Biodegradable insulated shipping containers and related systems and methods

Abstract

A biodegradable shipping container for protecting transported payload items from thermal effects and physical damage. An insulation panel for forming a biodegradable shipping container, the insulation panel being formed from biodegradable packing pellets placed in a corrugated cardboard box in a compressed state. A method for manufacturing an insulation panel for use in forming an insulated shipping container.

Description

[Technical Field]

[0001] (Related Applications) (0001) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 404,583, filed September 8, 2022, the entire contents of which are incorporated herein by reference.

[0002] (0002) Various embodiments herein relate to insulated shipping containers, and more particularly to shipping containers in which the insulation is biodegradable. [Background technology]

[0003] (0003) When shipping containers are used to transport items, it is often desirable to keep the payload items (e.g., the items being transported) at relatively low temperatures, e.g., temperatures below ambient temperature. Certain materials used to prevent damage to the transported goods and / or to provide thermal protection or insulation to the payload goods during transport may be harmful to the environment, for example, through their manufacture, use, or disposal.

[0004] (0004) Therefore, there is a need for shipping containers that can protect the transported payload goods and maintain the payload goods within a desired temperature range for a period of time, while doing so using materials that reduce or minimize harm to the global environment. Summary of the Invention

[0005] (0005) According to embodiments of the present invention, a shipping container may include a plurality of insulating panels arranged to form a receptacle having an interior cavity capable of receiving and holding a payload item. In some embodiments, the receptacle may be sized to fit within an outer box. The interior cavity of the receptacle may be sized to receive and hold a payload box capable of holding a payload item. In some embodiments, the interior cavity may also hold one or more cooling means, such as ice packs. Various components of the shipping container may be formed from renewable materials.

[0006] (0006) According to embodiments of the present invention, an insulating panel for use in forming an insulated shipping container may include a panel box and a plurality of pellets or packing peanuts within the panel box. In some embodiments, a film layer is formed around or on the exterior of the panel box, which may provide a seal to prevent moisture from entering the panel box during use. In some embodiments, the pellets or packing peanuts are placed between layers of material to help give the pellets a form or shape before placement within the panel box. In some embodiments, the pellets are placed between layers of kraft paper and compressed to form a layer sized and shaped to fit within the panel box of the insulating panel. In various embodiments, one or more molds may be used to form the packing peanuts and / or the panel box. For example, a first mold may be used on the exterior of the panel box, and a second mold may be used to form the packing pellets or packing peanuts into the desired shape and size (with or without a layer of kraft paper or laminate around the pellets) before placement in the panel box. Various components of the insulating panel may be formed from renewable materials. In some embodiments, the pellets may be biodegradable pellets, such as pellets formed from cornstarch or other plant-based materials or plant-based starches.

[0007] (0007) According to some embodiments of the present invention, a process for manufacturing an insulating panel may include filling a panel box with biodegradable pellets, compressing the pellets within the box, releasing pressure on the panel box to close the box, and sealing the exterior of the panel box with a biodegradable film. In some alternative embodiments, the compression of the pellets may be performed separately from the box using a mold, and the compressed layer of pellets may then be placed within the panel box. In some cases, a second mold may be used to maintain the shape of the panel box while the formed layer of pellets is placed within the panel box.

[0008] (0008) Those skilled in the art will more fully appreciate the advantages of various embodiments of the present invention from the following Description of Exemplary Embodiments, which is set forth with reference to the drawings summarized below. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an exploded top perspective view of an exemplary shipping container according to some embodiments of the present disclosure. [Figure 2] 1 is a cross-sectional view of an exemplary insulation panel of a shipping container according to some embodiments of the present disclosure. [Figure 3A] 3 is a flow chart illustrating steps of an exemplary method for forming the insulation panel of FIG. 2. [Figure 3B] 11B is a flowchart illustrating steps of an exemplary method for forming the insulation panel of FIG. 11A. [Figure 4] FIG. 1 is a top view of an exemplary payload box with payload items and testing equipment used in a shipping container, according to some embodiments of the present disclosure. [Figure 5] 1 is a plot of performance test results under summer conditions for shipping containers and payload items according to some embodiments of the present disclosure. [Figure 6]1 is a plot of performance test results under winter conditions for shipping containers and payload items according to some embodiments of the present disclosure. [Figure 7] 1 is a plot of performance test results under high temperature and humidity conditions for shipping containers and payload articles according to some embodiments of the present disclosure. [Figure 8] 1 is a plot illustrating the consistency of performance test results under summer conditions for consecutive sets of similar payload items in shipping containers according to some embodiments of the present disclosure. [Figure 9] 1 is a plot illustrating the consistency of performance test results under summer conditions for consecutive sets of similar payload items in shipping containers according to some embodiments of the present disclosure. [Figure 10] 1 is a plot illustrating the consistency of performance test results under summer conditions for consecutive sets of similar payload items in shipping containers according to some embodiments of the present disclosure. [Figure 11]

