Insulated packaging systems and related methods

Abstract

An insulated packaging system includes a container having an interior surface defining an interior volume; and a liner disposed within the interior volume and at least partially defining a compartment configured to receive articles for adiabatic transportation. The liner includes a first sleeve made of a cellulosic material and at least partially defines a channel. The first sleeve has an outer wall disposed adjacent to the container and an opposite inner wall disposed adjacent to the compartment configured to receive the article for transport, the channel disposed between the inner wall and the outer wall. At least one insulating sheet is disposed within the channel of the first sleeve, the at least one insulating sheet being made of a cellulosic material and forming a plurality of recesses thereon.

Description

[0001] This application is a divisional application of the patent application filed on November 1, 2019, with application number 201980076610.0 (international application number PCT / US2019 / 059539) and title "Insulated Packaging System and Related Method". Technical Field

[0002] This disclosure relates to an insulated packaging system with improved insulation capabilities for transport, and related methods. Background Technology

[0003] To facilitate and extend the shelf life of some perishable products from manufacturing to distribution, a temperature-controlled supply chain (sometimes referred to as the cold chain) is often required. For example, an uninterrupted cold chain typically involves a series of continuous storage and distribution activities that maintain the product's environment within a desired, relatively low temperature range at all times. Therefore, the packaging used in cold chain transportation must frequently maintain the product's environment within the desired, relatively low temperature range for extended periods, thereby ensuring that the product's temperature remains within the appropriate range throughout the entire duration of the cold chain, from manufacturing to final use.

[0004] Products requiring cold chain transport are typically cooled before shipment, placed in thermal insulation material, and then transported with only a small amount of ice or refrigerant to absorb heat flowing into the packaging from the external environment through the insulation. Molded expanded polystyrene (“EPS”) containers have been used as thermal insulation for cold chain transport for many years. For example, perishable goods are often placed inside EPS containers (i.e., coolers) before being placed inside cardboard shipping boxes.

[0005] While EPS containers offer satisfactory insulation and are generally lightweight, they also present several challenges. For instance, EPS is a "foamed" incompressible material composed of numerous small air bubbles formed within a polystyrene matrix. Consequently, EPS exhibits poor volumetric efficiency, potentially leading to increased transportation costs when delivering empty containers to the point of use, increased warehousing costs when storing containers before use, and higher transportation costs due to the need for containers that are often larger than required to hold the product. Furthermore, it necessitates the use of more coolant.

[0006] Growing environmental concerns, including those regarding global warming and excessive packaging waste, have also raised various environmental concerns about EPS containers. EPS has poor volumetric efficiency, leading to an increase in container waste requiring recycling and / or disposal. Furthermore, EPS is not currently widely recyclable in all recycling facilities.

[0007] Therefore, various “green” or environmentally friendly packaging insulations have been developed for cold chain transportation applications, using inflated, foamed cornstarch or recycled EPS foam. However, such “green” options generally still lack satisfactory volumetric efficiency (i.e., product size to package size) and feasible (i.e., simple) recycling options. To replace traditional EPS and other insulating packaging materials, it is therefore desirable to provide insulating packaging materials that are not only made from renewable resources but also offer satisfactory insulation quality and volumetric efficiency. It is also desirable to provide an insulating packaging material that offers relatively simple recycling options using existing recycling infrastructure. Summary of the Invention

[0008] In a first independent aspect of this disclosure, an insulated packaging system comprises:

[0009] A container having an internal surface defining an internal volume; and

[0010] A liner, disposed within the internal volume of the container and at least partially defining a compartment configured to house articles for transport, the liner comprising:

[0011] A first sleeve, comprising a first cellulose material and at least partially defining a channel, the first sleeve having an outer wall disposed toward the container and an opposite inner wall disposed toward the compartment configured to receive the articles for transport, the channel being disposed between the inner wall and the outer wall; and

[0012] At least one insulating sheet is disposed within the channel of the first sleeve, the at least one insulating sheet comprising a second cellulose material and having a plurality of recesses formed thereon.

[0013] In one embodiment, the thickness of the cellulose material in the first sleeve ranges from about 0.8 mm to about 4.8 mm.

[0014] In another embodiment, the cellulose material of the first sleeve comprises a folded sheet of cardboard.

[0015] In another embodiment, the cardboard sheet is selected from corrugated, flat, and combinations thereof.

[0016] In another embodiment, the thickness of the cardboard sheet ranges from about 0.8 mm to about 4.8 mm.

[0017] In another embodiment, the cardboard sheet is more rigid than the at least one insulating sheet.

[0018] In another embodiment, the thickness of the cardboard sheet is greater than the thickness of the at least one insulating sheet.

[0019] In another embodiment, the cardboard sheet is not as rigid as the at least one insulating sheet.

[0020] In another embodiment, the cardboard includes a splice and a slot, the splice being received within the slot to secure the cardboard in a continuous loop surrounding the channel.

[0021] In another embodiment, the cardboard includes a plurality of spaced-apart tabs and a plurality of spaced-apart slots, the plurality of tabs being received within the plurality of slots to secure the cardboard in a continuous loop surrounding the channel.

[0022] Another embodiment further includes:

[0023] The first sleeve, the first sleeve having an end face with an opening communicating with the channel; and

[0024] A cover plate protruding from the end face of the first sleeve, the cover plate being folded to at least partially cover the opening.

[0025] In another embodiment, the folded cover plate sits directly against the inner surface of the container.

[0026] In another embodiment, the outer wall of the first sleeve is disposed directly against the inner surface of the container, and the inner wall of the first sleeve at least partially defines the compartment.

[0027] In another embodiment, the first sleeve disposed within the internal volume of the container has a U-shaped configuration.

[0028] In another embodiment, the channel of the first sleeve has a rectangular transverse cross-section.

[0029] In another embodiment, the lining further comprises:

[0030] A second sleeve, at least partially defining a channel, having an outer wall facing the container and an opposite inner wall facing the compartment configured to receive the articles for transport, the channel of the second sleeve being disposed between the inner wall and the outer wall of the second sleeve, the second sleeve being separate and discrete from the first sleeve and positioned such that the compartment is at least partially disposed between the first sleeve and the second sleeve; and

[0031] At least one insulating sheet is disposed within the channel of the second sleeve, the at least one insulating sheet comprising a cellulose material and having a plurality of recesses formed thereon.

[0032] Another embodiment further includes a first locking tab protruding from the first sleeve and a first locking slot formed on the second sleeve, the first locking tab being received within the first locking slot to secure the first sleeve to the second sleeve.

[0033] In another embodiment, the first sleeve has a U-shaped configuration and the second sleeve has a U-shaped configuration.

[0034] Another embodiment further includes:

[0035] The second sleeve has a first end face with an opening communicating with the channel;

[0036] A first cover plate protrudes from the first end face of the second sleeve;

[0037] A first locking tab protrudes from the first cover tab;

[0038] A first locking slot is formed on the second sleeve, and a first locking tab is housed within the first locking slot to secure the first sleeve to the second sleeve.

[0039] Another embodiment further includes:

[0040] The second sleeve has a second end face opposite to the first end face, having an opening communicating with the channel;

[0041] The second cover plate protrudes from the second end face of the second sleeve;

[0042] The second locking tab protrudes from the second cover tab;

[0043] A second locking slot is formed on the second sleeve, and a second locking tab is housed within the second locking slot to secure the first sleeve to the second sleeve.

[0044] In another embodiment, the first sleeve has a first sidewall and an opposite second sidewall extending between the outer wall and the inner wall, the first locking slot being formed on the first sidewall and the second locking slot being formed on the second sidewall.

[0045] Another embodiment further includes:

[0046] The first sleeve has an inner surface and an opposite outer surface;

[0047] A water-impermeable coating is applied to at least the inner surface or the outer surface of the first sleeve.

[0048] In another embodiment, the coating comprises plastic.

[0049] In another embodiment, the coating comprises polyethylene (PE), polylactide (PLA), a biodegradable polymer, or a combination thereof.

[0050] In another embodiment, the at least one insulating sheet is folded at least once.

[0051] In another embodiment, the at least one insulating sheet comprises a plurality of separate sheets of paper stacked together, each sheet of paper containing a cellulose material and having a plurality of recesses formed thereon.

[0052] In another embodiment, multiple stacked separate sheets of paper are folded twice to form a trifold.

[0053] In another embodiment, the plurality of separate sheets of paper includes at least 3, 5, 10, 15, 20, 25, or 30 sheets of paper.

[0054] In another embodiment, the plurality of separate sheets of paper are folded such that there are at least 5, 10, 15, 20, 25 or 30 vertically stacked layers of the plurality of separate sheets of paper.

[0055] Another embodiment further includes:

[0056] A first flat sheet, the first flat sheet having a top surface and an opposite bottom surface; and

[0057] A first embossed sheet has a top surface, an opposite bottom surface, and a plurality of spaced-apart first embosses, each first embossing protruding outward from the top surface and terminating at an end point and defining an openly exposed recess on the bottom surface, the end points of the first embosses being fixed to the bottom surface of the first flat sheet by an adhesive.

[0058] Another embodiment further includes:

[0059] A second flat sheet, the second flat sheet having a top surface and an opposite bottom surface; and

[0060] The first embossed sheet further includes a plurality of spaced-apart second embossings, each second embossing protruding outward from the bottom surface and terminating at an end point and defining an openly exposed recess on the top surface, the end points of the second embossings being fixed to the top surface of the second flat sheet by an adhesive, such that the first embossed sheet is disposed between the first flat sheet and the second flat sheet.

[0061] Another embodiment further includes a second embossed sheet having a plurality of outwardly projecting embossings, the embossings of the second embossed sheet being fixed to the top surface of the first flat sheet by an adhesive.

[0062] In another embodiment, the at least one insulating sheet comprises a sheet of paper with a thickness ranging from about 0.15 mm to about 0.4 mm.

[0063] In another embodiment, the at least one insulating sheet comprises a cellulose filler.

[0064] In another embodiment, the at least one insulating sheet comprises an embossed sheet of paper.

[0065] In another embodiment, the at least one insulating sheet includes a plurality of vertically stacked insulating sheets, with a plurality of holes defined between the plurality of vertically stacked insulating sheets.

[0066] In another embodiment, the lining extends over the inner surface of the container to enclose the compartment configured to receive the articles for transport.

[0067] In another embodiment, the thickness of the lining is at least 0.5 cm, 1 cm, or 1.5 cm.

[0068] In another embodiment, the insulation class (R value) of the lining, measured at an average temperature of 75°F, ranges from about 3.5 / inch to about 4.5 / inch.

[0069] In another embodiment, the container includes a box and contains cellulose material.

[0070] In another embodiment, the cellulose material of the container includes cardboard.

[0071] In another embodiment, the paperboard includes corrugated paperboard.

[0072] Another embodiment further includes:

[0073] The container, having an inner surface and an opposite outer surface; and

[0074] A coating of a water-impermeable material, said water-impermeable material coating being applied to at least the inner surface or the outer surface of the container.

[0075] In another embodiment, the coating comprises plastic.

[0076] In another embodiment, the coating comprises polyethylene (PE), polylactide (PLA), a biodegradable polymer, or a combination thereof.

[0077] In another embodiment, the container and the liner do not include expanded polystyrene or non-biodegradable plastics.

