Insulated compartmented container

Abstract

An insulated container for transporting temperature-sensitive materials includes insulated walls having inner walls and outer walls enclosing insulation material therebetween. The inner walls and outer walls are separated from each other by separation elements which can be engaged to and disengaged from at least one of the inner walls or outer walls, so as to reversibly connect the inner walls to the outer walls, thereby allowing the insulation material to be readily added to or removed from insulation compartments between the inner and outer walls. The inner and outer walls are advantageously made of plastic so that they can be readily cleaned and reused or recycled. The insulation material is also advantageously recyclable.

Description

INSULATED COMPARTMENTED CONTAINERField

[0001] The present application is directed to an insulated container for use in cold-chain transportation and storage. More specifically, the present application provides an insulated compartmented container for transporting temperature-sensitive materials, including biological materials.Background

[0002] It is often necessary to transport temperature-sensitive materials such as fresh or frozen food products, pharmaceuticals, and biological materials such as cultures of microorganisms, biological samples obtained from medical or other tests, clinical specimens and biological reagents to or from a commercial supplier, a laboratory or a medical or research facility. Such temperature-sensitive materials may need to be maintained at temperatures lower than ambient conditions (for example, at about 2°C to about 8°C) during transportation to protect their stability and integrity. In addition, such materials may need to be kept securely packaged during transport, as exposure to the materials under unprotected conditions may pose an environmental hazard or a biohazard. To meet this need, the transportation industry has developed techniques and practices known as “cold-chain logistics”.

[0003] Insulated containers are often used to package and transport temperature-sensitive materials which may be susceptible to damage or degradation if not maintained within an appropriate temperature range. Currently, shipping boxes made of expanded polystyrene foam are widely used to transport temperature-sensitive material including biological materials. Cooling substances or articles such as ice, dry ice, or pre-frozen or pre-chilled ice packs or gel-packs can be included with the contents of the shipping boxes to ensure that a low temperature is maintained. However, while polystyrene foam is effective as an insulating material, it is difficult and impractical to recycle or to deodorize and reuse if used to transport odiferous items such as fresh seafood. In addition, a significant portion of laboratory plastic waste disposed of in landfills is estimated to be from polystyrene shipping boxes.

[0004] Alternatives to expanded polystyrene foam containers for transporting temperaturesensitive materials have been proposed. A recyclable insulated container made of sheets of cardboard paper is described in US Patents No. 8,453,477; 9,139,319; 11 ,511 ,927; and 11 ,760,555. In addition, shipping boxes made from natural plant fibers have been suggested as an alternative to insulated polystyrene foam containers. However, these paper and natural fiber boxes are expensive and vulnerable to breakage or crushing during transport and often cannot withstand treatments required for disinfection such as spraying and wipingwith bleach or other disinfectants. Thus, such containers have a limited use for shipping materials where there is a risk of contamination, infection or other hazard in case of a spill. Furthermore, such containers may not withstand repeated use, and instead may need to be replaced and sent for disposal and / or recycling after use, increasing their cost and environmental impact.

[0005] In addition, plastic insulated cooler boxes or picnic coolers of the type typically used by family consumers in the summer to keep foods chilled in warm outdoor settings are not suitable for repeated use for professional shipping of biomaterials. Such containers have high manufacturing costs and often contain handles, wheels, hinges and other parts which contain numerous surfaces and recesses, and which are therefore difficult to thoroughly disinfect for reuse. In addition, such containers may also be difficult to stack, with each other or with other boxes, for transport in pickup trucks / vans such as those used by shipping companies, and may not be compatible with automated sorting machines or quickly and efficiently handled by transportation workers, such as pickup drivers or shippers.Additionally, such containers often contain a number of different types of plastic materials, often including polystyrene foam insulation, which are permanently bonded together, and are therefore difficult or impractical to recycle.

[0006] Therefore, there is a need for a recyclable or reusable insulated container which can be used for packing and shipping temperature-sensitive materials, including potentially hazardous biological materials.Summary

[0007] One aspect of the present application provides an insulated container for transporting temperature-sensitive materials, the container including one or more insulated walls which define an interior space configured to receive the temperature-sensitive material. The one or more insulated walls include: one or more outer walls comprising a first plastic material; one or more inner walls comprising a second plastic material, the one or more inner walls forming a contiguous surface adjoining the interior space; one or more separation elements separating the one or more outer walls from the one or more inner walls to define one or more insulation compartments between the one or more outer walls and the one or more inner walls; and insulation material, wherein the one or more insulation compartments are configured to receive the insulation material.

[0008] At least one of the one or more separation elements is configured to reversibly engage at least one of the one or more outer walls or at least one of the one or more innerwalls so as to reversibly connect at least one of the one or more outer walls to at least one of the one or more inner walls. Disengagement of the at least one of the one or more separation elements from the at least one of the one or more outer walls or the at least one of the one or more inner walls provides access to the one or more insulation compartments for addition or removal of the insulation material.

[0009] In at least one embodiment, the insulated container comprises a body portion and a lid, wherein the body portion comprises one or more of the one or more insulated walls to define the interior space, wherein the one or more inner walls comprise one or more inner walls of the body portion and wherein the one or more outer walls comprise one or more outer walls of the body portion, and wherein the lid comprises at least one of the one or more insulated walls and is configured to reversibly engage the body portion so as to enclose the interior space. In at least one embodiment, the body portion is assembled from a plurality of individual insulated panels. In at least one embodiment, the body portion is assembled from a unitary inner body comprising the one or more inner walls of the body portion and a unitary outer body comprising the one or more outer walls of the body portion. In at least one embodiment, the one or more separation elements comprise one or more edge projections unitary with one or more of the one or more inner walls or the one or more outer walls. In at least one such embodiment, the one or more edge projections comprise one or more openings. In at least one embodiment, the insulated container has the shape of a rectangular cuboid. In at least one embodiment, the insulated container is stackable with a second insulated container.

[0010] In at least one embodiment, the first plastic material is the same as the second plastic material. In at least one embodiment, the first plastic material is different from the second plastic material. In at least one embodiment, the first plastic material and the second plastic material are each selected from polyethylene (PE), polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyvinyl chloride (PVC). In at least one embodiment, the insulation material comprises cardboard or plant fiber. In at least one embodiment, one or more of the first plastic material, the second plastic material or the insulation material is recyclable.

