WO2018213470A1

WO2018213470A1 - Fully recyclable insulated shipping container

Info

Publication number: WO2018213470A1
Application number: PCT/US2018/033000
Authority: WO
Inventors: Benjamin Edward Lee MOORE; Wesley Robert JOHNSON
Original assignee: Tform Inc
Current assignee: Tform Inc
Priority date: 2017-05-16
Filing date: 2018-05-16
Publication date: 2018-11-22
Anticipated expiration: 2019-11-16
Also published as: US20180334308A1

Abstract

The present invention generally relates to an insulated shipping container made entirely of standard recyclable materials for use in transporting heated or cooled payloads. The entire container and its insulation may be placed in a standard recycling bin after use, without any disassembly or separation of materials. The container comprises multiple layers that are easily folded together by the transporter prior to the additional of a payload for delivery to an end user. The container contains multiple formed paper panels that provide a tight seal for insulation purposes.

Description

FULLY RECYCLABLE INSULATED SHIPPING CONTAINER

BACKGROUND OF THE INVENTION

[0001] 1 ) Field of the Invention

[0002] The present invention generally relates to insulated shipping containers and, more particularly, to a fully recyclable insulated paper box for transport of heated or cooled payloads constructed of 100% recycled materials.

[0003] 2) Background of the Invention

[0004] Prior art insulated shipping containers have been known for some time. Insulated boxes are used regularly for transport of heated or cooled payloads. Recently, the demand for such containers has risen sharply due to the rise in demand for food delivery services such as HelloFresh® and Blue Apron®. These services deliver portioned and curated food ingredients and recipes to customers' homes multiple times a week. The raw ingredients include meats and vegetables that must be kept cool to maintain freshness.

[0005] To accomplish this, raw ingredients are packed into a corrugate box, along with single or multiple ice packs. Surrounding the ingredients and ice packs is also typically a thermal insulating barrier that can consist of Styrofoam, PLA, or textile based insulating products. In the case of the latter two, a flexible container or wrapping consisting of paper or plastic is required to contain the loose insulating material, allowing for the easy insertion of the insulation liner in the box, and avoiding contact with the payload inside.

[0006] In addition to meal delivery services, pharmaceutical firms also utilize thermally insulated packaging to ship medicine that must stay below a certain temperature threshold. And some companies ship heated payloads, which require the same insulating effectiveness.

[0007] Regardless of the intended user, there are numerous deficiencies in these prior art insulated shipping products. They are expensive to manufacture and ship to customers, and they are made of multiple materials, many of which are not recyclable, or require multiple recycle channels.

[0008] What is needed is a fully recyclable insulated shipping container that customers may place directly into standard recycling containers after use without separating the container into individual parts or pieces. This is a solution that uses what is sometimes called a single channel recycling method.

[0009] What is also needed is a less expensive insulated shipping container that food distributors, and others, may receive in compact flat configurations or folded shipping configurations and then easily assemble on-site.

[0010] What is also needed is a less expensive insulated shipping container that integrates the insulation directly into the container to avoid additional assembly steps when used by food and pharmaceutical distributors for faster and simpler construction.

[0011] An object of the present invention is to provide a fully recyclable shipping container that will allow customers to simply place the entire product directly into current recycling containers without separation and without disassembly.

[0012] Another object of the present invention is to provide a less expensive shipping container that can itself save money by being capable of being placed flat for shipping to food and pharmaceutical suppliers. [0013] Another object of the present invention is to provide a less expensive shipping container that will allow food and pharmaceutical suppliers to utilize unskilled labor for assembly of the product.

SUMMARY OF THE INVENTION

[0014] The present invention accomplishes the foregoing objects by providing a fully recyclable shipping container that customers may simply place into standard, single- channel recycling receptacles for disposal and recycling. The present invention also accomplishes the foregoing objects by providing a shipping container that may be stacked and shipped to food and pharmaceutical distributors in a flat configuration. The present invention also accomplishes the foregoing objects by providing an insulated shipping container that may be easily assembled by unskilled labor employed by food and pharmaceutical distributors.