[0078] In another embodiment, the cold source is placed within the internal volume.

[0079] In another embodiment, the cold source includes dry ice.

[0080] In another embodiment, the cold source includes at least one cryogel pack.

[0081] In another embodiment, the cold source is placed in the compartment configured to house the articles for transport and is surrounded by the lining.

[0082] In another embodiment, the cold source includes the articles used for transportation.

[0083] In another embodiment, the cold source is configured to cool at least a portion of the compartment to a temperature below 11°C prior to transport.

[0084] Another embodiment further includes the article for transport, which is disposed within the internal volume.

[0085] In another embodiment, the cold source is positioned above and below the articles used for transportation.

[0086] In another embodiment, the cold source completely surrounds the article used for transportation.

[0087] In another embodiment, the articles for transport include biological materials.

[0088] In another embodiment, the first cellulose material of the first sleeve and the second cellulose material of the at least one insulating sheet may comprise the same cellulose material or different cellulose materials.

[0089] In another embodiment, the lining surrounds the compartment for receiving the items to be transported.

[0090] Another embodiment further includes:

[0091] A first sidewall and an opposite second sidewall, each extending between the outer wall and the inner wall; and

[0092] A first slot and a spaced-apart second slot pass through the inner wall to communicate with the channel and extend between the first sidewall and the second sidewall.

[0093] Another embodiment further includes:

[0094] A first V-shaped groove extends through the first sidewall and intersects with the first slot; and

[0095] The second V-shaped groove extends through the first sidewall and intersects with the second slot.

[0096] The second independent aspect of this disclosure includes:

[0097] A liner is positioned along the inner surface of the container such that the liner at least partially defines a compartment within the container, the liner comprising:

[0098] A first sleeve, comprising a first cellulose material and at least partially defining a channel, the first sleeve having, when positioned within the container, an outer wall facing the container and an opposite inner wall facing the compartment, the channel being disposed between the inner wall and the outer wall; and

[0099] At least one insulating sheet is disposed within the channel of the first sleeve, the at least one insulating sheet comprising a second cellulose material and having a plurality of recesses formed thereon;

[0100] The cold source is placed inside the container; and

[0101] The items intended for transport are placed in the compartments within the container.

[0102] The lining therein insulates the articles intended for transport during transport.

[0103] In one embodiment, the liner is removably disposed within the container.

[0104] In another embodiment, when positioned within the container, the first sleeve has a U-shaped configuration.

[0105] Another embodiment further includes:

[0106] A second sleeve, the second sleeve comprising cellulose material and at least partially defining a channel; and

[0107] At least one insulating sheet is disposed within the channel of the second sleeve, the at least one insulating sheet comprising a cellulose material and having a plurality of recesses formed thereon.

[0108] When positioned within the container, the second sleeve has a U-shaped configuration.

[0109] Another embodiment further includes inserting a locking tab protruding from the second sleeve into a locking slot formed on the second sleeve to couple the second sleeve to the first sleeve.

[0110] Another embodiment further includes biological materials.

[0111] In another embodiment, the first sleeve comprises a folded piece of cardboard.

[0112] In another embodiment, the cardboard sheet is more rigid than the at least one insulating sheet.

[0113] In another embodiment, the cardboard sheet is not as rigid as the at least one insulating sheet.

[0114] In another embodiment, the channel of the first sleeve has a rectangular transverse cross-section.

[0115] In another embodiment, the at least one insulating sheet comprises a plurality of separate sheets of paper stacked together, each sheet of paper containing a cellulose material and having a plurality of recesses formed thereon.

[0116] In another embodiment, multiple stacked, separate sheets of paper are folded.

[0117] In another embodiment, the plurality of separate sheets of paper includes at least 3, 5, 10, 15, 20, 25, or 30 sheets of paper.

[0118] In another embodiment, the at least one insulating sheet comprises a sheet of embossed cellulose filler.

[0119] In another embodiment, the container includes a cardboard box.

[0120] In another embodiment, the cold source includes dry ice.

[0121] In another embodiment, the cold source includes at least one cryogel pack.

[0122] In another embodiment, the insulation class (R value) of the lining, measured at an average temperature of 75°F, ranges from about 3.5 / inch to about 4.5 / inch.

[0123] The third independent aspect of this disclosure includes:

[0124] A cardboard sheet is folded around a plurality of insulating sheets such that the cardboard sheet surrounds the plurality of insulating sheets, and the cardboard sheet and the plurality of insulating sheets are combined to form a first lining portion; and

[0125] The first lining portion is positioned within the internal volume of the container.

[0126] One embodiment further includes inserting a tab of the cardboard sheet into a slot in the cardboard sheet to form a continuous loop surrounding the plurality of insulating sheets.

[0127] In another embodiment, each of the plurality of insulating sheets is held together by an adhesive.

[0128] In another embodiment, some of the plurality of insulating sheets are flat, while the others are embossed.

[0129] In another embodiment, the plurality of insulating sheets comprise multiple stacked sheets of paper not held together by adhesive, each sheet containing a cellulose material and having multiple recesses formed thereon.

[0130] In another embodiment, the plurality of insulating sheets comprises at least 3, 5, 10, 15, 20, 25, or 30 sheets of paper.

[0131] Another embodiment further includes folding the plurality of insulating sheets before folding the cardboard sheet around the plurality of insulating sheets.

[0132] In another embodiment, the cardboard sheet is folded to form a rectangular channel in which the plurality of insulating sheets are disposed.

[0133] In another embodiment, the first liner disposed within the internal volume of the container has a U-shaped configuration.

[0134] In another embodiment, the cardboard sheet is selected from corrugated, flat, and combinations thereof.

[0135] In another embodiment, the thickness of the cardboard sheet ranges from about 0.8 mm to about 4.8 mm.

[0136] In another embodiment, the cardboard sheet is more rigid than the plurality of insulating sheets.

[0137] Another embodiment further includes a water-impermeable material coating applied to at least the inner or outer surface of the cardboard.

[0138] In another embodiment, the coating comprises plastic.

[0139] In another embodiment, the coating comprises polyethylene (PE), polylactide (PLA), a biodegradable polymer, or a combination thereof.

[0140] In another embodiment, the insulation class (R value) of the first lining, measured at an average temperature of 75°F, ranges from about 3.5 / inch to about 4.5 / inch.

[0141] The fourth independent aspect of this disclosure includes:

[0142] A container having an internal surface defining an internal volume; and

[0143] A liner, which is disposed within the internal volume of the container and surrounds a compartment configured to house articles for transport, the liner including a first liner portion comprising a plurality of stacked insulating sheets held together by an adhesive, some of the stacked insulating sheets being flat while others being embossed, each of the stacked insulating sheets comprising a cellulose material.

[0144] Another embodiment further includes the plurality of stacked insulating sheets comprising the first liner portion thereof:

[0145] A first flat sheet, the first flat sheet having a top surface and an opposite bottom surface; and

[0146] A first embossed sheet has a top surface, an opposite bottom surface, and a plurality of spaced-apart first embosses, each first embossing protruding outward from the top surface and terminating at an end point and defining an openly exposed recess on the bottom surface, the end points of the first embosses being secured to the bottom surface of the first flat sheet by the adhesive.

[0147] In another embodiment, the plurality of stacked insulating sheets of the first liner portion further include:

[0148] A second flat sheet, the second flat sheet having a top surface and an opposite bottom surface; and

[0149] The first embossed sheet further includes a plurality of spaced-apart second embossings, each second embossing protruding outward from the bottom surface and terminating at an end point and defining an openly exposed recess on the top surface, the end points of the second embossings being secured to the top surface of the second flat sheet by the adhesive, such that the first embossed sheet is disposed between the first flat sheet and the second flat sheet.

[0150] Another embodiment further includes a second embossed sheet having a plurality of outwardly projecting embossings, the embossings of the second embossed sheet being fixed to the top surface of the first flat sheet by the adhesive.

[0151] In another embodiment, the plurality of stacked insulating sheets are not surrounded by a single cardboard sheet.

[0152] In another embodiment, the first lining portion has a U-shaped configuration.

[0153] In another embodiment, the lining includes a second lining portion comprising a plurality of stacked insulating sheets held together by an adhesive, some of which are flat while others are embossed, each of which comprises a cellulose material, and the second lining portion having a U-shaped configuration.

[0154] The fifth independent aspect of this disclosure includes:

[0155] A liner is positioned along the inner surface of the container such that the liner at least partially defines a compartment within the container. The liner includes a first liner portion comprising a plurality of stacked insulating sheets held together by an adhesive. Some of the stacked insulating sheets are flat, while others are embossed. Each of the stacked insulating sheets comprises a cellulose material.

[0156] The cold source is placed inside the container; and

[0157] The items intended for transport are placed in the compartments within the container.

[0158] The lining therein insulates the articles intended for transport during transport.

[0159] In one embodiment, the first lining portion has a U-shaped configuration.

[0160] In another embodiment, the lining includes a second lining portion comprising a plurality of stacked insulating sheets held together by an adhesive, some of which are flat while others are embossed, each of which comprises a cellulose material, and the second lining portion having a U-shaped configuration.

[0161] Each of the above independent aspects of this disclosure may further include any of the features, options, and possibilities set forth elsewhere in this document, including the features and options set forth below each of the above independent aspects. Attached Figure Description

[0162] Various embodiments of the present disclosure will now be discussed with reference to the accompanying drawings. It should be understood that these drawings depict only typical embodiments of the present disclosure and should therefore not be considered as limiting its scope.

[0163] Figure 1 It is a partial exploded perspective view of the packaging system, including the container and the lining for the container;

[0164] Figure 2 yes Figure 1 A perspective view of one of the lining sections shown, laid flat;

[0165] Figure 3 yes Figure 2 An exploded perspective view of the lining portion shown.

[0166] Figure 4A yes Figure 3 A cross-sectional view of the insulating sheet of the lining portion shown;

[0167] Figure 4B yes Figure 4A A cross-sectional view of an alternative arrangement in which the insulating sheet is folded, as shown;

[0168] Figure 4C yes Figure 4A The cross-sectional view shown is of an alternative arrangement in which the insulating sheet is folded into three folds;

[0169] Figure 5A yes Figure 3 The image shown is a top plan view of one of the insulating sheets having a recess formed thereon.

[0170] Figure 5B It is a top plan view of an alternative insulating sheet with a circular recess on it;

[0171] Figure 5C It is a top plan view of an alternative insulating sheet with rectangular recesses formed thereon;

[0172] Figure 5D It is a top plan view of the alternative insulating sheet with Z-shaped recesses formed on it;

[0173] Figure 5E It is a top plan view of the alternative insulating sheet with triangular recesses formed on it;

[0174] Figure 6It is a cross-sectional view of multiple stacked insulating sheets that form cavities in between;

[0175] Figure 7 yes Figure 1 A perspective view of the assembled lining portion shown;

[0176] Figure 8 yes Figure 1 A perspective view showing the first lining portion inserted into the container;

[0177] Figure 9 yes Figure 8 A perspective view of the assembly in which the second lining portion is housed;

[0178] Figure 10 yes Figure 1 The image shows a cross-sectional side view of an assembly and packaging system that houses a cold source and items for transport.