[0011] In an additional aspect, the present application provides a method of transporting a temperature-sensitive material, including placing the temperature-sensitive material in an interior space of an insulated container as described herein and transporting the insulated container. In at least one embodiment, the method further includes placing a temperature controlling material in the interior space. In at least one embodiment the temperature controlling material is configured to cool the interior space below ambient temperature. In atleast one embodiment, the temperature controlling material is selected from ice, dry ice, one or more ice packs, and one or more gel packs. In at least one embodiment, the temperature controlling material is selected to maintain the temperature of the interior space in a range of -20°C to 8°C. In at least one embodiment, the temperature controlling material is selected to maintain the temperature of the interior space in a range of 0°C to 8°C. In at least one embodiment, the temperature controlling material is selected to maintain the temperature of the interior space in a range of -80°C to -70°C. In at least one embodiment, the method further includes placing additional packaging material in the interior space. In at least one embodiment, the method further includes enclosing the insulated container in an external container prior to transporting the insulated container. In at least one embodiment, the method further includes providing an indication that the insulated container is returnable to a predetermined location.Brief Description of the Drawings

[0012] Further features of the present invention will become apparent from the following written description and the accompanying figures, in which:

[0013] Figure 1 is a front perspective view of one embodiment of an insulated container as described herein;

[0014] Figure 2 is an exploded view of the lid assembly of the embodiment of Figure 1 ;

[0015] Figure 3A is an exploded view of a panel forming an insulated wall of the body assembly of the embodiment of Figure 1 ;

[0016] Figure 3B is an exploded view of an embodiment of the body assembly and lid assembly of the embodiment of Figure 1 formed from panels of Figure 3A;

[0017] Figure 3C is a top perspective view of an alternative embodiment of the body assembly of the embodiment of Figure 1 formed from panels of Figure 3A;

[0018] Figure 4 is an exploded view of an alternative embodiment of the body assembly of the embodiment of Figure 1 ;

[0019] Figure 5 is an enlarged partial view of a fastener and complementary fastener for use with the lid assembly or body assembly of the embodiment of Figure 1 ;

[0020] Figure 6A is an exploded view of an alternative embodiment of the body assembly of the embodiment of Figure 1 ;

[0021] Figure 6B is a top perspective view of an alternative embodiment of the inner wall of the lid assembly of the embodiment of Figure 1 ;

[0022] Figure 6C is a partial top perspective view of an alternative embodiment of an inner body of the body assembly of the embodiment of Figure 1 ;

[0023] Figure 6D is a partial top perspective view of an alternative embodiment of an inner body of the body assembly of the embodiment of Figure 1 ;

[0024] Figure 7A is a front perspective view of an alternative embodiment of a lid assembly of the embodiment of Figure 1 ;

[0025] Figure 7B is a front perspective view of an alternative embodiment of a body assembly of the embodiment of Figure 1 ;

[0026] Figure 8A is a graph showing the variation of temperature over time measured as described in Example 1 of an insulated prototype of the present insulated container compared to an uninsulated container;

[0027] Figure 8B is a graph showing the variation of temperature over time measured as described in Example 2 of an alternative insulated prototype of the present insulated container compared to an uninsulated container; and

[0028] Figure 9 is a graph showing the variation of temperature over time measured as described in Example 4 of an embodiment of the present insulated container compared to a standard expanded polystyrene foam container.Detailed Description

[0029] One aspect of the present application provides an insulated container for transporting temperature-sensitive materials. As used herein, the term “temperature-sensitive materials” is intended to mean materials which are at risk of damage, spoilage or degradation if not maintained within an appropriate temperature range, and includes but is not limited to foods and food products, pharmaceuticals, and biological materials or biomaterials. As used herein, the term “food” or “food products” is intended to mean material intended for sale or use as food for humans or animals and includes but is not limited to fresh or frozen foods or beverages such as meat, fish, seafood, vegetables, fruits, dairy products, and other such perishable foods or products. As used herein, the term “pharmaceuticals” is intended to mean materials used as therapeutic or prophylactic medicines or drugs for humans or animals and includes but is not limited to drugs or medicines of natural or synthetic origin, small molecule drugs or medicines, vaccines, biologic drugs or medicines and the like. As used interchangeably herein, the terms “biological materials” and “biomaterials” are intended to mean materials of biological origin and materials intended for use in handling such materials of biological origin. Materials of biological origin include but are not limited to proteins, including but not limited to enzymes and antibodies, nucleic acids, including but not limited to RNA and DNA, carbohydrates, microorganisms or cultures thereof, samples of tissue or biological fluids, clinical specimens, and the like as will be understood in the art. Materials intended for use in handling such materials of biological origin include but are notlimited to biological reagents. As used herein, the term “biological reagents” is intended to refer to materials or kits used to transform or study materials of biological origin, including but not limited to in a research, laboratory, medical or clinical environment. Biological reagents include but are not limited to, gel stains for electrophoresis, transfection agents for cell transfection, fluorescent dyes for labelling cell components, culture media, and the like, as will be recognized by the skilled person. In certain embodiments, such biomaterials may pose a biohazard to organisms such as humans and other animals which are exposed to the biomaterials under unprotected conditions.

[0030] In at least one embodiment, the present insulated container has a shape of a regular parallelepiped, including but not limited to a cube or a rectangular cuboid. Thus, in at least one embodiment, the faces of the regular parallelepiped are rectangular or square and the internal angles of the vertices of the regular parallelepiped are about 90°. Such a shape is advantageous in that it allows for convenient and efficient stacking and packing of the present insulated containers to facilitate storage and shipping and minimize unused space in transport containers or vehicles or storage facilities.

[0031] In at least one embodiment in which the present insulated container has a shape of a regular parallelepiped as described above, the present insulated container can contain features which enhance its stackability with similar insulated containers. As used herein, the term “stackability” is intended to mean the capability of the present insulated container to be stacked vertically and / or horizontally, so as to minimize the presence of empty space between the stacked insulated containers. In at least one embodiment, features which enhance stackability include but are not limited to protrusions and matching recesses on the insulated container, configured such that protrusions on a first insulated container can be received into the matching recesses on a second insulated container stacked adjacent to the first insulated container. For example, protrusions located on the upper surface of the first insulated container may be received into matching recesses located on the lower surface of the second insulated container. Alternatively, recesses located on the upper surface of the first insulated container may receive matching protrusions located on the lower surface of the second insulated container. The person of skill in the art will be aware of other stackability-enhancing features in view of the teaching of the present description.

[0032] In at least one embodiment, the present insulated container can have any size which is convenient for transporting a desired temperature-sensitive material. In at least one embodiment, the present insulated container can have internal height, width and depth dimensions, each between about 5 inches and about 20 inches. In at least one embodiment, the present insulated container has internal dimensions similar to those of current standard shipping containers, including but not limited to about 8 inches wide by about 6 inches deepby about 7 inches high or about 8 inches wide by about 9 inches deep by about 10 inches high. However, smaller and larger embodiments of the present insulated container are also contemplated to accommodate contents of various sizes or amounts as needed, and can be readily made and used by the skilled person in view of the teaching of the present description.

