Packaging with Insulative Walls Having Condensation Wicking Layer and Bubble Foil Insulation Layer

BACKGROUND

Package delivery has become a significant part of commerce in today's economy. Today, a vast majority of companies that sell products often have those products available online and shipped to the purchaser. This has become increasingly true considering recent lockdowns pushed as a reactionary measure during a world pandemic. In some instances, the product being shipped may be perishable and/or adversely affected to changes in temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various examples of the principles described herein and are part of the specification. The illustrated examples are given merely for illustration, and do not limit the scope of the claims.

FIG. 1 is a block diagram of a packaging according to an example embodiment of the principles described herein.

FIG. 2 is a block diagram of a packaging according to another example embodiment of the principles described herein;

FIG. 3 is a flowchart showing a method of forming at least one insulating wall of a packaging according to an example embodiment of the principles described herein;

FIG. 4 is a flowchart showing a method of forming at least one insulating wall of a packaging according to another example embodiment, of the principles described herein;

FIG. 5 is a block diagram of a shipping container according to an example embodiment of the principles described herein;

FIG. 6 is a side cut-away view of an insulating walls according to an example embodiment of the principles described herein;

FIG. 7 is a plan view of a plurality of insulating walls according to an example embodiment of the principles described herein;

FIG. 8A is a top view of an open form used to form the insulating walls according to an example of the principles described herein;

FIG. 8B is a top view of an open form used to form the insulating walls according to another example embodiment of the principles described herein;

FIG. 8C is a top view of an open form used to form the insulating walls according to another example embodiment of the principles described herein;

FIG. 9 is a top plan view of the packaging according to another example of the principles described herein.

Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and/or implementations consistent with the description; however, the description is not limited to the examples and/or implementations provided in the drawings.

DETAILED DESCRIPTION

Shipping products across a geographical area includes packaging the product such that the product reaches the end consumer in the state that the consumer expects. Any damage to the products resulting from the shipping process may result in poor consumer satisfaction as well as returned product at the cost of the shipper, the consumer, and/or the manufacturer of the product.

To alleviate any potential damage to the product being shipped, the packaging used to ship the product in may be altered to prevent such potential damage. In an example, this may include adding a cooling device such as an ice pack in order to prevent overheating of certain types of products. However, the ice packs may limit the volumetric capacity of the packaging as well as fail to provide adequate cooling over the transit period of the shipped product.

In some embodiments herein, the packaging may also include temperature regulating layers. Among these temperature regulating layers may be a bubble foil insulation layer. The bubble foil insulation layer may be made of a heat reflective material that prevents the transfer of heat out from and into the package. With the inclusion of pockets of air in the bubble foil insulation layer, the transfer of heat from within the package to the exterior or from outside the package into the interior is also reduced. This extends the “operative lifetime” of the packaging by extending the time in which the package may be subjected to different environments and temperatures. It may also better maintain a specific temperature within the package despite those weather conditions.

In other embodiments, the packaging may also include a condensation wicking layer. This condensation wicking layer may absorb any water that may result in the slight changes in temperature or pressure within the package as the package is transported from one location to another. Indeed, changes in the water vapor pressure may change as, for example, when the package is transported via an airline or experiences changes in altitude thereby effecting the amount of potential condensation that can form on the interior of the package.

The present specification describes a packaging including at least one insulating wall and at least one cooling device embedded into the at least one wall. It is appreciated, however, that the packaging may include a plurality of insulating walls with one or more cooling devices embedded into those walls in order to cool the contents within the packaging.

The present specification further describes a method of forming at least one insulating wall of a package. In an embodiment, this may include placing a cooling device into a form; closing the form; injecting a liquid form of an expansive foam; and curing the foam. In another embodiment, the method of forming at least one insulating wall includes forming a bubble foil insulation layer on an outside surface of the insulating wall. This includes placing a bubble foil insulation layer on a first side of a form, injecting a liquid form of an expansive foam; and curing the foam with or without the placement of the cooling device into the form. In another embodiment, the method of forming at least one insulating wall includes forming a condensation wicking layer on an outside surface of the insulating wall. This includes placing a condensation wicking layer on a second side of a form, injecting a liquid form of an expansive foam; and curing the foam with or without the placement of the cooling device into the form. In another embodiment, the method of forming at least one insulating wall includes forming a bubble foil insulation layer on an outside surface of the insulating wall and forming a condensation wicking layer on an outside surface of the insulating wall. This includes placing a bubble foil insulation layer on a first side of a form, placing a condensation wicking layer on a second side of a form, injecting a liquid form of an expansive foam; and curing the foam with or without the placement of the cooling device into the form.

The present specification also describes a shipping container, that includes a box; six insulating walls, at least one side of each of the insulating walls laid against the surface of at least one wall of the box, each of the insulating walls comprising: four chamfered edges; and at least one hinge between one of the four chamfered edges of a first insulating wall and a chamfered edge of a second insulating wall, the chamfered edge being a 47-degree chamfer; a bubble foil insulation layer formed onto an outer surface of each of the insulating walls; and a condensation wicking layer formed onto an inner surface of each of the insulating walls.

As used in the present specification and in the appended claims, the term “chamfer” is meant to be understood as a transitional edge between two faces of an object. This chamfer edge, in an embodiment, may be greater than 45 degrees (e.g., 47 degrees) so that the edges of the individual insulating walls are pressed together to form a seal at the edges.

Turning now to the figures, FIG. 1 is a block diagram of a packaging 100 according to an example of the principles described herein. The packaging 100 may include an insulating wall 105. In an embodiment, the packaging 100 may also include a cooling device 110. In another embodiment, the packaging 100 does not include a cooling device 110. In an example, the packaging 100 may further include a box to encompass the insulating wall 105.

The insulating wall 105 may be any type of wall that may help to insulate a product from changes in temperature. In an example, the insulating wall 105 may include a plurality of insulating walls 105 that form a cube with an interior portion that is hollow. Although the present specification describes the packaging 100 as being a cuboidal shape, other shapes are also contemplated. The interior portion, during use of the packaging 100, provides for an object to be held therein. The object may be any type of object including both products to be shipped and, specifically, products that may be damaged due to changes in temperature had the packaging 100 not been present. By way of example, the product may be a chocolate product that, if subjected to an increase in temperature during transit, may melt damaging the quality and/or taste of the chocolate. By way of another example, the product may be a glass jar full of perishable foodstuffs. In this example, it may be disadvantageous for the glass jar to be subjected to extremely cold temperatures sufficient to freeze the perishable foodstuffs therein and causing the glass jar to break spilling the perishable foodstuffs in the packaging 100. The insulating wall 105, in this example, may therefore prevent the transmission of heat out of and into the packaging 100 according to thermodynamic principles. It is to be understood in the present specification that, although the principles described herein use a cooling device 110 as a means of maintaining temperature within the packaging 100, the principles described herein extend also to a heating device used in connection with the insulating wall 105.