[0179] Figure 11 It is a schematic diagram of an item for transport, including an inner container and an outer container;

[0180] Figure 12 yes Figure 10 The illustrated alternative embodiment of a packaging system in which the filler occupies a portion of one of the compartments;

[0181] Figure 13 yes Figure 1 Exploded perspective view of an alternative embodiment of the lining shown;

[0182] Figure 14 This is a partial exploded perspective view of an alternative embodiment of a packaging system using an improved lining portion;

[0183] Figure 15 yes Figure 14 A perspective view of one of the lining sections shown, laid flat;

[0184] Figure 16 yes Figure 15 An exploded perspective view of the lining portion shown.

[0185] Figure 17 yes Figure 14 A perspective view of another lining portion of the lining shown, laid flat;

[0186] Figure 18 yes Figure 17 An exploded perspective view of the lining portion shown.

[0187] Figure 19 yes Figure 14 A perspective view of the two lining sections coupled together;

[0188] Figure 20yes Figure 19 The placement shown is in Figure 14 A perspective view of the coupled lining portion inside the container;

[0189] Figure 21 This is a perspective view of the improved insulating sheet used for the lining;

[0190] Figure 22 yes Figure 21 An exploded view of the insulating sheet shown;

[0191] Figure 23 yes Figure 21 The side front view of the insulating sheet shown;

[0192] Figure 24 It is a graph comparing tests of four different packaging systems;

[0193] Figure 25 Is using Figure 21 Partial exploded perspective view of an alternative embodiment of a packaging system for insulating sheets without sleeves; and

[0194] Figure 26 yes Figure 25 The diagram shows a perspective view of the assembled insulating sheet. Detailed Implementation

[0195] Before describing this disclosure in detail, it should be understood that this disclosure is not limited to the specifically illustrated, varied structures, systems, methods, or process parameters. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments of this disclosure only and is not intended to limit the scope of this disclosure in any way.

[0196] All publications, patents and patent applications cited in this article, whether above or below, are hereby incorporated in their entirety by reference as if each individual publication, patent or patent application were explicitly and individually identified as incorporated by reference.

[0197] The term “comprising,” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional unlisted elements or method steps.

[0198] It should be noted that, as used in this specification and the appended claims, the singular forms “a / an” and “the” include plural references unless the content clearly indicates otherwise. Thus, for example, a reference to a “sheet” includes one, two, or more sheets.

[0199] As used in the specification and appended claims, directional terms such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” “upper part,” “lower part,” “near side,” “far side,” etc., are used only to indicate relative directions and are not intended to otherwise limit the scope of this disclosure or the claims.

[0200] Where possible, similar element numbering is used in multiple different figures. Furthermore, multiple instances of an element and / or a sub-element of a parent element may each include a separate letter appended to the element number. For example, two instances of a specific element "10" may be labeled "10A" and "10B". In such cases, an element designation without the appended letter (e.g., "10") may be used to generally refer to the element or an instance of any of these elements. An element designation including the appended letter (e.g., "10A") may be used to refer to a specific instance of the element or to distinguish or emphasize multiple uses of the element. Additionally, an element designation with the appended letter may be used to refer to alternative designs, structures, functions, embodiments, and / or examples of elements or features without the appended letter. Similarly, an element designation with the appended letter may be used to represent a sub-element of a parent element. For example, element "12" may include sub-elements "12A" and "12B".

[0201] Various aspects of the apparatus and system of the present invention can be illustrated by describing multiple components that are coupled, attached, and / or combined. As used herein, the terms “coupled,” “attached,” and / or “combined” are used to indicate a direct connection between two components, or, where appropriate, an indirect connection to each other via an intervening or intermediate component. In contrast, when a component is referred to as “directly coupled,” “directly attached,” and / or “directly combined” to another component, no intervening element is present. Furthermore, as used herein, the terms “connected,” “linked,” etc., do not necessarily imply direct contact between the two or more components.

[0202] Various aspects of the apparatus, system, and method of the present invention may be illustrated with reference to one or more exemplary embodiments. As used herein, the term "embodiment" means "serving as an example or instance" or "illustration" and should not necessarily be construed as being preferred or advantageous over other embodiments disclosed herein.

[0203] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. While various methods and materials similar to or equivalent to those described herein may be used in practice with respect to this disclosure, preferred materials and methods are described herein.

[0204] Generally, this disclosure relates to insulated packaging systems and related manufacturing methods and uses for perishable materials, such as biological materials, food, pharmaceuticals, and chemicals, that require transport at controlled temperatures to maintain their viability or usability. Such packaging systems can be used as part of a cold chain transportation process.

[0205] exist Figure 1 An embodiment of an insulated packaging system 10 is depicted, the insulated packaging system comprising a container 12 and a liner 14A designed to be housed within the container 12. As discussed in more detail below, the packaging system 10 may further include a cold source and articles for transport, which may also be positioned within the container 12.

[0206] Container 12 has an outer surface 18 and an inner surface 20. The inner surface 20 defines an internal volume 22. In the depicted embodiment, container 12 is a square or rectangular box or cube having a surrounding side wall 24 extending between a top wall 26 and an opposite bottom wall 28. The surrounding side wall 24 may include a front wall 30 and an opposite rear wall 32, which are arranged in a parallel alignment and extend between opposite side walls 34 and 36. Side walls 34 and 36 are also arranged in a parallel alignment. Each of the walls may be square or rectangular. As depicted, the top wall 26 may include a plurality of panels 38A, 38B, 38C, and 38D, which are hinged to the upper ends of walls 30, 32, 34, and 36 by means of a hinge such as a movable hinge. Panels 38 may be folded outward, such as... Figure 1 As shown, a top passage 40 is opened to access the internal volume 22. Panel 38 can also fold inward to cover and close the internal volume 22. The bottom wall 32 may also contain multiple panels that are hinged to the lower ends of walls 30, 32, 34 and 36 and can operate in the same manner as panel 38.

[0207] In other embodiments, the configuration of container 12 may differ. For example, the surrounding sidewall 24 of container 12 need not have a square or rectangular cross-section, but may be circular, elliptical, or have a cross-section of other polygons extending between the top wall and the opposite bottom wall. Other shapes and configurations may also be used.

[0208] The size of container 12, and therefore the size of its internal volume 22, can vary in part depending on the size of the items to be transported and the duration in which the items need to be kept cool. In some embodiments, the size of container 12 can be set such that the volume of internal volume 22 is at least or less than 1,500 cm³. 3 3,000cm 3 8,000cm 3 0.027m 3 0.125m3 Or within a range of any two of the above values. Other volumes may also be used.

[0209] Container 12 typically comprises one or more flexible sheets containing cellulosic materials such as wood, cotton, cloth, and / or recycled paper. More typically, container 12 comprises one or more sheets of paper, such as cardboard. The cardboard can be flat (i.e., without corrugations), corrugated, or a combination thereof. Cardboard typically includes hardboard such as corrugated cardboard. Therefore, container 12 can comprise a conventional cardboard box. The flexible or hardboard used to form container 12 is typically foldable and has a thickness ranging from 0.8 mm to 5 mm, and more typically from 0.8 mm to 3 mm or from 1 mm to 3 mm.

[0210] To help improve the insulation of container 12, a water-impermeable coating may be applied to the outer surface 18 and / or the inner surface 20. The coating may be plastic. Preferably, the coating is a biodegradable material, such as a biodegradable polymer, for example, polyethylene (PE) or polylactide (PLA). The coating may be applied by spraying, spraying, printing, or other means during or after the formation of the sheet used to form container 12. The coating may also be applied during or after the formation of container 12.

[0211] exist Figure 1 In the depicted embodiment, lining 14A includes a first lining portion 50A and a second lining portion 50B, both of which can be selectively folded into a U-shaped configuration. Go to Figure 2 The lining portion 50A is unfolded into a flat configuration. Typically, the lining portion 50A includes a tubular sleeve 52A defining a channel 54A extending along its length. In the depicted embodiment, the channel 54A has a rectangular cross-section. One or more insulating sheets 56A are disposed within the channel 54A. More specifically, the tubular sleeve 52A includes an outer wall 58A and an opposite inner wall 60A, both extending longitudinally between a first end 62A and an opposite second end 64A, and laterally between a first sidewall 66A and an opposite second sidewall 68A. The channel 54A is defined between the inner surfaces of the outer wall 58A and the inner wall 60A, and between the inner surfaces of the sidewalls 66A and 68A. The thickness of the lining portion 50A is T1, extending between the outer walls 58A and the outer surfaces of the inner walls 60A, typically at least or less than 0.5 cm, 1 cm, 1.5 cm, 2 cm, or 3 cm, or within any two of the above values. As discussed in more detail below, the length and width of the lining portion 50A may depend on the size of the container 12.

[0212] Similarly, Figure 2As shown, a pair of spaced-apart slots 70A and 72A pass through the inner wall 60A to reach the channel 54A and extend between side walls 66A and 68A. Extending through the first side wall 66A to communicate with the channel 54A and intersecting with slots 70A and 70B are V-shaped slots 74A and 76A, respectively. Similarly, V-shaped slots 75A and 77A (… Figure 3 It extends through the second sidewall 68A to communicate with the channel 54A and intersect with the slots 70A and 72A. The slots and notches allow the first lining portion 50A to be easily... Figure 2 The flat configuration shown is Figure 1 The U-shaped configuration shown is folded and unfolded to maximize the insulation capability of the lining portion 50A. For example, when the lining portion 50A is folded into a U-shaped configuration, the opposite edges of each slot and the opposite edges of each opening mate together or are positioned close to each other. Therefore, the inner corners of the lining portion 50A are defined on opposite sides by the outer wall 58 and the inner wall 60, as well as the opposite side walls 66 and 68. Thus, the insulation capability of the lining portion 50A at the inner corners is the same as or substantially the same as the insulation capability of the surfaces of the lining portion 50A spaced apart from the inner corners. In other embodiments, the slots and / or openings may be covered by a flexible sheet or film, or they may be eliminated, and the material at those locations may be pleated or otherwise processed or treated to allow for easy bending while still helping to maintain insulation capability.

[0213] The tubular sleeve 52A is typically made of a flexible / foldable sheet of material, which is cut or otherwise formed into a blank 80, such as... Figure 3 As shown, it is then folded and secured into sleeve 52A. As discussed above, the sheet of material used to form sleeve 52A can be any material that is the same as the material used to form container 12. For example, sleeve 52A is typically made of a sheet containing cellulose material and typically includes a sheet of paper such as cardboard. The cardboard can be flat or corrugated and typically includes cardboard or corrugated cardboard. The thickness and composition of the sheet forming sleeve 52A can also be the same as discussed above regarding the sheet used to form container 12.

