SHIPPING CONTAINER PACKAGING WITH THERMAL REGULATION

Abstract

Shipping container packaging has a top and bottom tray and a divider assembly including interconnected longitudinal and lateral panels and at least one thermal regulation element to form article surrounding voids or chambers. The at least one thermal regulation element includes heat transfer surfaces in direct radiant heat transfer relation to the articles. In one form, the thermal regulation element includes a refrigerant. In one form, the divider assembly includes plural thermal regulation elements. In one form, the assembly defines bottle surrounding chambers.

Claims

1. A shipping container packaging comprising: a bottom tray defining a plurality of bottom article receiving chambers, a top tray defining a plurality of top article receiving chambers, a divider assembly of intersecting longitudinal and lateral divider panels extending between said bottom and top trays, forming article surrounding chambers, wherein at least one of said longitudinal and lateral divider panels comprises a thermal regulation element.

2. A shipping container packaging as claimed in claim 1 wherein a plurality of said divider panels comprise thermal regulation elements.

3. A shipping container packaging as claimed in claim 2 wherein said divider assembly includes longitudinal and lateral divider panels interengaged to form said article surrounding chambers.

4. A shipping container packaging as claimed in claim 3 wherein said longitudinal and lateral cardboard divider panels support said thermal regulation elements.

5. A shipping container packaging as claimed in claim 4 wherein said thermal regulation elements define at least a portion of each of said article surrounding chambers.

6. A shipping container packaging as claimed in claim 5 wherein said lateral panels comprise thermal regulation elements.

7. A shipping container packaging as claimed in claim 6 where in said longitudinal divider panels includes at least one slot sized to receive and support said thermal regulation elements.

8. A shipping container packaging as claimed in claim 7 wherein said panel assembly includes two longitudinal divider panels and three lateral divider panels.

9. A shipping container packaging as claimed in claim 8 wherein at least a portion of two of said lateral divider panels comprise a thermal regulation element.

10. A shipping container packaging as claimed in claim 9 wherein said thermal regulation elements comprise a planar heat transfer surface in direct heat transfer relation with said article in each said article surrounding chamber.

11. A shipping container packaging as claimed in claim 10 wherein said thermal regulation elements include a quantity of refrigerant disposed for direct heat transfer with said articles.

12. A shipping container packaging as claimed in claim 11 further comprising flexible insulation batting surrounding said trays, divider assembly and product surrounding chambers.

13. A method of packaging articles comprising: providing a bottom tray defining a plurality of bottom article receiving chambers, providing a top tray defining a plurality of top article receiving chambers, providing a divider assembly of intersecting longitudinal and lateral divider panels extending between said bottom and top trays, forming article surrounding chambers, wherein at least one of said longitudinal and lateral divider panels comprises a thermal regulator element, the method comprising disposing an article in each article surrounding chamber.

14. The method of packaging articles as claimed in claim 13 wherein the articles comprises liquid containing bottles.

15. The method as claimed in claim 14 the steps further including: providing a plurality of divider panels comprising thermal regulation elements.

16. The method as claimed in claim 15 further comprising: providing longitudinal and lateral divider panels interengaged to form said article surrounding chambers, and wherein said thermal regulation elements define at least a portion of each said article surrounding chamber.

17. The method as claimed in claim 16 wherein said panel assembly includes two longitudinal divider panels and three lateral divider panels and wherein at least a portion of two of said lateral divider panels comprise a thermal regulation element.

18. The method as claimed in claim 17 wherein said thermal regulation elements comprise a planar heat transfer surface in direct heat transfer relation with articles in each said article surrounding chambers.

19. The method as claimed in claim 18 including providing thermal regulation elements containing a quantity of refrigerant.

20. The method as claimed in claim 19 further comprises providing flexible insulation batting surrounding said trays, divider assembly and article surrounding chambers.

Description

DESCRIPTION OF DRAWINGS

[0006] FIG. 1 is an exploded perspective view of an embodiment of the shipping container packaging of the disclosure and a surrounding carton.

[0007] FIG. 2 is a longitudinal sectional view of the embodiment of a shipping container packaging of FIG. 1.

[0008] FIGS. 3 and 4 are perspective views of the top tray of the shipping container packaging of the disclosure.

[0009] FIGS. 5 and 6 are perspective views of the bottom tray of the shipping container packaging of the disclosure.

[0010] FIG. 7 is a plan view of a component of the divider assembly of the shipping container packaging of the disclosure.

[0011] FIG. 8 is a plan view of a further component of the divider assembly of the shipping container packaging of the disclosure.