The insulating wall 105 may be made of any type of insulating material. In an example, the insulating wall 105 may be made of a foam. In an example, the insulating wall 105 may be manufactured using any type of expansion foam that is presented in, for example, a form such as a liquid and is allowed to cure thereby creating an insulating wall 105 according to the principles described herein. During the manufacturing process, the cooling device 110 may be incorporated into the insulating wall 105 itself. In the example embodiment manufacturing processes described herein, the cooling device 110 (or alternatively heating device) may be placed within a certain location with a form before a liquid expansive foam is introduced into the form. As the expansive foam is introduced into the form, the liquid expansive foam forms around the cooling device 110 (or alternatively the heating device) and the cooling device 110 is embedded into the insulating wall 105 after curing of the liquid expansive foam thereby forming a monolithic piece.

In an example, the liquid expansive foam product may include a mixture of a polyether polyol resin and a polymeric isocyanate. In this example, any type of polyether polyol resin and polymeric isocyanate may be used based on a number of criteria. These criteria include the length of time that the packaging 100 is to be subjected to increases and/or decreases in temperatures during transit of the packaging 100, the space available within the packaging 100, the thickness of the insulating wall 105, the curing time of the resulting expansive foam, among other criteria.

As shown in FIG. 1, the packaging 100 may include a bubble foil insulation layer 115. In an embodiment, the bubble foil insulation layer 115 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In an example, the fluid held within the bubble sections of the bubble foil insulation layer may be a polyatomic gas. In this embodiment, the polyatomic gas may include those gaseous molecules that are not harmful to humans but that store heat energy in other forms besides its kinetic energy thereby creating a thermal buffer between the elements and the interior void formed by the insulating walls 105. In this example embodiment, when heat energy is injected into this polyatomic gas, only part of that heat will go into increasing their kinetic energy, and hence increasing the temperature. A portion of the heat received at the polyatomic gas may go into, for example, contributing to non-thermal movement of the polyatomic molecules such as rotation of the molecules and vibration of the individual atoms relative to a center of mass of the polyatomic molecule.

In one example embodiment, the bubble foil insulation layer 115 is formed by operatively coupling a flat polyethylene (LDPE) layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the package 100. In an embodiment, the flat surface of the bubble foil insulation layer 115 that includes the flat layer of LDPE may be affixed to an outer surface of the at least one insulating wall 105. The inclusion of the bubble foil insulation layer 115 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating walls 105 formed into the cube packaging 100 as described herein. By including this bubble foil insulation layer 115, the temperature within the packaging 100 may remain at a relatively constant temperature over time as the packaging 100 is shipped from one location to another. In an embodiment, the bubble foil insulation layer 115 may be laminated on the outer surface of the plurality of insulating walls 105 during the formation process of the insulating wall 105 by placing a layer of the bubble foil insulation layer 115 within the form used to form the insulating wall 105 prior to injection of the expansion foam. In an embodiment, the inclusion of the bubble foil insulation layer 115 on the packaging 100 allows for less materials used to form the packaging 100. For example, by including the bubble foil insulation layer 115, the thickness of the insulating walls 105 may be reduced due to the increased insulative capabilities of the bubble foil insulation layer 115. This reduction in the thickness of the insulating walls 105 may or may not facilitate the inclusion of the cooling device 110 as described herein and, in some embodiments, the cooling device 110 may be excluded from the packaging 100.

As shown in FIG. 1, the packaging 100 may include a condensation wicking layer 120. During use of the packaging 100, the packaging 100 may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the packaging 100 as the packaging is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 120 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 120 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

The inclusion of the bubble foil insulation layer 115 on the outer surface of the insulating walls 105 and the condensation wicking layer 120 on the inner surface of the insulating wall 105, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulation layer 115, the temperature within the packaging 100 may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 120, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the packaging 100 is subjected to as well as extending the duration of transit for the packaging 100.

In an embodiment, the packaging 100 may include the bubble foil insulation layer 115 without the condensation wicking layer 120. In another embodiment, the packaging 100 may include the condensation wicking layer 120 without the bubble foil insulation layer 115. In yet another embodiment, the packaging 100 may include both the condensation wicking layer 120 and the bubble foil insulation layer 115. Therefore, the inclusion or exclusion of either of the condensation wicking layer 120 or bubble foil insulation layer 115 with the packaging 100 may be driven by a number of factors including, but not limited to, the purchasers shipping requirements, characteristic shipping requirements associated with the products being shipped in the packaging 100, as well as weight considerations due to the inclusion or exclusion of either of the condensation wicking layer 120 or bubble foil insulation layer 115, among other factors.

Additionally, the present specification contemplates that the cooling device 110 may or may not be included within the packaging 100. For example, because the bubble foil insulation layer 115 provides an increase insulative capabilities of the packaging 100, the insulating walls 105 may be made thinner. This may reduce the amount of space available within the thickness of the insulating walls 105 to incorporated a cooling device 110 therein. In this instance, other cooling devices may be placed within the hollow of the formed packaging 100 along with the goods being shipped. In this case, the type of cooling device 110 may also include dry ice (e.g., solid carbon dioxide) that may sublimate over time during transit of the packaging 100 and the goods. The considerations as to whether to include or exclude the use of the cooling devices 110 described herein may include the type of goods being shipped, the purchasers requested features of the packaging 100, the inclusion or exclusion of the bubble foil insulation layer 115, among other factors. Therefore, although FIG. 1 shows the packaging 100 including a cooling device 110, a bubble foil insulation layer 115, and condensation wicking layer 120, the inclusion or exclusion of these items may be selected based on the factors, among others, described herein.

