Patent Application
20180334308
The present invention generally relates to insulated shipping containers and, more particularly, to a fully recyclable insulated paper box for transport of heated or cooled payloads constructed of 100% recycled materials.
Prior art insulated shipping containers have been known for some time. Insulated boxes are used regularly for transport of heated or cooled payloads. Recently, the demand for such containers has risen sharply due to the rise in demand for food delivery services such as HelloFresh® and Blue Apron®. These services deliver portioned and curated food ingredients and recipes to customers' homes multiple times a week. The raw ingredients include meats and vegetables that must be kept cool to maintain freshness.
To accomplish this, raw ingredients are packed into a corrugate box, along with single or multiple ice packs. Surrounding the ingredients and ice packs is also typically a thermal insulating barrier that can consist of Styrofoam, PLA, or textile based insulating products. In the case of the latter two, a flexible container or wrapping consisting of paper or plastic is required to contain the loose insulating material, allowing for the easy insertion of the insulation liner in the box, and avoiding contact with the payload inside.
In addition to meal delivery services, pharmaceutical firms also utilize thermally insulated packaging to ship medicine that must stay below a certain temperature threshold. And some companies ship heated payloads, which require the same insulating effectiveness.
Regardless of the intended user, there are numerous deficiencies in these prior art insulated shipping products. They are expensive to manufacture and ship to customers, and they are made of multiple materials, many of which are not recyclable, or require multiple recycle channels.
What is needed is a fully recyclable insulated shipping container that customers may place directly into standard recycling containers after use without separating the container into individual parts or pieces. This is a solution that uses what is sometimes called a single channel recycling method.
What is also needed is a less expensive insulated shipping container that food distributors, and others, may receive in compact flat configurations or folded shipping configurations and then easily assemble on-site.
What is also needed is a less expensive insulated shipping container that integrates the insulation directly into the container to avoid additional assembly steps when used by food and pharmaceutical distributors for faster and simpler construction.
An object of the present invention is to provide a fully recyclable shipping container that will allow customers to simply place the entire product directly into current recycling containers without separation and without disassembly.
Another object of the present invention is to provide a less expensive shipping container that can itself save money by being capable of being placed flat for shipping to food and pharmaceutical suppliers.
Another object of the present invention is to provide a less expensive shipping container that will allow food and pharmaceutical suppliers to utilize unskilled labor for assembly of the product.
The present invention accomplishes the foregoing objects by providing a fully recyclable shipping container that customers may simply place into standard, single-channel recycling receptacles for disposal and recycling. The present invention also accomplishes the foregoing objects by providing a shipping container that may be stacked and shipped to food and pharmaceutical distributors in a flat configuration. The present invention also accomplishes the foregoing objects by providing an insulated shipping container that may be easily assembled by unskilled labor employed by food and pharmaceutical distributors.
The present invention is a fully recyclable shipping container referred to herein as an integrated box and insulation solution, where the outer shell of the box (preferably a corrugated paperboard or other such cellulose based material) is attached to an inner shell defined by a plurality of insulation containing panels (preferably molded paper form or other such cellulose based material) that holds an insulation material defining an insulated liner (preferably loose fill shredded paper or other cellulose based insulation material) between the outer shell and the inner shell panels. This integrated insulated box design consists of multiple sides which may or may not be of equal length, but is not limited to square or rectangular designs. In an illustrated embodiment, the unfolded interconnected wall sections of the out shell are arranged in a folding cross design, but could consist of other initial constructions as needed. The individual sides of the box can then be folded and attached to each other via interconnecting flaps and/or flaps with adhesive, tape, staples, straps, or other methods, leaving a final opening on one side that will allow the ice packs and payload to be placed inside a cargo receiving area when the wall sections are folded into an operable position, and finally sealed shut with a lid for transport.
The materials selected for the outer shell box structure, the inner shell insulation-containing panels, and the insulation material that forms the insulated liner are selected to be capable of disposal in the same recycling stream or channel, such that the entire assembled device can be placed by the consumer in a recycling stream without need for deconstruction or disassembly. For example, a corrugated paperboard outer shell box structure, paper or cellulose based insulation and paper-based inner shell insulation-containing panel material. Another example could be a corrugated PET outer shell box structure, PET inner shell panels, and a granulated PET plastic insulation material. The combination of similar materials for all components of the device creates an advantage in recycling, whereas other thermal insulating solutions which consist of nonbiodegradable or recyclable products that are mixed together i.e. plastic liners with paper corrugated boxes, causes recycling supply chain issues.