[0012] FIG. 9 is a perspective view of the thermal regulation element of the divider assembly of the shipping container packaging of the disclosure.

[0013] FIG. 10 is a perspective view of the shipping container packaging and surrounding carton of the disclosure illustrating a slightly modified carton format.

[0014] FIG. 11 is a plan view of a component of the shipping container packaging of FIGS. 12 and 13.

[0015] FIG. 12 is a partial perspective view of a shipping container packaging in accordance with the disclosure in a modified form.

[0016] FIG. 13 is a partial perspective view of the shipping container packaging of FIG. 11 with articles in place within article surrounding chambers.

DETAILED DESCRIPTION

[0017] Referring to the accompanying drawings, there is illustrated a shipping container packaging in accordance with the disclosure of prior U.S. Pat. Nos. 8,434,620 and 8,844,718. The illustrated container packaging is arranged to provide thermal regulation of the interior environment to ensure product integrity. As seen in FIG. 1, the shipping container packaging, designated 100, is housed in outer surrounding cardboard carton 110. The packaging ensures safe commercial transport of individual articles, here illustrated as bottles 102 of liquid, and additionally protects the payload (the liquid) against undesirable elevated temperatures. In this latter regard, the shipping container packaging is considered particularly suitable for shipping bottles containing wine. The shipping container packaging of the disclosure may, of course, be utilized for shipping any suitable commodity contained in a fragile vessel.

[0018] Turning now to the drawings where, whenever possible like reference numerals will refer to like elements. Carton 110 is generally rectangular with longitudinal side walls 112 and transverse or lateral side walls 113. Top and bottom walls of the carton 110 are bound by closure of movable major flaps 114 and minor flaps 115. The flaps are ultimately sealed with removeable tape (not shown) to close the carton 110 for shipping.

[0019] The interior surfaces of carton side walls 112 and 113 and the carton walls formed by top and bottom flaps 113 and 114 are lined with insulation to reduce heat transfer through the carton 110. Any sustainable insulation, common to commodity packaging is considered appropriate. For example, ClimaCell a product of TemperPack, is considered suitable. ClimaCell and TemperPack are registered trademarks of Temperpack Technologies, Inc., Richmond, VA.

[0020] In the illustrated embodiment this is accomplished with two segments 116 and 117 of flexible insulation batting. Approximately 1 inch thick, the flexible material segments are formed into engaged U shapes positioned against the interior surfaces of carton 110. One such segment 116 is arranged to cover the flaps 114 and 115 forming the bottom and top walls of the carton, and one vertical lateral side wall 113. The other segment 117 is sized and oriented within the carton 110 to cover one side wall 113 and the two longitudinal side walls 112. The flexibility of the insulation batting segments permits access to the bottles 102 on opening of the flaps 114 and 115 at the top wall of the carton 110.

[0021] The shipping container packaging, as described in prior U.S. Pat. Nos. 8,434,620 and 8,844,718 the disclosures of which are fully incorporated by reference herein, includes top tray 120 configured to secure and support the articles 102. There is further provided a bottom tray 130, configured to support individual articles 102 in a spaced apart configuration. The trays 120 and 130 of the disclosure, made of molded pulp fiber are vertically separated by divider assembly 150.

[0022] As seen in FIGS. 2, 3 and 4, top tray 120 has a perimeter edge 123 sized for slight interference fit with the inner surface of insulating batting segments 116 and 117 lining the walls of carton 110. It includes twelve (12) upper article or bottle receiving chambers defined by generally conical cup-like walls 124 terminating in ends 125 arranged for contact with the inner surface of insulation batting segment 116 extending under the top wall of carton 110 formed by major flaps 114 and minor flaps 115. Each end 125 includes a crushable protrusion 126, seen in FIG. 2 associated with the top of each bottle 102 to absorb loads imparted by forces incurred during shipping.

[0023] As described in the above-mentioned patents, top tray 120 includes structural elements to sustain the top tray against loads imparted during transport. Best seen in FIGS. 3 and 4, top tray 120 includes pillars 127 positioned along perimeter edge 123 and between and conical walls 124 having contact surfaces 128 for load transferring contact with the interior surface of insulation batting segment 116.

[0024] Shown in FIG. 4, the opposite ends of pillars 127, are formed with intersecting channels 129 aligned to engage with divider assembly 150 as discussed further below. Channels 129 are best seen in FIGS. 3 and 4.

