SHIPPING SYSTEM FOR STORING AND/OR TRANSPORTING TEMPERATURE-SENSITIVE MATERIALS

Abstract

Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls and bottom and top closure flaps. An insulation unit is positioned within the outer box. The insulation unit includes a base and a lid assembly hingedly connected to the base. The base includes vacuum insulated panels arranged to define a cavity and an inner shield mounted within the cavity. The lid assembly includes a support hingedly connected to the base. A vacuum insulated panel and a protective cover are mounted on a bottom surface of the support. A compressible pad is mounted on a top surface of the support, and a cover sheet is mounted over the compressible pad. The cover sheet includes an integral handle. A plurality of temperature-control members and a product box may be removably positioned in a cavity defined by the inner shield.

Claims

1. A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising: (a) an insulation unit, the insulation unit comprising (i) a base, the base comprising one or more base vacuum insulated panels configured to define a base cavity bounded by a bottom wall, one or more side walls, and an open top; and (ii) a lid assembly, the lid assembly comprising a lid vacuum insulated panel and a lid support, the lid support comprising a sheet folded to comprise a first portion and a second portion, the first portion being secured to one of the one or more side walls of the base, the second portion being secured to the lid vacuum insulated panel and being movable relative to the first portion between a first position in which the base cavity is open and a second position in which the base cavity is closed by the lid assembly; (b) a product box, the product box removably disposed within the base cavity; and (c) one or more temperature-control members removably disposed within the base cavity.

2. The shipping system as claimed in claim 1 further comprising an outer box, the outer box comprising a box cavity bounded by at least one side wall, at least one bottom closure flap, and at least one top closure flap, and wherein the base and the lid assembly of the insulation unit are removably disposed within the box cavity of the outer box.

3. The shipping system as claimed in claim 2 wherein the lid vacuum insulated panel is secured to a bottom surface of the second portion of the lid support and wherein the lid assembly further comprises a compressible pad, the compressible pad being secured to a top surface of the second portion of the lid support.

4. The shipping system as claimed in claim 3 wherein the lid assembly further comprises a pad cover, the pad cover being secured to a top surface of the compressible pad.

5. The shipping system as claimed in claim 4 wherein the pad cover is shaped to include an integral handle.

6. The shipping system as claimed in claim 5 wherein the integral handle comprises a hinged tab having a cutout.

7. The shipping system as claimed in claim 6 wherein the compressible pad comprises a recess and wherein the recess is aligned with the cutout of the pad cover.

8. The shipping system as claimed in claim 4 wherein the lid assembly further comprises a lid cover, the lid cover covering a bottom surface of the lid vacuum insulated panel.

9. The shipping system as claimed in claim 8 wherein the lid assembly is dimensioned so that the pad cover engages the at least one top closure flap of the outer box when the at least one top closure flap is closed, thereby ensuring that the lid cover fully closes the base cavity.

10. The shipping system as claimed in claim 2 wherein the insulation unit further comprises a shock absorbance pad and wherein the shock absorbance pad is positioned in the outer box below the base.

11. The shipping system as claimed in claim 1 wherein the first portion of the lid support is removably secured to the base.

12. The shipping system as claimed in claim 1 wherein the one or more base vacuum insulated panels comprise a bottom vacuum insulated panel and four side vacuum insulated panels, the four side vacuum insulated panels being disposed on top of the bottom vacuum insulated panel.

13. The shipping system as claimed in claim 12 wherein the base further comprises one or more binding members encircling the four side vacuum insulated panels.

14. The shipping system as claimed in claim 13 wherein the one or more binding members comprise one or more elastic bands.

15. The shipping system as claimed in claim 13 wherein the one or more binding members comprise a strip of stretch tape.

16. The shipping system as claimed in claim 13 wherein the base further comprises a base support, wherein the base support is shaped to comprise a central portion and four side portions, wherein the central portion is disposed under the bottom vacuum insulated panel, and wherein the four side portions are disposed between the four side vacuum insulated panels and the one or more binding members.

17. The shipping system as claimed in claim 16 wherein the base further comprises a plurality of corner boards, wherein the base support has a plurality of corners, and wherein one of the corner boards is positioned at each corner of the base support between the base support and the one or more binding members.

18. The shipping system as claimed in claim 16 wherein the base further comprises a shock absorbance pad and wherein the shock absorbance pad is positioned between the bottom vacuum insulated panel and the base support.

19. The shipping system as claimed in claim 13 wherein the base further comprises an inner shield, wherein the inner shield is removably disposed in the base cavity, and wherein the product box and the one or more temperature-control members are removably disposed within a space defined by the inner shield.

20. The shipping system as claimed in claim 1 wherein the first portion of the sheet and the second portion of the sheet are separated only by a single crease.

21. The shipping system as claimed in claim 1 wherein the first portion of the sheet and the second portion of the sheet are separated by a pair of creases forming a hinge.

22. A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising: (a) an insulation unit, the insulation unit comprising (i) a base, the base comprising one or more base vacuum insulated panels configured to define a base cavity bounded by a bottom wall, one or more side walls, and an open top; and (ii) a lid assembly, the lid assembly being pivotally mounted on the base to selectively cover and uncover the base cavity, the lid assembly comprising (A) a lid vacuum insulated panel, the lid vacuum insulated panel having a top surface and a bottom surface; (B) a first cover, the first cover positioned over and coupled to the top surface of the lid vacuum insulated panel, wherein the first cover is shaped to include an integral handle; (b) a product box, the product box removably disposed within the base cavity; and (c) one or more temperature-control members removably disposed within the base cavity.

23. The shipping system as claimed in claim 22 wherein the integral handle comprises a hinged tab having a cutout.

24. The shipping system as claimed in claim 23 wherein the lid assembly further comprises a compressible pad, the compressible pad being disposed between the lid vacuum insulated panel and the first cover.

25. The shipping system as claimed in claim 24 wherein the compressible pad comprises a recess and wherein the recess is aligned with the cutout of the first cover.