The integrated design also creates fundamental advantages in cost, because where other thermal insulating solutions must encapsulate the insulation material with a liner that is on all sides, the fully integrated design utilizes the outer shell box structure as one side of the insulation liner, eliminating one layer of material for each side of the container.
Another advantage of the integrated thermal insulation is in thermal performance. By positioning the insulation material directly against the outer shell structure and shaping the plurality of inner shell insulation-containing panels to conform to each other when folded into an operable position defining a shipping container, the thickness of the insulation material can be maintained in a uniform arrangement on all sides and corners of the device. This improves thermal performance by minimizing areas where gaps of insulation material are present, which is common in designs which use flexible insulating liners. The folds in the paper add structural stiffness to the overall assembly and leave less air gaps in the structure.
The above objectives are accomplished according to the present invention by providing an insulated shipping container comprising an outer shell defined by a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position; an inner shell defined by a series of insulation-containing panels carried by selected said wall sections, wherein at least one of said insulation-containing panels is carried on a selected said wall section and defines an enclosed insulation cavity between said wall section of said outer shell and an interior side of said insulation-containing panels; wherein said insulation-containing panels carried on at least said bottom wall and side walls abut each other to defining a cargo receiving area when said wall sections are folded into said operable position; an insulation material defining an insulated liner disposed in said insulation cavity that extends directly between said outer shell and an interior side of said inner shell; wherein said outer shell, said inner shell and said insulated liner are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.
In a further advantageous embodiment, said foldable interconnected wall sections include a top wall defining a lid section that encloses said cargo receiving area when folded into said operable position.
In a further advantageous embodiment, a detached lid section is mounted to said side walls; wherein said lid section encloses said cargo receiving area when said foldable interconnected wall sections are folded into said operable position.
In a further advantageous embodiment, a lid section is included having at least one said insulation-containing panel that abuts said insulation-containing panels carried by said side walls for enclosing said cargo receiving area.
In a further advantageous embodiment, said plurality of insulation-containing panels define a uniform insulation cavity so that a uniform insulation thickness of said insulated liner is formed among said wall sections and said lid section.
In a further advantageous embodiment, each of said insulation-containing panels includes a chamfered surface that abuts a complementary chamfered surface of an adjacent said insulation-containing panel when said wall sections are folded into said operable position.
In a further advantageous embodiment, said chamfered surfaces are formed at approximately a 45° angle along a perimeter edge portion of each said insulation-containing panels.
In a further advantageous embodiment, said chamfered surfaces on adjacent insulation-containing panels abut when a given said wall section is folded to approximately 90° relative to adjacent wall sections.
In a further advantageous embodiment, an adhesive is disposed along said chamfered surface of said insulation-containing panels, wherein said adhesive interlocks and seals together abutting said insulation-containing panels when said wall sections are folded into said operable position so that said cargo receiving area is sealed to resist air movement between abutting insulation-containing panels.
In a further advantageous embodiment, said outer shell is comprised of a corrugated paperboard.
In a further advantageous embodiment, said inner shell is comprised of a rigid or semi-rigid paper based material.
In a further advantageous embodiment, said inner shell is comprised of food grade based paper material.
In a further advantageous embodiment, said insulated liner comprises a loose fill cellulose based insulation material.
In a further advantageous embodiment, said loose fill cellulose based insulation material comprises shredded paper.
In a further advantageous embodiment, an air chamber extends around a perimeter of each of said insulation-containing panels and is defined by side surfaces of abutting said insulation-containing panels and said outer shell when said wall sections are folded into said operable position.
In a further advantageous embodiment, an insert panel is included carrying a secondary insulation container disposed in said cargo receiving area for providing layered insulation within said cargo receiving area.
In a further advantageous embodiment, said secondary insulation container comprises one of said insulation-containing panels with loose fill cellulose based insulation material contained within an insulation cavity defined between said insert panel and an inner surface of said insulation-containing panel.
In a further advantageous embodiment, said secondary insulation container comprises a bag containing loose fill cellulose based insulation material.