FIG. 2 is a block diagram of a packaging according to another example embodiment of the principles described herein. In an embodiment, the packaging 200 may include an insulating wall 205. In the embodiment shown in FIG. 2, the packaging 200 does not include a cooling device as shown and described in connection with FIG. 1. In an example, the packaging 200 may further include a box to encompass the insulating wall 205.

The insulating wall 205 may be any type of wall that may help to insulate a product from changes in temperature. In an example, the insulating wall 205 may include a plurality of insulating walls 205 that form a cube with an interior portion that is hollow. The interior portion that forms this hollow, during use of the packaging 200, provides for an object to be held therein. The object may be any type of object including both products to be shipped and, specifically, products that may be damaged due to changes in temperature had the packaging 200 not been present. By way of example, the product may be a chocolate product that, if subjected to an increase in temperature during transit, may melt damaging the quality and/or taste of the chocolate. By way of another example, the product may be a glass jar full of perishable foodstuffs. In this example, it may be disadvantageous for the glass jar to be subjected to extremely cold temperatures sufficient to freeze the perishable foodstuffs therein and causing the glass jar to break spilling the perishable foodstuffs in the packaging 200.

The insulating wall 205 may be made of any type of insulating material. In an example, the insulating wall 205 may be made of a foam. In an example, the insulating wall 205 may be manufactured using any type of expansion foam that is presented in, for example, a form such as a liquid and is allowed to cure thereby creating an insulating wall 205 according to the principles described herein. In the example embodiment manufacturing processes described herein, the liquid foam may be injected into the form after the form has been closed. As the expansive foam is introduced into the form, the liquid expansive foam forms around one or more ribs, walls, and chamfer walls formed in the form and, after curing of the liquid expansive foam, a monolithic piece is formed therein. At this point the form may be opened and the cured insulating wall 205 or walls may be removed.

As shown in FIG. 2, the packaging 200 may include a bubble foil insulation layer 215. In an embodiment, the bubble foil insulation layer 215 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In one example embodiment, the bubble foil insulation layer 215 is formed by operatively coupling a flat polyethylene (LDPE) layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the package 200. In an embodiment, the flat surface of the bubble foil insulation layer 215 that includes the flat layer of LDPE may be affixed to an outer surface of the at least one insulating wall 205. The inclusion of the bubble foil insulation layer 215 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating walls 205 formed into the cube packaging 200 as described herein. By including this bubble foil insulation layer 215, the temperature within the packaging 200 may remain at a relatively constant temperature over time as the packaging 200 is shipped from one location to another. In an embodiment, the bubble foil insulation layer 215 may be laminated on the outer surface of the plurality of insulating wall 205 during the formation process of the insulating wall 205 by placing a layer of the bubble foil insulation layer 215 within the form used to form the insulating wall 205 prior to injection of the expansion foam.

As shown in FIG. 2, the packaging 200 may include a condensation wicking layer 220. During use of the packaging 200, the packaging 200 may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the packaging 200 as the packaging is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 220 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 220 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

The inclusion of the bubble foil insulation layer 215 on the outer surface of the insulating walls 205 and the condensation wicking layer 220 on the inner surface of the insulating wall 205, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulation layer 215, the temperature within the packaging 200 may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 220, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the packaging 200 is subjected to and extending the duration of transit for the packaging 200.

In an embodiment, the packaging 200 may include the bubble foil insulation layer 215 without the condensation wicking layer 220. In another embodiment, the packaging 200 may include the condensation wicking layer 220 without the bubble foil insulation layer 215. In yet another embodiment, the packaging 200 may include both the condensation wicking layer 220 and the bubble foil insulation layer 215. Therefore, the inclusion or exclusion of either of the condensation wicking layer 220 or bubble foil insulation layer 215 with the packaging 200 may be driven by a number of factors including, but not limited to, the purchasers shipping requirements, characteristic shipping requirements associated with the products being shipped in the packaging 200, as well as weight considerations due to the inclusion or exclusion of either of the condensation wicking layer 220 or bubble foil insulation layer 215, among other factors.

Additionally, the present specification contemplates that the cooling device 210 may or may not be included within the packaging 200. For example, because the bubble foil insulation layer 215 provides an increase insulative capabilities of the packaging 200, the insulating walls 205 may be made thinner. This may reduce the amount of space available within the thickness of the insulating walls 205 to incorporated a cooling device (not shown) therein. In this instance, other cooling devices may be placed within the hollow of the formed packaging 200 along with the goods being shipped. In this case, the type of cooling device may also include dry ice (e.g., solid carbon dioxide) that may sublimate over time during transit of the packaging 200 and the goods. The considerations as to whether to include or exclude the use of the cooling devices 210 described herein may include the type of goods being shipped, the purchasers requested features of the packaging 200, the inclusion or exclusion of the bubble foil insulation layer 215, among other factors. Therefore, although FIG. 2 shows the packaging 200 including a bubble foil insulation layer 215, and condensation wicking layer 220, the inclusion or exclusion of these items may be selected based on the factors, among others, described herein.

FIG. 3 is a flowchart showing a method 300 of forming at least one insulating wall of a packaging according to an example of the principles described herein. The method 300 may begin at block 305 with placing a cooling device into a form used to create the insulating walls of the packaging such as those described in connection with FIGS. 1 and 2. In an example the form may be sized such that any insulating wall is formed around a cooling device after the form is closed at block 310. In an example, a heating or cooking device may also be placed in the form in place of the cooling device. In these examples, the heat from the heating or cooking device may maintain or increase the heat of any object placed within the packaging.

As described herein, a liquid form of expansive foam may be injected into the form at block 315. In an example, the form may include one or more liquid foam inlets into which a type of liquid foam may be passed. In an example, the liquid foam may be a mixture of a polyether polyol resin and a polymeric isocyanate. The placement of the cooling device(s) or heating devices into the form may depend on the intended cooling (or heating) characteristics within the packaging. In an example, the cooling device may be placed such that the cooling device is placed generally center to each of the insulating walls as the curing of the foam continues at block 320. Other placement options are possible and the present specification contemplates those other placements of the cooling device within the form.

