claim 26 wherein the natural fiber comprises hemp fiber.

28. The system of claim 27 wherein each flexible insulating panel is the form of a compressed mat comprising hemp fiber bound together by the binder.

29. The system of claim 28 wherein each compressed mat is formed by heating a mixture of the hemp fiber and the binder, and then compressing the heated mixture to form the mat.

30. The system of claim 28 wherein each compressed mat is shape-stable and configured to bend at least 90 degrees without breaking.

31. The system of claim 27 wherein the flexible insulating panels comprise substantially more hemp fiber than binder by volume.

32. The system of claim 27 wherein the flexible insulating panels comprise at least 40% hemp fiber by volume.

33. The system of claim 27 wherein the insulating composition consists essentially of hemp fiber and binder.

34. The system of claim 27 wherein the binder comprises polylactic acid.

35. The system of claim 26 wherein the top flexible, rectangular insulating panel lines the box top, wherein the bottom flexible, rectangular insulating panel lines the box bottom and further wherein the four flexible, rectangular side insulating panels collectively line the box sides.

36. The system of claim 26 wherein each of the four flexible, rectangular insulating panels has a flat interior surface, a flat exterior surface and a thickness of from about 0.5 to about 2 inches.

Description

DESCRIPTION

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0027] FIG. 1 is a perspective exploded view of an exemplary embodiment of a 2-panel system whereby each insulating panel covers three sides of the shipping container.

[0028] FIG. 2 is a cross-sectional view of an exemplary embodiment of an insulating panel suitable for various embodiments of the invention.

[0029] FIG. 3 is a perspective exploded view of an exemplary embodiment of a 3-panel system whereby one insulating panel covers the bottom of the shipping container, one insulating panel covers the top and one long insulating panel covers the 4 vertical sides of the shipping container.

[0030] FIG. 4 is a perspective exploded view of an exemplary 6-panel system whereby there is an independent insulating panel for each side of the shipping container.

[0031] FIG. 5a is a perspective exploded view of an exemplary stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as phase change material) that will help maintain the temperature inside the shipping container.

[0032] FIG. 5b is a see-through perspective exploded view of the stacked panel system of FIG. 5a, wherein 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container.

[0033] FIG. 6 is a perspective exploded view of a stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having a rectangular cut-out to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container.

[0034] FIG. 7 is a perspective exploded view of a wrap-around system whereby insulating panels are wrapped on the outside of the shipping container or assembly of shipping containers.

[0035] FIG. 8 is a perspective exploded view of a 3-panel pallet cover system whereby one insulating panel covers the bottom of the palletized payload and two panels cover two opposite sides of the palletized payload with two superimposed panels on top of the palletized payload.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

[0036] The present invention, as well as features and aspects thereof, is directed towards providing a hemp and/or other natural fiber-based insulated panel or panel system, as well as a temperature controlled shipping and/or short term storage system utilizing one or more of the insulating panels.

[0037] An exemplary embodiment of a device or shipping/storage container may include the following components: one or more properly sized, shape-stable insulating mats or panels made from natural fibers or hemp fibers and binders, that may be wholly or partially covered with a recyclable and/or biodegradable, perforated outer film, and assembled into one or more shapes that fit snugly together when placed into the interior or onto the exterior of a shipping container or assembly of several shipping containers or a payload. The result is a continuous or nearly continuous insulating layer that reduces the rate of heat transfer between the items in the interior of the container and the environment outside the container. The system thus better preserves the quality of temperature-sensitive goods that may be shipped or stored utilizing the device. The combination of the natural fiber or hemp insulating panels and the shipping container create a unique system that provides a superior system for transportation of thermally-sensitive goods. The addition of cold-packs (typically containing a phase change material such as frozen water with certain chemical additives, or frozen CO2) into the interior of the shipping container creates a system that can maintain a favorable temperature inside the shipping container for an extended period of time. Likewise, heat packs, such as packets containing iron, activated carbon and water, may be used to maintain the items at a warm temperature.

