Patent Application
20240278972
This specification generally relates to cartridge assemblies for temperature-sensitive payloads, as well as apparatuses and methods for manufacturing cartridge assemblies.
The shipping or transportation of various perishable materials (e.g., medical supplies, perishable food, and the like) frequently requires that such materials be maintained within a stable temperature range, either higher or lower than the ambient temperatures to which the shipping container housing the materials will be exposed. Accordingly, there are various different types of temperature controlled, insulated shipping containers that are utilized for these critical applications. However, the insulation materials included in such shipping containers sometimes have a propensity to leak (or escape) from the container and/or into a payload area of the container, which can degrade the performance of the shipping container and, in some cases, cause damage to the perishable materials. Accordingly, there is a need for improved insulated shipping containers that reduce insulation material leakage.
Disclosed herein are various embodiments of improved cartridge assemblies and shipping containers for temperature-sensitive payloads and techniques for manufacturing the same.
At least one aspect of the present disclosure is directed to a cartridge assembly for transporting temperature-sensitive materials. The cartridge assembly includes an inner half-slotted container for housing the temperature-sensitive materials and an outer half-slotted container containing the inner half-slotted container. Each of the inner half-slotted container and the outer half-slotted container includes an open, flapless proximal end and a sealable distal end. A flange couples the inner half-slotted container to the outer half-slotted container.
Various embodiments of this aspect of the disclosure may include the following features. In some embodiments, the flange includes a first plurality of flaps coupled to an inner surface of the inner half-slotted container. For example, the first plurality of flaps may be coupled to the inner surface of the inner half-slotted container via an adhesive. In some embodiments, each flap of the first plurality of flaps is coupled to a corresponding sidewall of a plurality of sidewalls of the inner half-slotted container. In some embodiments, the flange also includes a second plurality of flaps coupled to an outer surface of the outer half-slotted container. For example, the second plurality of flaps may be coupled to the outer surface of the outer half-slotted container via an adhesive. In some embodiments, each flap of the second plurality of flaps is coupled to a corresponding sidewall of a plurality of sidewalls of the outer half-slotted container.
In some embodiments, the cartridge assembly also includes insulation material disposed within a plenum space formed between the inner half-slotted container and the outer half-slotted container. For example, the insulation material may be disposed around a plurality of sidewalls of the inner half-slotted container. As another example, the insulation material may be disposed between the sealable distal end of the inner half-slotted container and the sealable distal end of the outer half-slotted container.
Another aspect of the present disclosure is directed to a shipping container for transporting temperature-sensitive materials. The shipping container includes the cartridge assembly described above and a regular slotted container housing the cartridge assembly.
Various embodiments of this aspect of the disclosure may include the following features. In some embodiments, the regular slotted container includes a sealable proximal end and a sealable distal end. In some embodiments, the shipping container includes a lid positioned within the regular slotted container atop the cartridge assembly. In some embodiments, the lid includes a hand grip. In some embodiments, the shipping container also includes insulation material disposed within a plenum space of the lid.
Yet another aspect of the present disclosure is directed to a method for manufacturing a cartridge assembly for transporting temperature-sensitive materials. The method includes inserting and positioning an inner half-slotted container for housing the temperature-sensitive materials within a first plenum space of an outer half-slotted container, coupling a flange to the inner half-slotted container and the outer half-slotted container, inserting insulation material into a second plenum space formed between the inner half-slotted container and the outer half-slotted container, and sealing a plurality of flaps of the outer half-slotted container. In some embodiments, each of the inner half-slotted container and the outer half-slotted container includes an open, flapless proximal end.
Various embodiments of this aspect of the disclosure may include the following features. In some embodiments, sealing the plurality of flaps of the outer half-slotted container includes sealing a distal end of the outer-half slotted container. In some embodiments, the method also includes sealing a plurality of flaps of a distal end of the inner half-slotted container. In various embodiments, coupling the flange to the inner half-slotted container includes coupling a first plurality of flaps of the flange to an inner surface of the inner half-slotted container. For example, the first plurality of flaps may be adhered to the inner surface of the inner half-slotted container. In some embodiments, each flap of the first plurality of flaps is coupled to a corresponding sidewall of a plurality of sidewalls of the inner half-slotted container.