[0015] The present invention is a fully recyclable shipping container referred to herein as an integrated box and insulation solution, where the outer shell of the box (preferably a corrugated paperboard or other such cellulose based material) is attached to an inner shell defined by a plurality of insulation containing panels (preferably molded paper form or other such cellulose based material) that holds an insulation material defining an insulated liner (preferably loose fill shredded paper or other cellulose based insulation material) between the outer shell and the inner shell panels. This integrated insulated box design consists of multiple sides which may or may not be of equal length, but is not limited to square or rectangular designs. In an illustrated embodiment, the unfolded interconnected wall sections of the out shell are arranged in a folding cross design, but could consist of other initial constructions as needed. The individual sides of the box can then be folded and attached to each other via interconnecting flaps and/or flaps with adhesive, tape, staples, straps, or other methods, leaving a final opening on one side that will allow the ice packs and payload to be placed inside a cargo receiving area when the wall sections are folded into an operable position, and finally sealed shut with a lid for transport.

[0016] The materials selected for the outer shell box structure, the inner shell insulation-containing panels, and the insulation material that forms the insulated liner are selected to be capable of disposal in the same recycling stream or channel, such that the entire assembled device can be placed by the consumer in a recycling stream without need for deconstruction or disassembly. For example, a corrugated paperboard outer shell box structure, paper or cellulose based insulation and paper-based inner shell insulation-containing panel material. Another example could be a corrugated PET outer shell box structure, PET inner shell panels, and a granulated PET plastic insulation material. The combination of similar materials for all components of the device creates an advantage in recycling, whereas other thermal insulating solutions which consist of nonbiodegradable or recyclable products that are mixed together i.e. plastic liners with paper corrugated boxes, causes recycling supply chain issues.

[0017] The integrated design also creates fundamental advantages in cost, because where other thermal insulating solutions must encapsulate the insulation material with a liner that is on all sides, the fully integrated design utilizes the outer shell box structure as one side of the insulation liner, eliminating one layer of material for each side of the container. [0018] Another advantage of the integrated thermal insulation is in thermal performance. By positioning the insulation material directly against the outer shell structure and shaping the plurality of inner shell insulation-containing panels to conform to each other when folded into an operable position defining a shipping container, the thickness of the insulation material can be maintained in a uniform arrangement on all sides and corners of the device. This improves thermal performance by minimizing areas where gaps of insulation material are present, which is common in designs which use flexible insulating liners. The folds in the paper add structural stiffness to the overall assembly and leave less air gaps in the structure.

[0019] The above objectives are accomplished according to the present invention by providing an insulated shipping container comprising an outer shell defined by a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position; an inner shell defined by a series of insulation-containing panels carried by selected said wall sections, wherein at least one of said insulation-containing panels is carried on a selected said wall section and defines an enclosed insulation cavity between said wall section of said outer shell and an interior side of said insulation-containing panels; wherein said insulation-containing panels carried on at least said bottom wall and side walls abut each other to defining a cargo receiving area when said wall sections are folded into said operable position; an insulation material defining an insulated liner disposed in said insulation cavity that extends directly between said outer shell and an interior side of said inner shell; wherein said outer shell, said inner shell and said insulated liner are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.

[0020] In a further advantageous embodiment, said foldable interconnected wall sections include a top wall defining a lid section that encloses said cargo receiving area when folded into said operable position.

[0021] In a further advantageous embodiment, a detached lid section is mounted to said side walls; wherein said lid section encloses said cargo receiving area when said foldable interconnected wall sections are folded into said operable position.

[0022] In a further advantageous embodiment, a lid section is included having at least one said insulation-containing panel that abuts said insulation-containing panels carried by said side walls for enclosing said cargo receiving area.

[0023] In a further advantageous embodiment, said plurality of insulation- containing panels define a uniform insulation cavity so that a uniform insulation thickness of said insulated liner is formed among said wall sections and said lid section.

[0024] In a further advantageous embodiment, each of said insulation-containing panels includes a chamfered surface that abuts a complementary chamfered surface of an adjacent said insulation-containing panel when said wall sections are folded into said operable position.

[0025] In a further advantageous embodiment, said chamfered surfaces are formed at approximately a 45° angle along a perimeter edge portion of each said insulation-containing panels. [0026] In a further advantageous embodiment, said chamfered surfaces on adjacent insulation-containing panels abut when a given said wall section is folded to approximately 90° relative to adjacent wall sections.