26. The shipping system as claimed in claim 22 wherein the lid assembly further comprises a second cover, the second cover covering the bottom surface of the lid vacuum insulated panel.

27. The shipping system as claimed in claim 26 further comprising an outer box, the outer box comprising a box cavity bounded by at least one side wall, at least one bottom closure flap, and at least one top closure flap, and wherein the base and the lid assembly of the insulation unit are removably disposed within the box cavity of the outer box.

28. The shipping system as claimed in claim 27 wherein the lid assembly is dimensioned so that the first cover engages the at least one top closure flap of the outer box when the at least one top closure flap is closed, thereby ensuring that the second cover fully closes the base cavity.

29. The shipping system as claimed in claim 22 wherein the lid assembly further comprises a support, the support comprising a first portion and a second portion, the first portion being secured to one of the one or more side walls of the base, the second portion being positioned between and secured to each of the lid vacuum insulated panel and the first cover.

30. The shipping system as claimed in claim 29 wherein the first portion of the support and the second portion of the support are separated only by a single crease.

31. The shipping system as claimed in claim 29 wherein the first portion of the support and the second portion of the support are separated by a pair of creases forming a hinge.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The accompanying drawings, which are hereby incorporated into and constitute a part of this specification, illustrate various embodiments of the invention and, together with the description, serve to explain the principles of the invention. These drawings are not necessarily drawn to scale, and certain components may have undersized and/or oversized dimensions for purposes of explication. In the drawings wherein like reference numerals represent like parts:

[0043] FIGS. 1A and 1B are front, right, top, partly exploded perspective and rear, left, partly exploded perspective views, respectively, of a first embodiment of a shipping system suitable for use in storing and/or transporting temperature-sensitive materials, the shipping system being constructed according to the present invention;

[0044] FIG. 2 is a front, left, top, partly exploded perspective view of the shipping system shown in FIG. 1A, with the product box and the temperature-control members not being shown;

[0045] FIGS. 3A and 3B are front, left, top perspective views of the insulation assembly of FIG. 2, with the lid of the insulation assembly being shown partially open and with the handle of the lid being shown in closed and extended positions, respectively;

[0046] FIG. 4 is a partly exploded perspective view of the insulation assembly of FIG. 2;

[0047] FIG. 5 is a top perspective view of the base of the insulation assembly of FIG. 2;

[0048] FIG. 6 is a partly exploded perspective view of the insulation base of FIG. 2;

[0049] FIGS. 7A and 7B are rear, left, top perspective and front, right, bottom perspective views, respectively, of the insulation lid assembly of FIG. 2;

[0050] FIG. 8 is a front, right, bottom, exploded perspective view of the lid assembly shown in FIG. 7A;

[0051] FIG. 9 is a partly exploded perspective view of a second embodiment of a shipping system suitable for use in storing and/or transporting temperature-sensitive materials, the shipping system being constructed according to the present invention;

[0052] FIG. 10 is a partly exploded perspective view of the insulation unit shown in FIG. 9;

[0053] FIG. 11 is a top perspective view of the lid shown in FIG. 10;

[0054] FIG. 12 is a bottom perspective view of the lid shown in FIG. 10;

[0055] FIG. 13 is a bottom view of the lid shown in FIG. 10, the lid being shown with two fasteners secured thereto; and

[0056] FIG. 14 is an exploded perspective view of the lid shown in FIG. 10.

DETAILED DESCRIPTION OF THE INVENTION

[0057] Referring now to FIGS. 1A, 1B, and 2, there are shown various views of a first embodiment of a shipping system suitable for use in storing and/or transporting temperature-sensitive materials, the shipping system being constructed according to the present invention and being represented generally by reference numeral 11. For clarity and/or ease of illustration, certain details of shipping system 11 that are discussed elsewhere in this application or that are not critical to an understanding of the invention may be omitted from one or more of FIGS. 1A, 1B, and 2 or may be shown therein in a simplified manner.

[0058] System 11 may be used to maintain a payload within a desired temperature range for an extended period of time. Solely for illustrative purposes and not to be limited thereto, system 11 may be configured to maintain a parcel-sized payload within a temperature range of +2 C. to +8 C. for a period of up to 96 hours or longer or, alternatively, may be configured to maintain a parcel-sized payload within a temperature range of +15 C. to +25 C. for a period of up to 96 hours or longer or, alternatively, may be configured to maintain a parcel-sized payload within a temperature range of 15 C. to 25 C. for a period of up to 96 hours or longer.

[0059] System 11 may be similar in certain respects to one or more of the shipping systems disclosed in U.S. Pat. No. 11,511,928 B2 and/or U.S. Patent Application Publication No. US 2022/0002070 A1.

[0060] To this end, system 11 may comprise an outer box 13. Outer box 13, which may be, for example, a conventional corrugated cardboard box or carton (or, in another embodiment, a plastic corrugate box or carton), may comprise a rectangular prismatic cavity 25 bounded by a plurality of rectangular side walls 27-1 through 27-4, a plurality of bottom closure flaps (not shown), and a plurality of top closure flaps 29-1 through 29-4. Adhesive strips of tape or other closure means (not shown) may be used to retain, in a closed condition, the bottom closure flaps and/or top closure flaps 29-1 through 29-4. A label 30 may be adhered to or otherwise affixed to the exterior of outer box 13.

[0061] One difference between outer box 13 and the respective outer boxes of U.S. Pat. No. 11,511,928 B2 and U.S. Patent Application Publication No. US 2022/0002070 A1 is the sizing of their respective top closure flaps. More specifically, in the case of the outer boxes of U.S. Pat. No. 11,511,928 B2 and U.S. Patent Application Publication No. US 2022/0002070 A1, the top closure flap to which a lid assembly is mounted is sized to substantially match the footprint of the lid assembly; therefore, said top closure flap is dimensioned to extend nearly entirely across the cavity of the outer box. In addition, the top closure flap that is opposite to the top closure flap that is used to mount the lid assembly is also of a similar size. Such a box construction is non-standard and, therefore, costly. By contrast, none of top closure flaps 29-1 through 29-4 of outer box 13 is used to mount a lid assembly; consequently, all of top closure flaps 29-1 through 29-4 may extend only about halfway across cavity 25 of outer box 13. Such a box construction, which may be in the form of a regular slotted container (RSC), is more common and, therefore, less costly. Moreover, the taping of a regular slotted container can be performed with a conventional taping machine.

