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.-9. (canceled)

10. An insulated container comprising: an insulation layer, formed from a post-industrial, pre-consumer cotton waste, comprising a pair of insulation pads wherein each one of the pads has a top surface, a bottom surface, and four edge surfaces; a rigid container surrounding the insulation layer; and a natural fiber lamination layer applied to the top surface and/or the bottom surface of the insulation pads but not to any of the edge surfaces of the insulation pads; wherein the cotton waste includes cotton waste generated from one or more of cotton processing, cotton manufacturing, and/or cotton converting; and wherein the insulation layer is biodegradable in an anaerobic environment.

11. A method of making an insulated container comprising the steps of: a. providing a rigid container; b. providing a quantity of post-industrial, pre-consumer cotton waste; c. processing the post-industrial cotton waste into a sheet; d. converting the waste via one or more converting processes including, carding, airlay, and needle punch to achieve a specified thickness and density; d. cutting the sheet into rectangular sections; e. forming the rectangular sections into interlocking C-shaped members; and f. placing the interlocking C-shaped into the rigid container.

12. The method of claim 11 further comprising the step of laminating a natural fiber lamination layer to the sheet.

13. The method of claim 12 wherein the cotton waste includes cotton waste generated from one or more of cotton processing, cotton manufacturing, and/or cotton converting.

14. The method of claim 12 wherein the insulation layer 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 placed at the top and bottom below a payload.

15. The method of claim 12 wherein the insulation layer is biodegradable in an anaerobic environment.

16. The insulated container of claim 10 wherein the insulation layer is non-woven material for providing consistent density throughout the insulation layer.

17. The insulated container of claim 10 wherein the rigid container is made from cardboard.

18. The insulated container of claim 10 wherein insulation pads comprise a pair of interlocking C-shaped members forming an enclosed cube-shaped cavity.

19. The insulated container of claim 18 wherein one of the interlocking C-shaped members has a top portion which is integrally hingedly formed in the member for providing access to an interior portion of the insulated container.

20. The insulated container of claim 10 wherein the insulation layer 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 placed at the top and bottom below a payload.

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.