Triple insulated box

Abstract

The invention relates to an insulated box (1) closed by a lid (2) and a method for obtaining it. The side walls (3, 4, 5, 6) and the bottom (7) of said box are formed by an outer skin and an inner skin between which a central thermal insulation material is disposed, said insulation material being a central thermal insulation plate composed of silica, vacuum-conditioned under a metallized film or not, incorporated into a layer of peripheral cellular thermal insulation. Figure 1

Description

Title of the invention: Triple insulated insulated box FIELD OF THE INVENTION

[0001] The technical sector of the present invention is that of heat-insulated packaging and more precisely of insulated boxes. STATE OF THE ART

[0002] For the storage and transport of certain types of products that are particularly fragile and sensitive to heat, it is sometimes necessary to provide insulated packaging. This is particularly the case for many food, pharmaceutical or veterinary products for which boxes of various sizes are used, which can, for example, be made of polystyrene, cardboard covered with a metallized sheet or by placing expanded polyurethane foam injected between two cardboard walls.

[0003] The applicant has described in French patent FR-2911122 an insulated box of the type comprising an internal envelope and an external envelope between which is arranged a polymer or copolymer foam lining. This box has at least one envelope consisting of a closed-cell foam sheet, at least one face of which is secured to a metallized film. It is understood that this embodiment is bulky.

[0004] Boxes are already known that are manufactured by injecting polyurethane foam between two walls made of cardboard, card, paper or plastic. Here, card is understood to mean cardboard without fluting. Another proposed system consists of covering cardboard boxes with six insulated panels, namely a base, a lid, two panels for the two lengths and two panels for the two widths of the box, panels made of polystyrene or cut polyurethane foam. This rudimentary covering system requires users to manage supplies and stocks of six separate elements, which constitutes a significant constraint. Thus, the thermal insulation of boxes on the market is based on the thickness of the polyurethane foam partitions and the sealing of these boxes is not optimized.

[0005] The aim of the present invention is to overcome the drawbacks of the prior art by providing insulated boxes whose mass is reduced and having a very high thermal insulation coefficient, making it possible to maintain the temperature required by heat-sensitive products over much longer periods with equal partition thickness. Statement of the invention

[0006] The invention therefore relates to an insulated box closed by a cover consisting of side walls and a bottom, characterized in that the side walls and the bottom of said box are constituted by an external skin and an internal skin between which a central thermal insulating material is arranged, said insulating material being constituted by a central plate of thermal insulation incorporated in a layer of peripheral cellular thermal insulation.

[0007] According to a characteristic of the invention, the outer skin and the inner skin are made of a material chosen from the group consisting of cardboard, aluminized cardboard, polypropylene, aluminized polypropylene or aluminized polypropylene foam.

[0008] According to another characteristic of the invention, the free edge of said box is constituted by a fold of the external and internal skins delimiting a continuous flat surface.

[0009] According to yet another characteristic of the invention, the inner skin is made of aluminized polypropylene or aluminized polypropylene foam and the outer skin is made of cardboard, aluminized cardboard, polypropylene, aluminized polypropylene or aluminized polypropylene foam.

[0010] According to yet another characteristic of the invention, the central thermal insulation plate is made of silica vacuum-packed under metallized or non-metallized film.

[0011] According to yet another characteristic of the invention, the peripheral cellular thermal insulation is made up of injected polyurethane expanded on either side of the central thermal insulation plate composed of silica vacuum-packed under metallized or non-metallized film.

[0012] According to yet another characteristic of the invention, the thermal insulation plates composed of silica vacuum-packed under metallized or non-metallized film of the side walls and the bottom are arranged in a jointed manner between them without discontinuity.

[0013] According to yet another characteristic of the invention, the cover of said box comprises the external and internal skins and a central thermal insulation plate composed of silica vacuum-packed under metallized film or not integrated in a layer of peripheral cellular thermal insulation consisting of injected expanded polyurethane.

[0014] According to yet another characteristic of the invention, the cover comprises a first edge intended to engage in the space delimited by the side walls of said box and a second edge bearing on the free edge of said box.

[0015] The invention also relates to a method for producing the insulated box, characterized in that it comprises the following steps: • the internal skin is positioned continuously against the walls of a mold, • the central thermal insulation plate composed of silica vacuum-packed under metallized film or not is then placed near the internal skin, ensuring continuity at the level of the side walls and the bottom, • the external skin is then placed continuously near the central thermal insulation plate composed of silica vacuum-packed under metallized film or not, • and the peripheral cellular thermal insulation is injected so as to surround the central thermal insulation plate composed of silica vacuum-packed under metallized or non-metallized film, • finally, the mold is closed to ensure stabilization of the peripheral honeycomb thermal insulation.

[0016] Advantageously, the cover is produced in the following manner: • an internal skin is positioned in a mold to create a first border, • the central thermal insulation plate composed of silica vacuum-packed under metallized film or not is placed near this internal skin, • we then place an external skin in continuity with the internal skin by delimiting a second border, • and a peripheral alveolar thermal insulation is injected on either side of the central thermal insulation plate composed of silica vacuum-packed under metallized film or not, • finally, the mold is closed to ensure stabilization of the peripheral honeycomb thermal insulation.