[0062] Another difference between outer box 13 and the outer boxes of U.S. Pat. No. 11,511,928 B2 and U.S. Patent Application Publication No. US 2022/0002070 A1 is that outer box 13 may comprise one or more through-holes or cutouts in opposite side walls of outer box 13, which cutouts may serve as handles for carrying system 11. In the present embodiment, such cutouts 31-1 and 31-2 may be generally oval-shaped openings provided in side walls 27-2 and 27-4, respectively, of outer box 13. As seen best in FIG. 2, cutouts 31-1 and 31-2 may be reinforced with handle inserts 33-1 and 33-2, respectively, which may be made of a rigid polymer or the like. In other embodiments (not shown), handle inserts 33-1 and 33-2 may be omitted, or the combination of cutouts 31-1 and 31-2 and handle inserts 33-1 and 33-2 may be omitted.

[0063] System 11 may further comprise an insulation unit 51. Insulation unit 51, which is also shown separately in FIGS. 3A, 3B, and 4, may comprise a base 53, a lid assembly 55, and a pad 57.

[0064] Base 53, which is also shown separately in FIGS. 5 and 6, may comprise a plurality of vacuum insulated panels 54-1 through 54-5, which may be conventional and may be similar or identical to one another in composition. Vacuum insulated panels 54-1 through 54-5 may be arranged such that vacuum insulated panels 54-2 through 54-5 are positioned perpendicularly relative to and sitting directly on top of vacuum insulated panel 54-1, thereby collectively defining a generally prismatic cavity bounded by a bottom wall and four side walls. The four side walls, which may be similar or identical to one another in size and shape, may be positioned relative to one another in a pinwheel-type arrangement, wherein one end of each vacuum insulated panel abuts the inside major surface of its adjacent vacuum insulated panel. Alternatively, the four side walls may be positioned relative to one another so that one end of each of two parallel vacuum insulated panels abuts the inside major surface of each of the two remaining parallel vacuum insulated panels. The bottom wall, which may be defined by vacuum insulated panel 54-1, may be similar or identical in size and shape to the four side walls (or may be differently dimensioned than the four side walls), which may be defined by vacuum insulated panels 54-2 through 54-5. Preferably, vacuum insulated panels 54-1 through 54-5 are oriented so that all seams face outwardly. In another embodiment (not shown), two or more of vacuum insulated panels 54-1 through 54-5 may be coupled together with a living hinge (e.g., a plastic corrugate living hinge) or may be integrally formed as a one-piece structure. For example, the four side walls may be hinged together as a unit.

[0065] Base 53 may additionally comprise a support 61. Support 61, which may be made of corrugated cardboard or the like, may be a blank adapted to be folded into a unitary box-like structure configured to include a central portion and four side portions. (When folded, the adjacent edges of the side portions may be spaced apart by a small distance.) The central portion may be rectangular, and each of the four side portions may extend upwardly from a different one of the four sides of the central portion. Support 61 may be appropriately dimensioned so that the central portion of the support may be positioned under vacuum insulated panel 54-1 and so that the side portions of support 61 may be positioned along the outside faces of vacuum insulated panels 54-2 through 54-5, as well as along the peripheral edges of vacuum insulated panel 54-1. As will be discussed below, support 61 may be used, in conjunction with other structural members, to help keep vacuum insulation panels 54-1 through 54-5 assembled together. In addition, support 61 may also provide some additional thermal insulation to base 53. A label 62 may be affixed to support 61.

[0066] Base 53 may further comprise one or more binding members 69-1 through 69-4, which may be wrapped around the four sides of support 61 and which may be used to help retain vacuum insulated panels 54-1 through 54-5 in an assembled state and to keep support 61 in a folded state. In the present embodiment, binding members 69-1 through 69-4 may comprise elastic bands (such as natural rubber elastic bands); however, binding members 69-1 through 69-4 are not limited to elastic bands and may alternatively and/or additionally comprise plastic binding straps, strips of adhesive tape, or the like. It is to be understood that, although four binding members 69-1 through 69-4 are shown in the present embodiment, there could be as few as one binding member or as many as five or more binding members. Where, as in the present embodiment, binding members 69-1 through 69-4 are elastic bands, such elastic bands may be, for example, natural rubber elastic bands, with each elastic band providing about 20 lbs of compressive force.

[0067] Base 53 may further comprise a plurality of corner boards 71-1 through 71-4, which may be similar or identical to one another. Corner boards 71-1 through 71-4 may be made of Kraft paper and may have a thickness, for example, of 0.06 to 0.08 inch. Corner boards 71-1 through 71-4, which may be oriented vertically at the four exterior corners defined by support 61 and which may be positioned between support 61 and binding members 69-1 through 69-4, may help to increase the thermal life of base 53 by keeping panels 54-1 through 54-5 together and tighter for a longer period of time and by protecting support 61 and panels 54-1 through 54-5 from physical damage that may be caused by binding members 69-1 through 69-4, particularly at the four corners of base 53. Preferably, corner boards 71-1 through 71-4 are dimensioned so that their top ends are no closer than about 0.125 inch from the top edges of panels 54-2 through 54-5. Corner boards 71-1 through 71-4 also may help to increase the length of time that binding members 69-1 through 69-4 are able to hold a minimal required tension in a reuse application. Notwithstanding the above, in another embodiment, system 11 may omit one or more of corner boards 71-1 through 71-4.

