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 be characterized by a lack of any wrapping material. The insulation layer may be manufactured using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven material for providing consistent density throughout the insulation layer. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer. The insulation layer may be biodegradable in an anaerobic environment.

Claims

1. An insulator configured for installation inside of a cuboid container to insulate the container, the insulator comprising: an insulation layer comprising a plurality of insulation pads configured to be arranged in an operating position inside the container, wherein the plurality of insulation pads in the operating position form a cuboid shape configured to line a top, a bottom, and four sides of the container when installed inside of the container, such that each of the insulation pads has a contact surface configured to face inward toward contents of the container when installed inside of the container in the operating position, and wherein the plurality of insulation pads comprise a cotton fiber material; and a covering layer comprising a plurality of cover members covering at least the contact surfaces of the plurality of insulation pads, wherein the covering layer is configured to permit the cotton fiber material of each of the plurality of insulation pads to be exposed to an environment within the container.

2. The insulator of claim 1, wherein the cotton fiber material is formed from post-industrial, pre-consumer cotton waste, and wherein the insulation layer is biodegradable in an anaerobic environment.

3. The insulator of claim 1, wherein the cuboid shape formed by the plurality of insulation pads in the operating position is a cubic shape having six 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 plurality of insulation pads comprise a first insulation pad and a second insulation pad each configured to line a portion of an inner periphery of the container when installed in the operating position.

5. The insulator of claim 4, wherein the first insulation pad and the second insulation pad are together configured to line an entirety of the inner periphery of the container when installed in the operating position.

6. The insulator of claim 4, wherein the first insulation pad is folded into a plurality of panels when arranged in the operating position.

7. The insulator of claim 6, wherein the second insulation pad is folded into a plurality of panels when arranged in the operating position.

8. The insulator of claim 6, wherein the panels of the first insulation pad are configured to line a plurality of the four sides of the container when installed inside of the container and arranged in the operating position.

9. The insulator of claim 8, wherein the second insulation pad is configured to line the top of the container when installed inside of the container and arranged in the operating position.

10. The insulator of claim 9, wherein each of the first and second insulation pads has an outer surface opposite the contact surface, and the covering layer further covers the outer surfaces of the first and second insulation pads.

11. The insulator of claim 1, wherein the covering layer is a single layer, such that each of the cover members has a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.

12. The insulator of claim 1, wherein each of the plurality of insulation pads has an outer surface opposite the contact surface, and the covering layer further covers the outer surfaces of the plurality of insulation pads.

13. A method of preparing an insulated container comprising: providing an insulation layer comprising a plurality of insulation pads formed from a cotton fiber material, each of the plurality of insulation pads having a contact surface, the insulation layer having a covering layer comprising a plurality of cover members covering at least the contact surfaces of the plurality of insulation pads; and installing the insulation layer in an operating position inside a cuboid container having a top, a bottom, and four sides, wherein the plurality of insulation pads in the operating position form a cuboid shape lining the top, the bottom, and the four sides of the container, such that the contact surfaces of the insulation pads face inward toward contents of the container when installed inside of the container in the operating position, wherein the covering layer is configured to permit the cotton fiber material of each of the plurality of insulation pads to be exposed to an environment within the container.

14. The method of claim 13, wherein the container has an inner periphery comprising the top, the bottom, and the four sides, and the plurality of insulation pads comprise a first insulation pad and a second insulation pad each lining a portion of the inner periphery of the container when installed in the operating position.

15. The method of claim 14, wherein the first insulation pad and the second insulation pad are together configured to line an entirety of the inner periphery of the container when installed in the operating position.

16. The method of claim 14, wherein installing the insulation layer comprises folding the first insulation pad into a plurality of panels to arrange the first insulation pad in the operating position.

17. The method of claim 16, wherein the panels of the first insulation pad line a plurality of the four sides of the container when installed inside of the container and arranged in the operating position.

18. The insulator of claim 17, wherein the second insulation pad lines the top of the container when installed inside of the container and arranged in the operating position.

19. The insulator of claim 18, wherein each of the first and second insulation pads has an outer surface opposite the contact surface, and the covering layer further covers the outer surfaces of the first and second insulation pads.

20. The method of claim 13, wherein the cuboid shape formed by the plurality of insulation pads in the operating position is a cubic shape having six 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.