At block 305, in an embodiment, the method 300 may include placing a plastic wrap on the interior surfaces of the form prior to placing the cooling device in the form and prior to closing the form at block 310 and injecting the liquid form of expansion foam into the form at block 315. Placing plastic wrap on the interior surfaces of the form may be done to allow the cured foam (e.g., cured at block 320) to release from the interior surfaces of the form. Additionally, the plastic wrap may be used as an exterior layer to the cured foam members created via the method 300. After the foam is cured, the plastic and foam may be trimmed to a desired shape. Trimming may be accomplished using any type of cutting tool including razor blades. In an example, the thickness of the plastic wrap is between 2 and 5 thousandths of an inch. In an example, the thickness of the plastic wrap is 4 thousandths of an inch. In an embodiment, the process of placing a plastic wrap on the interior surfaces of the form prior to placing the cooling device in the form and prior to closing the form may be eliminated and the condensation wicking layer and bubble foil insulation layer described herein may be laminated directly onto the surface of the insulation walls.

In an example, the insulating walls may be formed via this method 300 either individually or together based on the forms used during the method 300 described herein. In an example, three walls may be formed in form at a time. In this example, the insulating walls placed within the box may include two panels consisting of three walls each. The total of six walls forming the cuboid shape within the box may then be arranged to surround a shipped product within the cardboard box.

The form may be any form that creates the insulating wall as described herein. In an example, the form may include a number of chamfered ends such that the completed insulating walls include at least one chamfered edge. In an example, the angle of the chamfered edge is 47 degrees relative to, for example, an outer surface of the insulating wall. This allows a snug fit between panels of the insulating walls during packaging in order to ensure a tight fit between seams when the insulating walls are assembled together.

The method 300, in an embodiment, may further include placing the fabricated insulating walls into a freezer. The freezer will freeze the contents of the cooling devices embedded into the insulating walls in preparation for use in packaging of objects and shipment. Any level of freezing or cooling of the cooling devices may be achieved based on one or more factors including what is being shipped using the packaging, what temperature the object is to be maintained at, how the long the packaging is to be in transit, among other factors.

FIG. 4 is a flowchart showing a method 400 of forming at least one insulating wall of a packaging according to another example embodiment, of the principles described herein. The method 400 may begin at block 405 with placing a bubble foil insulation layer onto a first side of a form. In this embodiment, and in the embodiment described in connection with FIGS. 8A through 8C, the form may include a first side that is closed onto a second side in order to provide a space into which a liquid form of expansive foam may be injected into the form as described herein. In an embodiment, the first side of the form may be a side of the form used to form an outside surface of the insulating walls described herein. As such, the bubble foil insulation layer may be laid on the first side of the form so that when the liquid foam is injected into the form it is affixed or laminated onto the outside surface of the insulating walls.

The method 400, at block 410, may also include placing a condensation wicking layer on a second side of the form. Again, in an embodiment and with reference to the embodiments described in connection with FIGS. 8A through 8C, the form may include a first side that is closed onto a second side in order to provide a space into which a liquid form of expansive foam may be injected into the form as described herein. In an embodiment, the second side of the form may be a side of the form used to form an inside surface of the insulating walls described herein. As such, the condensation wicking layer may be laid on the second side of the form so that when the liquid foam is injected into the form it is affixed or laminated onto the inside surface of the insulating walls. As described herein, the condensation wicking layer is placed in the form for, at least two purposes. First, the presence of the condensation wicking layer may absorb any water that may result in the slight changes in temperature or pressure within the package as the package is transported from one location to another. Second the presence of the condensation wicking layer in the form prevents the expansion foam, when injected into the form, from sticking to the interior surfaces of the form.

In an alternative embodiment, instead of placing a condensation wicking layer on a second side of the form at block 410, a plastic film may be placed on the second side of the form. Like the condensation wicking layer, this plastic film may prevent any expanding foam from sticking to the interior surfaces of the form when injected into the closed form.

In an embodiment, the method may also include placing a cooling device or a heating device into the form used to create the insulating walls of the packaging such as those described in connection with FIGS. 1 and 2. However, according to this embodiment, the cooling devices and/or heating devices may not be added. In an example embodiment where the cooling devices and/or heating devices are placed within the form, the cooling devices and/or heating devices may be sized such that any insulating wall is formed around a cooling device and/or heating device after the form is closed at block 415. In an example, a heating or cooking device may also be placed in the form in place of the cooling device. In these examples, the heat from the heating or cooking device may maintain or increase the heat of any object placed within the packaging.

Whether a heating or cooking device and/or a cooling device is added into the form, the method 400 includes, at block 415, closing the form. In an embodiment, the form may include a latching mechanism that secures the first side of the form to the second side of the form and in a closed position. Because the liquid form of expansive foam expands, the form and its latches may prevent excessive leakage of the expanding foam and cause the foam to expand completely into the corners of voids within the closed form.

As described herein, the method includes injecting a liquid form of expansive foam into the form at block 420. In an example, the form may include one or more liquid foam inlets into which a type of liquid foam may be passed. As described herein in an example embodiment, the liquid foam may be a mixture of a polyether polyol resin and a polymeric isocyanate. The placement of the cooling device(s) or heating devices into the form may depend on the intended cooling (or heating) characteristics within the packaging. In an example, the cooling device may be placed such that the cooling device is placed generally center to each of the insulating walls as the curing of the foam continues at block 425. Other placement options are possible and the present specification contemplates those other placements of the cooling device within the form. In an embodiment, the injection of the expansion foam may occur prior to the closing of the form depending on the expansive properties of the expansion foam and time available

The method 400 may also include, at block 430, with removing the cured foam form the form and trimming the foam where and if necessary. In an embodiment, the expansion foam may expand outside or between cracks within the form. Here, the form may include spaces for the expansion foam to expand into so that the walls may be completely formed. Because this extra expanded foam is attached to the cured walls, this may be removed so that the walls may be sized to fit tightly as described herein in order to maintain a temperature within the walls of the packaging.

In an example, the insulating walls may be formed via this method 400 either individually or together based on the forms used during the method 400 described herein. In an example, three walls may be formed in form at a time. In this example, the insulating walls placed within the box may include two panels consisting of three walls each. The total of six walls forming the cuboid shape within the box may then be arranged to surround a shipped product within the cardboard box.

In an example, a plastic sheeting may be added around all finished sides of the cuboid shape. In this example, the plastic may be made of a high-density polyethylene (HDPE) having a thickness of between 0.010 thousandths of an inch and 0.050 thousandths of an inch. In an example, the sheet of HDPE is 0.030 millimeters thick. In this embodiment, this plastic sheeting may be formed between the condensation wicking layer and the inner side of the insulating wall and/or between the bubble foil insulation layer and the outer side of the insulating wall. Here, the method may further include, at 410 with placing the plastic sheeting on top of the bubble foil insulation layer and condensation wicking layer prior to the form being closed at block 415.