[0068] Base 53 may further comprise an inner shield 75. Inner shield 75 may be similar in structure to support 61 but may be smaller in size so that inner shield 75 may be removably inserted into the cavity defined by vacuum insulated panels 54-1 through 54-5 of base 53. Inner shield 75 may comprise a single sheet of corrugated cardboard, chipboard, or similar material and may be folded to define a cavity 76 bounded by a bottom 77, a front 79, a rear 81, a left side 83, and a right side 85. Inner shield 75 may be dimensioned so that, when inner shield 75 is inserted into base 53, bottom 77 of inner shield 75 may be seated on vacuum insulated panel 54-1 (or may be closely spaced therefrom), and one or more of right side 85, front 79, left side 83, and rear 81 of inner shield 75 may abut vacuum insulated panels 54-2 through 54-5, respectively (or may be closely spaced therefrom). Inner shield 75 may be incapable of maintaining a folded state on its own and may be maintained in a folded state by virtue of being snugly received within the cavity of base 53; alternatively, inner shield 75 may be maintained in a folded state on its own or may be maintained in a folded state by adhesive tape or other suitable means.

[0069] Inner shield 75 may obviate the need for a liner of the type used in U.S. Pat. No. 11,511,928 B2 and/or in U.S. Patent Application Publication No. US 2022/0002070 A1. Notwithstanding the above, in another embodiment (not shown), system 11 may further comprise, or may alternatively comprise, such a liner.

[0070] Lid assembly 55, which is also shown separately in FIGS. 7A, 7B, and 8, may be pivotally mounted on base 53 in such a way as to be reversibly convertible between an open position, in which cavity 76 is open or uncovered, and a closed position, in which cavity 76 is closed or covered. Lid assembly 55 may comprise a support 111. Support 111 may comprise a single sheet of plastic corrugate (e.g., polypropylene corrugate), corrugated cardboard, chipboard, or similar material and may be folded along a crease 112-1 to define a rear panel 112-2 and a top panel 112-3. Rear panel 112-2 may be secured to base 53 using one or more fasteners 113, which may be permanent or removable fasteners. In the present embodiment, lid assembly 55 is removably secured to base 53, and fasteners 113 are removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 113 may be hook and loop fasteners where rear panel 112-2 and base 53 are equipped with complementary hook and loop fasteners. It is to be understood that, although four fasteners 113 are shown in the present embodiment, the number of fasteners 113 may be varied and may be as few as one fastener or more than four fasteners.

[0071] Lid assembly 55 may further comprise a vacuum insulated panel 115. Vacuum insulated panel 115, which may be conventional and, in fact, may be similar or identical to vacuum insulated panel 54-1, may be secured to the bottom face of top panel 112-3 using one or more fasteners 116, which may be permanent or removable fasteners. In the present embodiment, fasteners 116 are preferably removable fasteners and may be removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 116 may be hook and loop fasteners where the bottom face of top panel 112-3 and vacuum insulated panel 115 are equipped with complementary hook and loop fasteners. It is to be understood that, although four fasteners 116 are shown in the present embodiment, the number of fasteners 116 may be varied and may be as few as one fastener or more than four fasteners. An adhesive label 118 may be secured to the bottom surface of vacuum insulated panel 115.

[0072] Lid assembly 55 may further comprise a protective cover 119, which may be used to protect the exposed bottom and side surfaces of vacuum insulated panel 115. Protective cover 119 may be secured to the bottom face of vacuum insulated panel 115 using one or more fasteners 121, which may be permanent or removable fasteners. In the present embodiment, fasteners 121 are preferably removable fasteners and may be removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 121 may be hook and loop fasteners where the bottom surface of vacuum insulated panel 115 and the top surface of protective cover 119 are equipped with complementary hook and loop fasteners. It is to be understood that, although four fasteners 121 are shown, the number of fasteners 121 may be varied and may be as few as one fastener or more than four fasteners. Notwithstanding the above, protective cover 119 may be omitted.

[0073] Lid assembly 55 may further comprise a compressible pad 125. Compressible pad 125 may be secured to the top surface of top panel 112-3 using an adhesive (not shown) or other suitable means. Compressible pad 125, which may be made of an open-cell foam material with high elasticity, such as, but not limited to, an open-cell polyurethane foam with a density of about 1.7 lbs/ft.sup.3, may be appropriately constructed and dimensioned to provide sufficient upward pressure to ensure that, when top flaps 29-1 through 29-4 of outer box 13 are fully closed, protective cover 119 is pushed sufficiently downwardly to abut the upper edges of base 53, thereby completely closing cavity 76. To provide such compression, the top surface of lid assembly 55 is preferably at least 1/16.sup.th inch above the top of the cavity of outer box 13. Compressible pad 125 may be shaped to comprise a cutout 127 along a front edge thereof, the purpose of cutout 127 becoming apparent below.

[0074] Lid assembly 55 may further comprise a cover sheet 131. Cover sheet 131, which may comprise a single sheet of plastic corrugate (e.g., polypropylene corrugate), corrugated cardboard, chipboard, or similar material, may be secured to the top surface of compressible pad 125 using an adhesive (not shown) or other suitable securing means. Cover sheet 131 may be shaped to include a hinged tab 133, which may be positioned over and aligned with cutout 127 of compressible pad 125. Hinged tab 133 may comprise a through-hole or cutout 135 that may be appropriately dimensioned to serve as a handle for use in pivoting lid assembly 55 towards or away from base 53. Cutout 135 may be reinforced with a handle insert 137, which may be made of a rigid polymer or the like. In another embodiment (not shown), handle insert 137 may be omitted.