[0025] Bottom tray 130, best seen in FIGS. 2, 5 and 6, has a perimeter edge 133 sized for slight interference fit with the inner surface of batting segments 116 and 117 lining wall of carton 110. It includes twelve (12) article or bottle receiving chambers 130 defined by generally cylindrical cup-like walls 134 each with a bottom wall 135. In an assembled shipping container 100 bottom walls 135 are supported upon the inner surface of insulation batting 116 positioned over major flaps 114 and minor flaps 115 forming the bottom wall of the carton 110. Each top wall 135 includes a crushable circular protrusion 136, seen in FIG. 2 to absorb loads imparted to bottles 102 during shipping.

[0026] As described in prior U.S. Pat. Nos. 8,434,620 and 8,844,718 bottom tray 130 includes adequate structural elements to sustain the bottom tray against loads imparted during transport of the shipping container. Best seen in FIG. 5, bottom tray 130 includes pillars 137 along perimeter edge 133 and between and conical walls 134 having contact surfaces 138 for load transferring contact with the interior surface of insulation batting segment 116.

[0027] Shown in FIG. 5, the opposite ends of pillars 137, are formed with intersecting channels 139 aligned to engage with divider assembly 150 as discussed further below.

[0028] Integrated between molded pulp formed top tray 120 and bottom tray 130, divider assembly 150 provides columnar strength to shipping container packaging 100. Made of cardboard, with flutes running horizontally, longitudinal and lateral divider panels 152 and 162 isolate the product containing bottles 102 from the adverse effects of shipping and handling mishaps. In this disclosure, the divider panels 152 and 162 delineate separate voids or chambers designated 104 in FIGS. 1, 2 and 10 that separately surround each article or bottle 102.

[0029] With reference to FIGS. 1 and 7, the illustrated embodiment includes two longitudinal divider panels 152 extending horizontally between vertical edges 153. The vertical edges contact the inner surface of insulation batting segments 116 and 117 adjacent opposing lateral side walls 113. The longitudinal divider panels extend vertically between horizontal edges 154 disposed in channels 129 and 139 formed by top tray 120 and bottom tray 130.

[0030] As seen in FIG. 7, longitudinal divider walls 152 include a central vertical narrow slot 155 having a width about the thickness of the cardboard divider panels, extending vertically from top edge 154 to about midway of the panel 152. Slot 155 includes T shaped slit 157 at its distal end and resides in, and engages with lateral divider panel 162 as discussed further below.

[0031] In addition, longitudinal divider panels 152 include wide slots 156 extending vertically from an upper horizontal edge 154 having bottom edges 158 disposed nearly to, but spaced from lower or bottom edge 154. The wide slots having a width discussed below, are spaced from central lateral panel narrow slot 155 in alignment with channels 129 and 139 of top and bottom trays 120 and 130.

[0032] In the illustrated embodiment, with reference to FIGS. 1, 2, and 5, divider assembly 150 includes one lateral, or transverse divider panel 162 extending laterally between vertical edges 163 in contact with the inner surface of insulation batting segment 117 overlying longitudinal side walls 112 of carton 110. Divider panel 162 extends vertically between upper and lower horizontal edges 164 disposed in channels 129 and 139 of top tray 120 and bottom tray 130 as seen in FIG. 2.

[0033] Referring to FIG. 8, lateral divider panel 162 include a pair of narrow slots 165 extending from lower or bottom horizontal edge 165 upward to about midway of the panel 162. Slots 165 may include T shaped slits 167 at their distal end. The slots are positioned to engage narrow slots 155 and slit 157 in longitudinal divider panels 152 to maintain lateral spacing of longitudinal divider panels 152 within divider assembly 150.

[0034] In accordance with the disclosure and with reference to FIGS. 1, 2 and 9, divider assembly 150 includes thermal regulation elements 172 supported within wide slots 156 of longitudinal divider panels 152. Thermal regulation elements 172 extend between vertical edges 173 and horizontal upper and lower horizontal edges 174 to define vertical planar heat transfer surfaces 176.

[0035] As shown in FIGS. 1, 2 and 9, thermal regulation elements 172, reside in wide slots 156 of longitudinal divider panels 152. In the embodiment of FIGS. 1 to 9, vertical edges 173 contact the inner surface of insulation batting segment 117 covering longitudinal side walls 112 of cartons 110. Lower horizontal edge 174 of thermal regulation elements 172 is in supporting contact with the bottom edge 158 of wide slots 156 of longitudinal divider panels 152. Upper horizontal edge 174 is in contact with aligned channels 129 of top tray 120.