[0038] By using hemp and/or other natural fiber-based insulation, this shipping system is recyclable, biodegradable, and is more environmentally friendly than other shipping systems.

[0039] It should further be noted that, due to the moisture absorbing properties of the natural fiber or hemp insulation being used, and the presence of perforations in the film covering the natural fiber or hemp insulating panels in whole or in part, the insulating mats reduce the accumulation of moisture on the inside of the shipping container that may otherwise take place if other insulating materials are used. This in turn, leads to better preservation of the quality of the goods inside of the shipping container during transportation.

[0040] It should also be noted that unlike some other insulating materials, the natural fiber or hemp fiber insulation helps absorb shocks and vibration occurring during transportation. Advantageously, this aspect of the various embodiments provides an improved protection of the goods being transported.

[0041] It should also be noted that should the natural fiber or hemp insulation become moist or wet, the insulating properties of natural fiber or hemp insulation degrade much less than other types of bio-based insulation. Advantageously, this can result in better thermal protection of the good being transported.

[0042] It should also be noted that because of the semi-ridged structure of the natural fiber or hemp insulation, stable cut-outs can be made in the hemp insulation which will allow for a customized space in which the goods being transported can be placed. These specialized cut-outs may provide for easier assembly of the goods into the package prior to shipping and also better protection of the goods during transport. Furthermore, the cut-outs from the hemp panels can be readily put back into the feedstock for manufacture of additional mats with almost zero wasted material.

[0043] It should also be noted that the film placed on the outside of the natural fiber or hemp insulation may include a reflective surface on one or both sides to enhance the insulating properties of the insulating mat or panel.

[0044] It should also be noted that the use of a film or covering on the outside of the natural fiber or hemp insulating mat is not a requirement. The natural fiber or hemp mats or panels without a covering have excellent insulating properties.

[0045] It should also be noted that the performance of the shipping system may be further enhanced by placing the temperature sensitive goods along with the phase change materials inside a sealable bag before placing the goods inside the insulated shipping container.

[0046] It should also be noted for embodiments that specifically include hemp, that because of the nature of hemp cultivation and hemp fiber processing, the hemp insulation requires fewer acres of cultivated land or space than other fibers, such as cotton, to yield a similar amount of usable insulation (same area of insulation with same insulating properties). When compared with the production of other insulation materials, for each unit of usable insulation, hemp sequesters more CO2, uses fewer chemicals, uses less water and creates less chemical pollution. This may also be true for other natural plants for producing natural fibers.

[0047] An exemplary form of performing the creation method associated with the disclosed device may include the following steps: natural fiber or hemp fibers manufactured from sustainably grown plants, mechanically processed into fibers using little to no chemicals (or an unsubstantial amount of chemicals), with such fibers then combined with a quantity and type of binder chemical so that the resulting fiber-binder mix is compostable and recyclable, with that same fiber-binder mix then processed using heat, pressure and other means into a shape-stable insulating mat. One or more of these insulating mats are then trimmed, optionally covered in whole or in part with a breathable exterior film and assembled into one or more shapes that fit tightly together when placed into the interior or onto the exterior of a shipping container, or assembly of several shipping containers or payload. The result is a continuous or nearly continuous insulating layer that reduces the rate of heat transfer between the items on the interior of the container and the environment outside container.

[0048] Referring now to figures in which like labels represent like elements throughout the several views, further exemplary embodiments, functions, aspects and characteristics of the various embodiments are presented.