The form may be any form that creates the insulating wall as described herein. In an example, the form may include one or more chamfered ends such that the completed insulating walls include at least one chamfered edge. In an example, the angle of the chamfered edge is 47 degrees relative to, for example, an outer surface of the insulating wall. This allows a snug fit between panels of the insulating walls during packaging in order to assure a tight fit between seams when the insulating walls are assembled.

The method 400, in an embodiment, may further include placing the fabricated insulating walls into a freezer in those embodiments where the cooling device is embedded into the insulating walls. The freezer will freeze the contents of the cooling devices embedded into the insulating walls in preparation for use in packaging of objects and shipment. Any level of freezing or cooling of the cooling devices may be achieved based on one or more factors including what is being shipped using the packaging, what temperature the object is to be maintained at, how the long the packaging is to be in transit, among other factors. In the embodiment where a heating device is embedded within the insulating walls, the heating device may be activated prior to shipping of the packaging.

FIG. 5 is a block diagram of a shipping container 500 according to an example of the principles described herein. The shipping container 500 may include a box 530, a plurality of insulating walls 505, and, at least one, cooling device and/or heating device 525. As described herein, the shipping container 500 may include either or both of a cooling device or a heating device in order to control or maintain a temperature or range of temperatures within the insulating walls 505 formed into a cubic shape with a hollow therein to place an item to be shipped.

The box 530 may be any type of box that can hold an assembly of the plurality of insulating walls 505 together as described herein. In an example, the box 530 may be made of cardboard similar to those used in the package delivery services. This box 530 may also impart a level of insulation to the insulating walls 505 in order to prevent the transfer of heat into and/or out of the shipping container 500. In an example, the box 530 may also impart a level of rigidity to the assembly of insulating walls 505 as described herein. In an example, the box 530 may be made of corrugated cardboard having a c-flute interior having and edge crush test (ECT) of 32 or greater.

The insulating walls 505 may be similar to those insulating walls (FIG. 1, 105) described in connection with FIG. 1. The insulating walls 505 may be any type of wall that may help to insulate a product from changes in temperature. In an example, each of the insulating walls 310 may be between 1.5-3 inches at its thickets point. The insulating walls 505 may have an R-value of 5 in an example embodiment.

The plurality of insulating walls 505 may be formed with each of the insulating walls 505 being a wall of a cube. The formed cube includes a cubic-void therein formed by the insulating walls 505 such that an object may be placed therein. The cubic-void formed within the insulating walls 505 may vary in size depending on the thickness of the insulating walls 505, the height and width of the insulating walls 505, a temperature to be maintained within the inner void, and the item to be shipped in the shipping container 500, among other factors. The object to be shipped in the shipping container 500 may include any type of object that may be protected from changes in temperature as the shipping container 500 is shipped from its originating location to its destination. This is true for either objects that are to be held at a relatively high temperature compared to the temperature exterior to the box 530 or objects that are to be held at a relatively low temperature compared to the temperature exterior to the box 530.

As described herein, the insulating walls 505 may each have a chamfer formed at least one edge of the insulating walls 505. In an example, the angle of the chamfer may be between 40 and 55 degrees relative to a planar surface of the insulating walls 505 that butts against the box 305 as described herein. In an example, the angle of the chamfer may be 47 degrees relative to a planar surface of the insulating walls 505 that butts against the box 530 as described herein. In an example, each of the edges of each of the insulating walls 505 may have an angle of 47 degrees. By setting the angle to this specific degree, the temperature within the cube formed by the insulating walls 505 may be maintained better relative to other angles. In an example, a lid may be formed out of one of the insulating walls 505 to provide access to a user into the center of the insulating walls 505. This lid may have a thickness of between 1 to 3 inches. In an example, the thickness of all insulating walls 505 is between 1 to 3 inches. In an example, the thickness of the lid may be 1.5 inches. In an example, the thickness of all insulating walls is 1.5 inches.

The cooling device and/or heating device 525 may be any type of cooling device or heating device that can help to maintain a temperature level and/or a range of temperatures within the box 530 during transit. As described herein, a heating device may be used to help maintain a temperature within the box 530. For ease of explanation, however, the present example will be described in connection with implementing a cooling device and/or heating device 525.

Where applicable, the cooling device may be any type of cooling device. In an example, the cooling device may include a bag with the bag full of a crystal polymer and liquid such as water. In this example embodiment, 2-3 grams of the crystal polymer may be added to 26-30 ounces of water. As described herein, the cooling device may be formed into at least one of the insulating walls 505. This may be done by placing the cooling device into a form. The form may have an interior sufficient to allow an expansion foam to be introduced and form the insulating walls 505. As the expansion foam expands within the form, the cooling device is embedded into the formed insulating walls 505.

As shown in FIG. 5, the shipping container 500 may include a bubble foil insulating layer 515. In an embodiment, the bubble foil insulating layer 515 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In one example embodiment, the bubble foil insulating layer 515 is formed by operatively coupling a flat polyethylene (LDPE) layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the shipping container 500. In an embodiment, the flat surface of the bubble foil insulating layer 515 that includes the flat layer of LDPE may be affixed to an outer surface of the at least one insulating wall 505. The inclusion of the bubble foil insulating layer 515 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating walls 505 formed into the shipping container 500 as described herein. By including this bubble foil insulating layer 515, the temperature within the shipping container 500 may remain at a relatively constant temperature over time as the shipping container 500 is shipped from one location to another. In an embodiment, the bubble foil insulating layer 515 may be laminated on the outer surface of the plurality of insulating walls 505 during the formation process of the insulating walls 505 by placing a layer of the bubble foil insulating layer 515 within the form used to form the insulating walls 505 prior to injection of the expansion foam.

As shown in FIG. 5, the shipping container 500 may include a condensation wicking layer 520. During use of the shipping container 500, the shipping container 500 may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the shipping container 500 as the shipping container 500 is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 520 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 520 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

With the inclusion of the bubble foil insulating layer 515 on the outer surface of the insulating walls 505 and the condensation wicking layer 520 on the inner surface of the insulating walls 505, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulating layer 515, the temperature within the shipping container 500 may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 520, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the shipping container 500 is subjected to as well as extending the duration of transit for the shipping container 500.