[0033] In at least one embodiment, the present insulated container is free of hinges, handles, wheels or other exterior surface features which may impede efficient stacking or packing of the insulated container. In at least one alternative embodiment, the present insulated container may contain one or more exterior handles to facilitate loading and handling of the present insulated container by workers. In at least one embodiment, such handles may be in the form of recessed indentations formed in opposing outer walls of the insulated container and permitting the insulated container to be conveniently lifted and / or carried by a worker, as will be understood by those skilled in the art. Embodiments including such recessed indentations may advantageously facilitate stacking of the present insulated container. Such alternative embodiments including handles or such recessed indentations may be advantageously used to transport contents including but not limited to fresh foods and food products.

[0034] The present insulated container includes one or more insulated walls which together define an interior space for receiving the temperature-sensitive material. In at least one embodiment, one or more of the insulated walls of the present insulated container can form a body portion surrounding the interior space, while one of the insulated walls of the present insulated container can be formed as a lid which can be placed on the body portion to complete the enclosure of the interior space and prevent heat transfer between the interior space and the exterior of the insulated container.

[0035] In at least one embodiment, the temperature-sensitive material may be contained in one or more individual packages which can be received into the interior space of the body portion. In at least one embodiment, additional packaging material may be received in the interior space to further protect the temperature-sensitive material from damage during transport. In at least one embodiment, such additional packaging material includes, but is not limited to, paper, cardboard or corrugated cardboard, foam wrap, bubble wrap, expanded foam pieces, including but not limited to expanded polystyrene “peanuts”, “popcorn” or “noodles”, sealed air-filled inflated bags or pillows, and other such packaging materials known in the art to cushion and protect materials during transport. Such additional packaging material may form part of the packaging of individual packages of the temperature-sensitive material and / or may be inserted separately into the interior space to fill spaces between the one or more individual packages of temperature-sensitive material.

[0036] In at least one embodiment, the interior space may also receive a temperature controlling material to maintain the temperature-sensitive material at a temperature or temperature range at which damage to or degradation or spoilage of the temperaturesensitive material is reduced, minimized or prevented. In at least one embodiment, the temperature controlling material is a cooling material which can maintain the temperature of the temperature-sensitive material at a temperature lower than that of the ambient surroundings. Such cooling materials are well known in the art and include but are not limited to water ice and ice packs, dry ice (solid carbon dioxide, including but not limited to in the form of pellets or chunks having dimensions ranging from about 0.5 inch to several inches or more, as is known in the art), and gel packs which can be frozen or chilled to a desired temperature, including but not limited to gel packs containing water, additives which lower the freezing point of the gel or help maintain its fluidity at colder temperatures, such as salts, glycerol or propylene glycol, and polymers such as sodium polyacrylate or hydroxyethyl cellulose. It is also contemplated that the temperature controlling material can be a warming material which can maintain the temperature of the temperature-sensitive material at a temperature higher than that of the ambient surroundings. The skilled person would be readily able to select the type and amount of temperature controlling material appropriate for transport of a particular shipment of temperature-sensitive material in a present insulated container in view of the teaching of the present application. Once the temperature-sensitive material and, optionally, the temperature controlling material is placed inside the interior space of the body portion, the lid can be put in place to enclose and seal the interior space.

[0037] The one or more insulated walls include one or more outer walls comprising a first plastic material and one or more inner walls comprising a second plastic material. The one or more inner walls form a contiguous surface adjoining the interior space and, in use, may come into contact with the temperature-sensitive material and any temperature controlling material which may be present in the interior space. Thus, in at least one embodiment, any temperature-sensitive material or temperature controlling material which may have spilled or leaked from its individual packaging inside the interior space may be kept contained within the contiguous surface formed by the one or more inner walls.

[0038] In at least one embodiment, the first plastic material may be identical to the second plastic material. In at least one alternative embodiment, the first and second plastic materials may be different from each other. As used herein, the term “plastic” is intended to mean a wide range of synthetic or semi-synthetic materials that include one or more polymers. The plasticity of such materials makes it possible for a plastic material to be molded, extruded or pressed into solid objects of various shapes. Plastic materials include but are not limited tothermoplastic materials which can be heated with minimal or no change in their chemical composition and which can therefore be re-shaped repeatedly by heating the thermoplastic material to melt or soften it, re-shaping the softened or melted thermoplastic material by molding, injection molding, extrusion, pressing or other re-shaping methods known in the art, and re-cooling the re-shaped material to harden and set it.

[0039] In at least one embodiment, the first and / or second plastic material is a thermoplastic material. In at least one embodiment, the first and / or second plastic material is hard or rigid at temperatures at which the present insulated container is contemplated for use, including but not limited to ambient or internal temperatures ranging from about -80°C to about 40°C. Such embodiments may be advantageous in that the insulated container can be more resistant to damage from crushing or breakage compared to containers made of cardboard or expanded polystyrene foam, providing better protection for fragile or potentially hazardous contents.

[0040] In addition, such embodiments may be advantageous in that the outer and inner walls can be readily cleaned and sanitized, deodorized or disinfected in case of exposure to odiferous or biohazardous material. In at least one embodiment, the outer and inner walls can be cleaned, sanitized, deodorized and / or disinfected by washing, spraying or wiping with a cleaning agent, deodorizer and / or disinfectant, including but not limited to an aqueous detergent or soap solution; bleach or aqueous sodium hypochlorite solution, for example, at a concentration of 0.1% to 0.5% NaOCI; an alcoholic disinfectant, including but not limited to ethanol and isopropanol, for example, 60%-90% aqueous ethanol; a quaternary ammonium compound disinfectant; and hydrogen peroxide solution, for example at a concentration of at least 0.5% H2O2. Furthermore, such embodiments of the present insulated container can be advantageously durable through multiple cycles of cleaning and re-use.

[0041] In at least one embodiment, the surfaces of the inner walls and the outer walls of the present insulated container are smooth, flat and free from grooves, ridges or other surface features which might impede efficient cleaning, sanitization, deodorization or disinfection. In embodiments of the present insulated container having protrusions and matching recesses to facilitate stacking, and / or having handles in the form of recessed indentations in opposing outer walls, the protrusions and matching recesses and / or recessed indentations are also advantageously smooth, flat and free from grooves, ridges or other surface features which might impede efficient cleaning, sanitization, deodorization or disinfection.