[0049] FIG. 1 is a perspective exploded view of a 2-panel system whereby each insulating panel covers three sides of the shipping container. The exploded view perspective of a 2-panel system 100 includes two insulating panels (120 and 130) whereby each insulating panel covers three internal sides of the shipping container 110, all insulating panels containing natural fibers or hemp fibers as shown in FIG. 2. The first insulating panel 120 is C-shaped or folded into a C-shape form from and unfolded flat form and inserted in the shipping container 110 in such a manner that it covers the bottom, one vertical side and the top of the payload 140 inside the shipping container 110. The second insulating panel 130 is also C-shaped or then folded into a C-shape form from an unfolded flat form and inserted into the shipping container 110 in such a manner that it covers the three remaining sides of the payload 140 inside the shipping container 110. The two C-shape insulating panels (120 and 130) are arranged in a way whereby they define an interior cavity for receiving and housing the payload 140 and, they form a continuous or nearly continuous layer inside the shipping container 110, thus creating a barrier to heat transfer between the inside and the outside of the 2-panel system 100. The payload 140 inside the shipping container 110 is thus kept at a more optimum and consistent temperature while within the cavity defined by the 2-panel system, such as during transportation or storage. A device or several devices such as phase change materials (not shown) may be added between the payload 140 and the interior surfaces of the insulating panels (120 and 130) to maintain a certain temperature range for a certain duration. A Phase Change Material (PCM) provides advanced thermal protection when shipping or storing temperature-sensitive products. When PCMs melt and freeze, or change phases of matter between solid and liquid, they maintain a constant temperature equal to their melting/freezing point. A phase-change material suitable for packaging is generally an organic or inorganic substance that acts as a payload’s heating or cooling agent. As the payload’s temperature increases or decreases (depending on several factors, from ambient external temperature to the type of insulation being used), the PCM works to maintain a stable, consistent temperature for the duration of its trip or storage.

[0050] There are several commonly used phase-change materials within the shipping industry, and each comes with its own benefits and drawbacks. It should be noted that a PCM alone is not effective in maintaining temperature, as the PCM should be utilized in conjunction with a packaging and insulation system. As a participant in the temperature regulator for packaging systems, however, it’s important to choose a PCM carefully. For example, the following considerations should be examined in selecting a PCM:

[0051] If a payload needs to be kept at a particular temperature or temperature range, such as at 14° C., with acceptable excursions ranging from 11° C. to 17° C., a PCM should be selected to maintain the temperature within that range.

[0052] If the payload requires a consistent temperature for a particular period of time, such as 24 to 48 hours or if the payload has an extended travel/storage period, such as 120 hours, a PCM should be selected to that meets these characteristics.

[0053] If the payload vibration or shack sensitive, special packaging solutions may be examined to provide sufficient room for and protection of the payload for the duration of the trip. For example, using dry ice as a PCM may be effective for materials that need to be kept frozen (below -18° C.). However, once the ice sublimates, it results in creating room for the payload to move around and possibly become damaged.

[0054] Creating contours or cut-outs in the insulating panels can advantageously alleviate issues that may arise in this scenario.

[0055] If the cost of shipment is a concern, a packaging solution or PCM as a more expensive option may not be the best suited for the particular shipping needs. Reusable solutions also may appear more expensive, but based on cost per use may be more affordable.

[0056] If environmental impact is a concern, an appropriate PCM can be selected. For instance, determining what the PCM composed of, and if it is renewable. Further, it should be determined if the PCM is toxic or non-toxic and if it can be used repeatedly.

[0057] There are several types of technology utilized for PCMs. A few non-limiting examples include:

[0058] Water-based gel packs. Water-based gel packs are among the most inexpensive forms of PCMs available. However, and gel packs can sometimes provide inconsistent temperature control. Gel packs also may need to be conditioned hours before use to avoid thermally shocking the payload. They are, however, non-toxic, and intact gel packs may be used several times.

[0059] Dry ice (frozen CO2). This PCM option is also inexpensive and readily available (but not reusable). Dry ice works well with deep frozen payloads traveling short distances. Using dry ice as a PCM requires careful packing to ensure payloads remain safe even as the dry ice sublimates. Thus, the use of cut-outs or contours suitable for the payload may be required.

[0060] Vegetable oil-based PCMs. This PCM technology can achieve virtually any temperature range and maintain it for extended durations of time. Vegetable oil-based PCMs are also biodegradable, non-toxic, and experience no thermal degradation after many uses.