The above objectives are further accomplished according to the present invention by providing a method of forming an insulated shipping container, said method comprising the steps of providing an outer shell having a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position; mounting a series of insulation-containing panels to selected said wall sections to form an inner shell; inserting an insulation material into an insulation cavity disposed between said outer shell and an interior side of said inner shell; wherein said outer shell, said inner shell and said insulation material are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.
In a further advantageous embodiment, the method includes the step of folding said outer shell so that said insulation-containing panels carried on said wall sections abut each other to define a cargo receiving area when said wall sections are folded into said operable position.
The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. While the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims.
With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described.
Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise.
Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.
Referring now to
Outer shell 1 is comprised of a series of foldable interconnected wall sections, 1a, 1b, 1c and the like that when folded from a flat arrangement to an operable position for a shipping container which in the illustrated embodiment is a generally square box. The wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position, as shown in
Inner shell 2 is comprised of multiple operably associated insulation-containing panels, 2a, 2b, 2c and the like. These insulation-containing panels are generally rigid or semi-rigid paper based material. In one embodiment, inner shell 2 is comprised of food grade based paper material, including but not limited to Parchment Paper/Pan Liner Paper/Baking Paper; Waxed Paper; Glassine Paper; Polycoated Paper such as low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, ionomers, metallocene, polypropylene, EVA, EMA, acid copolymers; Board Stock; and Kraft and Butcher Paper.
At least one of the insulation-containing panels is carried on a selected wall section 1a, 1b, 1c and the like, and defines an enclosed insulation cavity between a given wall section of the outer shell 1 and an interior side of the insulation-containing panels. When the wall sections are folded into the operable position forming the shipping container (such as in
An insulated liner 3 is disposed in an enclosed insulation cavity formed by each of the insulation-containing panels. In the illustrated embodiment, insulated liners 3a, 3b, 3c and the like are positioned in direct contact with wall section 1a, 1b, 1c and other selected section of out shell 1 and extend to an interior side of each of the insulation-containing panels comprising the inner shell.
The outer shell 1, further depicted in
The outer box structure (outer shell 1) of
In a preferred embodiment, as illustrated in
In another embodiment of the invention, all outer flaps have a section of 2-sided tape applied in advance so that the user may simply remove the non-stick layer of the 2-sided tape to provide an adhesive surface for gluing the outer flaps to the surface of the outer shell.
By the same token, another useful aspect of the invention is that the various formed paper inner shell sections are capable of advertisement by forming these sections during the formed paper process used to create the formed paper inner shell sections. Referring now to
The inner shell section panels provide a container for the insulation material, as shown in
The inner shell panels can be constructed with several techniques, including, without limitation, forming, cutting, bending, and adhering. An example construction method, shown in
To create flanges and flaps in the panel 5c, a cutting operation by means of a die, or cutting knife may be performed. The attachment flanges are bent, as well as the main walls of the panel container, as shown in
The insulation material 3a of
The process of assembling the inner shell sections is illustrated in more detail in
Referring now to
Referring to
While the invention is shown with outer shell 1 forming a box structure ready for shipping, the container may optionally be used as an insert placed into another exterior shipping container.
Referring to
Referring to
In the manufacturing of the container, the outer shell can be provided from sheets or rolled stock and cut and creased appropriately to define a bottom wall or side walls. The side walls can be cut from the stock so that they are connected to the bottom wall or an adjacent side wall. Creases for folding can be formed in the stock. The panels can be formed by molding pulp, fiber or sheets using a press mold or heated press mold that can result in a molded panel. The mold can include a design that can be imprinted in the panel. Insulation material can be placed in a panel and the panel affixed to a portion of the outer shell. The insulation material can be loose, matted or other form. The manufacturing process can include a manufacturing machine that can perform these steps in parallel or series resulting the insulated shipping container. The outer shell, panels and insulation can be made from recycled paper or other cellulose material.
The panel can be formed from compression molding where the molding material can be preheated and placed in an open heated mold cavity having a mold with one or more mold surfaces. The mold is closed and pressure applied to force the molding material into contact with all mold areas. Heat and pressure are maintained until the molding material is partially or completely cured. The panel can be coated with a water resistance material in some embodiments.
While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.
| Number | Date | Country | |
|---|---|---|---|
| 62506934 | May 2017 | US |