[0075] Although cover sheet 131 is shown in the present embodiment as having a rear edge that is substantially flush with the rear edge of compressible pad 125, the rear edge of cover sheet 131, which may be sharp, may be moved forwardly relative to the rear edge of compressible pad 125 to minimize the possibility that the rear edge of cover sheet 131 may catch on and cause damage to the inner surface of outer box 13 as lid assembly 55 is pivoted away from or towards base 53. In another embodiment (not shown), the rear edges of both cover sheet 131 and compressible pad 125 may be moved forwardly from the position shown to minimize the possibility of such damage to outer box 13. Alternatively, cover sheet 131 could further include a downward flap at its rear end to minimize the possibility of such damage to outer box 13.

[0076] Pad 57, which may comprise a sheet of expanded polypropylene (or other expanded polymer), a sheet of corrugated cardboard, or the like, may be positioned under base 53 and may be secured thereto using a suitable adhesive (not shown) or other suitable securing means. Pad 57 may provide some shock absorbance, as well as some thermal protection, to insulation unit 51. In the present embodiment, pad 57 may be a sheet of expanded polypropylene having a thickness of about inch and a density of about 2 lbs/ft.sup.3. In another embodiment, pad 57 may be positioned between vacuum insulated panel 54-1 and support 61.

[0077] As seen best in FIG. 2, system 11 may further comprise a riser 141. Riser 141 may be a unitary structure shaped to define a rectangular frame having a front 143-1, a rear 143-2, a left side 143-3, a right side 143-4, and a central opening 145. Riser 141, which may be made of a dimensionally stable foam or similarly suitable material, may be dimensioned to be removably received within cavity 76 of inner shield 75. Riser 141 may be used to position one or more temperature-control members relative to a product box also positioned in cavity 76 of inner shield 75. For example, riser 141 may help to position those temperature-control members that face the side walls of the product box so that such temperature-control members are substantially centered relative to such side walls of the product box.

[0078] Referring back now to FIGS. 1A and 1B, system 11 may further comprise a product box 151. Product box 151 may be used to removably receive temperature-sensitive materials (not shown). Product box 151, which may be a conventional corrugated cardboard box, may be appropriately dimensioned to be removably received within cavity 76 of inner shield 75. In the present embodiment, product box 151 may be dimensioned to hold a payload volume of, for example, approximately 1.3 L; however, it is to be understood that product box 151, as well as the other components of system 11, may be altered to accommodate a lesser or greater volume and/or may have a different shape than that shown.

[0079] System 11 may further comprise a plurality of temperature-control members 161-1 through 161-3. Temperature-control members 161-1 through 161-3, which may be identical to one another, may be appropriately dimensioned to be received, along with product box 151, within cavity 76 of inner shield 75. Temperature-control members 161-1 through 161-3 may be exemplified by, but are not limited to, conventional ice packs, conventional gel packs, or refrigerant packs of the type disclosed in one or more of U.S. Pat. No. 9,598,622 B2, inventors Formato et al., issued Mar. 21, 2017; U.S. Patent Application Publication No. US 2021/0070539 A1, inventors Chasteen et al., published Mar. 11, 2021; and U.S. Patent Application Publication No. US 2018/0093816 A1, inventors Longley et al., published Apr. 5, 2018, all of which are incorporated herein by reference.

[0080] Alternatively, in another embodiment (not shown), temperature-control members 161-1 through 161-3 may each comprise a rigid bottle containing a phase-change material. The phase-change material contained in such a bottle may be, for example, but is not limited to, a salt/water solution having a phase-change temperature of 23 C., such as the phase-change material present in the 500-ST series KOOLIT gel pack or saddlebag from Cold Chain Technologies, LLC (Franklin, MA). Such a phase-change material may be used, for example, to maintain a payload within a temperature range of 15 C. to 25 C. for an extended period of time.

[0081] In the present embodiment, three temperature-control members 161-1 through 161-3 are shown, with each of temperature-control members 161-1 through 161-3 having two discrete volumes of phase-change material, each volume facing and substantially entirely covering a different side of product box 151. It is to be understood that the number of temperature-control members 161-1 through 116-3 in the present embodiment is merely illustrative and that there may be a greater number or lesser number of such temperature-control members. Moreover, it is to be understood that the number of discrete volumes shown in each of temperature-control members 161-1 through 116-3 in the present embodiment is merely illustrative and that there may be a greater number or lesser number of such volumes and that the dimensions of said volumes relative to that of product box 151 may be varied.

[0082] Also, although not shown in the present embodiment, system 11 may include multiple layers of temperature-control members, such as an inner layer of temperature-control members and an outer layer of temperature-control members, which layers may contain the same or different phase-change materials preconditioned to the same or different temperatures.

[0083] Riser 141 may be appropriately dimensioned so that a lower pouch of temperature-control member 161-3 may be received within central opening 145, so that an upper pouch of temperature-control member 161-3 may be seated upon rear 143-2, so that a lower pouch of temperature-control member 161-2 may be seated upon right side 143-4, so that an upper pouch of temperature-control member 161-2 may be seated on top of product box 151, so that a first pouch of temperature-control member 161-1 may be seated upon left side 143-3, and so that a second pouch of temperature-control member 161-1 may be seated upon front 143-1. The thickness of riser 141 may be selected so that the vertical portions of temperature-control members 161-1 through 161-3 may be substantially centered relative to product box 151.

[0084] Preferably, inner shield 75, riser 141, product box 151, and temperature-control members 161-1 through 161-3 are dimensioned so that temperature-control members 161-1 through 161-3 fit snugly around product box 151 within inner shield 75.

[0085] Although not shown, system 11 may further comprise one or more environmental data loggers, one or more temperature indicators, or the like, such as are disclosed in U.S. Patent Application Publication No. US 2019/0210790 A1. Such a data logger, temperature indicator or the like may be positioned within cavity 171 of pad 57 or in another suitable location.

[0086] To use system 11, pad 57 may be positioned at the bottom of cavity 25 of outer box 13, and base 53 may be positioned on top of pad 57. Temperature-control members 161-1 through 161-3, which have preferably been appropriately preconditioned, and product box 151, which holds the payload, may be positioned within cavity 76 of inner shield 75. Lid assembly 55 may be pivoted closed such that protective cover 119 is positioned on top of base 53, and top flaps 29-1 through 29-4 of outer box 13 may be closed and preferably sealed shut, thereby causing protective cover 119 to close cavity 76 of base 53. System 11 may then be used to store and/or to transport the payload.