FIG. 6 is a side cut-away view of an insulating wall 605 according to an example embodiment of the principles described herein. Although FIG. 6 shows a single insulating wall 605, the present specification contemplates the use of a plurality of insulating walls 310 and in some examples, insulating walls 605 that are coupled together at the chamfer 645 edges. In this example, a hinge may be formed at the terminal ends of the insulating wall 605 where the chamfer 645 has been formed.

The insulating wall 605 may have first side of the insulating wall 635 and a second side of the insulating wall 640. The first side of the insulating wall 635 forms part of an interior wall within the box. Having six interior walls formed by six insulating walls 605, for example, creates a void within the six insulating walls 605 allowing for the placement of the object or product as described herein. The second side of the insulating wall 640 is to abut an interior surface of at least one side of the box or other outer surface as described in an example embodiment herein. In an example embodiment, the second side of the insulating wall 640 may be laminated with a bubble foil insulating layer 615. In an embodiment, the bubble foil insulating layer 615 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In one example embodiment, the bubble foil insulating layer 615 is formed by operatively coupling a flat LDPE layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the shipping container. In an embodiment, the flat surface of the bubble foil insulating layer that includes the flat layer of LDPE may be affixed to an outer surface of the second side of the insulating wall 640. The inclusion of the bubble foil insulating layer 615 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating wall 605 formed into the shipping container as described herein. By including this bubble foil insulating layer 615, the temperature within the shipping container may remain at a relatively constant temperature over time as the shipping container is shipped from one location to another. In an embodiment, the bubble foil insulating layer 615 may be laminated on the outer surface of the plurality of the second side of the insulating wall 640 during the formation process of the insulating wall 605 by placing a layer of the bubble foil insulating layer 615 within the form used to form the insulating wall 605 prior to injection of the expansion foam.

The first side of the insulating wall 635 may also include a condensation wicking layer 620 laminated onto the surface of the first side of the insulating wall 635. During use of the shipping container, the shipping container may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the shipping container as the shipping container is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 620 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 620 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

With the inclusion of bubble foil insulating layer 615 on the surface of second side of the insulating wall 640 and the condensation wicking layer 620 on the surface of the first side of the insulating wall 635, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulating layer 615, the temperature within the shipping container may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 620, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the shipping container is subjected to as well as extending the duration of transit for the shipping container.

In an embodiment, with six insulating walls 605, the insulating walls 605 form a cube or other type of polyhedron having six sides that may fit into a box, a packaging, or other shipping container. In this example embodiment, a void may be created within the six sides of the insulating walls 605 used to house the product or item being shipped via the shipping container.

FIG. 6 also indicates that the chamfer 645 at the edge of the insulating wall 605. The chamfer 645 may have an angle (θ). The angle (θ) may be of any angle relative to the second side of the insulating wall 640 and/or the first side of the insulating wall 635. As described herein, the angle (θ) may be 47 degrees relative to the second side 415. In an embodiment, the angle of the chamfer 645 may be measured from a 90° angle relative to the second side of the insulating wall 640 and/or bubble foil insulating layer 615. In this example, the angle (θ) of the chamfer 645 is about 137° relative to the planar surface of the second side of the insulating wall 640 as shown in FIG. 6. In an embodiment, the angle (θ) of the chamfer 645 is about 223° relative to the planar surface of the first side of the insulating wall 635. By making the chamfer 645 grater than 45° relative to a perpendicular angle formed from the second side of the insulating wall 640, a snug fit between panels of the insulating walls may be realized. Indeed, this ensures a tight fit between seams when the insulating walls are assembled preventing heat transmission from outside the shipping container into the shipping container. In this embodiment, as the six insulating wall 605 are assembled a pressure between the ends of the insulating walls 605 where the chamfer 645 is created may be overcome thereby compressing these ends together in order to form the cubic shape of the shipping container.

FIG. 7 is a plan view of a plurality of insulating walls 705 according to an example of the principles described herein. In this example, the insulating walls 705 may each be coupled together at their edges via a wall hinge 750 as described herein. In this example, the wall hinges 750 allow each of the insulating walls 705 to be connected while being formed into a cube or, generally, a six-sided polyhedron if the dimensions of the insulating walls 705 are not square.

In the example shown in FIG. 7, the insulating walls 705 may be bent at the wall hinges 750 in order to form the interior void to house the object or product to be shipped. The insulating walls 705 thus formed, may then be placed within a box such as a cardboard box. In this example, the interior surfaces of the box may abut the exterior surfaces of the insulating walls 705 or the second sides (e.g., FIG. 6, 640) of each of the insulating walls 705. In this manner, a shippable container may be produced that allows a perishable product to be transported without being subjected to changes in temperature. As such, products such as frozen goods, chocolates, among others may be shipped without being destroyed by, for example, the temperature outside of the shipping container and/or box.

Although FIG. 7 shows all six insulating walls 705 being coupled together using a wall hinge 750, this is meant as an example only. Indeed, the present specification contemplates that any number of insulating walls 705 may or may not be coupled together in any form. In an example, the six insulating walls 705 may be coupled together to form two different pieces such that the two pieces can be formed together to create the polyhedron as described herein.

As described herein, the insulating walls 705 may have a condensation wicking layer formed onto a first side of the insulating wall and a bubble foil insulating layer formed on a second side of the insulating wall as described herein in connection with FIG. 6. Although FIG. 7 does not show these layers, the present specification contemplates that the insulating walls 705 may include either or both the bubble foil insulating layer and condensation wicking layer.

FIG. 8A is a top view of an open form 800 used to form the insulating walls according to an example of the principles described herein. The form 800 may include a form lid 805 and a form base 810.

The form lid 805 may have a flat interior surface that interfaces with the form base 810 when in a closed state. This flat interior surface of the form lid 805 may interface with the form base 810 in order to form the second side (FIG. 6, 640) of the insulating walls as described herein.

In an example, the form lid 805 may further include one or more liquid expansion foam holes 840 into which a user may introduce the liquid expansion foam as described herein. The liquid expansion foam may cure as it is pumped into the closed form 800. The form lid 805 may also include one or more form hinges 835 that allow the form 800 to be closed.

