BACKGROUND
Temperature sensitive storage and shipping (commonly referred to as cold chain shipping) utilizes insulated packaging and containers to store and transport temperature sensitive items such as food, pharmaceuticals, and medical specimens. Traditionally, such cold chain containers have been constructed entirely or partially from foam based materials, such as expanded polystyrene (EPS) and/or polyurethane, wherein the foam based materials generally provide insulation during transportation. Most foam based materials and/or products are not curbside recyclable, at least not in the mainstream recycling readily accessible to consumers. Foam based materials and/or products usually are bulky and require a great deal of space to be shipped, which generally increases shipping costs.
Other containers that are configured to transport temperature sensitive items may include a combination of materials, such as foam based materials and/or paperboard. Most containers of this nature are not recycled, because the materials generally must be separated from one another to be recycled in the mainstream. Moreover, these containers generally are not reused. Containers that are not recycled and not reused may end up in landfills, negatively impacting the environment. Additionally, some insulated containers use materials as insulation that is very dense and carries significant weight penalties when shipped, which may increase the cost to ship the container.
Temperature control performance of containers that are at least in part recyclable is not optimal, rendering such containers unusable in circumstances where temperature control is critical and maintenance of a defined temperature range is required. Significant temperature loss and inconsistent changes in temperature ranges result from inherencies in the materials used and in the construction of such products, including loose tolerances of component assemblies and gaps between insulation materials. Such products are not able to store or transport sensitive items within a consistent temperature range for an extended period of time.
There exists a need for a sustainable insulated shipper pack assembly container that overcomes these drawbacks. Specifically, the temperature shipping market has a long-felt desire for a fully curbside recyclable alternative to expanded polystyrene coolers and polyurethane shippers that maintain critical temperature control and that do not carry a weight or cost penalty.
SUMMARY
The present invention is directed generally to a sustainable shipper pack assembly that is insulated to transport temperature sensitive and perishable items such as food, pharmaceuticals, and medical specimens within a consistent temperature range for an extended period of time. The sustainable insulated shipper pack assembly is preferably made of entirely recyclable materials to enable curbside recycling. The materials of the containers are not required to be separated from one another to be recycled in the mainstream. Materials used include, for example cellulose, cardboard, corrugated cardboard, and paper-based insulation, with at least a portion of the materials preferably being made from postconsumer paper, and other environmentally friendly materials such as for example, starch, hemp, cotton, and the like.
The sustainable insulated shipper pack assembly of the present invention in one embodiment comprises an outer container, an intermediate sleeve, an inner tray, bottom insulation pad, side insulation pads, and a lid with a top insulation pad. The components of the shipper pack assembly are configured to form a close fit with one another to eliminate or significantly reduce the possibility of exposed gaps between components and between the insulation materials to minimize or eliminate temperature loss from gaps or edge loss from the contents being transported or stored.
In an embodiment, the sustainable insulated shipper pack assembly comprises an outer container having a top, a bottom, and sides, the outer container having a plurality of bottom panels foldable to form the bottom of the outer container, a plurality of side panels forming the sides and surrounding an interior of the outer container, the interior being accessible from the top of the outer container, and a plurality of top panels foldable to close the top of the outer container; a bottom insulation pad, the size and shape of the bottom insulation pad corresponding to the size and shape of the bottom of interior of the outer container; an intermediate sleeve sized and configured to be inserted within the interior of the outer container, the intermediate sleeve having an interior space defined by internal facing sides of the intermediate sleeve; a side insulation pad sized and configured to be inserted into the interior space and along the internal facing sides of the intermediate sleeve; an inner tray having a bottom and sides surrounding a content receiving cavity, the inner tray being sized and configured to be inserted into the interior space of the inner space, the side insulation pad being positioned between the intermediate sleeve and the inner tray; a lid having an interior area; and a top insulation pad contained within the interior area of the lid.
In an embodiment of the insulated shipper pack assembly, the side insulation pad has a generally rectangular shape with free ends.
In an embodiment of the insulated shipper pack assembly, the side insulation pad has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 37 in. to 74¾ in., and a width of approximately 16⅜ in.
In an embodiment of the insulated shipper pack assembly, the bottom insulation pad fits against the interior facing surfaces of the sides and into the corners of the interior of the outer container to minimize air gaps between the bottom insulation pad and the sides and ensures a tight seal against gaps or edge loss to minimize or eliminate temperature loss from within the insulated shipper pack assembly.