[0214] Fold lines 82 may be formed on the blank 80 before or after it is folded into the desired configuration. Specifically, fold lines 82A1 are formed at the intersection between the inner wall 60A and the second side wall 68A, fold lines 82A2 are formed at the intersection between the outer wall 58A and the second side wall 68A, fold lines 82A3 are formed at the intersection between the outer wall 58A and the first side wall 66A, and fold lines 82A4 are formed at the intersection between the first side wall 66A and the tab 78A protruding from the first side wall 66A. Fold lines 82 can be formed by pressing or compressing sheets together along the fold lines, or by using other conventional techniques used in forming fold lines in blanks for conventional cardboard boxes. When the blank 80 is folded into the desired configuration for the sleeve 52A, the sleeve 52A can be secured in the tubular configuration using tape, adhesive, or locking structures. Figure 3 In the depicted embodiment, a tab 78A is formed protruding from the edge of the sidewall 66A. When the blank 80 is folded into the sleeve 52A, the tab 78A can be positioned above or below the inner wall 60A. An adhesive can be applied to the tab 78A to permanently secure the sidewall 66A to the inner wall 60A, thereby securing the sleeve 52A in a continuous loop.

[0215] Similar to container 12, to help improve the insulation capability of sleeve 52A, a water-impermeable coating may be applied to the outer and / or inner surfaces of the blank 80 or the formed sleeve 52A. In other words, the coating may be sprayed, sprayed, printed, or otherwise applied during or after the formation of blank 80. The coating may also be applied during or after the formation of sleeve 52A. The coating may include plastics and is typically a biodegradable material, such as a biodegradable polymer, for example, polyethylene (PE) or polylactide (PLA).

[0216] Insulating sheet 56A comprises a flexible / foldable sheet containing cellulose materials such as wood, cotton, rice, cloth, and / or recycled paper. Typically, insulating sheet 56A comprises multiple sheets of paper, and more commonly includes filler, padding, or tissue paper. Other types of paper may also be used. Each sheet of insulating sheet 56A is typically thinner, more flexible, and less rigid than the sheet of material used to form container 12 and / or sleeve 52A. In some embodiments, the thickness of each sheet of insulating sheet 56A may be less than 1 mm, 0.5 mm, 0.4 mm, 0.25 mm, or 0.15 mm, or within any two of the above values; for example, the thickness range may be between 0.4 mm and 0.15 mm. Other thicknesses may also be used. A common way to measure paper is by “lb bond,” which is the weight per 500 sheets. Using this measurement, the lb bond measurement increases with increasing sheet thickness. In some embodiments of this disclosure, the lb adhesion measurement value per sheet of insulating sheet 56A can be at least or less than 5, 10, 15, 20, 25, or 30, or within a range of any two of the above values. For example, the lb adhesion measurement value range can be between 5 and 15. Other measurement values ​​may also be used.

[0217] The thickness of each insulating sheet 56A is typically 60% or 40% less than the thickness of the sheets used to form the container 12 and / or sleeve 52A. One or more insulating sheets 56A may be used in the formation of the lining portion 50A. The number of separate sheets used in the insulating sheets 56A of the lining portion 50A is typically at least 3, 5, 10, 15, 20, 25, or 30 sheets, or within any two of the above values. For example, the number of separate sheets used in the insulating sheet 56A typically ranges between 5 and 30.

[0218] Insulating sheet 56A is placed to create vertically stacked overlaps. The number of vertically stacked overlaps is typically at least 5, 10, 15, 20, 25, or 30, and the range is generally between 5 and 30 layers, with between 10 and 25 layers or between 15 and 25 layers being more common. For example... Figure 4A As shown, the desired number of layers can be achieved by vertically stacking separate discrete insulating sheets 56A equal to the desired number of layers, or by folding a selected number of insulating sheets 56 once, twice, three times, or more times. For example, Figure 4A Nine discrete insulating sheets 56A are shown stacked vertically without folds to create nine vertical overlapping layers. Figure 4B Nine discrete insulating sheets 56A are shown stacked vertically, and then folded once on top to create 18 vertically stacked overlapping layers. Similarly, Figure 4CNine discrete insulating sheets 56A are shown stacked vertically, and then folded twice on top to create 27 vertically stacked overlapping layers in a triple-fold arrangement. Other arrangements can also be used. For example, instead of stacking the insulating sheets 56A vertically and then folding them simultaneously on all the sheets, each individual insulating sheet 56A can be folded the desired number of times first, and then the individually folded sheets can be stacked vertically to achieve the desired number of overlapping layers.

[0219] like Figure 5A As depicted, to help improve the insulation capability of insulating sheet 56A, each insulating sheet in insulating sheet 56A may have a plurality of recesses 84 formed on one or both sides of its opposite side. The recesses 84 can be formed in various different ways and can have various different sizes and shapes. In one embodiment, conventional embossing techniques can be used to emboss the recesses 84 into the insulating sheet 56. The perimeter of each recess 84 can be polygonal, irregular, or other desired configurations. For example, Figure 5A The recess 84A shown has a square perimeter. Figure 5B The recess 84B shown has a circular perimeter. Figure 5C The recess 84C shown has a slender rectangular perimeter. Figure 5D The recess 84D shown has a substantially Z-shaped perimeter, and Figure 5E The recess 84E shown has a triangular perimeter.

[0220] One purpose of overlapping insulating sheets 56A is to trap air or other gases within the cavities defined between each pair of adjacent insulating sheets 56A. These cavities, which trap air, contribute to improving the insulating capacity of the insulating sheets 56A. For example, in Figure 6 The image depicts a cross-sectional side view of several vertically stacked insulating sheets 56A. Due to embossing, folding, and other forces acting on the insulating sheets 56A, the insulating sheets 56A do not necessarily lie flat on top of each other. In other words, some of the insulating sheets 56A can be bent or flexed, resulting in spaced contact between adjacent insulating sheets 56A. Holes 85 are formed between the sheets 56A and are separated by areas in which the insulating sheets 56A directly contact each other. Therefore, the holes 85 can have different sizes and shapes. For example, as shown... Figure 6As shown, when adjacent insulating sheets are separated, cavities, such as cavity 85A, can be formed. These cavities comprise the area of ​​the space between the separated insulating sheets 56A and the area of ​​a plurality of recesses 84 communicating with the space. In other cases where the overlapping sheets 56A are in direct contact with each other, cavities, such as cavity 85B, may comprise only the area of ​​a single recess 84. However, compared to simply flat overlapping sheets, the number of cavities 85 formed per unit area increases by forming recesses 84 in the sheets 56A. By increasing the number of cavities 85, more air / gas is trapped, thereby improving the insulating capability of the insulating sheets 56A.

[0221] In one embodiment, the volume range of each recess 84 can be between 8 mm. 3 Up to 200mm 3 Between, with the most common being between 10mm 3 Up to 100mm 3 Between and between 10mm 3 With 40mm 3 Other volumes may also be used. Furthermore, the number of recesses 84 is typically at least 10, 20, 40, 60, 80, 100, or 150 per square inch, or in a range between any two of the above values, for example, between 20 and 100 per square inch.

[0222] like Figures 5A-5E As depicted, the recesses 84 can be formed as discrete, spaced-apart recesses arranged in a uniform pattern. This formation and positioning of the recesses 84 can give the stacked insulating sheets 56A more uniform insulating properties and can help limit air movement between the insulating sheets 56A. However, in other embodiments, the recesses 84 can have a variety of different sizes and shapes and can be spaced evenly or randomly. For example, the recesses 84 can be formed by wrinkling the insulating sheets 56A. In other embodiments, the recesses 84 can be formed by creating multiple folds on the insulating sheets 56A, such as accordion folds, which create recesses 84 in the form of elongated channels. However, such elongated channels may reduce the ability to limit air movement between adjacent insulating sheets 56A.

[0223] In one embodiment, all insulating sheets 56A and their overlapping layers may have recesses 84 formed thereon. In other embodiments, some insulating sheets 56A or their overlapping layers may have recesses 84 formed thereon, while other insulating sheets 56A may simply be flat without recesses 84. For example, any other insulating sheet 56A or layer may be flat without recesses 84, or only the outer top and bottom insulating sheets 56A or layers may be flat without recesses 84. Furthermore, the insulating sheets 56 and / or their layers may be oriented such that all recesses 84 face a single direction. For example, all recesses 84 may face upwards or downwards. In other embodiments, the insulating sheets 56 and / or their layers may be oriented such that some recesses 84 face upwards and others face downwards. For example, in Figure 4B In the illustrated embodiment, the recess 84 in the lower half of the layer can face upwards, while the recess in the upper half of the layer can face downwards. Similarly, in Figure 4A In this configuration, every other insulating sheet 56A can be inverted, such that the recesses 84 of adjacent insulating sheets 56A face each other, or the recesses 84 of adjacent insulating sheets 56A face away from each other. The recesses 84 of adjacent insulating sheets 56A or layers can also be configured to be vertically aligned or vertically offset from each other.

[0224] return Figure 3 During assembly, insulating sheets 56A are stacked and folded if necessary to achieve a desired number of overlapping layers. The resulting stacked insulating sheets 56A are sized such that their width is equal to or substantially equal to the width of the outer wall 58 and / or the inner wall 60, i.e., the width of the channel 54A; their length is equal to or substantially equal to the length of the outer wall 58 and / or the inner wall 60, i.e., the length of the channel 54A; and their thickness is equal to or substantially equal to the height of the channel 54A. As used in the specification and appended claims, the term “substantially” when used in conjunction with values ​​of length, area, or volume is intended to mean equal to or within + / - 10% of said value. The stacked insulating sheets 56A are placed on the inner surface of the outer wall 58 or the inner wall 60 of the blank 80. The blank 80 is then folded over the insulating sheets 56A and secured in a continuous loop as discussed above to form a sleeve 52A. In this configuration, the insulating sheets 56A and the cavity 85 defined therefrom occupy or substantially occupy the volume of the channel 54. In one embodiment, the insulation class (R value) of the resulting lining portion 50A, measured at an average temperature of 75°F, ranges from about 3.5 / inch to about 4.5 / inch.

[0225] return Figure 1The diagram shows an assembled liner portion 50A folded into a U-shaped configuration. In this configuration, the liner portion 50A can be defined as having a rear portion 90A with a first leg 92A and a second leg 94A projecting orthogonally outward from opposite ends of the rear portion 90A. An open channel 95A is defined between the legs 92A and 94A. As previously discussed, the legs 92A and 94A can pivot freely relative to the rear portion 90A, such as... Figure 2 As shown, the outrigger is positioned in the same plane as the rear portion 90A and protrudes orthogonally from the rear portion 90A, as... Figure 1 As shown.

[0226] The configuration, components, forming method, and alternatives of liner portion 50B can be the same as those previously discussed with respect to liner portion 50A. Thus, all disclosure herein regarding liner portion 50A and its alternatives also applies to liner portion 50B. Similar elements between liner portions 50A and liner portions 50B are identified by similar reference numerals, except that the reference numerals for liner portion 50B include the suffix "B" instead of "A". One difference between liner portions 50A and 50B is that, as discussed in more detail below, liner portion 50B is smaller than liner portion 50A, such that liner portion 50B can fit within the channel 95A of liner portion 50A.