The form base 810 may include one or more form wells 820 defined by one or more form walls 815. The form walls 815 may each have a chamfer wall 830 next to it. The chamfer walls 830 create the chamfer (FIG. 6, 645) of the insulating walls described herein. Although the form 800 shows that each form wall 815 includes a chamfer wall 830, it can be appreciated that any number of chamfer walls 830 can be eliminated to create a non-chamfered wall. FIGS. 8A-8C show four form wells 820 used to form four walls of a packaging described herein. Although these figures show only four form wells 820, it is appreciated that the form 800 may include more than four or less than four form wells 820 used to form one or more insulating walls as described herein. In an embodiment, a form 800 may be used to form a portion of a six-sided packaging. This portion may include a subset of six insulating walls that, when matched up with a complimentary number of insulating walls forms the cuboidal shape of the packaging. In an embodiment, the form 800 may include six form wells 820 used to form six connected insulating walls each used to form a side of the insulating walls of the packaging. Additionally, in an embodiment, the size and shape of the form wells 820 may be different from other form wells 820 such that the size and shape of the insulating walls may form different sizes of insulating walls.

The form base 810 may also include one or more form ribs 825 that also help to form the chamfer (FIG. 6, 645) of the insulating walls described herein. In an example, some or all of the form ribs 825 may extend as tall as the form walls 815 and therefore interface with the form lid 805 when the form 800 is closed. In this example, no space is provided between a tallest portion of the form ribs 825 and the form lid 805 thereby preventing the wall hinges (e.g., FIG. 7, 750) between the insulating walls described herein from being formed. In an example, some space is provided between a tallest portion of the form ribs 825 and the form lid 805 thereby creating the hinges (FIG. 7, 750) between the insulating walls described herein.

In an example, a plastic sheeting may be laid on top of the surface the includes, at least, the form wells 820, form walls 815, and form ribs 825. In this example, a second sheet of plastic may be laid on the bottom side of the form lid 805 that interfaces with the form base 810 and may include holes that match the liquid expansion foam holes 840. During use, the two plastic sheets may prevent the liquid expansion foam, when injected, from sticking to the surfaces of the form 800. In other embodiments, this plastic sheeting may be replaced or supplemented with the use of the condensation wicking layer and bubble foil insulating layer.

FIG. 8B is a top view of an open form 800 used to form the insulating walls according to another example embodiment of the principles described herein. FIG. 8B may be similar to FIG. 8A in that the form 800 also includes a form lid 805 with a form base 810 operatively coupled to the form lid 805 via one or more form hinges 835.

Similar to FIG. 8A, the form lid 805 of FIG. 8B may include one or more liquid expansion foam holes 840 formed therein to receive a liquid expansive foam. Additionally, the form base 810 of FIG. 8B may include the form walls 815, form wells 820, form ribs 825, and chamfer walls 830 that are used to also form one or more insulating walls as described in connection with FIG. 8A.

FIG. 8B also shows that a bubble foil insulating layer 850 has been laid onto the surface of the form lid 805. The bubble foil insulating layer 850 is shown overlaying the form lid 805 with the form lid 805 being shown in ghost with dashed lines. Here, the bubble foil insulating layer 850 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In one example embodiment, the bubble foil insulating layer 850 is formed by operatively coupling a flat LDPE layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the package.

In an embodiment, the flat surface of the bubble foil insulating layer 850 that includes the flat layer of LDPE may be affixed to an outer surface of the at least one insulating wall. The inclusion of the bubble foil insulating layer 850 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating walls formed into the cube packaging as described herein. By including this bubble foil insulating layer 850, the temperature within the packaging may remain at a relatively constant temperature over time as the packaging is shipped from one location to another. In an embodiment, the bubble foil insulating layer 850 may be laminated on the outer surface of the plurality of insulating walls during the formation process of the insulating wall by placing a layer of the bubble foil insulating layer 850 within the form 800 used to form the insulating wall prior to injection of the expansion foam. In this embodiment, the bubbled side of the bubble foil insulating layer 850 may be placed against the surface of the form lid 805 so that the flat layer of LDPE is affixed or laminated onto the second side of the insulation layer when the liquid expansive foam is introduced into the closed form 800. In an embodiment, the bubble foil insulating layer 850 may include one or more holes that match the layout of the liquid expansion foam holes 840 formed on the form lid 805. In another example embodiment, one or more holes may be formed through the bubble foil insulating layer 850 at the locations of the liquid expansion foam holes 840 after the bubble foil insulating layer 850 has been placed against the form lid 805.

In the embodiment shown in FIG. 8B, the bubble foil insulating layer 850 may be used to form the insulating walls in the form 800 with or without the inclusion of a condensation wicking layer. Therefore, the example embodiments include those embodiments where the bubble foil insulating layer 850 is included without the condensation wicking layer, where the bubble foil insulating layer 850 is included with the condensation wicking layer, and where the bubble foil insulating layer 850 is not include where the condensation wicking layer is included.

FIG. 8C is a top view of an open form 800 used to form the insulating walls according to another example embodiment of the principles described herein. FIG. 8C may be similar to FIGS. 8A and 8B in that the form 800 also includes a form lid 805 with a form base 810 operatively coupled to the form lid 805 via one or more form hinges 835.

Similar to FIGS. 8A and 8B, the form lid 805 of FIG. 8C may include one or more liquid expansion foam holes 840 formed therein to receive a liquid expansive foam. Additionally, the form base 810 of FIG. 8C may include the form walls 815, form wells 820, form ribs 825, and chamfer walls 830 that are used to also form one or more insulating walls as described in connection with FIGS. 8A and 8B.

As described herein, the form base 810 may be overlaid with a condensation wicking layer 845. In this embodiment, the bubble foil insulating layer 850 is shown overlaying the form lid 805 with the form lid 805 being shown in ghost with dashed lines much like in FIG. 8B. Similarly, the condensation wicking layer 845 is shown overlaying the form base 810 with the form base 810 being shown in ghost with dashed lines. As described herein, the packaging formed via the insulating walls may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the packaging as the packaging is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 845 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 845 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

In the embodiment shown in FIG. 8C, the bubble foil insulating layer 850 may be used to form the insulating walls in the form 800 with or without the inclusion of a condensation wicking layer 845. Therefore, the example embodiments include those embodiments where the bubble foil insulating layer 850 is included without the condensation wicking layer 845, where the bubble foil insulating layer 850 is included with the condensation wicking layer 845, and where the bubble foil insulating layer 850 is not include where the condensation wicking layer 845 is included.