[0027] In a further advantageous embodiment, an adhesive is disposed along said chamfered surface of said insulation-containing panels, wherein said adhesive interlocks and seals together abutting said insulation-containing panels when said wall sections are folded into said operable position so that said cargo receiving area is sealed to resist air movement between abutting insulation-containing panels.

[0028] In a further advantageous embodiment, said outer shell is comprised of a corrugated paperboard.

[0029] In a further advantageous embodiment, said inner shell is comprised of a rigid or semi-rigid paper based material.

[0030] In a further advantageous embodiment, said inner shell is comprised of food grade based paper material.

[0031] In a further advantageous embodiment, said insulated liner comprises a loose fill cellulose based insulation material.

[0032] In a further advantageous embodiment, said loose fill cellulose based insulation material comprises shredded paper.

[0033] In a further advantageous embodiment, an air chamber extends around a perimeter of each of said insulation-containing panels and is defined by side surfaces of abutting said insulation-containing panels and said outer shell when said wall sections are folded into said operable position. [0034] In a further advantageous embodiment, an insert panel is included carrying a secondary insulation container disposed in said cargo receiving area for providing layered insulation within said cargo receiving area.

[0035] In a further advantageous embodiment, said secondary insulation container comprises one of said insulation-containing panels with loose fill cellulose based insulation material contained within an insulation cavity defined between said insert panel and an inner surface of said insulation-containing panel.

[0036] In a further advantageous embodiment, said secondary insulation container comprises a bag containing loose fill cellulose based insulation material.

[0037] The above objectives are further accomplished according to the present invention by providing a method of forming an insulated shipping container, said method comprising the steps of providing an outer shell having a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position; mounting a series of insulation- containing panels to selected said wall sections to form an inner shell; inserting an insulation material into an insulation cavity disposed between said outer shell and an interior side of said inner shell; wherein said outer shell, said inner shell and said insulation material are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.

[0038] In a further advantageous embodiment, the method includes the step of folding said outer shell so that said insulation-containing panels carried on said wall sections abut each other to define a cargo receiving area when said wall sections are folded into said operable position. DESCRIPTION OF THE DRAWINGS

[0039] The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:

[0040] Fig. 1 is an exploded view showing the main components of the container according to the present invention.

[0041] Fig. 2 is an isometric view of an embodiment of an outer shell box structure showing the flaps and creases for the sides of the box according to the present invention.

[0042] Fig. 3 is an exploded view showing the insulation material filled in the panels, with the outer shell box structure ready to be attached according to the present invention.

[0043] Fig. 4 is an isometric view of the outer box structure with the panel to box adhesive, and the box side to box flap adhesive according to the present invention.

[0044] Fig. 5 is an isometric view of the container pre-assembled according to the present invention.

[0045] Fig. 6 is a cross section view of the container pre-assembled according to the present invention.

[0046] Fig. 7 is a cross section view of the container pre-assembled according to the present invention.

[0047] Fig. 8 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0048] Fig. 9 is an isometric view of the partially folded container in the process of assembly according to the present invention. [0049] Fig. 10 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0050] Fig. 1 1 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0051] Fig. 12 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0052] Fig. 13 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0053] Fig. 14 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0054] Fig. 15 is an isometric view of the partially folded container in the process of assembly according to the present invention.

[0055] Fig. 16 is an isometric view of the fully folded and assembled container according to the present invention.

[0056] Fig. 17 is an isometric view of the fully folded and assembled container, with logo applied to outer box structure according to the present invention.

[0057] Fig. 18 is a view of an inner shell panel, showing the container, the attachment flanges and a formed logo according to the present invention.

[0058] Fig. 19 is a bottom and side view of an inner shell panel according to the present invention.

[0059] Fig. 20 is a close-up view of the assembled container, highlighting an adhesive applied to the chamfered sealing surface on the panels and the foldable tabs according to the present invention. [0060] Fig. 21 is a close-up view of an inner shell panel, highlighting the foldable tabs according to the present invention.

[0061] Fig. 22 is a close-up view of an inner shell panel, highlighting the foldable tabs according to the present invention.

[0062] Fig. 23 is a view of two inner shell panels, illustrating the chamfered corner sealing interface and the multiple layers of the inner shell according to the present invention.

[0063] Fig. 24 is a view of two inner shell panels, illustrating the chamfered corner sealing interface and the multiple layers of the inner shell according to the present invention.