[0227] When lining portions 50A and 50B are produced, the packaging system 10 is assembled by inserting lining portions 50A and 50B (i.e., lining 14A) into the internal volume 22 of the container 12, such that lining 14A defines compartments within the internal volume 22. Although not strictly necessary, in some embodiments, lining 14A may sit directly against the internal surface 20 of the container 12. In other embodiments, lining 14A may cover or substantially cover all internal surfaces 20 of the container 12. Figure 6 This illustrates how the lining portions 50A and 50B fit together when enclosed within container 12. Container 12 is not... Figure 7The diagram illustrates the positioning of lining portions 50A and 50B for better understanding. Lining portions 50A and 50B are fitted together by rotating lining portion 50B 90 degrees relative to lining portion 50A and inserting it into channel 95A of lining portion 50A. Lining portion 50B is fitted such that its support leg 92B abuts the inner surface of rear portion 90A and extends vertically between the inner surfaces of support legs 92A and 94A on a first side of lining portion 50A. Similarly, support leg 94B of lining portion 50B abuts the inner surface of rear portion 90A and extends vertically between the inner surfaces of support legs 92A and 94A on a opposite second side of lining portion 50A. Rear portion 90B of lining portion 50B extends between the inner surfaces of support legs 92A and 94A at its free end. With lining portions 50A and 50B mated together, the lining portions define compartment 96.

[0228] In one assembly method, lining portions 50A and 50B can be fitted together first, such as... Figure 6 As shown, and then slides into the internal volume 22 of container 12 ( Figure 1 However, more generally, refer to Figure 8 By positioning the first leg 92A on top of the bottom wall 28 and the rear portion 90A against the surrounding side wall 24, the lining portion 50A is first inserted into the internal volume 22 of the container 12. In the depicted embodiment, the rear portion 90A is positioned against the rear wall 32, but in other embodiments, it may also be positioned against any of the walls 30, 34, or 36. In this embodiment, the first leg 92A is sized to cover or substantially cover the bottom wall 28, and the rear portion 90A is sized to cover or substantially cover the rear wall 32. In this configuration, the second leg 94A can still pivot freely.

[0229] Next, as Figure 9 The description, as previously mentioned Figure 7 The lining portion 50B is fitted within the channel 95A of the lining portion 50A. In this positioning, the lining portion 50B is relative to the previously discussed... Figure 7The lining portion 50A discussed has the same positioning and their combination defines compartment 96. Additionally, legs 92B and 94B can be positioned directly against the inner surfaces of the side walls 34 and 36 of container 12, respectively, and the rear portion 90B can be positioned directly against the inner surface of the front wall 30. As previously described, when container 12 is folded closed, the combination of lining portions 50A and 50B, i.e., lining 14A, can cover or substantially cover all internal surfaces 20 of container 12. In the assembled configuration, the outer wall 58 of each sleeve 52 is positioned adjacent to container 12, while the opposite inner wall 60 is positioned adjacent to compartment 96 configured to house articles for transport.

[0230] like Figure 9 As shown, while the outrigger 94A can still move freely into the compartment 96, the cold source 100 and the items 102 used for transport are... Figure 10 Located within compartment 96. (Reference) Figure 11 Article 102 for transport includes material 104, wherein it is desirable to maintain material 104 at a cooled temperature during the transport period. For example, material 104 may be biological material, food, beverage, pharmaceutical, chemical, and other materials requiring refrigeration to maintain their viability. Specific examples of biological material include, but are not limited to, reagents, cell cultures, vaccines, cryopreserved cells, competent cells, proteins, enzymes, and antibodies. Although not always necessary, article 102 for transport typically includes a container 106 for containing material 104. Examples of container 106 include syringes, bottles, bags, vials, boxes, cartons, shells, cans, packaging, etc. In other embodiments, article 102 for transport may also include an outer container 108 for containing container 106. The outer container 108 is not always necessary and can be eliminated. An example of when an outer container 108 may be used is when a second container is desired as a safety measure in the event of failure of container 106. The outer container 108 may also be used to securely hold multiple containers 106 to prevent unintended movement or damage to the containers 106. Examples of outer containers 108 may also include bags, boxes, cardboard boxes, shells, cans, packaging, etc.

[0231] Cold source 100 may include dry ice, ice, cryogel packs, and phase change materials, which are typically used to cool materials for a relatively short period of time. Dry ice is typically used in granular, plate-like, or other desired shapes and sizes. Cold source 100 may also include separate containers containing dry ice, ice, cryogel packs, and phase change materials. Examples of such containers include bags, bottles, plastic containers, etc.

[0232] It should be understood that the cold source 100 and the articles 102 used for transport can be housed within the compartment 96 in various different methods and configurations. For example, see reference... Figure 10First, a certain number of cold sources 100 (such as dry ice pellets) can be placed on the bottom plate of compartment 96. Then, the transported item 102 can be centered on top of the cold sources, such that the transported item 102 is spaced apart from the liner 14A on all sides. Then, another number of cold sources 100, such as additional dry ice pellets, can be positioned to fill the remaining portion of compartment 96, i.e., cover all sides and the top 102 of the transported item. Then, the support legs 94A ( Figure 9 The liner 14A is closed by folding against the top liner portion 50B. The top wall 26 of the container 12 can then be closed, thereby placing the packaging system in a transportable state. Figure 10 As shown.

[0233] Depending on the duration and temperature at which the article 102 for transport must remain cold, the cold source 100 may be applied in other ways. For example, the cold source 100 may be applied only against the bottom of the article 102 for transport, only against the top of the article 102 for transport, or only against the top and bottom of the article 102 for transport, without applying it against any of its sides. In other embodiments, the cold source 100 may be applied only against one or more of the sides of the article 102 for transport, without applying it against the top or bottom of the article 102 for transport. In yet another embodiment, the cold source 100 may be applied only against one or more of the sides of the article 102 for transport, and against both the top and bottom of the article 102 for transport. In one embodiment, the article 102 for transport may be frozen or cooled before being placed in the compartment 96 and may act as a cold source. In other words, no other cold source is located in the compartment 96 besides the article 102 for transport.

[0234] As previously stated, the size of container 12 depends on the size of the item 102 being transported and the duration for which the item 102 needs to be kept cool. In other words, the size of container 12 increases as the size of the item 102 being transported increases and / or the time required to keep the item 102 being transported cool increases. By increasing the size of container 106, the size of compartment 96 can also be increased, thereby freeing up more space for additional cold sources 100. Packaging system 10 is typically configured to maintain the compartment 96 contained therein or the item 102 being transported at a temperature below 11°C, 8°C, 2°C, or -10°C for a period of at least 10 hours, 15 hours, 20 hours, 30 hours, 40 hours, or 50 hours, or a time range between any two of the above values, for example, between 10 hours and 40 hours.

[0235] In some embodiments, not all the space required by compartment 96 may be needed. In this embodiment, filler can be placed within compartment 96 to occupy unused space. For example, as Figure 12 As depicted, filler 110 is positioned within compartment 96 between cold source 100 and leg 94A of lining portion 50A. In one embodiment, filler 110 may include an insulating sheet 56A of additional sheet material. In other embodiments, filler 110 may include conventional padding, wadding filler, filler, or other space-occupying packaging materials, and is typically recyclable, biodegradable, and / or cellulose material.

[0236] Selected embodiments of the packaging system 10 can have many unique advantages. For example, in one embodiment, the container 12 and liner 14 can be made solely of biodegradable and / or recyclable materials, thereby making the packaging system more environmentally friendly. Therefore, the container 12 and liner 14 can be free of polymeric foams, such as expanded polystyrene and non-biodegradable plastics.

[0237] The liner 14A described herein also achieves unique advantages of the packaging system 10. For example, combining the sleeve 52 with the insulating sheet 56 yields surprising and unexpected results compared to using the insulating sheet 56 alone. In other words, while the insulating sheet 56 helps trap and retain air pockets 85 to improve insulation, the use of the sleeve 52 improves insulation beyond what would be expected simply based on increased material thickness. For example, because the sleeve 52 is made of a harder and more flexible material than the insulating sheet 56, the sleeve 52 helps prevent or limit compression of the insulating sheet 56 caused by the cold source 100 and / or the articles 102 used for transport. In other words, without the sleeve 52, the cold source 100 and / or the articles 102 used for transport press against the insulating sheet 56 due to their weight and / or due to the movement of the packaging system 10 during transport. Compression of the insulating sheet 56 compresses or removes the air pockets 85, thereby reducing insulation. In contrast, limiting the compression of the insulating sheet 56 helps to maximize and maintain the cavitation 85, and thus improves insulation throughout the transport process.

[0238] Furthermore, when dry ice evaporates, it produces gas. Without the sleeve 52, the gas can pass more freely through the insulating sheet 56, causing airflow within the cavity 85 and thus reducing insulation capacity. In contrast, by using the sleeve 52 to surround the insulating sheet 56, the gas is guided to flow out through the crack between liner portions 50A and 50B, and less flows out through the insulating sheet 56, thereby again improving the insulation capacity of the liner 14A.

[0239] The use of a sleeve 52 around the insulating sheet 56 also provides other benefits. For example, the sleeve 52 has relatively rigid characteristics because it is made of a sheet that is more rigid than the insulating sheet 56, and because the sleeve is formed as a tubular structure with improved mechanical strength compared to a flat sheet, the tube has greater strength to resist compression and greater strength to resist buckling along its length compared to a flat sheet. Therefore, placing the liner 14 around the inner surface of the container 12 significantly improves the structural strength of the container 12, and thereby helps to prevent or limit damage to the container 12 during the transport of the articles 102. Limiting damage to the container 12 is useful because damage to the container 12 can significantly reduce the insulation capability of the packaging system 10, and thereby jeopardize the viability of the articles 102 for transport.

[0240] In alternative embodiments, it should be understood that the liner 14 can have a variety of different configurations. For example, in Figure 13 Alternative configurations of liner 14B that can be used in embodiments of this disclosure are depicted. Similar features between liners 14A and 14B are identified by similar reference numerals. Liner 14B is configured to be received within the internal volume 22 of container 12 to define a compartment 96 therein. Again, compartment 96 is configured to house the cold source 100 and the articles 102 for transport, as discussed above with respect to liner 14A.

[0241] Liner 14B includes a first lining portion 114, a second lining portion 116, and a third lining portion 118. The first lining portion 114 includes a sleeve 120 defining a channel 122 extending therethrough. As previously discussed, an insulating sheet 56 is disposed within the channel 122. The sleeve 120 can be made of the same material using the same methods and has the same alternatives discussed previously with respect to sleeve 52A. The only difference is that sleeve 120 only includes the legs 92A of sleeve 52A. Figure 1 And therefore does not have a slot or groove extending through it. The first lining portion 114 is configured to sit on and cover or substantially cover the inner surface of the bottom wall 28 of the container 12.

[0242] The second lining portion 116 includes a sleeve 126 defining a channel 128 extending therethrough. As previously discussed, an insulating sheet 56 is disposed within the channel 128. The sleeve 126 may be made of the same material using the same methods and has the same alternatives discussed previously with respect to sleeve 52A. Figure 2The only difference is that sleeve 126 has three spaced slots 130A-130C that extend across and through the inner wall 60, and have a corresponding notch at each opposite end. Due to the slots 130A-130C, sleeve 126 can be easily folded into a square or rectangular shape surrounding compartment 96. A second lining portion 116 is positioned within the internal volume 22 of container 12 to sit on the top surface of the first lining portion 114. The second lining portion 116 may also directly contact and / or cover a portion of the internal surface 20 of the surrounding sidewall 24.