[0017] A very first advantage of the insulated box according to the invention lies in the reduction of the weight of the box and the increase of its useful volume.

[0018] Another advantage of the insulated box according to the invention lies in its solidity and its resistance to shocks during handling.

[0019] Another advantage of the insulated box according to the invention is the additional improvement in sealing due to the fact that the internal and external skins are made of a single piece.

[0020] Another advantage of the insulated box according to the invention lies in the very significant increase in the duration of maintaining the cold chain, making it possible to replace refrigerated transport while reducing CO2 emissions.

[0021] Another advantage of the insulated box according to the invention lies in the possibility of reverse logistics which significantly reduces waste. Brief description of the drawings

[0022] Other characteristics, details and advantages of the invention will emerge more clearly from the description given below for information purposes in relation to figures in which:

[0023] - [Fig.l] represents a three-dimensional view of an exemplary embodiment of the box according to the invention,

[0024] - [Fig.2] is a sectional view of a wall of the box, and

[0025] - [Fig.3] represents a section of the cover of the box.

[0026] The invention will now be described in greater detail. The insulated box according to the invention is intended to safely contain and transport various products or components whose temperature must be maintained. These boxes require very high thermal insulation for a relatively long time.

[0027] The insulated box according to the invention meets these objectives.

[0028] In [Fig.l], there is shown a view of the box 1 according to the invention closed by a cover 2 whose other side walls 3, 4, 5, 6 and the bottom 7 are constituted by an external skin 8 and an internal skin 9 between which a composite thermal insulating material 10 is arranged.

[0029] The composite insulating material 10 is here constituted by a central plate 11d of thermal insulation incorporated in a layer of peripheral cellular thermal insulation 12.

[0030] For information purposes, the outer skin 8 and the inner skin 9 are made of a material chosen from the group consisting of cardboard, aluminized cardboard, polypropylene or aluminized polypropylene or aluminized polypropylene foam. It is preferable to choose an inner skin 9 made of aluminized propylene foam and an outer skin 8 of cardboard. Those skilled in the art will be able to determine, depending on the intended application, whether to choose other materials suitable for producing these two skins.

[0031] In the figure, it can be seen that the free edge 15 of said box is constituted by a fold of the internal skin delimiting a continuous flat surface. This fold is constituted by a suitable flap either of one or the other skin, or of one of the skins alone. Preferably, a flap coming from aluminized polypropylene will be chosen.

[0032] The central plate 11 of thermal insulation is preferably made up of a layer of silica vacuum-packed under metallized or non-metallized film. This material is known in itself but is receiving for the first time an interesting application in the field of insulated boxes. This layer of silica vacuum-packed under metallized or non-metallized film is embedded within a cellular thermal insulator 12 made up by expanded polyurethane injected on either side of the thermal insulation plate 11.

[0033] [Fig. 2] is a section of one of the side walls intended to illustrate its structure. It can be seen that the thermal insulation plates of the side walls 3-6 and the bottom 7 are arranged in a contiguous manner with each other without discontinuity. Thus, the box 1 according to the invention does not have any thermal bridges likely to harm its performance. In other words, the intimate junction of these different walls and the injection of expanded polyurethane greatly reduces transmission between the inside and the outside of the box and eliminates the effects of thermal bridges.

[0034] In [Fig. 3], a section of the cover is shown, completing the box 1 in order to constitute a closed, airtight enclosure. Similarly, the cover 2 of said box comprises the outer 8 and inner 9 skins and a thermal insulation plate 11 composed of silica vacuum-packed under metallized film or not integrated in a layer of cellular thermal insulation 12 consisting of injected expanded polyurethane.

[0035] In this figure, it can be seen that the cover 2 has a first edge 13 intended to engage in the space delimited by the side walls of said box and a second edge 14 intended to come to bear on the free edge of said box. Advantageously, the internal and external skins of the cover can be made of the same material, for example aluminized polypropylene foam. Thus, the box 1 and its cover 2 constitute protection for the object or the member introduced without loss of temperature or at least a negligible loss of temperature during its transport.

[0036] The method described below illustrates the manufacture of the insulated box according to the invention.

[0037] This process is carried out in the following manner.

[0038] The inner skin 9 is positioned against the walls of a manufacturing mold by continuously lining the side walls and the base of the mold. The inner skin 9 can be produced separately using a suitable template and then introduced into the mold. This inner skin 9 can be, according to the invention, a material of the aluminized polypropylene foam type.

[0039] The thermal insulation plate composed of silica vacuum-packed under metallized or non-metallized film 11 is then placed in the vicinity of the inner skin 9, ensuring continuity at the side walls and the bottom. This plate may be a silica material vacuum-packed under metallized or non-metallized film. Thus, the faces of the skin 9 are provided with the plates 11 and the adjacent edges of these plates are arranged in a tight fit.

[0040] The outer skin 8 is then placed in the vicinity of the thermal insulation plate 11, continuously covering these plates with thermal insulation. This outer skin 8 may be, for example, cardboard.

[0041] The peripheral cellular thermal insulation 12 is then injected so as to surround the central plate 11 with thermal insulation. This peripheral cellular insulation 12 spreads due to the injection pressure between the outer 8 and inner 9 skins and around the central thermal insulation plates composed of silica vacuum-packed under metallized or non-metallized film 11.

[0042] Finally, the mold is closed to ensure stabilization of the peripheral cellular thermal insulation 12.

[0043] A material of the expanded polyurethane type has preferably been chosen to constitute the peripheral cellular thermal insulation 12. This material can therefore be easily injected between the skins and the silica plate packaged under vacuum under metallized or non-metallized film and is distributed regularly in the space delimited by the two skins.

[0044] The cover 2 of the box 1 is produced in a similar manner. To this end, the internal skin 9 is positioned in a mold, producing a first edge 13.

[0045] The central plate 11 of thermal insulation is placed in the vicinity of this internal skin.

[0046] The outer skin 8 is then arranged in continuity with the inner skin 9, delimiting a second border 14.

[0047] The peripheral cellular thermal insulation 12 is injected on either side of the central plate 11 of thermal insulation composed of silica vacuum-packed under metallized or non-metallized film.

[0048] Finally, the manufacturing mold is closed to ensure stabilization of the peripheral cellular thermal insulation 12.

[0049] The box 1 and its cover 2 constitute an airtight enclosure because the first edge 13 is sized to fit tightly at the level of the internal skin 9. In addition, the second edge 14 comes to bear against the free edge of the box, reinforcing the seal.

Claims

Claims

1. Insulated box (1) closed by a cover (2) consisting of side walls (3, 4, 5, 6) and a bottom (7), characterized in that the side walls (3, 4, 5, 6) and the bottom (7) of said box are constituted by an external skin (8) and an internal skin (9) between which a central thermal insulating material (10) is arranged, said insulating material being constituted by a central plate (11), made of silica vacuum-packed under metallized film, incorporated in a layer of a peripheral cellular thermal insulator (12) consisting of expanded polyurethane.

2. Insulated box (1) according to claim 1, characterized in that the outer skin (8) and the inner skin (9) are made of a material chosen from the group consisting of cardboard, aluminized cardboard, polypropylene, aluminized polypropylene or aluminized polypropylene foam.

3. Insulated box (1) according to claim 1 or 2, characterized in that the free edge (12) of said box is constituted by a fold of the external and internal skins delimiting a continuous flat surface.

4. Insulated box (1) according to claim 2, characterized in that the inner skin (8) is made of aluminized polypropylene or aluminized polypropylene foam and the outer skin (9) is made of cardboard, aluminized cardboard, polypropylene, aluminized polypropylene or aluminized polypropylene foam.

5. Insulated box (1) according to any one of the preceding claims, characterized in that the thermal insulation plates composed of silica vacuum-packed under metallized film of the side walls (3-6) and the bottom (7) are arranged in a contiguous manner with each other without discontinuity.

6. Insulated box (1) according to any one of the preceding claims, characterized in that the cover (2) of said box comprises the external (8) and internal (9) skins and a central plate (11) of thermal insulation composed of silica vacuum-packed under metallized film integrated in a layer of peripheral cellular thermal insulation (12) consisting of expanded injected polyurethane.

7. Insulated box (1) according to claim 6, characterized in that the cover (2) has a first edge (13) intended to engage in the space delimited by the side walls of said box and a second edge (14) resting on the free edge of said box.

8. Method for producing the insulated box (1) according to any one of the preceding claims, characterized in that it comprises the following steps: • the internal skin (9) is positioned continuously against the walls of a mold, • the central plate (11) of thermal insulation composed of silica vacuum-packed under metallized film is then placed in the vicinity of the internal skin (9), ensuring continuity at the level of the side walls and the bottom, • the external skin (8) is then placed continuously in the vicinity of the central plate (11) of thermal insulation composed of silica vacuum-packed under metallized film, • and the peripheral cellular thermal insulation (12) is injected so as to surround the central plate (11) of thermal insulation composed of silica vacuum-packed under metallized film, • the mold is finally closed to ensure the stabilization of the peripheral cellular thermal insulation (12).

9. Method for producing the insulated box (1) according to claim 8, characterized in that the cover (2) is produced in the following manner: • the internal skin (9) is positioned in a mold, producing a first edge, • the central thermal insulation plate (11) composed of silica vacuum-packed under metallized film is placed in the vicinity of this internal skin, • the external skin (8) is then placed in continuity with the internal skin (9) by delimiting a second edge, • and the peripheral cellular thermal insulation (12) is injected on either side of the central thermal insulation plate (11) composed of silica vacuum-packed under metallized film, • the mold is finally closed to ensure the stabilization of the peripheral cellular thermal insulation (12).

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