[0061] Petroleum-based PCMs are derived from crude oil. The cost of this PCM technology thus fluctuates with the price of crude oil similar to the price of gasoline. Depending on the petroleum derivative used to create the PCM, most are toxic and thus, disposal of them may be difficult.

[0062] Heavy water (deuterium oxide). This PCM technology is very useful for refrigerated payloads (such as items that need to be maintained at a range of 2-8° C.). The heavy water PCMs freeze at 3.82° C. While this technology is quite effective as a PCM, it must be used with caution, may be difficult to obtain and can be costly.

[0063] Eutectic salts. A generic term for many materials that contain a salt in solution at a concentration that yields the lowest freezing point, eutectic salts can vary in safety, price, and effectiveness, based on their composition. There may also be disposal or customs issues, based on the material used.

[0064] One or more of the insulating panels may or may not be encapsulated, in whole or in part, in a plastic film or a film made of other materials, and the film may be perforated or not. In one particular and illustrative, yet non-limiting, embodiment of the 2-panel system 100, the unfolded insulating panel 120 may have a length of approximately 35 inches, a width of approximately 12 inches and a thickness of approximately 1.5 inches whereas the unfolded insulating panel 130 may have a length of approximately 32 inches, a width of approximately 9 inches and a thickness of approximately 1.5 inches. Of course, these measurements are merely illustrative and insulating panels of any length, width and thickness that include the features described herein are intended to be within the scope of the various embodiments of the invention and disclosure, which has many different embodiments. In this and all other embodiments, a material such as an adhesive or a device such as a hook and loop material (e.g., VELCRO) may be used along the edges where the insulating panels meet so as to minimize any gaps between the insulating panels. In other embodiments, at locations where an edge of a first panel rest on the surface of a second panel, a groove can be formed in the surface of the second panel so that the edge of the first panel can rest within the groove creating a tongue-in-groove construction. Further, the adhesive or loop and hook material may also be applied to the edge and groove to further secure the panels in place. The payload 140 is shown for illustrative purposes and is not part of the 2-panel system.

[0065] FIG. 2 is a cross-sectional view of an exemplary embodiment of an insulating panel suitable for various embodiments of the invention. Referring to FIG. 2, a cross-sectional view of an exemplary insulating panel 200 includes a mat made primarily of natural or hemp fibers 230 and a film 210 in which the insulating panel 200 may be wholly or partially encapsulated. In the illustrated embodiment, the encapsulating film 210 includes an array of micro-perforations or apertures 220 on one side that faces the payload 140 once inserted in the shipping container 110. In some implementations, the micro-perforations 220 are present on the entire film 210 while in other embodiments, the micro-perforations 220 are present on portions of the panel that are adjacent to and/or proximate to the payload 140. In various embodiments, the encapsulating film 210 may be constructed of plastic, bio-plastic, paper or other materials. In some implementations, the film 210 may also include a reflective surface on one or both sides to enhance the insulating properties of the insulating panel 200. In some implementations, the insulating panel 200 is not encapsulated with an encapsulating film 210. In some embodiments, the film may be a stand-alone material that is applied to the hemp fibers 230, or a sheath that is slid over the hemp fibers 230 or even a material that is sprayed onto the hemp fibers and then perforated after application. In some embodiments, the film may be naturally porous or configured such that moister or air may pass through the surface, while in other embodiments the film may be water and/or air tight. In some embodiments, super-absorbent beads may be included between the film 210 and the natural or hemp fibers 230 for further facilitate the collection of moister. In other embodiments, the film 210 may include pockets for housing super-absorbent beads or material such that the pockets can be removed for proper disposal while the remainder of the material can be recycled.