21. An insulator configured for installation inside of a cuboid container having an inner periphery including a top, a bottom, and four sides, to insulate the container, the insulator comprising: a first insulation pad formed from a cotton fiber material and having a first contact surface, the first insulation pad configured to be installed within the container to line a first portion of the inner periphery of the container, such that the first contact surface is configured to face inward toward contents of the container when installed inside of the container; a first covering member covering at least the first contact surface of the first insulation pad, wherein the first covering layer is configured to permit the cotton fiber material of the first insulation pad to be exposed to an environment within the container; a second insulation pad formed from the cotton fiber material and having a second contact surface, the second insulation pad configured to be installed within the container to line a second portion of the inner periphery of the container, such that the second contact surface is configured to face inward toward the contents of the container when installed inside of the container; and a second covering member covering at least the second contact surface of the second insulation pad, wherein the second covering layer is configured to permit the cotton fiber material of the second insulation pad to be in fluid communication with the environment within the container.

22. The insulator of claim 21, wherein the cotton fiber material is formed from post-industrial, pre-consumer cotton waste.

23. The insulator of claim 21, wherein the first insulation pad and the second insulation pad are together configured to line an entirety of the inner periphery of the container when installed within the container.

24. The insulator of claim 21, wherein the first insulation pad is folded into a plurality of panels when arranged to be installed within the container.

25. The insulator of claim 24, wherein the second insulation pad is folded into a plurality of panels when arranged to be installed within the container.

26. The insulator of claim 24, wherein the panels of the first insulation pad are configured to line a plurality of the four sides of the container when installed inside of the container.

27. The insulator of claim 26, wherein the second insulation pad is configured to line the top of the container when installed inside of the container.

28. The insulator of claim 27, wherein the first insulation pad has a first outer surface opposite the first contact surface, and the first covering member further covers the first outer surface of the first insulation pad, and wherein the second insulation pad has a second outer surface opposite the second contact surface, and the second covering member further covers the second outer surface of the second insulation pad.

29. The insulator of claim 21, wherein the first covering member and the second covering member are single layers, each having a first surface facing the cotton fiber material and a second surface facing away from the cotton fiber material.

30. The insulator of claim 21, wherein the first insulation pad has a first outer surface opposite the first contact surface, and the first covering member further covers the first outer surface of the first insulation pad, and wherein the second insulation pad has a second outer surface opposite the second contact surface, and the second covering member further covers the second outer surface of the second insulation pad.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] 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:

[0027] FIG. 1 is a perspective view of a prior art insulated container where the insulating material is expanded polystyrene foam;

[0028] FIG. 2 is a perspective view of a prior art insulated container where the insulating material is enclosed in plastic;

[0029] FIG. 3 is an exploded view of the insulated container in a partially assembled state;

[0030] FIG. 4 is an exploded view of the insulated container in a partially assembled state;

[0031] FIG. 5 is an exploded view of the insulated container in an unassembled state;

[0032] FIG. 6 is an exploded view of the insulated container in a partially assembled state;

[0033] FIG. 7 is an exploded view of the insulated container in a partially assembled state;

[0034] FIG. 8 is an exploded view of the insulated container in a partially assembled state;

[0035] FIG. 9 is an exploded view of the insulated container in a partially assembled state;

[0036] FIG. 10 is an exploded view of the insulated container in a partially assembled state;

[0037] FIG. 11 is a perspective view of the insulated container in an assembled state;

[0038] FIG. 12 is a perspective view of the insulated container in an assembled state;

[0039] FIG. 12A is sectional view of the insulated container;

[0040] FIG. 13 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;

[0041] FIG. 14 is a heat stress chart;

[0042] FIG. 15 is a heat stress chart; and

[0043] FIG. 16 is a cold stress chart.

DETAILED DESCRIPTION OF THE INVENTION

[0044] FIG. 1 and FIG. 2 show prior art insulated containers. In particular, FIG. 1 shows a prior art insulated container having a rigid foam insulation layer. FIG. 2 shows a prior art insulated container having an insulation layer which is wrapped in plastic.

[0045] Generally, FIGS. 3 through 10, 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. 13 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. 13 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.

[0046] Referring to FIG. 3, 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.

[0047] 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.

[0048] 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.

[0049] When assembled, as shown in FIG. 4, 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.

[0050] As shown in FIGS. 5-10, the insulation layer 20 of the insulated container 10 may be assembled by folding respective C-shaped members 22, 24. As shown in FIG. 5, the C-shaped members 22, 24 may have in unfolded state that is a flat rectangular shape. As shown in FIGS. 6-9, 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.

[0051] FIG. 11 shows the fully assembled insulated container 10 with the lid of the rigid container 50 open. FIG. 12 visualized the cross-section A-A which is shown in FIG. 12A. 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.

[0052] FIG. 13 shows the insulated container 10 of FIGS. 3-12A 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.

[0053] 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. 14 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.

[0054] 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. 15 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.

[0055] 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. 16 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.

[0056] 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.

[0057] 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.

[0058] An insulated container 10 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.