[0064] Fig. 25 is a perspective cross section view of an embodiment of the insert panel and secondary insulation container illustrating the insulation material disposed therein according to the present invention.

[0065] Fig. 26 is a side view of an embodiment of the insert panel and secondary insulation container according to the present invention.

[0066] Fig. 27 is a chart illustrating temperature of the container over time.

[0067] Fig. 28 shows a perspective view of an embodiment of the container pre- assembled according to the present invention.

[0068] Fig. 29a shows a front perspective view of the container in an assembled condition with the outer shell folded into an operational position according to the present invention. [0069] Fig. 29b shows a rear perspective view of the container in an assembled condition with the outer shell folded into an operational position according to the present invention.

[0070] It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. While the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0071] With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described.

[0072] Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction "and" should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as "and/or" unless expressly stated otherwise. Similarly, a group of items linked with the conjunction "or" should not be read as requiring mutual exclusivity among that group, but rather should also be read as "and/or" unless expressly stated otherwise.

[0073] Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as "one or more," "at least," "but not limited to" or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.

[0074] Referring now to Fig. 1 , an exploded view showing the three main components of the unassembled insulated shipping container 100 is provided. A preferred embodiment of the shipping container comprises a foldable outer shell 1 , a foldable formed paper inner shell 2, and an insulation material defining an insulated liner 3. Outer shell 1 , inner shells 2, and insulation material 3 are constructed an arranged to form a series of foldable interconnecting sections that when folded into an operable position form a shipping container, as shown in Figure 16 in one embodiment.

[0075] Outer shell 1 is comprised of a series of foldable interconnected wall sections, 1 a, 1 b, 1 c and the like that when folded from a flat arrangement to an operable position for a shipping container which in the illustrated embodiment is a generally square box. The wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position, as shown in Figs. 16, 17, 29a and 29b.

[0076] Inner shell 2 is comprised of multiple operably associated insulation- containing panels, 2a, 2b, 2c and the like. These insulation-containing panels are generally rigid or semi-rigid paper based material. In one embodiment, inner shell 2 is comprised of food grade based paper material, including but not limited to Parchment Paper/Pan Liner Paper/Baking Paper; Waxed Paper; Glassine Paper; Polycoated Paper such as low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, ionomers, metallocene, polypropylene, EVA, EMA, acid copolymers; Board Stock; and Kraft and Butcher Paper.

[0077] At least one of the insulation-containing panels is carried on a selected wall section 1 a, 1 b, 1 c and the like, and defines an enclosed insulation cavity between a given wall section of the outer shell 1 and an interior side of the insulation-containing panels. When the wall sections are folded into the operable position forming the shipping container (such as in Figs. 16, 17, 29a and 29b), insulation-containing panels carried on at least the bottom wall and side walls abut each other to defining a cargo receiving area.

[0078] An insulated liner 3 is disposed in an enclosed insulation cavity formed by each of the insulation-containing panels. In the illustrated embodiment, insulated liners 3a, 3b, 3c and the like are positioned in direct contact with wall section 1 a, 1 b, 1 c and other selected section of out shell 1 and extend to an interior side of each of the insulation- containing panels comprising the inner shell.

[0079] The outer shell 1 , further depicted in Fig. 2, can begin as a flat sheet of rigid paper products, including but not limited to cardboard, or other various paperboard and paper based materials, with various cuts 1 d and creases 1 e to constitute the final folded geometry and to aid in assembly. The flat box (outer shell 1 ), as shown in Fig. 2, consists of wall section 1 a, 1 b, 1 c, and the like which when folded create the three-dimensional box, and flaps 1f, which are folded and adhered to the sides of the box to create a rigid structure, in the illustrated embodiment. In an optional embodiment, printed logos or other images and text can be placed on the sides or flaps of the box structure as illustrated in Fig. 17.