[0066] FIG. 3 is a perspective exploded view of an exemplary embodiment of a 3-panel system whereby one insulating panel covers the bottom of the shipping container, one insulating panel covers the top and one long insulating panel covers the 4 vertical sides of the shipping container. Referring now to FIG. 3, the illustrated 3-panel system 300 in accordance with an exemplary embodiment of the invention is shown as including three insulating panels (310 and 320) and a shipping container 110. In the illustrated embodiment, the combination of the three panels cover all internal walls of the shipping container 110. The insulating panels may be primarily constructed of natural fibers or hemp fibers as shown on FIG. 2. In the illustrated embodiment, one insulating panel 310 covers the bottom of the shipping container 110, one insulating panel 310 covers the top of the shipping container 110 and one long insulating panel 320 covers the 4 vertical internal walls of the shipping container 110. To assemble the 3-panel system 300, the insulating panel 310 is inserted flat at the bottom of the shipping container 110. The insulating panel 320 is then inserted inside the shipping container 110 and folded in a way that it covers the four internal vertical sides of the shipping container 110 with each fold or the meeting junction of the edges of the long insulating panel 320 being inserted into the corners of the shipping container 110. It should also be appreciated that the insulating panel 320 may be constructed as a box without a top or bottom and then slid into the shipping container or over the payload. The insulating panel 310 is added on top of the insulating panel 320 to form a continuous or nearly continuous insulating layer inside the shipping container 110 which surrounds the payload 140 being transported. A device or several devices (such as gel-packs containing phase change materials) may be added between the payload 140 and the insulating panels (310 and 320). The payload 140 is shown for illustrative purposes and is not part of the 3-panel system.

[0067] FIG. 4 is a perspective exploded view of an exemplary 6-panel system whereby there is an independent insulating panel for each side of the shipping container. Referring now to FIG. 4, the exemplary 6-panel system 400 includes 6 insulating panels (3 styles 410, 411, 412) and a shipping container 110 whereby there is an independent insulating panel for each internal side of the shipping container 110. All insulating panels are primarily made of natural fibers or hemp fibers such as shown on FIG. 2. To assemble the 6-panel system 400, one of the insulating panels 410 is inserted flat at the bottom of the shipping container 110. The insulating panels 411 are then inserted inside the shipping container 110 and laid against two opposite vertical walls of the shipping container 110. The insulating panels 412 are then inserted in the shipping container 110 and laid against the two remaining opposite walls, orthogonally to the insulating panels 411, of the shipping container 110. The remaining insulating panel 410 is added on top of the vertical insulated walls 411 and 412 to form a continuous or nearly continuous insulating layer inside the shipping container 110 which surrounds the payload 140 being transported. A device or several devices such as phase change materials may be added between the payload 140 and the insulating panels (410, 411, 412). The payload 140 is shown for illustrative purposes and is not part of the 6-panel system.

[0068] FIG. 5a is a perspective exploded view of an exemplary stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as phase change material) that will help maintain the temperature inside the shipping container. Referring now to FIG. 5a, the exemplary stacked panel system 500 is shown as including 3 insulating panels stacked vertically on top of each other and a shipping container 110. As illustrated, the middle panel 520 includes multiple cut-outs 530 that can be made of differing sizes and shapes to hold payload. In the illustrated embodiment, the cut-outs are shown as being circular or cylindrical as a non-limiting example. The top and bottom panels 510 have cut-outs to hold phase change materials. All insulating panels are primarily made of natural fibers or hemp fibers such as shown on FIG. 2. To assemble the exemplary stacked panel system 500, the insulating panel 510 is inserted flat at the bottom of the shipping container 110. The insulating panel 520 is then inserted flat on top of the insulating panel 510. A third insulating panel 510 is inserted flat on top of the stack. The cut-outs 540 in the insulating panels 510 are designed to hold a device or several devices such as phase change materials. The cut-outs 530 in the insulating panel 520 are designed to hold a payload. As shown on FIG. 5b, the cut-outs 530 in the middle panel 520 are cut all the way through the insulating panel. In some implementations, the cut-outs may not pass all the way through the insulating panel 520 and as such, a bottom surface within the cut-outs can provide support for the payload.