[0087] Referring now to FIG. 9, there is shown a partly exploded perspective view of a second embodiment of a shipping system suitable for use in storing and/or transporting temperature-sensitive materials, the shipping system being constructed according to the present invention and being represented generally by reference numeral 211. For clarity and/or ease of illustration, certain details of shipping system 211 that are discussed elsewhere in this application or that are not critical to an understanding of the invention may be omitted from FIG. 9 or may be shown therein in a simplified manner. For example, the product box and the passive temperature-control members of system 211 are not shown in FIG. 9.

[0088] System 211 may be similar in many respects to system 11 discussed above. To this end, system 211 may comprise an outer box 213. Outer box 213 may be, for example, a conventional corrugated cardboard box or carton and, more specifically, may be a corrugated cardboard box of the regular slotted container variety. (In another embodiment (not shown), outer box 213 may be a plastic corrugate box or carton.) Outer box 213 may comprise a rectangular prismatic cavity 225 bounded by a plurality of rectangular side walls 227-1 through 227-4, a plurality of bottom closure flaps (not shown), and a plurality of top closure flaps 229-1 through 229-4. Adhesive strips of tape or other closure means (not shown) may be used to retain, in a closed condition, the bottom closure flaps and/or top closure flaps 229-1 through 229-4. A label 230 may be adhered to or otherwise affixed to the exterior of outer box 213.

[0089] One or more handles may be provided in outer box 213 and/or may be secured to outer box 213. For example, in the present embodiment, one or more looped handles 233 may be secured to each of side walls 227-2 and 227-4.

[0090] System 211 may further comprise an insulation unit 251, which may be similar in certain respects to insulation unit 51 of system 11. Insulation unit 251, which is also shown separately in FIG. 10, may comprise a base 253 and a lid assembly 255, wherein lid assembly 255 may be secured to base 253 in such a manner that lid assembly 255 may be reversibly convertible between an open position, in which cavity 276 is open or uncovered, and a closed position, in which cavity 276 is closed or covered.

[0091] Base 253 may comprise a plurality of vacuum insulated panels 254-1 through 254-5, which may be conventional and may be similar or identical to one another in composition. Vacuum insulated panels 254-1 through 254-5 may be arranged such that vacuum insulated panels 254-2 through 254-5 are positioned perpendicularly relative to and sitting directly on top of vacuum insulated panel 254-1, thereby collectively defining a generally prismatic cavity bounded by a bottom wall and four side walls. The four side walls, which may be similar or identical to one another in size and shape, may be positioned relative to one another in a pinwheel-type arrangement, wherein one end of each vacuum insulated panel abuts the inside major surface of its adjacent vacuum insulated panel. Alternatively, the four side walls may be positioned relative to one another so that one end of each of two parallel vacuum insulated panels abuts the inside major surface of each of the two remaining parallel vacuum insulated panels. The bottom wall, which may be defined by vacuum insulated panel 254-1, may be similar or identical in size and shape to the four side walls (or may be differently dimensioned than the four side walls), which may be defined by vacuum insulated panels 254-2 through 254-5. Preferably, vacuum insulated panels 254-1 through 254-5 are oriented so that all seams face outwardly. In another embodiment (not shown), two or more of vacuum insulated panels 254-1 through 254-5 may be coupled together with a living hinge (e.g., a plastic corrugate living hinge) or may be integrally formed as a one-piece structure. For example, the four side walls may be hinged together as a unit.

[0092] Base 253 may additionally comprise a support 261, which may be similar or identical to support 61 of system 11. Support 261, which may be made of corrugated cardboard or the like, may be a blank adapted to be folded into a unitary box-like structure configured to include a central portion and four side portions. (When folded, the adjacent edges of the side portions may be spaced apart by a small distance.) The central portion may be rectangular, and each of the four side portions may extend upwardly from a different one of the four sides of the central portion. Support 261 may be appropriately dimensioned so that the central portion of the support may be positioned below vacuum insulated panel 254-1 and so that the side portions of support 261 may be positioned along the outside faces of vacuum insulated panels 254-2 through 254-5, as well as along the peripheral edges of vacuum insulated panel 254-1. As will be discussed below, support 261 may be used, in conjunction with other structural members, to help keep vacuum insulation panels 254-1 through 254-5 assembled together. In addition, support 261 may also provide some additional thermal insulation to base 253. A label 262 may be affixed to support 261.

[0093] Base 253 may additionally comprise a pad 257, which may be similar or identical to pad 57 of system 11. Pad 257, which may comprise a sheet of expanded polypropylene (or other expanded polymer), a sheet of corrugated cardboard, or the like, may be positioned between vacuum insulated panel 254-1 and the central portion of support 261. Pad 257 may provide some shock absorbance, as well as some thermal protection, to insulation unit 251. In the present embodiment, pad 257 may consist of or comprise a sheet of expanded polypropylene having a thickness of about inch and a density of about 2 lbs/ft.sup.3.

[0094] Base 253 may further comprise one or more binding members 269, which may be wrapped around the four sides of support 261 and which may be used to help retain vacuum insulated panels 254-1 through 254-5 in an assembled state and to keep support 261 in a folded state. In the present embodiment, the one or more binding members 269 may comprise a single binding member in the form of a strip of tape, which may be, but is not limited to, a stretch tape. Preferably, the strip of stretch tape is a 9-inch wide web of polyethylene-backed adhesive tape, which may be wrapped centrally around support 261 one or more times, preferably in a direction opposite to the pinwheeling direction of vacuum insulated panels 254-2 through 254-5. The strip of stretch tape may be red in color to hold up to UV cleaning, or the strip of stretch tape may be white. An example of a suitable tape for use as binding member 269 may be, but is not limited to, PE34 UV resistant stucco masking tape, Intertape Polymer Group (Sarasota, FL). The aforementioned PE34 tape comprises a polyethylene film backing and a synthetic rubber pressure-sensitive adhesive, with an adhesion to steel of 20.5 N per 25 mm of width (ASTM D3330), a tensile strength of 92 N per 25 mm of width (ASTM D3759), a total thickness of 0.178 mm (ASTM D3652), an elongation of 75% at break (ASTM D3652), an application temperature range of +7 C. to +49 C., and an operating temperature range of 7 C. to +93 C. Preferably, the stretch tape used to form binding member 269 is applied at a tension about 30 lbf, with a maximum of 90 lfb.