[0080] The outer box structure (outer shell 1 ) of Fig. 2 and 3 preferably begins as a flat sheet of stiff paper such as cardboard. With the insulation-containing panels filled with insulation material 3a, they are attached to selected wall sections of outer shell 1 . The insulation 3a is contained between the panel and box, creating a thermal insulating barrier. With the insulation 3a contained within the panels 2a, 2b, 2c and the like, and the panels attached to the outer shell box structure, a single structure is created as seen in Fig. 5. The structure can then be folded, as depicted in Figs. 8 to 16, into a box shape. The outer flaps 1 i, 1 j, 1 k and the like can then be folded and adhered to the exterior side of various walls sections of the box with an adhesive material, creating a rigid structure. Referring to Figures 12 and 16, the foldable interconnected wall sections 1 a, 1 b, 1 c, and the like include a top wall defining a lid section 1 m for enclosing the cargo receiving area when folded into the operable position (Fig. 16). The lid section 1 m, allows for the placement of cold packs and the payload along with any other desired packaging or marketing materials inside the cargo receiving area of the box. The lid 1 m can then be closed and the flaps folded down and attached via adhesive, as seen in Figs. 13 to 16. The fully assembled and sealed box, ready for transport is shown in Fig. 16. Referring to Figs. 12 and 13, lid section 1 m preferably incudes at least one insulation-containing panel that abuts the insulation-containing panels carried by the side walls for enclosing the cargo receiving area. In an alternative embodiment, lid section 1 m is detached from the other wall section forming the rest of the box. Preferably, lid section 1 m includes a handle portion that is integrally form with or mounted to an exterior side of lid section 1 m or to the various side walls of the box.

[0081] In a preferred embodiment, as illustrated in Fig. 3, the insulated liner panels/sections 3a, 3b, 3c and the like, are inserted into the inner panels/sections 2a, 2b, 2c, and the like. In this preferred embodiment, each of 3a, 3b, 3c and the like, are form cut and shaped to fit snugly into each of 2a, 2b, 2c and the like to better aid in the insulation properties of container 100. The first step of assembly is also indicated in Fig. 3, whereby the insulating liner 3 is inserted into the foldable formed paper inner shell 2.

[0082] Figs. 4 and t shows the next step of assembly from a view of the outer layer 1 . Here, foldable outer shell 1 is now attached to foldable formed paper shell 2 with insulation liner 3 sandwiched in between. Prior to the next step of assembly, in a preferred embodiment, as illustrated in Fig. 4, standard adhesive may be applied to the side sections 1 g of the box structure (outer shell 1 ) to adhere the insulation containing panels (inner shell 2) to the box structure, as well as to adhere the folding flaps 1 h of the box to itself to create the final folded assembly, as shown in later figures. In addition to the adhesive applied to the outer box structure, as shown in Fig. 4, an adhesive or adhesive strip 17a can be applied to the chamfered sealing edge of the panels to hold the entire device together during assembly, and or to improve the thermal insulation properties of the device by ensuring a tight seal between the panels, as shown in Fig. 20.

[0083] Fig. 5 provides another view of the same step from a view of the inner layer 2. Here inner sections, 2a, 2b, 2c and the like are operably attached to the outer sections 1 a, 1 b, 1 c and the like, wherein the multiple operably connected insulation sections, 3a, 3b, 3c and the like are sandwiched in between and therefore not visible. Figs. 6 and 7 provides a cutaway view that illustrates insulation section 3a disposed between inner section 2a and outer section 1 a.

[0084] Fig. 8 illustrates the next step of assembly from a view of the inner liner. Here the various foldable sections of inner sections and outer sections are illustrated being folded together. Figs. 9 and 10 continue the process by further folding the foldable sections as illustrated.

[0085] Fig. 1 1 illustrates all but the top section of the various outer panels now in contact with corresponding inner panels, where outer panel flaps 1 i, 1 j, and 1 k are not yet folded into final position. At this point, in a preferred embodiment, a standard adhesive is applied to the inner portion of each outer flap 1 i, 1j, and 1 k, as well as other outer flaps not visible in Fig. 1 1 . The adhesive chosen is preferably one that is easily recycled with other paper products so that no portion of container 100 must be later separated before deposit into a standard recycling receptacle. [0086] Fig. 12 continues the assembly process by beginning the fold of outer panel flaps 1 i, 1j, and 1 k. Fig. 13 shows outer panel flaps 1 i, 1j, and 1 k fully folded, where sections 1 i and 1j now glued to the outer portion of section 1 c.

[0087] Fig. 13 also illustrates the next step where the top section 1 m of outer shell 1 is now folded to close container 100. It is also preferable to first insert the payload that is to be shipped, and then apply adhesive to the outer flaps 1 n, 1 o, and 1 p of the top section 1 m prior to closing container 100.