[0042] In at least one embodiment, the first and / or second plastic material is recyclable. Such embodiments of the present insulated container may be advantageous in that, if the outer or inner walls become damaged or no longer suitable for use, or if the insulatedcontainer reaches the end of its service life, the plastic material can be recycled for use to form new plastic products.

[0043] Suitable first and / or second plastic materials include but are not limited to polyethylene (PE), including high density polyethylene (HDPE), linear low density polyethylene (LLDPE) and low density polyethylene (LDPE), polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyvinyl chloride (PVC). In at least one embodiment, the first and / or second plastic material is polypropylene (PP), polyethylene (PE), high density polyethylene (HDPE) or linear low density polyethylene (LLDPE). In at least one embodiment, the first and / or second plastic material is acrylonitrile butadiene styrene (ABS). In at least one embodiment, the first plastic material is polypropylene (PP), high density polyethylene (HDPE) or linear low density polyethylene (LLDPE). In at least one embodiment, the second plastic material is polyethylene (PE) or polytetrafluoroethylene (PTFE). Such embodiments may be advantageous in that polyethylene and polytetrafluoroethylene are effective at resisting breakage at temperatures near or below -20°C, to which the one or more inner walls may be exposed during use, especially if cooling materials such as dry ice (with a sublimation temperature of -78.5°C) are used as a temperature controlling material. The person of skill in the art would be readily able to identify and select suitable first and / or second plastic materials in view of the teaching of the present application based on considerations including but not limited to ease of re-shaping or molding, rigidity and resistance to breakage at low temperatures.

[0044] In embodiments of the present insulated container intended for use with temperature controlling materials such as dry ice, so as to maintain an extremely cold interior temperature (for example, -70°C to -80°C), it is contemplated that the interior space of the insulated container may be lined with a material including but not limited to cardboard or rubber to further insulate the temperature-sensitive material and the temperature controlling material.

[0045] In at least one embodiment, the one or more outer walls and / or the one or more inner walls have a thickness of at least 0.5 mm. In at least one embodiment, the one or more outer walls and / or the one or more inner walls have a thickness of at least 1 mm to 2 mm or more. Advantageously, the one or more outer walls and / or the one or more inner walls are thick enough to withstand stress and shocks expected to be experienced during transport or shipping.

[0046] The one or more outer walls are separated from the one or more inner walls to define one or more insulation compartments between the one or more outer walls and the one or more inner walls. The one or more insulation compartments are configured to receiveinsulation material. In at least one embodiment, the insulation material inside the insulation compartments is advantageously protected from exposure to the contents of the interior space by the one or more inner walls. As used herein, the term “insulation material” is intended to mean material used in thermal insulation to reduce heat transfer between objects having a different temperature from each other. Suitable insulation material generally has a low thermal conductivity and includes but is not limited to wood pulp products, including but not limited to cardboard or paper, plant fibers, including but not limited to coconut shells or agave plant fibers, plastic foams including but not limited to polystyrene foam, expanded polystyrene foam or expanded polypropylene foam, fiberglass, mineral wool, cellulose, polyisocyanurate, polyurethane, perlite, cementitious foam, phenolic foam, rubber, silicone, and other insulation materials well known to those skilled in the art.

[0047] In at least one advantageous embodiment, the insulation material is recyclable and / or biodegradable. In at least one such embodiment, the insulation material is a wood pulp product, including but not limited to paper cardboard. In at least one such embodiment, the insulation material is prepared from plant fibres. In at least one alternative embodiment in which the insulation material is difficult to recycle, such as, for example, a plastic foam, the insulation material may be reprocessed for re-use. Such reprocessing methods may include but are not limited to autoclaving, UV irradiation, electron beam irradiation and exposure to a disinfectant such as bleach to remove any microorganisms, including but not limited to viruses, bacteria, fungi or mold that may have contaminated the insulation material.

[0048] In at least one embodiment, the insulation material fits snugly inside the one or more insulation compartments. In at least one embodiment, the insulation material can be in the form of sheets which can be stacked together to fill the insulation compartments. In at least one alternative embodiment, the insulation material can be in the form of a single sheet or block dimensioned and configured to fill one or more of the insulation compartments. In at least one such embodiment, the insulation material can be formed to include air pockets or cavities, such as, for example, sheets or blocks of corrugated cardboard. In at least one such embodiment, the insulation material can include folds between segments such that a single continuous or unitary piece of insulation material can be used to fill more than one insulation compartment.

[0049] The one or more insulation compartments have a thickness which can be defined by the distance by which the one or more outer walls are separated from the one or more inner walls. In at least one embodiment, the one or more insulation compartments can have a thickness of between about 0.5 inch and about 2 inches. In at least one embodiment, the one or more insulation compartments can have a thickness of about 1 inch. Those skilled in the art can determine a suitable thickness of the one or more insulation compartments,based on, for example, the insulation properties of the insulation material and the length of time the temperature-sensitive material and other contents of the insulated container need to be kept at the requisite temperature and the desired size of the insulated container.

[0050] The one or more outer walls are separated from the one or more inner walls to form the one or more insulation compartments by one or more separation elements. In at least one embodiment, the one or more separation elements can be one or more projections connected to or unitary with the one or more outer walls or the one or more inner walls. The one or more projections can extend from the one or more outer walls and the one or more inner walls at an edge or from a surface of the one or more outer walls and the one or more inner walls. When the one or more projections extend from an edge of the one or more outer walls or the one or more inner walls, the edge projections may extend along the length of the edge or multiple edge projections may project from a number of isolated locations along the edge. Thus, in at least one embodiment, the one or more edge projections can form a rim or flange extending along at least one edge of the one or more outer walls or the one or more inner walls. In at least one alternative embodiment, the one or more projections can project from a surface of the one or more outer walls and the one or more inner walls, for example, in the form of pillars or struts.

[0051] In at least one embodiment, the one or more projections can project from the one or more outer walls and the one or more inner walls at an angle of from about 30° to about 150°. In at least one embodiment, the one or more projections can project from the one or more outer walls and the one or more inner walls at an angle of from about 60° to about 120°. In at least one embodiment, the one or more projections can project from the one or more outer walls and the one or more inner walls at an angle of about 45° or about 135°. In at least one embodiment, the one or more projections can project from the one or more outer walls and the one or more inner walls at an angle of about 90°.

[0052] At least one of the one or more separation elements is configured to reversibly engage at least one of the one or more outer walls or the one or more inner walls, so as to reversibly connect at least one of the one or more outer walls to at least one of the one or more inner walls and allow ready access to the one or more insulation compartments. In at least one embodiment, the at least one of the one or more separation elements can include one or more fasteners which can reversibly engage one or more complementary fasteners in the at least one of the one or more outer walls or the one or more inner walls. Any suitable fasteners known in the art may be used to reversibly connect the one or more separation elements to the at least one of the one or more outer walls or the one or more inner walls, such that the fasteners can be readily disengaged from each other to disconnect the at least one of the one or more outer walls from the at least one of the one or more inner walls.