In various embodiments, coupling the flange to the outer half-slotted container includes coupling a second plurality of flaps of the flange to an outer surface of the outer half-slotted container. For example, the second plurality of flaps may be adhered to the outer surface of the outer half-slotted container. In some embodiments, each flap of the second plurality of flaps is coupled to a corresponding sidewall of a plurality of sidewalls of the outer half-slotted container.
In various embodiments, inserting the insulation material into the second plenum space formed between the inner half-slotted container and the outer half-slotted container includes blowing the insulation material into the second plenum space.
The above and other preferred features, including various novel details of implementation and combination of events, will now be more particularly described with reference to the accompanying figures and pointed out in the claims. It will be understood that the particular systems and methods described herein are shown by way of illustration only and not as limitations. As will be understood by those skilled in the art, the principles and features described herein may be employed in various and numerous embodiments without departing from the scope of any of the present inventions. As can be appreciated from the foregoing and the following description, each and every feature described herein, and each and every combination of two or more such features, is included within the scope of the present disclosure provided that the features included in such a combination are not mutually inconsistent. In addition, any feature or combination of features may be specifically excluded from any embodiment of any of the present inventions.
The foregoing Summary, including the description of some embodiments, motivations therefor, and/or advantages thereof, is intended to assist the reader in understanding the present disclosure, and does not in any way limit the scope of any of the claims.
In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
In some existing applications, an insulated shipping container includes a cardboard outer box, synthetic insulating material (e.g., expanded polystyrene (“EPS”) panels, pieces of insulation, and so forth), and phase change materials (e.g., gel packs, bricks, and the like) used to heat or cool the interior of the shipping container. Although these shipping containers are effective for their intended purpose, the combined use of both cardboard and inorganic insulation, e.g., EPS and/or other plastic materials, in a single shipping container poses problems for recycling of the container in traditional recycling programs as the different materials must be separated for recycling of each material, or cannot be recycled at all, requiring dumping into a landfill.
Due to increasing demands from environmentally conscious businesses, customers, and the general public, there is a growing need to utilize shipping containers that are fully recyclable without requiring the separation of any component parts.
In some applications, the regular slotted container 18 may be a corrugated box providing a plenum space 17 that is structured and arranged to accommodate the liner portion 14, the lid 12, and a recyclable insulation material (e.g., cellulose). Preferably, the regular slotted container 18 may have a closed distal (e.g., bottom) end and an open proximal (e.g., top) end that, once the payload, liner portion 14, and lid 12 have been inserted, can be closed using a plurality of (e.g., four) flaps 19.
The liner portion 14 may be structured and arranged to provide a payload area for containing a relatively small, temperature-sensitive item(s) to be shipped. In some implementations, the liner portion 14 may be manufactured of a recyclable corrugated box material and may be dimensioned to fit within the plenum space 17 provided by the regular slotted container 18. In addition, a recyclable insulation material (e.g., cellulose) may be placed between the outer surface of the sidewalls of the liner portion 14 and the inner surface of the sidewalls of the regular slotted container 18 to provide additional thermal insulation to the payload. In some variations, a flange 16 may be formed about the open end of the liner portion 14. Advantageously, the flange 16 may be manufactured of a recyclable corrugated box material and may be dimensioned to provide a tight, interference fit with the inner sidewalls of the regular slotted container 18. In some implementations, the flange 16 may include a plurality of inner flaps 13 that may be used to attach the flange 16 to the liner portion 14 and a corresponding plurality of outer flaps 15 that may be used to (e.g., adhesively) attach the flange 16 (as well as the liner portion 14) to the regular slotted container 18.
Creation of a robust sealed unit involves adhering the outer surfaces of the outer flaps 15 of the flange 16 to the inner surface of the regular slotted container 18 and adhering the inner flaps 13 of the flange 16 to the inside wall of the liner 14. For example, the outer flaps 15 may be (e.g., adhesively) attached to the inner surface of the regular slotted container 18 by applying an adhesive (e.g., glue and the like) to the outer surface of the outer flaps 15 and/or to the inner surface of the sidewall of the regular slotted container 18. Once the outer flaps 15 of the flange 16 of the liner portion 14 are (e.g., adhesively) attached to the inner surface of the regular slotted container 18, the payload may be disposed within the liner portion 14 and the open end of the liner portion 14 may be sealed by positioning the lid 12 within the regular slotted container 18 against the opening. Finally, the flaps 19 of the regular slotted container 18 may be folded over the lid 12 and (e.g., adhesively) sealed, e.g., using a tape.
While the thermally-insulated shipping container 10 depicted in
Accordingly, it is desirable to provide a shipping container for larger, temperature-sensitive payloads that avoids diminution of the mating bond and that makes assembly of the shipping container economical, ergonomic, and rapid.
Various embodiments provided herein relate to a recyclable, thermally insulated shipping container that is constructed from all wood fiber material and/or other organic recyclable materials. In some embodiments, the thermally insulated shipping container does not contain any plastic materials. In some embodiments, the thermally insulated shipping container is curbside recyclable and 100% repulpable.
As will be more fully described hereinafter, a recyclable, thermally insulated shipping container in accordance with the teachings of the present invention may be entirely constructed from recyclable organic fiber materials (container and insulation) in such a manner that the entire container assembly is curbside recyclable without any separation of component materials.
The term “recyclable organic fiber” in the context of a box material is intended to include any type of natural wood fiber or plant fiber material which can be provided as a panel or corrugated panel material, such as corrugated cardboard, for forming a box structure.
The term “recyclable organic fiber” in the context of an insulating material is intended to include any type of natural wood fiber or plant fiber material which can be provided as a loose-fill insulating material. Exemplary materials include loose-fill cellulose insulation, other non-woven wood or paper materials, rice, hemp, flax, wool, and the like.
A regular slotted container (“RSC”) is intended to include a shipping container having four sidewalls that, when properly assembled, create a plenum space between the inner surfaces of the sidewalls. The RSC includes proximal and distal ends, which each include a plurality of (e.g., four) flaps that may be folded and temporarily sealed to close both ends of the RSC.
A half-slotted container (“HSC”) is intended to include a shipping container having four sidewalls that, when properly assembled, create a plenum space between the inner surfaces of the sidewalls. In some embodiments, the HSC is smaller than the regular slotted container so that the HSC may be operatively disposed within the regular slotted container. The HSC includes proximal and distal ends; however, only one of the ends (e.g., the distal end) includes a plurality of (e.g., four) flaps that may be folded and temporarily sealed. The opposing (e.g., proximal) end is flapless and open.
The inner half-slotted container 44 may be structured and arranged to provide a payload area for containing a relatively large, temperature-sensitive item(s) to be shipped. In some implementations, the inner half-slotted container 44 may be manufactured of a recyclable corrugated box material and may be configured to provide a plurality of (e.g., four) sidewalls 46. Advantageously, the inner half-slotted container 44 is open (and flapless) at a proximal end and sealable at a distal end. The outer half-slotted container 48 may also be manufactured of a recyclable corrugated box material and be configured to provide a plurality of (e.g., four) sidewalls 49. Advantageously, the outer half-slotted container 48 is also open (and flapless) at a proximal end and sealable at a distal end.
In some variations, the flange 42 may be structured and arranged to (e.g., adhesively) attach the open, proximal ends of the inner half-slotted container 44 and outer half-slotted container 48 when they have been assembled. Advantageously, the flange 42 may also be manufactured of a recyclable corrugated box material and may be dimensioned to provide a tight, interference fit with the inner sidewalls of a regular slotted container 54 (see,
Once the flange 42, the inner half-slotted container 44, and the outer half-slotted container 48 have been assembled, recyclable organic fiber 45, 47 or recyclable insulation material (e.g., cellulose) 45, 47 may be added to (e.g., blown into) the plenum space between the outer surface of the sidewalls 46 of the inner half-slotted container 44 and the inner surface of the sidewalls 49 of the outer half-slotted container 48. By coupling the flange 42 to the inner surface of the inner half-slotted container 44 and to the outer surface of the outer half-slotted container 48, insulation leakage through the mating surfaces of the flange 42 (e.g., at flaps 41, 43) is reduced. As shown in
Once the plenum space between the outer surface of the sidewalls 46 of the inner half-slotted container 44 and the inner surface of the sidewalls 49 of the outer half-slotted container 48 has been filled with recyclable organic fiber 45, 47, the distal end of the outer half-slotted container 48 may be sealed (e.g., using the plurality of flaps 57 (see,
In some applications, the regular slotted container 54 may be a corrugated box providing a plenum space 56 that is structured and arranged to accommodate the cartridge assembly 40 and the lid 52. Preferably, the regular slotted container 54 includes a sealable distal (e.g., bottom) end and a sealable proximal (e.g., top) end that, once the payload, cartridge assembly 40, and lid 52 have been inserted, can be closed using a plurality of (e.g., four) flaps 58 and sealed (e.g., using tape, adhesive, and the like).