In an embodiment of the insulated shipper pack assembly, the close tolerance of the side insulation pad between the sides of the outer container and the intermediate sleeve functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly.
In an embodiment of the insulated shipper pack assembly, the bottom insulation pad is a rectangle and corresponds to the shape of the interior of the intermediate sleeve.
In an embodiment of the insulated shipper pack assembly, the bottom insulation pad, the side insulation pad, and the top insulation pad are made of a recyclable material.
In an embodiment of the insulated shipper pack assembly, the insulation material is a two-piece pre-consumer paper insulation adhered between two paper layers best suited for applications where temperature control is critical during transportation and can be discarded in curbside recycle bins.
In an embodiment of the insulated shipper pack assembly, the insulation material includes at least one of cellulose, cotton/denim jute, starch, hemp, and PET recycled plastic.
In an embodiment of the insulated shipper pack assembly, the inner tray is made of a recyclable corrugated cardboard or other recyclable materials.
In an embodiment of the insulated shipper pack assembly, the inner tray is formed of a plurality of bottom panels forming the bottom of the inner tray, a plurality of top panels including a plurality of scored sections that allow the top panels to be bent or folded along the score line to be positioned over and to cover a portion of the side insulation pad.
In an embodiment of the insulated shipper pack assembly, the inner tray is inserted into the intermediate sleeve with the side insulation pad installed therebetween, the intermediate sleeve fits tightly against interior facing surfaces of the sides of the outer container and into the interior of the outer container to minimize air gaps between the intermediate sleeve and the sides of the outer container.
In an embodiment of the insulated shipper pack assembly, the inner tray fits tightly against the interior facing surfaces of the side insulation pad to snugly hold the side insulation pad between the intermediate sleeve and the inner tray.
In an embodiment of the insulated shipper pack assembly, there is a close tolerance between the inner tray, insulation pad, and the intermediate sleeve, and a close tolerance between the intermediate sleeve and the outer container function to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly.
In an embodiment of the insulated shipper pack assembly, the insertion of the inner tray into the intermediate sleeve creates a double-walled structure with the side insulation pad therebetween to further enhance the insulating capability to maintain a desired temperature range within the interior of the outer container.
In an embodiment of the insulated shipper pack assembly, the lid is a rectangular box having a top, bottom, sides, and ends surrounding the interior area, the lid have a flap to cover the ends of the lid.
In an embodiment of the insulated shipper pack assembly, the top insulation pad has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 20¼ in., and a width of approximately 19⅜ in.
In an embodiment of the insulated shipper pack assembly, the top insulation pad is placed inside the lid, the lid is securely placed on top of the inner container and inserted inside the outer container, the lid closes a top content-receiving cavity of the inner tray and functions as an insulated cover for the top of the outer container.
In an embodiment of the insulated shipper pack assembly, the lid containing the top insulation pad is fitted against the interior facing surfaces of the sides and into the corners of the interior of the outer container to minimize air gaps between the lid and sides of the outer container and to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly.
In an embodiment of the insulated shipper pack assembly, the top panels of the outer container are folded to close the top of the outer container.
These as well as still further features, objects and benefits of the invention will now become clear upon a review of the following detailed description of illustrative embodiments, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide further understanding of the present invention disclosed in the present disclosure and are incorporated in and constitute a part of this specification, illustrate aspects of the present invention and together with the description serve to explain the principles of the present invention. In the drawings:
FIG. 1A is a top plan view of an outer container with the top panels in an open position of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 1B is a bottom plan view of the outer container with the panels in a closed position of the insulated shipper pack assembly in FIG. 1A;
FIG. 1C is a front elevation view of the outer container of the insulated shipper pack assembly in FIG. 1A;
FIG. 1D is a rear elevation view of the outer container of the insulated shipper pack assembly in FIG. 1A;
FIG. 1E is a left side elevation view of the outer container of the insulated shipper pack assembly in FIG. 1A, the right side elevation view being a mirror image thereof;
FIG. 2A is a top plan view of an intermediate sleeve of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 2B is a bottom plan view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 2A;
FIG. 2C is a front elevation view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 2A;
FIG. 2D is a rear elevation view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 2A;
FIG. 2E is a left side elevation view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 2A;
FIG. 2F is a right side elevation view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 2A;
FIG. 3A is a top plan view of top insulation pad of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 3B is a bottom plan view of the top insulation pad of the insulated shipper pack assembly in FIG. 3A;
FIG. 3C is a first side elevation view of the intermediate sleeve of the insulated shipper pack assembly in FIG. 3A, the second, third, and fourth sides being a mirror image thereof;
FIG. 4A is a left side elevation view of a side insulation pad of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 4B is a right side elevation view of a side insulation pad of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 4C is a bottom plan view of the side insulation pad of the insulated shipper pack assembly in FIG. 4A;
FIG. 4D is a top plan view of the side insulation pad of the insulated shipper pack assembly in FIG. 4A;
FIG. 4E is a side elevation view of a pair of side insulation pads of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 5A is a top plan view of an inner tray of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 5B is a bottom plan view of the inner tray of the insulated shipper pack assembly in FIG. 5A;
FIG. 5C is a front elevation view of the inner tray of the insulated shipper pack assembly in FIG. 5A;
FIG. 5D is a rear elevation view of the inner tray of the insulated shipper pack assembly in FIG. 5A;
FIG. 5E is a left side elevation view of the inner tray of the insulated shipper pack assembly in FIG. 5A, the right side elevation view being a mirror image thereof;
FIG. 6A is a top plan view of top lid of an insulated shipper pack assembly in accordance with an embodiment of the present invention;
FIG. 6B is a bottom plan view of the top lid of the insulated shipper pack assembly in FIG. 6A;
FIG. 6C is a front elevation view of the top lid with a top insulation pad inserted therein of the insulated shipper pack assembly in FIG. 6A;
FIG. 6D is a rear elevation view of the top lid of the insulated shipper pack assembly in FIG. 6A;
FIG. 6E is a left side elevation view of the top lid of the insulated shipper pack assembly in FIG. 6A;
FIG. 6F is a right side elevation view of the top lid of the insulated shipper pack assembly in FIG. 6A;
FIG. 7 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly with an intermediate sleeve inserted into an outer container in accordance with an embodiment of the present invention;
FIG. 8 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly of FIG. 7 showing an intermediate sleeve with a bottom insulation pad being positioned therein in accordance with an embodiment of the present invention;
FIG. 9 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly of FIG. 7 showing an intermediate sleeve with a bottom insulation pad being positioned therein and seated at the bottom of the outer container in accordance with an embodiment of the present invention;
FIG. 10 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly of FIG. 7 showing an intermediate sleeve with a bottom insulation pad seated at the bottom of the outer container and side insulation pads installed within the intermediate sleeve in accordance with an embodiment of the present invention;
FIG. 11 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly of FIG. 7 showing an intermediate sleeve with a bottom insulation pad seated at the bottom of the outer container and side insulation pads installed, the flaps of the intermediate sleeve being folded over the side insulation pads in accordance with an embodiment of the present invention;
FIG. 12 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly showing an inner tray being inserted into the intermediate sleeve in accordance with an embodiment of the present invention;
FIG. 13 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly showing the inner tray being inserted and seated into the intermediate sleeve in accordance with an embodiment of the present invention;
FIG. 14 is a top perspective view of a partially assembled sustainable insulated shipper pack assembly showing a top lid being inserted into the outer container and over the intermediate sleeve and inner tray in accordance with an embodiment of the present invention;