[0069] FIG. 5b is a see-through perspective exploded view of the stacked panel system of FIG. 5a, wherein 3 insulating panels are stacked on top of each other with the middle panel having circular cut-outs to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container. As shown on FIG. 5b, the cut-outs 540 are not cut all the way through the insulating panels 510. In this particular embodiment, the insulating panels are not encapsulated in a film. Other implementations may include insulating panels encapsulated, either in whole or in part in a film as previously described. Other implementations may have a different number of insulating panels not necessarily arranged in a vertical stack. Insulating panels may be placed side-by-side or in other arrangements. Other implementations may have cut-outs in only one panel or cut-outs in several panels. Cut-outs to a device or several devices (such as gel-packs containing phase change materials) may be placed on the sides of the panel holding the payload in addition or instead of being on top and/or at the bottom of the payload panel.

[0070] FIG. 6 is a perspective exploded view of a stacked panel system whereby 3 insulating panels are stacked on top of each other with the middle panel having a rectangular cut-out to hold payload and the top and bottom panels have cut-outs to hold devices (such as gel-packs containing phase change material) that will help maintain the temperature inside the shipping container. Referring to FIG. 6, the exemplary stacked panel system 600 includes 3 insulating panels stacked on top of each other and a shipping container 110, whereby the middle panel 610 has a rectangular cut-out 620 to hold payload and the top and bottom panels 510 have cut-outs to hold one or more devices such as phase change materials that will help maintain a desired temperature range for a prolonged period of time, such as during transportation or storage. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. The stacked panel system 600 is assembled the same way as the stacked panel system 500. The middle panel 610 has a rectangular cut-out 620 all the way through the insulating panel 610. Other implementations may have a cut-out that does not pass all the way through the insulating panel 610. Similar to the stacked panel 500, some embodiments may present a different number of insulating panels and panel arrangements with or without cut-outs.

[0071] FIG. 7 is a perspective exploded view of a wrap-around system whereby insulating panels are wrapped on the outside of the shipping container or assembly of shipping containers. Referring now to FIG. 7, the exemplary wrap-around system 700 is illustrated as including 6 insulating panels that cover the outside of an assembly of shipping containers or assembly of goods 740, such as a palletized load of boxes. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. Thus, this embodiment includes two side panels 710, two end panels 720 and a top and bottom panel 730. It should be appreciated that in some embodiments, each of the panels may be identically dimensioned (i.e. for a cubical load) or one or more of the panels may have different dimensions from one or more of the other panels. For assembly, the bottom panel 730 can be placed on a surface and the payload 740 can be stacked on top of the bottom panel 730. Once the load is in place, the side panels 710 and end panels 720 can be placed into position and finally, the top panel 730 can be placed on top of the payload 740. In some embodiments, the panels can be secured to the payload 740 by a cellophane wrapping, shipping tape, adhesive on the inside surface of the panels, straps, metal strips, clamps, a sheath, hook and nook fasteners or tape as non-limiting examples. The payload can be covered in a material, such as paper or plastic wrap and the panels can be attached thereto. Further, as illustrated in other embodiments, one or more of the panels 710, 720 and 730 may include recessed areas or cut-outs for receiving and containing devices such as phase change materials that will help maintain a desired temperature range for a prolonged period of time, such as during transportation or storage.

[0072] FIG. 8 is a perspective exploded view of a 3-panel pallet cover system whereby one insulating panel covers the bottom of the palletized payload and two panels cover two opposite sides of the palletized payload with two superimposed panels on top of the palletized payload. Referring now to FIG. 8, an exemplary 3-panel cover system 800 for a large shipping container, assembly of multiple shipping containers or assembly of goods in accordance is illustrated. For simplicity, this embodiment is referred to herein as a “pallet cover system,” although a pallet need not be used as part of this system or in its various embodiments. For simplicity, the payload illustrated as being covered in the illustrated embodiment of the pallet cover system is referred to herein as a “shipping container,” although the payload may be a single large shipping container, an assembly of shipping containers, or an assembly of goods. As shown, the 3-panel pallet cover system includes one insulating panel 810 laying on a pallet 750, a second insulating panel 820 covering the top of the shipping container 740 and also covering two opposite sides of the shipping container 740, and a third insulating panel 830 covering the top of the first insulating panel 820 and the two remaining exposed sides of the shipping container 740. All insulating panels are primarily made of hemp fibers such as shown on FIG. 2. In some embodiments, the insulating panel 820 and the insulating panel 830 are rigidly formed in a C shape or U shape. In other embodiments the insulating panel 820 and 830 may be hinged using any of a wide variety of techniques, such a scoring, creasing, using an actual hinge, using a thinner portion of material, using interlocking pieces, using tongue and groove joints, bendable or otherwise foldable along lines 822a and 822b for insulating panel 820 and 832a and 832b for insulating panel 830. Advantageously, the embodiments that can be folded are also suitable for flat-pack shipping and thus more cost effective for shipping to various locations. As such, the foldable panels can be packaged and shipped in a cost effective manner and then the panels can be folded so that they adapt to the shape of the shipping container 740. In some embodiments, the panels can be secured to the payload 740 by a cellophane wrapping, shipping tape, adhesive on the inside surface of the panels, straps, metal strips, clamps, a sheath, hook and nook fasteners or tape as non-limiting examples. The payload can be covered in a material, such as paper or plastic wrap and the panels can be attached thereto. The insulating panels may be encapsulated in a film made of materials such as but not limited to plastic, bioplastics and paper. The surface of the film may have reflective properties. In one particular and illustrative, yet non limiting, embodiment of the 3-panel pallet cover system 800, the insulating panel 810 may have a length of approximately 48 inches, a width of approximately 40 inches and a thickness of approximately 1 inch, the insulating panel 820 may have a length of approximately 136 inches, a width of approximately 40 inches and a thickness of approximately 1 inch and the insulating panel 830 may have a length of approximately 140 inches, a width of approximately 52 inches and a thickness of approximately 1 inch. Of course, these measurements are merely illustrative and insulating panels of any length, width and thickness that include the features described herein are intended to be within this disclosure and make up the overall invention, which has many different embodiments.

[0073] As previously described, the insulating panels may be held together or joined in a variety of manners. The use of adhesive or hook and loop (VELCRO) materials have been described. In addition, the use of tongue and groove type connections have been described as being molded, carved or cut into the panels to create a connection. Further, the use of tabs and spaces can be utilized such that the tabs of a panel align with the spaces of another panel, and vice versa, thereby creating a connection. Other techniques may also be used including bio-degradable tape, fasteners, pins, etc.

[0074] In some embodiments, the container may be constructed to include pockets on the interior or exterior. These pockets can also be used to receive and securely hold the insulating panels in place. It should also be appreciated that in some embodiments, the insulating panels, when assembled and secured, can operate as the shipping container as well. In such embodiments a water resistant film can be applied to the exterior of the insulating panels to further protect the contents.

[0075] While the various embodiments have been described as predominantly rectangular cubes in shape, it should be appreciated that the present invention could be applied in any shape, including spherical, orbed, pyramidal, tubular, etc. The various panels may be created in a mold, extruded or carved from larger sections of material.

[0076] Different features, variations and multiple different embodiments have been shown and described with various details. What has been described in this application at times in terms of specific embodiments is done for illustrative purposes only and without the intent to limit or suggest that what has been conceived is only one particular embodiment or specific embodiments. It is to be understood that this disclosure is not limited to any single specific embodiments or enumerated variations. Many modifications, variations and other embodiments will come to mind of those skilled in the art, and which are intended to be and are in fact covered by this disclosure. It is indeed intended that the scope of this disclosure should be determined by a proper legal interpretation and construction of the disclosure, including equivalents, as understood by those of skill in the art relying upon the complete disclosure present at the time of filing.

[0077] In the description and claims of the present application, each of the verbs, “comprise”, “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements, or parts of the subject or subjects of the verb.

[0078] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art.

[0079] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined by the claims that follow.