[0053] In at least one embodiment in which the one or more separation elements are one or more edge projections extending from an edge of the one or more outer walls or the one or more inner walls, the one or more fasteners can include but are not limited to one or more tabs located on the one or more edge projections, each of which can be resiliently snapped, slid or rotated into engagement with a complementary recess located on the at least one of the one or more inner walls or the one or more outer walls. In at least one alternative embodiment in which the one or more separation elements are one or more edge projections extending from an edge of the one or more outer walls or the one or more inner walls, the one or more fasteners can include but are not limited to a detent on a resilient tongue which engages a complementary detent on a complementary fastener with a snap fit or a clasping fit. In at least one embodiment in which the one or more separation elements are one or more pillars or struts projecting from the surface of one of the one or more inner walls or the one or more outer walls, the one or more fasteners can include one or more complementary recesses located on the other of the one or more inner walls or the one or more outer walls into which the one or more pillars or struts can be snugly received with a sliding friction fit.

[0054] The connection of the one or more separation elements to the at least one of the one or more outer walls and the one or more inner walls can allow transfer of heat between the one or more outer walls and the one or more inner walls through the material of the one or more separation elements by conduction, thereby slightly reducing the effectiveness of the interior space to maintain a temperature different from that of the environment and the surrounding outer walls. Therefore, it is advantageous if the separation elements, or portions of the inner or outer walls to which the separation elements connect, comprise a minimum of material and / or if the separation elements contact the one or more outer walls and the one or more inner walls with a minimum of contact area. Thus, in at least one embodiment in which the one or more separation elements are one or more edge projections extending from an edge of the one or more outer walls or the one or more inner walls, the one or more edge projections, or the one or more portions of the inner or outer walls to which the separation elements connect, can include one or more openings to reduce the amount of material through which heat may be transferred between the one or more outer walls and the one or inner walls by conduction. Suitable embodiments include but are not limited to edge projections or portions of the inner or outer walls to which the separation elements connect having openings arranged in a repeating or lattice pattern. In such embodiments, the material between the openings can have a cross-sectional area which is sufficient to avoid breakage under the stresses experienced by the insulated container during handling and transport. Similarly, in one or more alternative embodiments in which the one or more separation elements are one or more pillars or struts projecting from the surface of one ofthe one or more inner walls or the one or more outer walls, the pillars or struts can have a cross-sectional area which reduces heat transfer between the one or more inner walls and the one or more outer walls, but which maintains a connection between the one or more inner walls and the one or more outer walls which is resistant to breaking under such stresses.

[0055] Disengagement of the at least one of the one or more separation elements from the at least one of the one or more outer walls or the at least one of the one or more inner walls provides access to the one or more insulation compartments for addition or removal of the insulation material. Thus, the insulation material may be contained inside the insulation compartments and separated from the interior space and the exterior of the insulated container by engaging the one or more separation elements with the one or more outer walls and / or the one or more inner walls. This can serve to protect the insulation material from exposure to the environment or to the contents of the interior space. However, if it is desired to remove or add insulation material in the one or more insulation compartments, the one or more separation elements can be disengaged, providing ready access to the one or more insulation compartments.

[0056] In use, an insulated container according to the present application can be assembled by positioning insulation material between the one or more inner walls and the one or more outer walls, and engaging the one or more separation elements with the one or more inner walls or the one or more outer walls to form the one or more insulated walls. In at least one embodiment, the one or more insulated walls can be assembled individually by connecting each outer wall separately to a corresponding inner wall to form an individual or modular insulated panel containing insulation material between the outer wall and the inner wall. In such embodiments, the one or more insulated panels can be arranged or reversibly attached to each other to form a body assembly of the present insulated container such that the one or more inner walls form a contiguous surface adjoining an interior space. In at least one embodiment, the one or more insulated panels can be attached to each other with removable fasteners including but not limited to screws; or adhered to each other with an adhesive which allows the adhered panels to be readily released and separated from each other; or enclosed in an outer container such as a cardboard box, from which the panels can be easily removed. In at least one embodiment, a separate assembled insulated panel can serve as a lid for the present insulated container.

[0057] In one or more alternative embodiments, a series of inner walls can be attached to each other or molded to form a unitary inner body, in which the inner walls form a contiguous surface adjoining an interior space. Similarly, a series of outer walls can be attached to each other or molded to form a unitary outer body, the outer body being sized and dimensioned toenclose the inner body and to form insulation compartments between the inner walls of the inner body and the outer walls of the outer body. One or more separation elements can be attached to or formed unitarily with one or more of the inner body and the outer body and configured to reversibly engage the other of the inner body and the outer body as described herein. Insulation material can then be placed against the outer walls of the outer body such that when the inner body is placed inside the outer body, the insulation material is contained between each inner wall and the corresponding outer wall. The one or more separation elements can then be engaged with the inner body or the outer body to enclose the insulation material and form an alternative embodiment of a body assembly of the present insulated container. Again, in at least one embodiment, a separate assembled insulated panel can serve as a lid for the present insulated container.

[0058] Thus, once the present insulated container is formed, temperature-sensitive material can be placed in the interior space of the insulated body assembly, optionally along with a temperature controlling material and / or additional packaging material, and an insulated lid can be placed on the body assembly to enclose and seal the interior space. In at least one embodiment, the lid can be sealed to the body assembly, for example, with tape prior to transport. In at least one embodiment, the insulated container can be placed inside a shipping container, such as, for example, a cardboard shipping box prior to transport. To facilitate transport, a shipping label or waybill indicating directions for shipping or transport can be affixed to the insulated container or to an exterior shipping container such as a cardboard box in which the insulated container is placed. Once transport is complete, the lid can be removed from the insulated container and the temperature-sensitive material and any temperature controlling material can be removed from the interior space.

[0059] In at least one embodiment, the present insulated container can be returned to an identified location for reuse. Thus, in at least one embodiment, the shipping label or waybill can include an indication that the insulated container is returnable to an identified location, including but not limited to the sender of the contents of the insulated container, the originator of the insulated container or a facility for re-using or recycling the insulated container.