FIG. 15 is a top perspective view of an assembled sustainable insulated shipper pack assembly showing a top lid inserted into the outer container and seated over the intermediate sleeve and inner tray in accordance with an embodiment of the present invention;
FIG. 16A is an exploded top perspective view of an insulated shipper pack assembly in accordance with the present invention;
FIG. 16B is an exploded bottom perspective view of an insulated shipper pack assembly in accordance with the present invention;
FIG. 17A is a partially exploded top perspective view of an insulated shipper pack assembly with a top lid having a top insulation pad partially inserted therein in accordance with the present invention;
FIG. 17B is a partially disassembled top perspective view of the insulated shipper pack assembly of FIG. 17A showing a wall of the outer container unfolded to reveal a side of the intermediate sleeve;
FIG. 17C is a partially disassembled top perspective view of the insulated shipper pack assembly of FIG. 17A showing a wall of the outer container unfolded to reveal a side of the intermediate sleeve and a flap of the intermediate sleeve being unfolded;
FIG. 17D is a partially disassembled top perspective view of the insulated shipper pack assembly of FIG. 17A showing a wall of the outer container unfolded, a wall of the intermediate sleeve unfolded, and a portion of a side insulation pad unfolded to reveal a side of the inner tray;
FIG. 17E is a partially disassembled top perspective view of the insulated shipper pack assembly of FIG. 17A showing a wall of the outer container unfolded, a wall of the intermediate sleeve unfolded, and a portion of a side insulation pad unfolded to reveal the interior of the intermediate sleeve, and the inner tray in a removed position;
FIGS. 18A and 18B are schematics of an embodiment of an outer container and a cut blank in the unfolded position of the outer container of the insulated shipper pack assembly in accordance with the present invention;
FIGS. 19A and 19B are schematics of an embodiment of an intermediate sleeve and a cut blank in the unfolded position of the intermediate sleeve of the insulated shipper pack assembly in accordance with the present invention;
FIG. 20 is a schematic of an embodiment of a cut blank of the top and bottom insulation pads and a cut blank of the side insulation pad in the unfolded position of the insulated shipper pack assembly in accordance with the present invention;
FIGS. 21A and 21B are schematics of an embodiment of an inner tray and a cut blank in the unfolded position of the inner tray of the insulated shipper pack assembly in accordance with the present invention;
FIGS. 22A and 22-B are schematics of an embodiment of a top lid and a cut blank in the unfolded position of the top lid of the insulated shipper pack assembly in accordance with the present invention; and
FIG. 23A is an example of another embodiment of the insulated shipper pack assembly in accordance with the present invention; and FIG. 23B is a table of technical data for an insulation material for the insulation pads for use in the insulated shipper pack assembly in accordance with the present invention.
DETAILED DESCRIPTION
The detailed description set forth below is intended as a description of various configurations of the present invention and is not intended to represent the only configurations in which the present invention may be practiced. It will be apparent, however, to those of ordinary skill in the art that the present invention is not limited to the specific details set forth herein and may be practiced without these specific details.
FIGS. 1A-23B show an embodiment of a sustainable insulated shipper pack assembly 100 in accordance with the present invention. In an embodiment, pack 100 comprises an outer container 200, an intermediate sleeve 300, an inner tray 500, and insulation pads 400, 700, 702 and a lid 600. In one embodiment, outer container 200 is preferably a Regular Slotted Container (RSC) made of a recyclable corrugated cardboard or other recyclable material suitable for the intended purposes of forming an RSC. Outer container 200 in an embodiment is formed of various panels such as shown in FIGS. 1A-1E and 18 as one example. Bottom panels 202a-d are folded and secured closed with paper tape to close the bottom of outer container 200.
As shown in FIG. 1B, the bottom of outer container 200 is taped closed and flipped over such that interior 210 surrounded by side panels 204a-d is accessible from the top of outer container 200 with top panels 206a-d in the open position.
As shown in FIG. 8, bottom insulation pad 702 is inserted and seated in interior 310 of intermediate sleeve 300. The size and shape of bottom insulation pad 702 closely corresponds to the size and shape of interior 310. Once inserted, bottom insulation pad 702 fits tightly against the interior facing surfaces of side panels 304a-d and into the corners of interior 310 to minimize the presence of any air gaps between insulation pad 702 and side panels 304a-d. This close tolerance between the insulation pad and intermediate sleeve 300 functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly 100. In a preferred configuration, bottom insulation pad 702 is a square to match the shape of interior 310 of intermediate sleeve. In one embodiment, bottom insulation pad 702 has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 20¼ in., and a width of approximately 19⅜ in.
FIGS. 4A-4D show side insulation pad 400 preferably having a generally rectangular shape with free ends 402, 404. In one embodiment, side insulation pad 400 has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 37 in. to 74¾ in., and a width of approximately 16⅜ in.
FIGS. 3A-3D show top insulation pad 700 is preferably a square shape to match the shape of interior area of lid 600 and fits within interior 310 of intermediate sleeve.
Bottom insulation pad 702, side insulation pad 400, and top insulation pad 700 (described below) are preferably made of a recyclable material such as for example, but not limited to, the insulation material available from MP Global Products, LLC in Norfolk, NE, commercially known as Cellulose curbside recyclable and repulpable insert (See FIGS. 23A and 23B). In this example, the insulation material is a two-piece pre-consumer paper insulation adhered between two kraft paper layers best suited for applications where temperature control is critical during transportation and can be discarded in curbside recycle bins. The insulation material provides a temperature-controlled environment for perishable deliveries and sensitive medical products with a proven R-Value and wall-to-wall stability for delicate items. It is appreciated that other curbside recyclable materials suitable for the intended purpose of transporting temperature sensitive perishables and sensitive medical products can be used in the insulated shipper pack assembly without departing from the spirit and scope of the present invention. Another example of the insulation material suitable for use in the sustainable insulated shipper pack assembly in accordance with the present invention is available from Bonded Logic in Chandler, AZ. While specific examples of insulation materials have been provided, it is appreciated that other insulation materials suitable for use in the sustainable insulated shipper pack assembly in accordance with the present invention are either commercially available or can be manufactured to specification as desired without departing from the scope of the present invention. It is further appreciated that the insulated shipper pack assembly of the present invention can be made of various sustainable substrates with insulating properties such as cellulose, cotton/denim jute, starch, hemp, and PET (recycled plastic). Regardless of the substrate, the construction of the insulated shipper pack assembly of the present invention ensures a tight seal against gaps or edge loss to minimize or eliminate temperature loss.
FIGS. 5A-5E and 21A and 21B show, an inner tray 500 preferably in the form of a Half Slotted Container (HSC) made of a recyclable corrugated cardboard or other recyclable material suitable for the intended purposes of forming a HSC. Inner tray 500, in an embodiment, is formed of various panels. Bottom panels 502a-d are folded and secured preferably with paper tape 406 to close the bottom of inner tray 500.
As shown in FIGS. 9-13 and 19A and 19B, top panels 306a-d include scored sections that allow top panels 306a-d to be bent or folded along the score line to be positioned over a portion of insulation pad 400. Once inner tray 500 is inserted into intermediate sleeve 300 with side insulation pad 400 installed therebetween, the intermediate sleeve 300 fits tightly against the interior facing surfaces of side panels 204a-d and into interior 210 to minimize the presence of any air gaps between intermediate sleeve 300 and side panels 204a-d. Similarly, inner tray 500 fits tightly against the interior facing surfaces of insulation pad 300 to snugly hold insulation pad 400 between intermediate sleeve 300 and inner tray 500.
This close tolerance between the inner tray 500, insulation pad 400, and intermediate sleeve 330, and close tolerance between intermediate sleeve 300 and outer container 200, functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly 100. The insertion of inner tray 500 into intermediate sleeve 300 creates a “double-walled” structure with insulation 400 there between and further enhancing the insulating capability to maintain a desired temperature range within interior 510 for an extended period of time.
FIG. 13 shows intermediate sleeve 300, inner tray 500 with insulation 400 installed and respective portions of top panels 306a-d folded over insulation 400 are inserted into interior 310 of intermediate sleeve 300. Inner tray 500 is pushed all the way down into intermediate sleeve 300 to form a snug fit inside interior 310 of intermediate sleeve 300. This close tolerance between the insulation 400 and outer container 200 functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly 100.
As shown in FIGS. 6A-6F, 14, 15,17A-17E, and 22A and 22B, lid 600 is formed from a rectangular box having a top, bottom, sides, ends, and a flap to cover the ends of the rectangular box. A top insulation pad 700 is positioned inside lid 600 and then the ends of the rectangular box are covered by the end flaps. In one embodiment (and similar to bottom insulation pad 702), top insulation pad 700 has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 20¼ in., and a width of approximately 19⅜ in.
After top insulation pad 700 is placed inside lid 600, lid 600 is securely placed on top of inner container 500 and inserted inside outer container 200. Lid 600 closes the top content-receiving cavity 508 of inner tray 500 and functions as an insulated cover for the top of outer container 200. Once inserted, lid 600 containing top insulation pad 700 fits tightly against the interior facing surfaces of side panels 204a-d and into the corners of interior 210 to minimize the presence of any air gaps between lid 600 and side panels 204a-d. This close tolerance between lid 600 and outer container 200 and the placement of top insulation pad 700 over inner container 500 to close content-receiving cavity 510 functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly 100.
Referring to FIGS. 1A, 18A, and 18B, top panels 206a-d of outer container 200 are folded and secured together, preferably taped together, to close the top of the outer container 200. The insulated shipper pack assembly can then be shipped or transported in a manner suitable for the intended purpose, while maintain the temperature of the contents contained therein.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub combination.
Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the broad scope of the disclosure.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein.
Patent Application
20240359899