[0088] In another embodiment of the invention, all outer flaps have a section of 2- sided tape applied in advance so that the user may simply remove the non-stick layer of the 2-sided tape to provide an adhesive surface for gluing the outer flaps to the surface of the outer shell.

[0089] Fig. 14 and 15 illustrate the next step in the process of using the container 100. Here, container 100 is fully assembled and now in the process of being closed. The user will have placed the payload of refrigerated or heated materials inside container 100 by this point, and now the top section 1 m of the outer shell 1 is being closed for shipment, where the only remaining step is to fold and glue the outer flaps 1 m, 1 n, 1 o to the outer portion of shell 1 .

[0090] Fig. 16 illustrates the fully-assembled and ready-to-ship container 100, where all flaps are glued in place and container 100 is now fully sealed to insulate and maintain temperature of the heated or cooled payload for delivery.

[0091] Fig. 17 illustrates container 100 with a company logo 4 applied to the top portion 1 m. This is a useful feature for the expected users (food and pharmaceutical companies) to help distinguish their products and services over competitors. [0092] By the same token, another useful aspect of the invention is that the various formed paper inner shell sections are capable of advertisement by forming these sections during the formed paper process used to create the formed paper inner shell sections. Referring now to Figs. 18 and 19, a formed paper section is illustrated with a company logo directly formed into the formed paper section 5a. A preferred embodiment of the panel section 5a results in a raised inner panel section, wherein the insulation section can later be inserted. Chamfered surfaces 5b illustrate the depth of the formed paper inner shell section 5a, leaving flaps 5c where the adhesive is applied to attach each inner shell panel section to the outer shell panel sections. Chamfered surfaces 5b are also formed to provide a tight seal for insulation purposes. When all the various panels are folded together chamfered surfaces 5b come in direct contact from each of the sides to seal up the inner portion of container 100. In the illustrated embodiments, chamfered surfaces are formed at approximately a 45° angle along a perimeter edge portion of each said insulation-containing panels. Chamfered surfaces on adjacent insulation-containing panels abut when a given said wall section is folded to approximately 90° relative to adjacent wall sections. Referring to Fig. 20, an adhesive 17a is disposed along the chamfered surface of insulation-containing panels 7, wherein the adhesive interlocks and seals together abutting insulation-containing panels 7 when the wall sections are folded into the operable position so that the cargo receiving area is sealed to resist air movement between abutting insulation-containing panels.

[0093] The inner shell section panels provide a container for the insulation material, as shown in Figs. 6 and 7. Referring to Fig. 19, these inner shell panels preferably consist of a container shelf 5d, may have equal or unequal sides, attachment flanges 5c for adhering the panel to the outer box structure, and a bottom side that can include a formed logo, image, or contain stiffening geometry. The bottom edges of the container can also contain chamfered surfaces 5b, as illustrated in Fig. 18, around the perimeter of the container that provide a sealing interface with surrounding panels when the entire box structure is folded, as shown in Fig. 23. The inner panel sections are preferably created out of a formable material that can include traditional paper, formable paper, or a variety of thermoformable plastics.

[0094] The inner shell panels can be constructed with several techniques, including, without limitation, forming, cutting, bending, and adhering. An example construction method, shown in Fig. 19, begins with a flat formable paper sheet, where the lower section of the panel container shelf 5d is formed along with any logos or stiffening geometry on the bottom face of the panel, in addition to the chamfered lower corners 5b. This geometry in the lower section of the panel can be created by means of a thermoforming process, where the panel material is heated and then inserted between a male and / or female mold that is in the shape of the desired geometry. An alternate method can involve an embossing process, where heat is not applied to the panel material, but the panel material is formed by means of a high application pressure between two mold pieces.

[0095] To create flanges and flaps in the panel 5c, a cutting operation by means of a die, or cutting knife may be performed. The attachment flanges are bent, as well as the main walls of the panel container, as shown in Figs. 21 and 22, creating the container shelf in which the insulation is contained. To increase the stiffness of the structure, a corner flap 9a, shown in Figs. 21 and 22, can also be bent on each corner of the container and then adhered by means of an adhesive to the wall of the container. In the case of a paper-based panel material, the adhesive can be applied to the paper after the forming process or could be integrated into the paper by means of a thermoplastic substrate. With the thermoplastic substrate case, the corner flap can be folded onto the container wall, and then a heating element applied to cause the thermoplastic layer of the corner flap to adhere to the thermoplastic layer of the container wall.