[0060] In at least one embodiment, the indication can include a scannable code, including but not limited to a QR code or a bar code. In such embodiments, when the code is scanned by a device such as a cell phone or tablet which is connected to the internet, information can be displayed on an application installed on the device. Such information can include, but is not limited to, a return procedure by which the insulated container can be sent to the identified location, the number of times the insulated container has been previously reused, possible impact on the environment of returning or not returning the insulated container, andthe like. Without being bound by theory, it is contemplated that such an indication can provide an incentive to the recipient of the insulated container to return the insulated container, and can facilitate that return. In addition, when the code is scanned by a device such as a cell phone or tablet which is connected to the internet, information may be sent to one or more recipients at the identified location indicating an intent to return the insulated container.

[0061] Furthermore, in at least one embodiment, a return shipping label or waybill can be provided with or pre-affixed to the insulated container to facilitate return of the insulated container to the identified location. In at least one embodiment, the return shipping label or waybill is not visible during transport of the insulated container and its contents to the recipient, but can be exposed or affixed for return to the identified location so as to be visible during the return transport.

[0062] Once the present insulated container has been emptied at its destination and / or returned to the identified location, the lid and body assembly of the empty insulated container can be cleaned, sanitized, deodorized, or disinfected as described herein and reused. In at least one embodiment, the present insulated container may be able to be reused at least 10 times, or up to 50 times or 100 times or more. The expected service life or maximum number of uses of embodiments of the present insulated container can be readily determined by the skilled person by routine and / or periodic quality testing, for example.

[0063] Alternatively, the insulated container can be disassembled, for example, for replacement of insulation material, or if the container is damaged or showing signs of failure, has undergone a pre-determined maximum number of uses or is at the end of its service life. In embodiments in which the body assembly has been assembled from individual insulated panels, the panels can be separated from each other by removing any fasteners or adhesive holding the panels together, or by removing the panels from an enclosing container. The individual panels of the body assembly and the lid can then each be disassembled by disengaging the separation elements so as to disconnect the inner walls from the outer walls, and the insulation material can be removed from the insulation compartments. In embodiments in which the body assembly has been assembled from an inner body and an outer body, the inner body can be disconnected from the outer body by disengaging the one or more separation elements and the insulation material can be removed from the insulation compartments. The disassembled insulation material can be recycled, composted or disposed of, and the plastic inner and outer walls of the disassembled lid and panels or the plastic inner and outer bodies of the body assembly can be stored for reassembly with reused or new insulation material when needed or, if damaged or at the end of their service life, can be recycled.

[0064] An embodiment of the present insulated container is shown in Figure 1. Insulated container 10 includes a lid assembly 20 and a body assembly 40 having an interior space 50. Lid assembly 20 includes outer wall 22, inner wall 24 and edge projections or rims 26 separating outer wall 22 from inner wall 24. As best seen in Figure 2, edge projections 26 projecting from outer wall 22 include tabs 32 which engage recesses 34 on inner wall 24 to connect outer wall 22 to inner wall 24 and form insulation compartment 28 to enclose insulation material 30. In addition, inner wall 24 of lid assembly 20 includes interior portion 36 and flanking portions 38. In at least one embodiment, interior portion 36 is raised or is bounded by a raised border 37, and is sized to fit within interior space 50 so as to facilitate closure of lid assembly 20 onto body assembly 40 in use.

[0065] Returning to Figure 1 , body assembly 40 includes outer walls 42 on the sides and bottom of the body assembly, inner walls 44 adjoining interior space 50 on the sides and bottom of the interior space 50, and edge projections or rims 46 separating the upper edges of outer walls 42 from the upper edges of inner walls 44 to enclose insulation compartments 48, containing insulation material 30.

[0066] In at least one embodiment, body assembly 40 can be assembled from insulated panels 60. As seen in Figure 3A, insulated panel 60 can be assembled similarly to lid assembly 20, by inserting insulation material 30 into insulation compartment 48 formed by edge projections 46 and outer wall 42. Recesses 34 in inner wall 44 can then be brought into engagement with tabs 32 in edge projections 46 to enclose insulation material 30 between outer wall 42 and inner wall 44. Panels 60 can then be assembled into body assembly 40 by using fasteners such as screws to attach the panels 60 to each other at pre-drilled receptacles 62, as seen in Figure 3B. Alternatively, the panels can be assembled into body assembly 40 by insertion into an outer container 64, such as, for example, a cardboard shipping box. As will be evident to the skilled person, in such embodiments, the panels 60 can be sized and shaped to form an insulated container 10 of desired dimensions or to fit snugly within the inner dimensions of the outer container 64. Thus, it is contemplated that the panels used to form the present body assembly can be identical or different from each other in size and shape. In either case, once body assembly 40 has been assembled, temperature-sensitive material can be inserted into interior space 50, optionally along with temperature controlling material and / or additional packaging material, and lid assembly 20 can be aligned with box assembly 40 such that interior portion 36 of inner wall 24 fits inside interior space 50. The assembled insulated container 10 can then be prepared for shipping by sealing the lid assembly to the body assembly, for example with shipping tape, or by placing the insulated container 10 inside a cardboard shipping box and sealing the box, and affixing appropriate shipping labels.

[0067] When it is appropriate or necessary to disassemble the insulated container 10, the panels 60 can be removed from the outer container 64 or disassembled by removing any fasteners holding the panels together. Each panel can then be disassembled by disengaging tabs 32 from recesses 34, optionally by using a commonly available tool such as a screwdriver, removing inner wall 24, 44 from engagement with edge projections 26, 46, and removing insulation material 30 from insulation compartment 28, 48. Each of the inner and outer walls, edge projections and insulation material can then be reused or recycled.

[0068] An alternative embodiment of the body assembly 140 is shown in Figure 4. In this embodiment, outer walls 42 of the body assembly form the sides and bottom of an outer body 142 and inner walls 44 form the sides and bottom of an inner body 144. Inner body 144 is smaller than outer body 142 in width, length and height, such that insulation compartments 148 are present between inner walls 44 and outer walls 42 on the sides and bottom of body assembly 140. Rim or edge projection 146 surrounds inner body 144 and contains fasteners 134 in the form of a recess which can engage complementary fasteners 132 in the form of a tab on outer body 142. In an alternative embodiment, shown in Figure 5, edge projection 146 can include a resilient tongue 234 containing a detent which can engage, with a snap fit, a complementary detent in recess 232 located on the interior surface of an outer wall 42 of outer body 142.