[0036] As illustrated, particularly in FIGS. 1, 2, and 9, assembled divider assembly 150 divides the space or volume between top tray 120 and bottom tray 130 into voids or chambers 104 surrounding a major portion of each of the product containing articles or bottles 102. Significantly each such void or chamber 104 is partially defined by a portion of a vertical planar heat transfer surface 176 of thermal regulation elements 172. Thus, there exists direct, un-obstructed radiant heat transfer between thermal regulation elements 172 and each article 102 within shipping container 110. This relationship, with direct exposure of each bottle 102 to an associated heat transfer surface 176 maximizes effectiveness of the thermal regulation elements 172 as well as providing for direct exposure of the articles being shipped to the thermal regulation elements.

[0037] Any suitable thermal regulation element 172 may be employed. For example, Glacier Foam Bricks, foam-filled refrigerant blocks from Pelton Shepherd Industries, Stockton, CA have been found effective. In the embodiment illustrated, the thermal regulation element may have the following approximate dimensions: height 7 inches, width 13 inches, depth 1 inch. Each thermal regulation element may include a quantity of refrigerant, for example fifty-two (52) ounces. The illustrated foam bricks are a water based semi-solid that maintain their shape during freezing and thawing and contribute to the structural rigidity of the divider assembly 150. It is also contemplated that phase-change material may be successfully used to form the thermal regulation element 172.

[0038] In the embodiment illustrated, the shipping container packaging is configured to receive twelve (12) bottles within the twelve voids 104 defined by the divider assembly 150. The disclosure is merely illustrative, and not limiting. As can be appreciated, the shipping container packaging 100 can be configured for 6, 9 or 15 bottles without departing form the principles of the disclosure. Moreover, the protected product need not be wine. The disclosed shipping container packaging is useful to provide the disclosed benefits to articles shipped to, or within elevated temperature environments.

[0039] FIG. 10 illustrates a slightly modified configuration of the disclosed arrangement. For ease of understanding, pulp formed top tray 120 is not shown.

[0040] FIG. 10 generally illustrates the assembly 100 as seen in FIGS. 1 through 9 with the insulation batting segments 116 and 117 eliminated. That is to say, the walls 112 and 113 of carton 110 directly surround the top and bottom trays 120 and 130 and interposed divider assembly 150. The shipping container packaging is unchanged, and as illustrated, retains and protects liquid containing bottles 102 in voids 104 as previously described above. Such an arrangement, complete in the manner disclosed herein except with the absence of internal insulation batting elements 116 and 117, is deemed suitable to provide safe transit with adequate thermal regulation advantages in less arduous environments.

[0041] Turning now to FIGS. 11 to 13 there is illustrated a modified form of the shipping container packaging of the present disclosure. Here there is illustrated a configuration for shipping six (6) articles with the advantageous features of structural integrity disclosed in U.S. Pat. Nos. 8,434,620 and 8,844,718 as well as providing the thermal regulation advantages of the present disclosure.

[0042] FIGS. 12 and 13 show a carton 210, having longitudinal side walls 212 and transverse or lateral side walls 213 defining a space to receive shipping container packaging 200. Carton 210 includes top and bottom closure flaps similar to the carton 110 of the embodiment of FIGS. 1 to 9 but not shown here for ease of description.

[0043] Flexible insulation batting segments 216 and 217 may be positioned within carton 210 substantially is illustrated. A top portion of segment 216 may be raised to a vertical position to provide access to the interior of the carton 210. (Top portion of segment 216 is cutaway for ease of description) When fully assembled, and the carton 210 closed, the insulation batting 216 and 217 completely surround the shipping container packaging 200 and the articles 202 shipped within carton 210. Optionally, for shipments to less demanding environments a carton, such as illustrated in FIG. 10 may be employed with the shipping container packaging 100 in direct contact with carton walls 212 and 213.

[0044] As illustrated, a pulp-formed bottom tray 230 is similar in configuration to bottom tray 130 but sized to receive six (6) articles for transit rather than twelve (12). A top tray, not shown, is also a component of shipping container packaging 200. It is similar in structure and function to top tray 120 but, again, sized to transport six (6) articles.

[0045] As best illustrated in FIG. 11, a divider assembly 250 extends between the top tray and bottom tray 230 and in functionally equivalent to the divider assembly 150 of FIGS. 1 to 9. Divider assembly 250 divides the space between top tray 120 and bottom tray 230 into six (6) article surrounding chambers or voids 204.

[0046] In this embodiment the divider assembly has a simplified configuration. Divider assembly 250 comprises a unitary cardboard sheet having two lateral divider portions 262 joined by a central web 268 which, when installed, resides against insulation batting 217 along longitudinal side wall 212 of carton 210.