[0096] The insulation material 3a of Figs. 6 and 7 preferably has a low thermal conductivity. In a preferred embodiment, the material can be paper-derived, plastic, fiberglass, denim, or similar insulator. The insulation material can be of a loose fill, semisolid, or rigid type, but ultimately fills the volume of the panel container and creates the thermal barrier to minimize heat transfer from the payload to the ambient conditions outside of the device. Preferably, insulation material 3a is a loose fill cellulose based material, for example, including but not limited to shredded paper.

[0097] The process of assembling the inner shell sections is illustrated in more detail in Figs. 20 to 24. Tabs 6a are released and folded after the inner shell panel section 7 is formed in the paper forming process. This allows the various outer flaps 6b to be folded and/or glued in the assembly process.

[0098] Referring now to Figs. 21 and 22, the various outer flaps 6b of a typical inner shell panel 8 are illustrated. Tabs 9a are folded to add strength to the formed paper structure of inner shell section 8.

[0099] Figs. 23 and 24 illustrate the structure of two inner shell panel sections 10 and 1 1 as they are folded in the assembly process. Outer flaps 12 and 13 are visible but now the extra layer in the formed paper becomes visible as 14. This extra layer provides strength, rigidity and additional insulation capability for container 100. More specifically, the interior layer shown as chamfered edge 16 is disposed on top of the exterior layer 15, which bends to form the additional structure 14 to add this strength and rigidity. Further, an air chamber extends 15a is provided around a perimeter of each of said insulation- containing panels and is defined by side surfaces of abutting insulation-containing panels and outer shell when wall sections are folded into said operable position. Air chamber 15a operates as an insulation layer around the edges and corners of the box.

[0100] Referring to Figs. 25 and 26, an insert panel 20 is shown carrying a secondary insulation container 22 which is placed in the cargo receiving area of the box for providing layered insulation within the cargo receiving area. In the embodiment of Fig. 25, secondary insulation container 22 comprises one of insulation-containing panels with loose fill cellulose based insulation material 3a contained within an insulation cavity defined between insert panel 20 and an inner surface of insulation-containing panel 22. In an alternative embodiment shown in Fig. 26, secondary insulation container 22 comprises a bag containing loose fill cellulose based insulation material.

[0101] While the invention is shown with outer shell 1 forming a box structure ready for shipping, the container may optionally be used as an insert placed into another exterior shipping container.

[0102] Referring to Fig. 27, a chart shows the performance of a shipping container "tF" made according to the present invention. The container "tF" provides the same or better insulation over a period of 45 hours as compared to insulated shipping containers currently used on the mark that are not made exclusively from paper based materials to allow for a single channel 100% recycling. Accordingly, the present invention provides for a more efficient and environmentally responsible solution to insulated shipping containers without any sacrifice in performance.

[0103] Referring to Fig. 28, an alternative embodiment of the shipping container is shown with a different folding arrangement. In this instance, the insulation-containing panels of the inner shell are glued to selected portions of the outer shell wall sections as described herein above, but the wall sections interconnect with various tabs 24 received in complementary slots 26, as well as, interconnecting flaps 28 that do not require adhesive to maintain the operation position of the box structure. The completed folded shipping container is shown in Figs. 29a and 29b.

[0104] In the manufacturing of the container, the outer shell can be provided from sheets or rolled stock and cut and creased appropriately to define a bottom wall or side walls. The side walls can be cut from the stock so that they are connected to the bottom wall or an adjacent side wall. Creases for folding can be formed in the stock. The panels can be formed by molding pulp, fiber or sheets using a press mold or heated press mold that can result in a molded panel. The mold can include a design that can be imprinted in the panel. Insulation material can be placed in a panel and the panel affixed to a portion of the outer shell. The insulation material can be loose, matted or other form. The manufacturing process can include a manufacturing machine that can perform these steps in parallel or series resulting the insulated shipping container. The outer shell, panels and insulation can be made from recycled paper or other cellulose material.

[0105] The panel can be formed from compression molding where the molding material can be preheated and placed in an open heated mold cavity having a mold with one or more mold surfaces. The mold is closed and pressure applied to force the molding material into contact with all mold areas. Heat and pressure are maintained until the molding material is partially or completely cured. The panel can be coated with a water resistance material in some embodiments.

[0106] While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.

Claims

What is claimed is:

1 . An insulated shipping container comprising:

an outer shell defined by a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position;

an inner shell defined by a series of insulation-containing panels carried by selected said wall sections, wherein at least one of said insulation-containing panels is carried on a selected said wall section and defines an enclosed insulation cavity between said wall section of said outer shell and an interior side of said insulation-containing panels; wherein said insulation-containing panels carried on at least said bottom wall and side walls abut each other to defining a cargo receiving area when said wall sections are folded into said operable position;

an insulation material defining an insulated liner disposed in said insulation cavity that extends directly between said outer shell and an interior side of said inner shell; wherein said outer shell, said inner shell and said insulated liner are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.

2. The insulated shipping container of claim 1 wherein said foldable interconnected wall sections include a top wall defining a lid section that encloses said cargo receiving area when folded into said operable position.

3. The insulated shipping container of claim 1 including a detached lid section mounted to said side walls; wherein said lid section encloses said cargo receiving area when said foldable interconnected wall sections are folded into said operable position.

4. The insulated shipping container of claim 1 including a lid section having at least one said insulation-containing panel that abuts said insulation-containing panels carried by said side walls for enclosing said cargo receiving area.

5. The insulated shipping container of claim 4 wherein said plurality of insulation-containing panels define a uniform insulation cavity so that a uniform insulation thickness of said insulated liner is formed among said wall sections and said lid section.

6. The insulated shipping container of claim 1 wherein each of said insulation- containing panels includes a chamfered surface that abuts a complementary chamfered surface of an adjacent said insulation-containing panel when said wall sections are folded into said operable position.

7. The insulated shipping container of claim 6 wherein said chamfered surfaces are formed at approximately a 45° angle along a perimeter edge portion of each said insulation-containing panels.

8. The insulated shipping container of claim 7 wherein said chamfered surfaces on adjacent insulation-containing panels abut when a given said wall section is folded to approximately 90° relative to adjacent wall sections.

9. The insulated shipping container of claim 6 including an adhesive disposed along said chamfered surface of said insulation-containing panels, wherein said adhesive interlocks and seals together abutting said insulation-containing panels when said wall sections are folded into said operable position so that said cargo receiving area is sealed to resist air movement between abutting insulation-containing panels.

10. The insulated shipping container of claim 1 wherein said outer shell is comprised of a corrugated paperboard.

1 1 . The insulated shipping container of claim 1 wherein said inner shell is comprised of a rigid or semi-rigid paper based material.

12. The insulated shipping container of claim 1 1 wherein said inner shell is comprised of food grade based paper material.

13. The insulated shipping container of claim 1 wherein said insulated liner comprises a loose fill cellulose based insulation material.

14. The insulated shipping container of claim 13 wherein said loose fill cellulose based insulation material comprises shredded paper.

15. The insulated shipping container of claim 1 wherein an air chamber extends around a perimeter of each of said insulation-containing panels and is defined by side surfaces of abutting said insulation-containing panels and said outer shell when said wall sections are folded into said operable position.

16. The insulated shipping container of claim 1 including an insert panel carrying a secondary insulation container disposed in said cargo receiving area for providing layered insulation within said cargo receiving area.

17. The insulated shipping container of claim 16 wherein said secondary insulation container comprises one of said insulation-containing panels with loose fill cellulose based insulation material contained within an insulation cavity defined between said insert panel and an inner surface of said insulation-containing panel.

18. The insulated shipping container of claim 16 wherein said secondary insulation container comprises a bag containing loose fill cellulose based insulation material.

19. A method of forming an insulated shipping container, said method comprising the steps of:

providing an outer shell having a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position;

mounting a series of insulation-containing panels to selected said wall sections to form an inner shell;

inserting an insulation material into an insulation cavity disposed between said outer shell and an interior side of said inner shell;

wherein said outer shell, said inner shell and said insulation material are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.

20. The method of claim 19 including the step folding said outer shell so that said insulation-containing panels carried on said wall sections abut each other to define a cargo receiving area when said wall sections are folded into said operable position.