[0069] In use, when assembling body assembly 140, insulation material 30 is placed within outer body 142 so as to line the side and bottom outer walls 42 of outer body 142. The insulation material 30 may be in the form of separate pieces, each of which is placed against a different outer wall 42 at the sides and bottom of outer body 142. Alternatively, the insulation material 30 may be in the form of one or more unitary pieces containing folds to facilitate placement of portions of the insulation material 30 against the side and bottom outer walls 42 of outer body 142 simultaneously. Inner body 144 is then placed within outer body 142 and the fasteners 132 and 134, or 232 and 234, are mutually engaged to enclose the insulation material 30 in insulation compartments 148. Temperature-sensitive material and optionally, temperature controlling material and / or additional packaging material can then be placed in interior space 50 of assembled body assembly 140, and lid assembly 20 can be placed on body assembly 140 to enclose interior space 50. The closed insulated container can then be used to transport temperature-sensitive material as described previously. At the end of its service life, disassembly of body assembly 140 can be readily accomplished by disengaging fasteners 132, 232 from fasteners 134, 234 and removing inner body 144 to expose insulation material 30 inside outer body 142 for removal and recycling. The outer body 142 and inner body 144 can also be recycled.

[0070] In at least one embodiment, illustrated in Figures 6A, 6C and 6D, edge projections 46, 146 may include openings 65 in order to minimize heat transfer between inner wall 44 or inner body 144 and outer wall 42 or outer body 142 of the body portion by conduction through the material of edge projections 46, 146. Similarly, as seen in Figure 6B, flanking portions 38 of inner wall 24 of lid assembly 20 may also include openings 65 to minimize heat transfer between interior portion 36 of inner wall 24 and edge projections 26. As will be understood by one skilled in the art in view of the teaching of the present description, the openings may have any pattern which will allow edge projections 46, 146 to separate and repeatedly engage and disengage inner wall 44 or inner body 144 and / or outer wall 42 or outer body 142 of the body portion, or will allow edge projections 26 to separate and repeatedly engage and disengage flanking portions 38 of the lid assembly, without undergoing breakage, allowing for repeated assembly and disassembly of the insulated container 10.

[0071] In at least one alternative embodiment, inner walls 24, 44 or inner body 144 and outer walls 22, 42 or outer body 142 can be connected by separation elements in the form of pillars 66 or legs 68 mounted on or unitary with outer wall 22, 42 or outer body 142 or mounted on or unitary with inner wall 24, 44 or inner body 144, as seen in Figures 7A and 7B, respectively. In such embodiments, inner wall 24 of the lid includes interior portion 36 but may or may not include flanking portions 38 or, if present, flanking portions 38 may or may not engage edge projections 26. Pillars 66 or legs 68 can fit into corresponding sockets located on the complimentary inner wall 24, 44 or inner body 144 or outer wall 22, 42 or outer body 142 to reversibly separate and connect outer wall 22, 42 or outer body 142 and inner wall 24, 44 or inner body 144 and form insulation compartments 28, 148. Insulation 30 can be arranged around the pillars 66 or legs 68 in insulation compartments 28, 148. This alternative arrangement also serves to minimize heat transfer between the outer walls 22, 42 and the inner walls 24, 44 by conduction.

[0072] As used herein, the terms “a” and “an” are intended to mean “at least one”, and include both singular and plural, unless otherwise indicated.

[0073] As used herein, the terms “about” or “approximately” as applied to a numerical value or range of values are intended to mean that the recited values can vary within an acceptable degree of error for the quantity measured given the nature or precision of the measurements, such that the variation is considered in the art as equivalent to the recited values and provides the same function or result. For example, the degree of error can be indicated by the number of significant figures provided for the measurement, as is understood in the art, and includes but is not limited to a variation of ±1 in the most precise significant figure reported for the measurement. Typical exemplary degrees of error arewithin 20 percent (%), preferably within 10%, and more preferably within 5% of a given value or range of values. Alternatively, and particularly in biological systems, the terms "about" and "approximately" can mean values that are within an order of magnitude, preferably within 5-fold and more preferably within 2-fold of a given value. Numerical quantities given herein are approximate unless stated otherwise, meaning that the term "about" or "approximately" can be inferred when not expressly stated.

[0074] As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” in a given position including but not limited to vertical, horizontal, or adjacent to or aligned with another object, would mean that the object is either completely in that position or nearly completely in that position. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.

[0075] The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, a composition that is “substantially free of’ an ingredient or element would either completely lack that ingredient or element, or so nearly completely lack that ingredient or element that the effect would be the same as if it completely lacked that ingredient or element. In other words, a composition that is “substantially free of’ an ingredient or element may still actually contain such item as long as there is no measurable or significant effect thereof.

[0076] As used herein, terms indicating relative direction or orientation, including but not limited to “upper”, “lower”, “top”, “bottom”, “vertical”, “horizontal”, “outer”, “inner”, “front”, “back”, and the like, are intended to facilitate description of the present invention by indicating relative orientation or direction in usual use, and are not intended to limit the scope of the present invention in any way to such orientations or directions.EXAMPLES

[0077] Other features of the present invention will become apparent from the following nonlimiting examples which illustrate, by way of example, the principles of the invention.Example 1 : Efficacy of cardboard as insulating material

[0078] A prototype of the present insulated container was prepared by placing a smaller polypropylene container (8.9 inches wide; 6.45 inches deep, 5.15 inches high) into a larger polypropylene container (12.75 inches wide; 9.3 inches deep, 7.65 inches high) and inserting corrugated cardboard sheets (2.5 mm thickness and cut to fit the available space) asinsulation material around and under the smaller container to fill the space between the two containers. A temperature sensor (Inkbird IBS-TH2 Wireless Bluetooth Thermometer) and two ice packs (Ice-Brix, type IB 8, Polar Tech industries, Inc. Illinois; pre-chilled at -20°C for at least 72 hours) were placed inside the smaller inner container and the lid of the smaller container was secured in place. Further corrugated cardboard sheets were placed on the closed lid of the smaller container and the lid of the larger outer container was secured in place over the cardboard sheets. A similar temperature sensor and two similar ice packs were added to an uninsulated control polypropylene container (10.6 inches x 7.6 inches x 6.3 inches) and the lid of the control container was secured in place. The interior temperature of the inner container of the prototype insulated container and of the uninsulated control container were allowed to equilibrate with the ambient room temperature and were measured at regular intervals for about 22 hours using the Engbird temperature logger app software. The data was analyzed using Excel.

[0079] As seen from the data presented in Figure 8A, the temperature of the interior of the prototype insulated box was maintained well below 8°C (the maximum temperature considered suitable for transporting certain temperature-sensitive materials) for at least 20 hours and showed a minimal fluctuation of ±1 °C. In contrast, the interior temperature of the uninsulated control container increased above the threshold of 8°C after only about 15 hours. These results demonstrate that corrugated cardboard is an effective insulation material for the present insulated container.Example 2: Efficacy of plant fibres as insulating material

[0080] A further prototype of the present insulated container was prepared as described in Example 1 , except that the smaller polypropylene container had dimensions of 7.5 inches wide; 4.3 inches deep, 5.7 inches high, the larger polypropylene container had dimensions of 13.8 inches wide; 7.5 inches deep, 9.4 inches high) and scrubbing pads (SCRUBIT™ Natural Scouring Pads) made of plant-based fiber (coconut shells and agave fibers) were used as insulating material. An uninsulated control polypropylene container had dimensions of 11 inches x 6.7 inches x 8.2 inches. The interior temperature of the inner container of the prototype insulated container and of the uninsulated control container were measured as described in Example 1 for about 45 hours.

[0081] As seen from the data presented in Figure 8B, the temperature of the interior of the prototype insulated container was maintained below 8°C for at least 35 hours and increased by only 4°C over that time. In contrast, the interior temperature of the uninsulated control container could only be maintained below 8°C for about 10 hours. These results demonstrate that plant-based fiber is an effective insulation material for the present insulated container.Example 3: Ability to withstand treatment with bleach

[0082] A 10% aqueous solution of bleach (final concentration of NaOCI estimated at about 0.25% - 1%) was dabbed on the surface of a polypropylene container with a paper towel and allowed to stand for one minute before being removed. The bleach treatment and removal was repeated 10 times. A container made of polyacrylonitrile-butadiene-styrene (ABS) was similarly treated in a separate experiment. In both cases, no noticeable effect was observed on the appearance of the plastic material, indicating that 10% bleach is a suitable cleaning and disinfection agent for the plastic surfaces of the present insulated container.Example 4: Insulating efficiency compared to expanded polystyrene foam

[0083] Seven gel packs pre-chilled to -12°C and two temperature sensors similar to that described in Examples 1 and 2 were placed in the interior space of an embodiment of the present insulated container including a lid as shown in Figure 1 and having inner and outer walls molded from polyacrylonitrile-butadiene-styrene (ABS). The internal dimensions of the interior space of the closed insulated container were 8 inches in length x 5.75 inches in width x 7 inches in height and the external dimensions of the closed insulated container were 11 inches in length x 9.5 inches in width x 11 inches in height, to define insulation compartments between the inner and outer walls of approximately 1 to 2 inches in thickness, into which paper cardboard was inserted as insulation material. Similar pre-chilled gel packs and a similar temperature sensor were placed in a standard expanded polystyrene foam (EPF; Styrofoam™) container (7 inches height x 8.5 inches width x 8 inches depth) currently used for shipping temperature-sensitive materials. The interior temperature of both the present insulated container and the comparison EPF container were monitored and recorded as described in Example 1 over a period of about 51 hours. The data were downloaded and analyzed using Excel software.

[0084] As seen from the data presented in Figure 9, an embodiment of the present insulated container showed at least comparable temperature control to a EPF container of comparable size over a period of at least 40 hours and in fact maintained a cooler interior temperature for a longer period of time than the EPF container.

[0085] The embodiments described herein are intended to be illustrative of the present compositions and methods and are not intended to limit the scope of the present invention. Various modifications and changes consistent with the description as a whole and which are readily apparent to the person of skill in the art are intended to be included. The appended claims should not be limited by the specific embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole.

Claims

CLAIMS1 . An insulated container for transporting a temperature-sensitive material, the container comprising one or more insulated walls defining an interior space configured to receive the temperature-sensitive material, the one or more insulated walls comprising: one or more outer walls comprising a first plastic material; one or more inner walls comprising a second plastic material, the one or more inner walls forming a contiguous surface adjoining the interior space; one or more separation elements separating the one or more outer walls from the one or more inner walls to define one or more insulation compartments between the one or more outer walls and the one or more inner walls; and insulation material, wherein the one or more insulation compartments are configured to receive the insulation material; wherein at least one of the one or more separation elements is configured to reversibly engage at least one of the one or more outer walls or at least one of the one or more inner walls so as to reversibly connect at least one of the one or more outer walls to at least one of the one or more inner walls, whereby disengagement of the at least one of the one or more separation elements from the at least one of the one or more outer walls or the at least one of the one or more inner walls provides access to the one or more insulation compartments for addition or removal of the insulation material.

2. The insulated container of claim 1 comprising a body portion and a lid, wherein the body portion comprises one or more of the one or more insulated walls to define the interior space, wherein the one or more inner walls comprise one or more inner walls of the body portion and wherein the one or more outer walls comprise one or more outer walls of the body portion; and wherein the lid comprises at least one of the one or more insulated walls and is configured to reversibly engage the body portion so as to enclose the interior space.

3. The insulated container of claim 2 wherein the body portion is assembled from a plurality of individual insulated panels.

4. The insulated container of claim 2 wherein the body portion is assembled from a unitary inner body comprising the one or more inner walls of the body portion and a unitary outer body comprising the one or more outer walls of the body portion.

5. The insulated container of any one of claims 1 to 4 wherein the one or more separation elements comprise one or more edge projections unitary with one or more of the one or more inner walls or the one or more outer walls.

6. The insulated container of claim 5 wherein the one or more edge projections comprise one or more openings.

7. The insulated container of any one of claims 1 to 6 having a shape of a rectangular cuboid.

8. The insulated container of any one of claims 1 to 7 wherein the insulated container is stackable with a second insulated container.

9. The insulated container of any one of claims 1 to 8 wherein the first plastic material is the same as the second plastic material.

10. The insulated container of any one of claims 1 to 9 wherein the first plastic material and the second plastic material are each selected from polyethylene (PE), polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyvinyl chloride (PVC).11 . The insulated container of any one of claims 1 to 10 wherein the insulation material comprises cardboard or plant fiber.

12. The insulated container of any one of claims 1 to 11 wherein one or more of the first plastic material, the second plastic material or the insulation material is recyclable.

13. A method of transporting a temperature-sensitive material, the method comprising placing the temperature-sensitive material in an interior space of an insulated container according to any one of claims 1 to 12 and transporting the insulated container.

14. The method of claim 13 further comprising placing a temperature controlling material in the interior space.

15. The method of claim 14 wherein the temperature controlling material is selected from ice, dry ice, one or more ice packs, and one or more gel packs.

16. The method of claim 14 or 15, wherein the temperature controlling material is selected to maintain a temperature of the interior space in a range of -20°C to 8°C, or in a range of 0°C to 8°C, or in a range of -80°C to -70°C.

17. The method of any one of claims 13 to 16 further comprising placing additional packaging material in the interior space.

18. The method of any one of claims 13 to 17, further comprising enclosing the insulated container in an external container prior to transporting the insulated container.

19. The method of any one of claims 13 to 18 further comprising providing an indication that the insulated container is returnable to a predetermined location.

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