[0243] Finally, the third liner portion 118 has the same configuration and can be made of the same material using the same methods and alternatives as the first liner portion 114. Thus, the third liner portion 118 also includes a sleeve 120 with a channel 122 in which an insulating sheet 56 is disposed. The third liner portion 118 is configured to sit on top of the second liner portion 116 to cover the compartment 96. Liner 14B can be used in the same manner as liner 14A and has essentially the same benefits as discussed above regarding liner 14A.

[0244] exist Figure 14 Another alternative configuration of liner 14C that can be used in embodiments of this disclosure is depicted. Similar features between liners 14A and 14C are identified by similar reference numerals. Liner 14C is also configured to be received within the internal volume 22 of container 12 in order to accommodate compartment 96 ( Figure 19 ) is defined therein. Again, compartment 96 is configured to house the cold source 100 and the articles 102 used for transport. Figure 10 It is contained therein, as discussed above with respect to lining 14A.

[0245] Lining 14C includes a first lining portion 50A1 and a second lining portion 50B1. (Go to...) Figure 15 The first liner portion 50A1 includes a tubular sleeve 52A1 surrounding an insulating sheet 56A. The insulating sheet 56A may include the same insulating sheet and alternatives as previously discussed. Similar elements between the tubular sleeves 52A and 52A1 are also identified by similar reference numerals. More specifically, the tubular sleeve 52A1 includes substantially all the elements of the tubular sleeve 52A, plus some additional tabs, baffles, and slots. As discussed in more detail below, these tabs, baffles, and slots partially help to lock the tubular sleeve 52A1 into a closed loop, closing the opposite ends of the tubular sleeve 52A1, and interlocking the first liner portion 50A1 and the second liner portion 50B1.

[0246] like Figure 16As shown, the tubular sleeve 52A1 is initially formed as a flat blank 80A, which includes an outer wall 58A, an inner wall 60A, and side walls 66A and 68A, as previously discussed. Similar elements between blanks 80 and 80A are identified by similar reference numerals. Blank 80A may be made of the same material and has the same dimensions, characteristics, and alternatives previously discussed with respect to blank 80. Grooves 74A and 76A divide the first side wall 66A into a side wall portion 66A1 disposed at a first end 62A, a side wall portion 66A2 disposed at a second end 64A, and a side wall portion 66A3 disposed therebetween. A tab 78A1 protrudes outward from the outer edge of side wall portion 66A1, while a tab 78A2 protrudes outward from the outer edge of side wall portion 66A2. Tabs 78A1 and 78A2 may be centered along their respective side wall portions or otherwise positioned. A pair of spaced-apart tabs 78A3 and 78A4 protrude outward from the outer edge of the sidewall portion 66A3. Tab 78A is typically formed as a single integral structure with the remainder of the blank 80A, and is therefore usually formed of cellulose material.

[0247] Similarly, the previously discussed slots 70A and 72A divide the inner wall 60A into an inner wall portion 60A1 located at the first end 62A, an inner wall portion 60A2 located at the second end 64A, and an inner wall portion 60A3 located therebetween. A baffle 140A1 protrudes from and extends along the outer edge of the inner wall portion 60A1, wherein a fold line 142A1 is formed at the intersection between the baffle 140A1 and the inner wall portion 60A1. The height of the baffle 140A1 is generally equal to the height of the side wall portion 66A1, but may be shorter. A slot 144A1 extends through the blank 80A at or near the fold line 142A1 and is configured to receive a tab 78A1 during assembly to lock the inner wall portion 60A1 and the outer wall 58A in a secure joint, thereby forming a continuous loop. The slot 144A1 may be formed on the baffle 140A1 and / or the inner wall portion 60A1.

[0248] A baffle 140A2 protrudes from and extends along the outer edge of the inner wall portion 60A2, wherein a fold line 142A2 is formed at the intersection of the baffle 140A2 and the inner wall portion 60A2. The height of the baffle 140A2 is typically substantially equal to the height of the side wall portion 66A2, but may be shorter. A slot 144A2 extends through the blank 80A at or adjacent to the fold line 142A2 and is configured to receive a tab 78A2 during assembly to lock the inner wall portion 60A2 and the outer wall 58A in a secure joint, thereby forming a continuous loop. The slot 144A2 may be formed on the baffle 140A2 and / or the inner wall portion 60A2.

[0249] A baffle 140A3 protrudes from and extends along the outer edge of the inner wall portion 60A3, with a fold line 142A3 formed at the intersection of the baffle 140A3 and the inner wall portion 60A3. The height of the baffle 140A3 is typically substantially equal to the height of the side wall portion 66A3, but may be shorter. A set of spaced-apart slots 144A3 and 144A4 extend through the blank 80A at or near the fold line 142A3 and are configured to receive tabs 78A3 and 78A4 respectively during assembly to lock the inner wall portion 60A3 and the outer wall 58A in a secure joint, thereby forming a continuous loop. Slots 144A3 and 144A4 may be formed on the baffle 140A3 and / or the inner wall portion 60A3. The baffle 140A is typically formed as a single integral structure with the remainder of the blank 80A and is therefore typically also formed of a cellulose material.

[0250] As will be discussed in more detail below, the blank 80A / tubular sleeve 52A1 also includes a locking slot 146A that passes through the blank 80A at or near the fold line 82A located between the outer wall 58A and the inner wall portion 60A3. The locking slot 146A is generally located at a central position between slots 70A and 72A and may extend through the side wall 68A and / or the outer wall 58A. The locking slot 146A also passes through the blank 80A at or near the fold line 82A3 located between the outer wall 58A and the side wall portion 66A3. In one embodiment, the locking slot 148A is centrally located between slots 74A and 76A and may extend through the side wall 66A and / or the outer wall 58A. Finally, cover plate 150A extends outward from and along the edge of outer wall 58A at the first end 62A, while cover plate 152A extends outward from and along the edge of outer wall portion 58A at the second end 64A. Fold line 154A is typically formed at the intersection between cover plate 150A and outer wall 58A, while fold line 155A is typically formed at the intersection between cover plate 152A and outer wall 58A.

[0251] During assembly, as previously discussed, the insulating sheet 56A is positioned on the blank 80A, and the inner wall portions 60A1, 60A2, and 60A3 are folded, thereby trapping the insulating sheet 56A between the inner wall portion 60A and the outer wall 58A, as... Figure 15As shown. Baffles 140A1, 140A2, and 140A3 are folded downwards toward the insulating sheet 56A, while sidewall portions 66A1, 66A2, and 66A3 are folded upwards against the outside of baffles 140A1, 140A2, and 140A3, respectively. Finally, tabs 78A1, 78A2, 78A3, and 78A4 are slid into slots 144A1, 144A2, 144A3, and 144A4, respectively, to mechanically secure the blank 80A into a continuous loop. Tabs 78A and slots 144A thus enable the blank 80A to be formed into a tubular sleeve 52A1 and a lining portion 50A1 without the need for separate attachment mechanisms such as tape or adhesive. Eliminating the need for adhesives can be particularly advantageous, as it avoids the complexity and complication typically associated with the use of adhesives, and also avoids the production delays required for adhesive curing.

[0252] Go to Figure 17 The second lining portion 50B1 includes a tubular sleeve 52B1 surrounding the insulating sheet 56A. Similar elements between the tubular sleeves 52A1 and 52B1 are identified by similar reference numerals, except that the letter "A" used to identify elements in the tubular sleeve 52A1 has been replaced by the letter "B". Figure 18 As shown, the tubular sleeve 52B1 is formed from a flat blank 80B. Again, the flat blank 80B can be made of the same material and substitutes as blank 80 as previously discussed. Blanks 80A and 80B are substantially the same, and similar elements are identified by similar reference numerals. Blank 80B differs from blank 80A in that tab 78A4 and slot 144A4 have been eliminated from blank 80B when centering tab 78A3 and slot 144A3. However, it should be noted that each of the sidewall portions 66A1, 66A2, and 66A3 and / or sidewall portions 66B1, 66B2, and 66B3 can have one, two, three, or more separate tabs protruding from them and corresponding slots for interlocking the blanks into a continuous loop. The positions of the tabs and slots can also be reversed.

[0253] The difference between blank 80B and blank 80A is that the former has eliminated locking slots 146A and 148A. However, blank 80B adds a locking tab 156B protruding outward from the outer edge of cover plate 150B at the first end 62B and a locking tab 158B protruding outward from the outer edge of cover plate 152B at the second end 64B. As discussed below, locking tabs 156B and 158B are configured to be received within locking slots 146A and 146B on the tubular sleeve 52A1. Figure 16Finally, as previously discussed with respect to tubular sleeves 52A and 52B, tubular sleeve 52B1 is smaller than tubular sleeve 52A1, such that tubular sleeve 52B1 can fit within the channel formed by tubular sleeve 52A1, as discussed below. Figure 17 As shown, blank 80B is fixed to the continuous loop surrounding insulating sheet 56A in the same manner as discussed above with respect to blank 80A, i.e., it is formed as tubular sleeve 52B1 and lining portion 50B1.

[0254] return Figure 14 This diagram shows the assembled lining portions 50A1 and 50B1 folded into the U-shaped configuration previously discussed with respect to lining portions 50A and 50B. In this configuration, each lining portion 50 can be defined as having a rear portion 90 having a first leg 92 and a second leg 94 projecting orthogonally outward from opposite ends of the rear portion 90. An open channel 95 is defined between legs 92 and 94. As previously discussed, legs 92 and 94 are freely pivotable relative to the rear portion 90, which is positioned in the same plane as the rear portion 90 and projects orthogonally from the rear portion 90. Leg 92A of lining portion 50A1 terminates at an end face 160A surrounding an opening 161A that communicates with a channel 54A in which an insulating sheet 56A is disposed. A cover flap 152A projects outward from end face 160A. Similarly, the legs 94A of the lining portion 50A1 terminate at an end face 162A surrounding an opening 163A, which communicates with a channel 54A in which an insulating sheet 56A is housed. A cover plate 150A protrudes outward from the end face 162A. The rear portion 90 has locking slots 146A and 148A from its opposite side.

[0255] Similar to the above, the leg 92B of the lining portion 50B1 terminates at the end face 160B surrounding the opening 161B, which communicates with the channel 54B in which the insulating sheet 56A is housed. Figure 17 The cover tab 152B and locking tab 158B protrude outward from end face 160B. Similarly, the leg 94B of the lining portion 50B1 terminates at end face 162B surrounding the opening 163B, which communicates with the channel 54B in which the insulating sheet 56A is housed. The cover tab 150B and locking tab 156B protrude outward from end face 162B.

[0256] With the lining portions 50A1 and 50B1 formed, the packaging system 10 is assembled by inserting the lining portions 50A1 and 50B1 (i.e., lining 14C) into the internal volume 22 of the container 12, such that lining 14C defines compartments within the internal volume 22. Although not strictly necessary, in some embodiments, lining 14C may sit directly against the internal surface 20 of the container 12. In other embodiments, lining 14C may cover or substantially cover all internal surfaces 20 of the container 12. Figure 19 This illustrates how the lining portions 50A1 and 50B1 are engaged before and after being positioned within the container 12. The lining portions 50A1 and 50B1 are engaged by rotating the lining portion 50B1 90 degrees relative to the lining portion 50A1 and inserting it into the channel 95A of the lining portion 50A1. The lining portion 50B1 is engaged such that the end face 160B of the leg 92B of the lining portion 50B1 abuts the inner surface of the rear portion 90A, i.e., the inner wall 60A, and the cover flap 152B is positioned against the side wall 68A of the rear portion 90A. Similarly, the end face 162B of the leg 94B of the lining portion 50B1 abuts the inner surface of the rear portion 90A, i.e., the inner wall 60A, and the cover flap 152B is positioned against the side wall 66A of the rear portion 90A. In this positioning, locking tabs 1156B and 158B are folded and inserted into locking slots 148A and 146B respectively, thereby mechanically coupling liner portions 50A1 and 50B1 together. With liner portions 50A1 and 50B1 thus engaged, the liner portions form liner 14C defining compartment 96.