[0095] Base 253 may further comprise a plurality of corner boards 271-1 through 271-4, which may be similar or identical to one another and to corner boards 71-1 through 71-4 of system 11. Corner boards 271-1 through 271-4 may be made of Kraft paper and may have a thickness, for example, of 0.06 to 0.08 inch. Corner boards 271-1 through 271-4, which may be oriented vertically at the four exterior corners defined by support 261 and which may be positioned between support 261 and binding member 269, may help to increase the thermal life of base 253 by keeping panels 254-1 through 254-5 together and tighter for a longer period of time and by protecting support 261 and panels 254-1 through 254-5 from physical damage that may be caused by binding member 269, particularly at the four corners of base 253. Corner boards 271-1 through 271-4 also may help to increase the length of time that binding member 269 is able to hold a minimal required tension in a reuse application. Notwithstanding the above, in another embodiment, system 211 may omit one or more of corner boards 271-1 through 271-4.

[0096] Base 253 may further comprise an inner shield 275, which may be similar or identical to inner shield 75 of system 11. Inner shield 275 may be removably inserted into the cavity defined by vacuum insulated panels 254-1 through 254-5 of base 253. Inner shield 275 may comprise a single sheet of corrugated cardboard, chipboard, or similar material and may be folded to define a cavity 276 bounded by a bottom, a front, a rear, a left side, and a right side. Inner shield 275 may be dimensioned so that, when inner shield 275 is inserted into base 253, the bottom of inner shield 275 may be seated on vacuum insulated panel 254-1 (or may be closely spaced therefrom), and one or more of the front, the left side, the rear, and the right side of inner shield 275 may abut vacuum insulated panels 254-2 through 254-5, respectively (or may be closely spaced therefrom). Inner shield 275 may be incapable of maintaining a folded state on its own and may be maintained in a folded state by virtue of being snugly received within the cavity of base 253; alternatively, inner shield 275 may be maintained in a folded state on its own or may be maintained in a folded state by adhesive tape or other suitable means.

[0097] Inner shield 275 may obviate the need for a liner of the type used in U.S. Pat. No. 11,511,928 B2 and/or in U.S. Patent Application Publication No. US 2022/0002070 A1. Notwithstanding the above, in another embodiment (not shown), system 211 may further comprise, or may alternatively comprise, such a liner.

[0098] Lid assembly 255 may comprise a lid 310, which is also shown separately in FIGS. 11, 12, 13, and 14. Lid 310 may comprise a support 311. Support 311, in turn, may comprise a single sheet of plastic corrugate (e.g., polypropylene corrugate), corrugated cardboard, chipboard, or similar material and may be folded along a pair of creases 312-1 and 312-2 to define a rear panel 314-1, a top panel 314-2, and a hinge 314-3, wherein hinge 314-3 may interconnect rear panel 314-1 and top panel 314-2 in a manner that permits top panel 314-2 to be pivoted relative to rear panel 314-1. Preferably, creases 312-1 and 312-2 are spaced apart by about 1 inch to enable the top portion of lid 310 to be pivoted outwardly over top panel 229-3 of outer box 213 (when top panel 229-3 is pivoted outwardly) without cantilevering.

[0099] Rear panel 314-1 may be secured to base 253 using one or more fasteners 313, which may be permanent or removable fasteners. By securing rear panel 314-1 to base 253, top panel 314-2 may be reversibly positioned between a first position in which top panel 314-2 is positioned over cavity 276 and a second position in which top panel 314-2 is positioned to the side of cavity 276. In the present embodiment, fasteners 313 are preferably removable fasteners and may be removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 313 may be hook and loop fasteners where rear panel 314-1 and base 253 are equipped with complementary hook and loop fasteners. It is to be understood that, although two fasteners 313 are shown in the present embodiment, the number of fasteners 313 may be varied and may be as few as one fastener or more than two fasteners.

[0100] Lid 310 may further comprise a compressible pad 325. Compressible pad 325 may be secured to the top surface of top panel 314-2 using an adhesive (not shown) or other suitable means. Compressible pad 325, which may be made of an open-cell foam material with high elasticity, such as, but not limited to, an open-cell polyurethane foam with a density of about 1.7 lbs/ft.sup.3, may be appropriately constructed and dimensioned to provide sufficient upward pressure to ensure that, when top flaps 229-1 through 229-4 of outer box 213 are fully closed, lid assembly 255 is pushed sufficiently downwardly to abut the upper edges of base 253, thereby completely closing cavity 276. To provide such compression, the top surface of lid assembly 255 is preferably at least 1/16.sup.th inch above the top of the cavity of outer box 213. Compressible pad 325 may be shaped to comprise a cutout 327 along a front edge thereof, the purpose of cutout 327 becoming apparent below.

[0101] Lid 310 may further comprise a cover sheet 331. Cover sheet 331, which may comprise a single sheet of plastic corrugate (e.g., polypropylene corrugate), corrugated cardboard, chipboard, or similar material, may be secured to the top surface of compressible pad 325 using an adhesive (not shown) or other suitable securing means. Cover sheet 331 may be shaped to include a hinged tab 333, which may be positioned over and aligned with cutout 327 of compressible pad 325. Hinged tab 333 may comprise a through-hole or cutout 335 that may be appropriately dimensioned to serve as a handle for use in pivoting lid assembly 255 towards or away from base 253.