[0047] The lateral divider portions 262 are formed by bending the divider portions 262 ninety degrees (90) at dashed lines 269, at central web 268. (See FIG. 11) Divider portions 262 have a length to extend to insulation batting 217 along opposite longitudinal side walls 212 of the carton 210. The vertical heights of divider portions 262 in such that they extend between the top tray and bottom tray 230 dividing the intervening space into three separate sections. Each divider portion 262 includes a vertical slot 256 open adjacent its top end and terminating at a bottom edge 258. The slots 256 are equidistant between longitudinal side walls 212 of carton 210.

[0048] In accordance with the disclosure, a thermal regulation element 272 is held in slots 256 of divider portions 262 and extends between insulation batting segments 216 and 217 along lateral side walls 213 of carton 210. It is sized to extend between top tray and bottom tray 230. Thermal regulation element 272 presents a vertical planar heat transfer surface 276 on each vertical side wall, and with divider portions 262 divides the space within the interior of the carton between top tray and bottom tray 230 into six (6) article surrounding chambers or voids 264 surrounding a major portion of each product containing article 202. Significantly each such chamber 204 is partially defined by a portion of a vertical planar heat transfer surface 276 of thermal regulation element 272. This relationship provides for direct radiant heat transfer between the contained articles 202 and the thermal regulation element 272.

[0049] In this embodiment, seen in FIGS. 11 to 13 the thermal regulation element 272 may have dimensions substantially the same as the thermal regulation element 172 of the embodiment of FIGS. 1 to 9. Notably, the embodiment illustrated may also be used in a carton such as illustrated in FIG. 10 where no insulation batting 216 or 217 is present.

[0050] In an exemplary process, product containing articles such as bottles of wine, possibly 750 mL are often shipped to consumers from distribution centers. Shipments may include delivery into environments where ambient temperature of 100 F. or more exist. The length of time a loaded carton may reside in transit may be two (2) to three (3) days. As an example, to load a shipment, a carton, such as carton 110 of FIGS. 1 to 9 is unfolded from a flattened condition and the bottom longitudinal major flaps 114 and lateral minor flaps 115 folded together and sealed in place.

[0051] Flexible insulation batting segments 116 and 117 may be first positioned within carton 110 substantially is illustrated in FIG. 1 with one segment 116 folded vertically to provide access to the interior of the carton 110. A top portion of segment 116 may be raised to a vertical position to provide access to the interior of the carton 110. When fully assembled, and the carton 110 closed, the insulation batting 116 and 117 completely surrounds the shipping container packaging 100 and the articles 102 shipped within carton 110. Optionally, for shipments to less demanding environments, a carton, such as illustrated in FIG. 10 may be employed with the shipping container packaging 100 in direct contact with carton walls 112 and 113.

[0052] A bottom tray 130 is placed into the carton adjacent the assembled bottom cardboard flaps supported upon insulation segment 116. A divider assembly 150, including interconnected cardboard longitudinal divider panels 152 and lateral divider panel 162 may be inserted with bottom edges supported in channel 139 of bottom tray 130. Twelve articles in the form of bottles 102 containing wine or other liquid may then be inserted, one in each article surrounding chamber 104.

[0053] Thermal regulation elements 172 normally stored at about zero degrees Fahrenheit (0 F.) may then be inserted into wide slots 156 in longitudinal divider panels 152. The thermal regulation panels rest upon bottom edges 158 of slots 156 and extend upwardly to the horizontal edge 154 of each divider panel 152.

[0054] When so positioned each article surrounding chamber 104 includes a portion of the vertical planar heat transfer wall surface 176 of one of the thermal regulation elements 172. These surfaces reside in direct radiant heat transfer relation to the articles 102.

[0055] The top tray 130 of the shipping container packaging 100 may then be positioned above the divider assembly 150 with the vertical edges 154 of longitudinal divider panels 152 and 164 of lateral divider panel 162 positioned within channels 129. The portion of insulated segment 116 may then be folded to a horizontal position covering the top of top tray 130. Flaps 114 and 115 at the top of carton 110 may then be closed and sealed making the carton 110 and its contents, articles 102, ready for shipment.

[0056] The mechanisms disclosed herein and the processes involved include some well known components, features and operating parameters commonly associated with article shipping containers. Though not specifically discussed, or shown in the accompanying drawings, these elements are considered inherent to the disclosure and fully understood by persons of ordinary skill in the art.

[0057] Various features of the present invention have been described with reference to the illustrative embodiments. It should be understood, however, that modifications may be made without departing from the scope of the disclosed subject matter.

[0058] Preferred embodiments of this invention are described therein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.