[0257] During further assembly, such as Figure 19 and 20 As depicted, the coupled liner portions 50A1 and 50B1, i.e., liner 14C, are lowered into the internal volume 22 of the container 12. In doing so, the cover flap 152A is folded upwards to cover the end face 160A and opening 161A of the liner portion 50A1. Figure 14 The cover flap 152A is held against the end face 160A by the container 12. Next, as previously discussed with respect to the liner 14A, the cold source 100 and the article 102 for transport are... Figure 10The liner 100 and the transported article 102, as well as their alternatives and placement methods, are also suitable for use with the liner 14C, as previously discussed with respect to the liner 14A. Once the cold source 100 and the transported article 102 are positioned within the compartment 96, the legs 94A of the liner portion 50A1 are folded into the container 12 to close the compartment 96. Before or during the folding of the legs 94A, the cover flap 150A is folded to cover the end face 162A and the opening 163A of the liner portion 50A1. In one embodiment, the height of the cover flap 150A may be sufficient to protrude beyond the end face 162A. In this case, the free protruding portion of the cover flap 150A can slide between the rear portion 90B of the liner portion 50B1 and the container 12. A tight tolerance fit between the liner 14C and the container 12 causes the cover flap 150A to abut against the end face 162A of the liner portion 50A1.

[0258] Liner 14C offers numerous unique benefits and advantages. For example, the mechanical securing of blanks 80A and 80B to the tubular sleeve using integral tabs and slots eliminates the need for separate attachment mechanisms such as tape or adhesives, which could complicate and delay the assembly process. Furthermore, the mechanical closure of blanks 80A and 80B achieves a tight seal around the insulating sheet 56, reducing gas flow through it and improving thermal efficiency. Additionally, the robust coupling of liner portions 50A1 and 50B1 together using locking tabs 156B and 158B with corresponding locking slots minimizes gas leakage or creates non-insulating gaps between liner portions 50A1 and 50B1. The use of locking tabs and locking slots is particularly useful when the outer container 12 is larger than liner 14C. In this case, the liner may move within container 12 during transport or movement, potentially creating gaps between liner portions. Mechanically securing the lining sections together helps prevent the formation of gaps that contribute to maximizing thermal efficiency during lining movement.

[0259] Furthermore, baffles 150A and 152A cover the exposed end faces and openings of the insulating sheet 56A in the liner portion 50A1. This covering of the end faces of the liner portion 50A1 helps restrict gas flow through the insulating sheet 56A, thereby improving thermal efficiency. Baffles 150B and 152B on the liner portion 50B1 also help prevent air from flowing into or out of the end faces of the liner portion 50B1, thus also improving thermal efficiency. Other advantages also exist.

[0260] It should also be understood that the insulating sheet disclosed herein can also have other configurations. For example, in Figure 21-23An alternative embodiment of the insulating sheet 56A1 is depicted. In this embodiment, the insulating sheet 56A1 comprises alternating layers of flat sheets 170 and embossed sheets 172. Each flat sheet 170 has a generally flat top surface 169 and an opposite bottom surface 171. In other words, the flat sheet 170 is generally formed as a flat, planar sheet on which no embossing is formed. Each embossed sheet 172 has a top surface 174 and an opposite bottom surface 176, and a plurality of spaced-apart first embossings 178. The first embossings 178 protrude from the bottom surface 176 and terminate at an end portion 180. Each first embossing 178 defines a recess 181 that is openly exposed from the top surface 174. Each embossed sheet 172 also includes a plurality of second embossings 182 that protrude outward from the top surface 174 and terminate at an end portion 184. Each second embossing 182 defines a recess 186 that is openly exposed from the bottom surface 176.

[0261] Although embossings 178 and 182 are depicted in the figures as having a hemispherical configuration, the recesses 181 and 186 of embossings 178 and 182 may have the same configuration, size, concentration, and other characteristics as previously discussed with respect to the recesses of insulating sheet 56A. Similarly, flat sheet 170 and embossed sheet 172 may be made of the same material as previously discussed with respect to the sheet of insulating sheet 56A and have the same dimensions and other characteristics.

[0262] However, unlike insulating sheet 56A, the separate sheets in insulating sheet 56A1 are held together by an adhesive. Specifically, using conventional methods known in the formation of corrugated cardboard, the adhesive is applied to the end faces 180 and 184 of embossing 178 and 182. For example, one or more rollers can be used to apply the adhesive to the end faces 180 and 184 of embossing 178 and 182. The flat sheet 170 is then applied to the end faces 180 and 184, such that the flat sheet 170 is secured to the opposite side of the embossed sheet 172. Any desired number of alternating layers of flat and embossed sheets can be used. For example, the total number of vertically stacked sheets held together by adhesive can typically be at least or less than 3, 5, 10, 15, 20, 25, or 30 sheets, or within any two of the above values. Additionally, the formed insulating sheet 56A1 can be folded once or twice, as previously discussed... Figure 4B and 4C The discussion focuses on this. In this case, a desired number of sheets can be stacked, but not all adjacent sheets can be held together with adhesive.

[0263] Insulating sheet 56A1 can replace all the uses of insulating sheet 56A disclosed herein and has many unique advantages. For example, since the embossed sheet 172 is fixed to the flat sheet 170 by an adhesive, small insulating cavities (which at least partially include recesses 181 and 186) are formed between the sheets that form cavities. Thus, the cavities help improve thermal efficiency by forming and maintaining the isolation of cavities. More specifically, the structure of insulating sheet 56A1 must restrict the flow of air through recesses 181 and 186. Furthermore, since the sheets are fixed together by an adhesive, the stacked sheets of insulating sheet 56A1 have greater rigidity than insulating sheet 56A. Due to the increased rigidity of insulating sheet 56A1, the likelihood of compression or other damage to the cavities or voids between the sheets during transport or movement of the container assembly is reduced, thereby maximizing thermal efficiency. In addition, because insulating sheet 56A1 has higher thermal efficiency, a thinner insulating sheet 56A1 can be used to achieve the same insulation coefficient as insulating sheet 56A. By using a thinner insulating sheet 56A1, the weight and / or size of the final transport assembly is reduced, thereby lowering transportation costs. Additionally, the increased rigidity of the insulating sheet 56A1 helps improve the rigidity of the entire lining in which it is used, thereby enhancing the overall stability of the assembly. Other benefits and advantages also exist.

[0264] exist Figure 24 The diagram depicts temperature versus time graphs of 500ml water bottles placed within four different insulating packaging systems disclosed herein. Water was cooled using two 16-ounce standard cryogel packs. As indicated by lines 190 and 192, a typical standard is to maintain the articles intended for transport at a temperature below 11°C for 32 hours while the insulating packaging system is under normal ambient conditions. Figure 24 The graphs shown indicate that, during the testing period, each of the four different insulation packaging systems met the International Society for Safe Transport (ISTA) 7E summer environmental conditions.

[0265] Line 194 of this graph plots the temperature versus time of the first insulating packaging system, which is incorporated into the lining 14A sealed within a cardboard box disclosed herein. As the graph shows, this initial system can only maintain the water temperature below 11°C for a period of approximately 31 hours.

[0266] Line 196 of the graph plots the temperature versus time relationship of the second insulating packaging system, except for the lining portions 50A and 50B of lining 14A (as shown in the figure). Figure 1 (As shown) Replace with lining portions 50A1 and 50A2 (as shown) Figure 14-18As shown in the figure, the graph keeps all variables of the first insulating packaging system constant. The graph shows that by using lining portions 50A1 and 50A2, which improve gas trapping within the lining portions and hold the lining portions together, the thermal efficiency of the system is improved, allowing the water temperature to be maintained below 11°C for a period slightly longer than 32 hours.

[0267] Line 198 of the graph plots the temperature versus time relationship of the third insulating packaging system. Except for changing the materials used to form the lining portions 50A1 and 50A2, the graph keeps all variables of the second insulating packaging system constant. Specifically, in the second packaging system, lining portions 50A1 and 50A2 are formed using standard 32ECT (edge ​​crush test) corrugated cardboard, while in the third packaging system, lining portions 50A1 and 50A2 are formed using 200 lb burst strength corrugated cardboard. 32ECT cardboard can typically be made from relatively lightweight and recycled paper. In contrast, cardboard with a burst strength of 200 lb is denser and typically requires virgin materials. Line 198 of the graph shows the time period during which the third insulating packaging system can maintain the water temperature below 11°C for approximately 34 hours. Therefore, using denser and stronger cardboard for lining portions 50A1 and 50A2 further improves the thermal efficiency of the packaging system.

[0268] Finally, line 200 of the graph plots the temperature versus time for the fourth insulating packaging system, keeping all variables from the second insulating packaging system described above constant, except that insulating sheet 56A is replaced by insulating sheet 56A1. Note that the total thickness of insulating sheet 56A1 used in the fourth insulating packaging system is smaller than the total thickness of insulating sheet 56A used in the second insulating packaging system. Line 200 of the graph shows the time period during which the fourth insulating packaging system can maintain the water temperature below 11°C for approximately 36 hours. Therefore, the graph shows that the thermal efficiency of the packaging system is significantly improved by using glued insulating sheet 56A1 compared to simply stacking insulating sheet 56A.

[0269] Due to the relative stiffness of the insulating sheet 56A1, in some applications, the insulating sheet 56A1 can be used as a liner without a tubular sleeve surrounding it. For example, in Figure 25 Another alternative configuration of liner 14D that can be used in embodiments of this disclosure is depicted. Similar features between liner 14A and 14D are identified by similar reference numerals. Liner 14D is also configured to be received within the internal volume 22 of container 12 in order to accommodate compartment 96 ( Figure 26 ) is defined therein. Again, compartment 96 is configured to house the cold source 100 and the articles 102 used for transport. Figure 10 It is contained therein, as discussed above with respect to lining 14A.

[0270] Liner 14D includes a first lining portion 200A and a second lining portion 200B. The first lining portion 200A includes an insulating sheet 56A1, wherein the individual sheets are bonded together by an adhesive, as previously discussed. Figure 21-23 The first lining portion 200A does not include a separate sleeve or sheet, such as a tubular sleeve 52A or 52A1, surrounding the insulating sheet 56A1. Instead, the insulating sheet 56A1 forming the first lining portion 200A is configured to sit directly against the container 12 and directly define a compartment 96 therein where the article 102 for transport is housed.