[0102] The rear edges of compressible pad 325 and cover sheet 331 may be substantially flush with crease 312-2. In this manner, the possibility that the rear edge of cover sheet 331 may catch on and cause damage to the inner surface of outer box 313 as lid assembly 255 is pivoted away from or towards base 253 may be minimized. Alternatively, cover sheet 331 could further include a downward flap at its rear end to minimize the possibility of such damage to outer box 313.

[0103] Lid assembly 255 may further comprise a vacuum insulated panel 315, which may be conventional and, in fact, may be similar or identical to vacuum insulated panel 254-1. Vacuum insulated panel 315 may be secured to the bottom face of top panel 314-2 of lid 310 using one or more fasteners 316, which may be permanent or removable fasteners. In the present embodiment, fasteners 316 are preferably removable fasteners and may be removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 316 may be hook and loop fasteners where the bottom face of top panel 314-2 and vacuum insulated panel 315 are equipped with complementary hook and loop fasteners. It is to be understood that, although four fasteners 316 are shown in the present embodiment, the number of fasteners 316 may be varied and may be as few as one fastener or more than four fasteners.

[0104] Lid assembly 255 may further comprise a protective cover 319, which may be used to protect the exposed bottom and side surfaces of vacuum insulated panel 315. Protective cover 319 may be secured to the bottom face of vacuum insulated panel 315 using one or more fasteners 321, which may be permanent or removable fasteners. In the present embodiment, fasteners 321 are preferably removable fasteners and may be removable or repositionable adhesive fasteners; alternatively, in another embodiment, fasteners 321 may be hook and loop fasteners where the bottom surface of vacuum insulated panel 315 and the top surface of protective cover 319 are equipped with complementary hook and loop fasteners. It is to be understood that, although four fasteners 321 are shown, the number of fasteners 321 may be varied and may be as few as one fastener or more than four fasteners. Notwithstanding the above, protective cover 319 may be omitted.

[0105] Although not shown, system 211 may further comprise a riser that is similar or identical to, for example, riser 141 of system 11, a product box that is similar or identical to, for example, product box 151 of system 11, and one or more temperature-control members that are similar or identical to, for example, temperature-control members 161-1 through 161-3 of system 11. Moreover, system 11 may further comprise one or more environmental data loggers, one or more temperature indicators, or the like, such as are disclosed, for example, in U.S. Patent Application Publication No. US 2019/0210790 A1.

[0106] System 211 may be used analogously to system 11.

[0107] Some advantages, features, observations, comments and/or aspects that may be applicable to one or both of systems 11 and 211 may include the following: [0108] In contrast with systems such as that of U.S. Pat. No. 11,511,928 B2, in which the lid VIP is coupled to the outer box and not to the VIP insulation unit, the lid VIPs of systems 11 and 211 are preferably coupled to the VIP base, as opposed to being coupled to the outer box. This is advantageous because the outer box is preferably not intended to be reused (i.e., the outer box is typically replaced after each use) whereas the VIP base is preferably intended to be reused. Systems 11 and 211 preferably couple the lid VIP (i.e., lids 115 and 315) to the reusable base (i.e., bases 53 and 253), instead of coupling it to the non-reusable outer boxes 13 and 213. Preferably, by separating the reusable components from the non-reusable components in systems 11 and 211, the amount of labor that is involved in reusing the system may be reduced. [0109] In the system of U.S. Pat. No. 11,511,928 B2, in which the VIP lid is attached to the outer box, closure of the VIP base (i.e., the insulation unit) with the VIP lid requires that vertical tolerances within the system be controlled sufficiently so that the closure of the outer box causes the insulation unit to be covered by the lid without an air gap between the insulation unit and the lid. By contrast, the preferred provision of compressible pad 125 in system 11 (and compressible pad 325 in system 211) helps to ensure that, when the top closure flaps of the outer box are closed, the combination of the VIP lid and its protective cover properly closes the insulation base. In other words, the lid assembly preferably is higher than the top of the cavity of the outer box so that, when the top closure flaps of the outer box are closed, the combination of the VIP lid and its protective cover is preferably compressed against the top of the insulation base. In this regard, compressible pad 125 (and compressible pad 325 in system 211) may be regarded as acting like a spring to put a loading force onto the combination of the VIP lid and its protective cover. [0110] The preferred inclusion of a living hinge in each of lid assemblies 55 and 255 enables the respective VIP lids to align with and to mate with the tops of VIP bases 53 and 253, respectively, in a facile manner. [0111] The preferred inclusion of an integrated handle in lid assemblies 55 and 255 permits the facile manipulation of lid assemblies 55 and 255. [0112] Using releasable fasteners (e.g., removable/repositionable fasteners, hook and loop fasteners, etc.) within lid assembly 55 and lid assembly 255 permits the selective removal and replacement of many of the components of these lid assemblies, which lid assemblies are intended to be reused. In a similar vein, individual components within bases 53 and 253 may be removed and replaced. [0113] The use of elastic bands and/or adhesive tape may be advantageous over plastic straps for use as the binding members. This may be because elastic bands and/or adhesive straps may tend to apply a compressive force more evenly than plastic straps. Moreover, whereas, for example, plastic straps are more rigid and may deform over time, elastic bands do not typically experience such deformation. [0114] Systems 11 and 211 may be scaled up or scaled down, depending on the size of the payload. [0115] Although, in the present embodiment, compressible pads 125 and 325 are generally rectangular structures that substantially cover the entire footprint of the top panel of their respective supports, except for cutouts 127 and 327, respectively, the size and/or shape of compressible pads 125 and 325 could be modified. For example, in one embodiment, the compressible pad may only cover the periphery of the top panel or a portion of said periphery (i.e., be frame-shaped or C-shaped).

[0116] The embodiments of the present invention described above are intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention.