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. An insulator configured for installation inside of a cuboid container to insulate the cuboid container, the insulator comprising: an insulation layer, operable from an unfolded position to an operating position and comprising a T shape in the unfolded position; and wherein, the operating position comprises a plurality of folds to form the insulation layer into a cuboid shape configured to fit within the cuboid container; wherein the insulation layer comprises a cotton fiber material; a lamination layer attached to at least one surface of the insulation layer, wherein at least an unwrapped portion of the insulation layer is not covered by the lamination layer, wherein, in the operating position, the insulation layer comprises six panels configured to line a top, a bottom, and four sides of the cuboid container and to define a compartment for receiving and insulating one or more articles, and wherein the unwrapped portion is configured to be exposed to an environment within the cuboid container.
2. The insulator of claim 1, wherein the lamination layer is a natural fiber lamination layer.
3. The insulator of claim 1, wherein the cuboid shape formed by the insulation layer in the operating position is a cubic shape, and the six panels are square panels, and the insulator is configured for installation inside the cuboid container in a cubic configuration where the top, the bottom, and the four sides of the cuboid container are squares.
4. The insulator of claim 1, wherein the lamination layer is a single layer, such that the lamination layer has a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.
5. The insulator of claim 1, wherein the cotton fiber material is formed from a post-industrial, pre-consumer cotton waste.
6. The insulator of claim 5, wherein the post-industrial, pre-consumer cotton waste comprises fiber material gleaned or trimmed as part of a cotton manufacturing and converting process.
7. The insulator of claim 1, wherein the insulation layer has an inner surface configured to face inwardly into the compartment in the operating position, an outer surface opposite the inner surface, and a plurality of edge surfaces extending between the inner surface and the outer surface, and wherein the lamination layer is attached to at least a contact surface of the inner surface of the insulation layer.
8. The insulator of claim 7, wherein the lamination layer is further attached to the outer surface of the insulation layer.
9. The insulator of claim 7, wherein the contact surface is configured for confronting the one or more articles when the insulation layer is in the operating position.
10. The insulator of claim 7, wherein the unwrapped portion includes the plurality of edge surfaces.
11. A method of preparing an insulated container comprising: providing an insulation layer comprising a cotton fiber material and formed in a T shape in an unfolded, flat position, wherein at least an unwrapped portion of the insulation layer is unwrapped, the insulation layer further having a lamination layer attached to at least one surface of the insulation layer, wherein at least an unwrapped portion of the insulation layer is not covered by the lamination layer; and folding the insulation layer into an operating position and placing the insulation layer into the insulated container, such that the insulation layer comprises six panels lining a top, a bottom, and four sides of the insulated container and defining a compartment for receiving and insulating one or more articles, wherein at least a portion of an outermost surface of the unwrapped portion is configured to be exposed to an environment within the insulated container.
12. The method of claim 11, wherein the insulation layer in the operating position has a cuboid shape, and the insulated container has a cuboid configuration.
13. The method of claim 12, wherein the insulation layer in the operating position has a cubic shape, and the six panels are square panels, and the cuboid container has a cubic configuration where the top, the bottom, and the four sides of the cuboid container are squares.
14. The method of claim 11, wherein the lamination layer is a natural fiber lamination layer.
15. The method of claim 11, wherein the lamination layer is a single layer, such that the lamination layer has a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.
16. The method of claim 11, wherein the cotton fiber material is formed from a post-industrial, pre-consumer cotton waste gleaned or trimmed as part of a cotton manufacturing and converting process.
17. The method of claim 11, wherein the insulation layer has an inner surface facing inwardly into the compartment in the operating position, an outer surface opposite the inner surface, and a plurality of edge surfaces extending between the inner surface and the outer surface, and wherein the lamination layer is attached to at least a contact surface of the inner surface of the insulation layer, and the unwrapped portion includes the plurality of edge surfaces.
18. The method of claim 17, wherein the contact surface is configured for confronting the one or more articles when the insulation layer is in the operating position.
19. An insulator configured for installation inside of a container to insulate the container, the insulator comprising: an insulation layer, operable from an unfolded position to an operating position and comprising a T shape in the unfolded position, the insulation layer having an inner surface configured to face inwardly into the container in the operating position, an outer surface opposite the inner surface, and a plurality of edge surfaces extending between the inner surface and the outer surface; wherein, the operating position comprises a plurality of folds to form the insulation layer into a shape configured to fit within the container, wherein the insulation layer comprises a cotton fiber material; and a lamination layer attached to at least one of the inner surface of the insulation layer and the outer surface of the insulation layer to form a wrapped portion of the insulation layer, wherein the insulation layer further has an unwrapped portion configured to be exposed to an environment within the container, and the unwrapped portion includes the plurality of edge surfaces.
20. The insulator of claim 19, wherein the lamination layer is a natural fiber lamination layer.
21. The insulator of claim 19, wherein the lamination layer is a single layer, such that the lamination layer has a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.
22. The insulator of claim 19, wherein the cotton fiber material is formed from a post-industrial, pre-consumer cotton waste gleaned or trimmed as part of a cotton manufacturing and converting process.
23. An insulator configured for installation inside of a container to insulate the container, the insulator comprising: an insulation layer comprising a cotton fiber material, operable from an unfolded position to an operating position and comprising a T shape in the unfolded position, the insulation layer having an inner surface configured to face inwardly into the container in the operating position, an outer surface opposite the inner surface, and a plurality of edge surfaces extending between the inner surface and the outer surface, wherein the operating position comprises a plurality of folds to form the insulation layer into a shape configured to fit within the container; and a lamination layer applied to at least at least a contact surface of the inner surface of the insulation layer, but not to any of the edge surfaces of the insulation layer.
24. The insulator of claim 23, wherein the lamination layer is a natural fiber lamination layer.
25. The insulator of claim 23, wherein the lamination layer is a single layer, such that the lamination layer has a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.
26. The insulator of claim 23, wherein the cotton fiber material is formed from a post-industrial, pre-consumer cotton waste gleaned or trimmed as part of a cotton manufacturing and converting process.
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 T 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. 38. 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.