[0271] The insulating sheet 56A1 is cut or otherwise formed such that the first liner portion 200A can fit suitably within the volume 22 of the container 12, as previously discussed with respect to liner 14A and the first liner portion 50A. More specifically, the first liner portion 200A has an inner surface 202A and an outer surface 204A of a rectangular configuration extending longitudinally between opposite end faces 206A and 208A and laterally between opposite sides 210A and 212A. As depicted, the first liner portion 200A can be selectively folded into a U-shaped configuration. When in the U-shaped configuration, the first liner portion 200A can be defined as having a rear portion 90A with a first leg 92A and a second leg 94A projecting orthogonally outward from opposite ends of the rear portion 90A. An open channel 95A is defined between the legs 92A and 94A. Outriggers 92A and 94A are freely pivotable relative to the rear portion 90A, the outriggers being positioned in the same plane as the rear portion 90A and projecting orthogonally from the rear portion 90A, such as... Figure 25 As shown.

[0272] To facilitate folding the first lining portion 200A into a U-shaped configuration, cut lines 214A and 216A may be formed on the inner surface 202A and extend linearly between opposite sides 210 and 212 at the folding point. In one embodiment, cut lines 214A and 216A may include linear cuts that only partially pass through the lining portion 200A. This cutting both forms a movable hinge and maintains the uncut thickness of the lining portion 200A, thereby helping to maintain thermal efficiency. In other embodiments, cut lines 214A and 216A may include V-shaped notches cut along the inner surface 202A at the folding point or otherwise formed.

[0273] The second liner portion 200B is also formed of insulating sheet 56A1 and has the same configuration, components, and characteristics as discussed above with respect to the first liner portion 200A. Thus, similar element liner portions 200A and 200B are identified by similar reference numerals, except that the reference numeral for the second liner portion 200B is incorporated with the letter "B" instead of the letter "A". However, as discussed further in detail below, the second liner portion 200B is smaller than the first liner portion 200A, such that the second liner portion 200B can fit within the channel 95A of the first liner portion 200A.

[0274] When lining portions 200A and 200B are produced, the packaging system is assembled by inserting lining portions 200A and 200B (i.e., lining 14D) into the internal volume 22 of container 12, such that lining 14D defines compartments 96 within the internal volume 22. Although not strictly necessary, in some embodiments, lining 14D may sit directly against the internal surface 20 of container 12. In other embodiments, lining 14D may cover or substantially cover all internal surfaces 20 of container 12. Figure 26 This illustrates how the lining portions 200A and 200B fit together when enclosed within container 12. Container 12 is not... Figure 26 The diagram shows the positioning of lining portions 200A and 200B for better illustration.

[0275] Liner portions 200A and 200B are fitted together by rotating liner portion 200B 90 degrees relative to liner portion 200A and inserting it into channel 95A of liner portion 200A. Liner portion 200B is fitted such that its support leg 92B abuts the inner surface 202A of rear portion 90A and extends vertically between the inner surfaces 202A of support legs 92A and 94A on a first side of liner portion 200A. Similarly, support leg 94B of liner portion 200B abuts the inner surface 202A of rear portion 90A and extends vertically between the inner surfaces 202A of support legs 92A and 94A of liner portion 200A on an opposite second side of liner portion 200A. The rear portion 90B of the lining portion 200B extends between the inner surfaces 202A of the legs 92A and 94A at the free ends of the legs 92A and 94A. When the lining portions 200A and 200B are fitted together, the lining portions define a compartment 96 that is typically arranged in a parallelepiped configuration. The lining portions 200A and 200B are generally designed to fit tightly together to minimize the gap between them.

[0276] In one assembly method, the lining portions 200A and 200BB can be fitted together first, such as... Figure 26 As shown, and then slides into the internal volume 22 of container 12 ( Figure 25 However, more generally, compared to previous discussions... Figure 8 and 9 The lining portions 50A and 50B are discussed similarly, and the lining portion 200A can be initially inserted into the internal volume 22 of the container 12 by positioning the first leg 92A on top of the bottom wall 28 and positioning the rear portion 90A against the surrounding side wall 24. The rear portion 90A is positioned against the rear wall 32, but in other embodiments, it may also be positioned against any of the walls 30, 34, or 36. The size of the first leg 92A can be set to cover all or substantially all of the bottom wall 28, and the size of the rear portion 90A can be set to cover all or substantially all of the rear wall 32. In this configuration, the second leg 94A can still pivot freely.

[0277] Next, regarding the previous discussion Figure 9 As discussed in the embodiments above, the lining portion 200B fits within the channel 95A of the lining portion 200A. In this positioning, the lining portion 200B is positioned relative to the above-described embodiments. Figure 26 The lining portion 200A under discussion has the same positioning and its combination defines compartment 96. Additionally, legs 92B and 94B can be positioned directly against the inner surfaces of the side walls 34 and 36 of the container 12, respectively, and the rear portion 90B can be positioned directly against the inner surface of the front wall 30. Figure 25 As previously described, when container 12 is folded closed, the combination of liner portions 200A and liner portions 200B, i.e., liner 14D, can cover all or substantially all of the internal surfaces 20 of container 12. In the assembled configuration, the outer surfaces 204 of each liner portion 200A and 200B are positioned adjacent to container 12, such as by directly abutting the container, while the opposite inner surfaces 202 are positioned adjacent to compartments 96 configured to receive articles 102 for transport, such as by directly defining the compartments. The cold source 100 and the articles 102 for transport can be positioned within the compartments 96 of liner 14D, as previously described with respect to liner 14A and 200B. Figure 10-11 The same is being discussed.

[0278] Because insulating sheet 56A1 is more rigid than insulating sheet 56A and therefore less prone to collapse or compression, insulating sheet 56A1 can be used to independently form lining portions 200A and 200B without sleeve 52. By eliminating the use of sleeve 52, manufacturing and assembly are simplified, and the resulting package assembly can be smaller and / or lighter while still having at least the same thermal efficiency. Other advantages also exist.

[0279] In addition to using insulating sheet 56A1 independently to form liners 200A and 200B, it should also be understood that insulating sheet 56A1 can also be used to independently form the first liner portion 114, the second liner portion 116, and the third liner portion 118 of liner 14B, as per [reference to...]. Figure 13 The present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. The described embodiments should be considered illustrative rather than restrictive in all respects. Therefore, the scope of this disclosure is indicated by the appended claims rather than by the foregoing description. All modifications falling within the equivalent meaning and scope of the claims should be covered within the scope of the claims.

Claims

1. An insulated packaging system, the packaging system comprising: A container having an internal surface that defines an internal volume; as well as A liner, disposed within the internal volume of the container and at least partially defining a compartment configured to house articles for transport, the liner comprising: A first sleeve, comprising a first cellulose material and at least partially defining a channel, the first sleeve having an outer wall disposed toward the container and an opposite inner wall disposed toward the compartment configured to receive the articles for transport, the channel being disposed between the inner wall and the outer wall; A second sleeve, at least partially defining a channel, having an outer wall facing the container and an opposite inner wall facing the compartment configured to receive the articles for transport, the channel of the second sleeve being disposed between the inner wall and the outer wall of the second sleeve, the second sleeve being separate and discrete from the first sleeve and positioned such that the compartment is at least partially disposed between the first sleeve and the second sleeve; and At least one insulating sheet is disposed within the channel of the first sleeve and the second sleeve, the at least one insulating sheet comprising a second cellulose material and having a plurality of recesses formed thereon.

2. The heat-insulating packaging system of claim 1, wherein the cellulose material of the first sleeve comprises a folded sheet of cardboard.

3. The heat-insulating packaging system of claim 2, wherein the cardboard sheet is more rigid than the at least one insulating sheet, and / or its thickness is greater than the thickness of the at least one insulating sheet.

4. The heat-insulating packaging system of claim 2, wherein the cardboard includes a splice and a slot, the splice being received within the slot to secure the cardboard in a continuous loop surrounding the channel.

5. The heat-insulating packaging system according to claim 1, further comprising: The first sleeve has an end face with an opening communicating with the channel; as well as A cover plate protruding from the end face of the first sleeve, the cover plate being folded to at least partially cover the opening.

6. The insulated packaging system of claim 1, wherein the outer wall of the first sleeve is disposed directly against the inner surface of the container, and the inner wall of the first sleeve at least partially defines the compartment.

7. The insulated packaging system of claim 1, wherein the first sleeve disposed within the internal volume of the container has a U-shaped configuration.

8. The heat-insulating packaging system of claim 1, further comprising a first locking tab protruding from the first sleeve and a first locking slot formed on the second sleeve, the first locking tab being received within the first locking slot to secure the first sleeve to the second sleeve.

9. The heat-insulating packaging system according to claim 1, further comprising: The second sleeve has a first end face with an opening communicating with the channel; A first cover plate protrudes from the first end face of the second sleeve; A first locking tab protrudes from the first cover tab; A first locking slot is formed on the second sleeve, and a first locking tab is housed within the first locking slot to secure the first sleeve to the second sleeve.

10. The heat-insulating packaging system of claim 1, wherein the at least one insulating sheet comprises a plurality of separate sheets of paper stacked together, each of the plurality of separate sheets of paper comprising a cellulose material and having a plurality of recesses formed thereon.

11. The heat-insulating packaging system of claim 1, wherein the at least one insulating sheet comprises: A first flat sheet, the first flat sheet having a top surface and an opposite bottom surface; as well as A first embossed sheet has a top surface, an opposite bottom surface, and a plurality of spaced-apart first embosses, each first embossing protruding outward from the top surface and terminating at an end point and defining an openly exposed recess on the bottom surface, the end points of the first embosses being fixed to the bottom surface of the first flat sheet by an adhesive.

12. The heat-insulating packaging system of claim 11, wherein the at least one insulating sheet further comprises: A second flat sheet, the second flat sheet having a top surface and an opposite bottom surface; and The first embossed sheet further includes a plurality of spaced-apart second embossings, each second embossing protruding outward from the bottom surface and terminating at an end point and defining an openly exposed recess on the top surface, the end points of the second embossings being fixed to the top surface of the second flat sheet by an adhesive, such that the first embossed sheet is disposed between the first flat sheet and the second flat sheet.

13. The heat-insulating packaging system of claim 12, further comprising a second embossed sheet having a plurality of outwardly projecting embossings, the embossings of the second embossed sheet being fixed to the top surface of the first flat sheet by an adhesive.

14. The heat-insulating packaging system of claim 1, wherein the at least one insulating sheet comprises a plurality of vertically stacked insulating sheets, and a plurality of cavities are defined between the plurality of vertically stacked insulating sheets.

15. The insulated packaging system of claim 1, wherein the container and the liner do not include expanded polystyrene or non-biodegradable plastics.

16. The heat-insulating packaging system of claim 1, wherein the first sleeve further comprises: A first sidewall and an opposite second sidewall, each extending between the outer wall and the inner wall; as well as A first slot and a spaced-apart second slot pass through the inner wall to communicate with the channel and extend between the first sidewall and the second sidewall.

17. The heat-insulating packaging system of claim 1, wherein the first cellulose material of the first sleeve and the second cellulose material of the at least one insulating sheet comprise the same cellulose material.

18. The heat-insulating packaging system of claim 1, wherein the first cellulose material of the first sleeve and the second cellulose material of the at least one insulating sheet comprise different cellulose materials.

19. The insulated packaging system of claim 1, comprising a cold source disposed within the container.

20. The heat-insulating packaging system of claim 19, wherein the cold source comprises a gel pack or dry ice.

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