The inclusion of the condensation wicking layer 845 on the outer surface of the insulating walls (e.g., second side of the insulating walls) and the condensation wicking layer 845 on the inner surface (e.g., first side of the insulating wall) of the insulating walls, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulating layer 850, the temperature within the packaging may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 845, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the packaging is subjected to as well as extending the duration of transit for the packaging.

In an embodiment, the formed packaging formed by arranging the insulating walls after removing the cured insulating walls from the form may include additional packaging materials. For example, before the formed insulating walls are placed in a cardboard box, the outside and/or inside of the insulating walls 105 may be lined by butcher paper. In this embodiment, the butcher paper may be aesthetically appealing to a recipient of the package such as when the package is used to transport frozen or fresh meats. In addition to providing an aesthetic appeal to the package, the butcher paper may be recyclable such that the package if relatively more eco-friendly. In an embodiment, the butcher paper may include promotional markings specific to the shipper, the customer, the company providing the goods, or other entities.

FIG. 9 is a top plan view of the packaging 900 according to another example of the principles described herein. The packaging 900 may include, in this example, six insulating walls 905, and a box (e.g., FIG. 3, 305) to hold the six insulating walls 905 therein. In this example embodiment, each of the insulating walls 905 includes a cooling device 910 as described herein. However, the present specification contemplates that the insulating walls 905 may or may not include a cooling device 910 and may or may not include a heating device as described herein. Although FIG. 9 shows a packaging 900 having six insulating walls 905 with each insulating wall 905 having a cooling device 910, the present specification contemplates that any number of the insulating walls 905 may include a cooling device 910 embedded therein. Additionally, more than six insulating walls 905 may be included that fit within the void defined by the insulating walls 905 shown in FIG. 9 such that different objects placed within the void in preparation for transit may be separated and further insulated between each other.

The packaging 900 further includes a box (e.g., FIG. 3, 305) as described herein. The box may provide stability to the insulating walls (FIG. 3, 310) held therein as well as provide additional insulation to the insulating walls 905. The box may include one nor more flaps 905. The flaps 905 may be used to close the packaging 900 after a top insulating wall 905 is closed in onto the other insulating walls 905 creating the void therein.

FIG. 9 shows each of the cooling devices 910 as being embedded generally in a central location within each of the insulating walls 905. However, the present specification contemplates the embedding of the cooling devices 910 within any portion of the insulating walls 905 to achieve any localized cooling (or heating) effects on the object as it is placed in the void.

As shown in FIG. 9, the packaging 900 may include a bubble foil insulating layer 915. In an embodiment, the bubble foil insulating layer 915 may include multiple layers that allow a gas or other fluid to be placed within bubbled sections formed between the layers. In one example embodiment, the bubble foil insulating layer 915 is formed by operatively coupling a flat LDPE layer with a bubbled layer of LDPE in order to trap a gas or other fluid between the layers of LDPE. The flat layer of LDPE may be sealed to the bubble layer of LDPE so that the gas or other fluid does not escape. In this embodiment, a reflective foil layer may be operatively coupled to the flat layer of LDPE. The reflective foil layer reduces radiant heat transmitted into the packaging 900. In an embodiment, the flat surface of the bubble foil insulation layer 115 that includes the flat layer of LDPE may be affixed to an outer surface of the at least one insulating wall 905. In the example embodiment shown in FIG. 9, the bubble foil insulating layer 915 is formed on the outside surface of each of the insulating walls 905 including the lid insulating wall 905 shown. Additionally, the bubble foil insulating layer 915 may be sandwiched in between the outer surface of the insulating walls 905 and the inner surface of the box into which the insulating walls 905 are placed.

The inclusion of the bubble foil insulating layer 915 prevents radiant heat transmission into and out of the hollow formed by the plurality of insulating walls 905 formed into the packaging 900 as described herein. By including this bubble foil insulating layer 915, the temperature within the packaging 900 may remain at a relatively constant temperature over time as the packaging 900 is shipped from one location to another. In an embodiment, the bubble foil insulating layer 915 may be laminated on the outer surface of the plurality of insulating walls 905 during the formation process of the insulating walls 905 by placing a layer of the bubble foil insulating layer 915 within the form (e.g., FIGS. 8A-8C, 800) used to form the insulating walls 905 prior to injection of the expansion foam.

As shown in FIG. 9, the packaging 900 may include a condensation wicking layer 920. During use of the packaging 900, the packaging 900 may be subjected to different temperatures, at different pressures, and at different dew points. These changes may result in the creation of condensation during transit of the packaging 900 as the packaging 900 is moved from land delivery vehicles, to delivery flights, and back again. The condensation wicking layer 920 may absorb an amount of condensation thereby preventing potential damage or spoiling of the products being shipped. In an embodiment, the absorption rate and absorption capabilities of the condensation wicking layer 920 may be sufficient to prevent spoilage or damage of the product being shipped during the entire transit of that product.

The inclusion of the bubble foil insulating layer 915 on the outer surface of the insulating walls 905 and the condensation wicking layer 920 on the inner surface of the insulating walls 905, the transit time and distance may be extended. Due to the inclusion of the bubble foil insulating layer 915, the temperature within the packaging 900 may be maintained for a longer period of time. Due to the inclusion of the condensation wicking layer 920, the changes in pressure, temperature, and dew point may be accommodated for allowing for more varied conditions under which the packaging 900 is subjected to as well as extending the duration of transit for the packaging 900.

The specification and figures describe a packaging that includes one or more insulating walls having a cooling device embedded therein. The packaging provides for the transport of any object including perishable objects that may be susceptible to changes in temperatures. The packing having the cooling devices embedded therein allows for the void created by the insulating walls to be used solely for the provision of placing objects therein.

The blocks of the flow diagrams of FIGS. 3 and 4 as well as the processes described in connection with FIGS. 8A through 8C or steps and aspects of the operation of the embodiments herein and discussed herein need not be performed in any given or specified order. It is contemplated that additional blocks, steps, or functions may be added, some blocks, steps or functions may not be performed, blocks, steps, or functions may occur contemporaneously, and blocks, steps or functions from one flow diagram may be performed within another flow diagram.

The preceding description has been presented to illustrate and describe examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.

Packaging with Insulative Walls Having Condensation Wicking Layer and Bubble Foil Insulation Layer

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