Having described a cartridge assembly 40 and a thermally-insulated shipping container 50 for transporting a relatively large, temperature-sensitive payload, a method of manufacturing the cartridge assembly 40 will now be described. Although the following description includes certain steps in a specific order, those of ordinary skill in the art can appreciate that the steps may be performed concurrently and/or in any order.
At step 602, the inner half-slotted container 44 is inserted and positioned within a plenum space 59 (see,
At step 604, the flange 42 is (e.g., adhesively) coupled to the inner half-slotted container 44 and the outer half-slotted container 48. More specifically, coupling the flange 42 may include, for example, (e.g., adhesively) attaching the inner flaps 41 of the flange 42 to the inner surface of the sidewalls 46 of the inner half-slotted container 44 and (e.g., adhesively) attaching the outer flaps 43 of the flange 42 to the outer surface of the sidewalls 49 of the outer half-slotted container 48.
At step 606, insulation material is inserted into the plenum space formed between the inner half-slotted container 44 and the outer half-slotted container 48. For example, once the flange 42, the inner half-slotted container 44, and the outer half-slotted container 48 have been attached to one another, recyclable organic fiber or recyclable insulation material (e.g., cellulose) may be introduced (e.g., blown) into the plenum space formed between the outer surface of the sidewalls 46 of the inner half-slotted container 44 and the inner surface of the sidewalls 49 of the outer half-slotted container 48. In some embodiments, the recyclable organic fiber or recyclable insulation material (e.g., cellulose) is introduced through the open distal (e.g., bottom) end of the outer half-slotted container 48, while the cartridge assembly 40 is inverted, as shown in
In some implementations, the recyclable organic fiber or recyclable insulation material (e.g., cellulose) may be introduced in lifts or stages, allowing for compaction between each lift or stage. For example, a first lift or stage of the recyclable organic fiber or recyclable insulation material (e.g., cellulose) may be introduced into the plenum space, after which the first lift or stage may be compacted. Subsequently, a second lift or stage of the recyclable organic fiber or recyclable insulation material (e.g., cellulose) may be introduced into the plenum space, after which the second lift or stage may be compacted, and so on.
At step 608, the plurality of flaps 57 of the outer half-slotted container 48 are sealed. For example, once the recyclable organic fiber or recyclable insulation material (e.g., cellulose) have filled (i) the plenum space formed between the outer surface of the sidewalls 46 of the inner half-slotted container 44 and the inner surface of the sidewalls 49 of the outer half-slotted container 48 and (ii) the base cavity between the distal (e.g., bottom) ends of the inner half-slotted container 44 and the outer half-slotted container 48, the plurality of flaps 57 of the outer half-slotted container 48 may be closed and sealed (e.g., using tape).
At step 702, the cartridge assembly 40 is inserted and positioned (or disposed) within the regular slotted container 54. At step 704, a payload is inserted within the payload area of the inner half-slotted container 44. At step 706, the lid 52 is inserted inside the regular slotted container 54, atop the cartridge assembly 40. In some embodiments, the lid 52 is positioned atop the flange 42 of the cartridge assembly 40. At step 708, the flaps 58 of the regular slotted container 54 are closed and sealed. For example, the open, proximal (e.g., top) end of the regular slotted container 54 may be sealed by taping shut the flaps 58 of the regular slotted container 54.
Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. The steps recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes described with reference to the accompanying figures do not necessarily require the particular order described, or sequential order, to achieve desirable results. Other steps or stages may be provided, or steps or stages may be eliminated, from the described processes. Accordingly, other implementations are within the scope of the following claims.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/447,085, titled “Cartridge Assembly for Temperature-Sensitive Payloads” and filed on Feb. 21, 2023, the entire contents of which are hereby incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63447085 | Feb 2023 | US |