[0023] Figure 11A is a cross-sectional view of an exemplary insulation panel of a shipping container according to some embodiments of the present disclosure, Figure 11B is a top perspective view of an exemplary pellet layer of an insulation panel for use in forming an insulated shipping container according to some embodiments of the present disclosure, and Figure 11C is a top perspective view of a partially formed insulation panel including a pellet layer and a panel box according to some embodiments of the present disclosure. [Figure 12] Figures 12A, 12B, and 12C are perspective views of an exemplary mold that may be used to form insulation panels and / or associated pellet layers according to various embodiments of the present disclosure. [Figure 13]Figures 13A, 13B, and 13C are perspective views of an exemplary mold used to form an insulation panel having associated pellet layers disposed therein according to various embodiments of the present disclosure. [Figure 14A] FIG. 14A is an exploded top perspective view of an exemplary arrangement of components of a shipping container according to some embodiments of the present disclosure. [Figure 14B] FIG. 14B is an exploded top perspective view of an exemplary arrangement of components of a shipping container according to some embodiments of the present disclosure. [Figure 14C] FIG. 14C is an exploded top perspective view of an exemplary arrangement of components of a shipping container according to some embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] (0024) Various embodiments herein relate to biodegradable insulated shipping containers and / or at least one biodegradable insulation panel comprising the insulated shipping container. In certain implementations, a biodegradable panel is provided that comprises a panel box, a plurality of compressed pellets disposed within the panel box, and a wrap disposed around the box. Further embodiments relate to a shipping container that comprises at least one insulation panel formed within an insulation receptacle, an outer box sized to receive the insulation receptacle, and an internal payload box positionable within the insulation receptacle.

[0011] (0025) While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. As realized, various embodiments can be modified in various obvious respects without departing from the spirit and scope thereof. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

[0012] (0026) FIG. 1 is an exploded perspective view of one exemplary embodiment of an insulated shipping container 10. The shipping container 10 includes an insulated receptacle 12 having an insulated lid 14 that can be placed within an outer cardboard box 16 and is sized and shaped to have an interior cavity 18 for receiving a payload item 24. In certain alternative embodiments, the container 10 can also have a payload box 22 that is dimensioned to be positioned within the interior cavity 18 of the receptacle 12 and receive the payload item 24. The insulated receptacle 12 and lid 14 are constructed from insulating panels 20. Furthermore, in some alternative embodiments, the interior cavity 18 is also dimensioned to receive at least one cooling means (e.g., ice, dry ice, gel packs, hard ice packs, and / or soft ice packs) in addition to the payload item 24 (and in some embodiments, the payload box 22). In the particular embodiment shown, the container 10 has two hard ice packs 26 and two soft ice packs 28. Various cooling means (eg, ice packs and / or phase change materials) may have housings made from renewable materials (eg, HDPE or LDPE, etc.).

[0013] (0027) In various embodiments, container 10 with two hard ice packs 26 and two soft ice packs 28 of a specific temperature range placed therein can protect any items housed within container 10 from variable environmental conditions. For example, container 10 can keep items within a temperature range of about 2°C to about 8°C for at least 48 hours across different ambient temperatures. Furthermore, container 10 also protects the items from any type of shipping damage (e.g., shock, vibration, compression) during that period.

[0014] (0028) In one embodiment, the outer cardboard box 16 is made from C-flute corrugated cardboard. Alternatively, the box 16 can be made from any known biodegradable cardboard material, such as paperboard. The box 16 can be formed into the shape of the box 16 by any method and / or configuration.

[0015] (0029) As previously mentioned, the container 10 includes at least one insulating panel 20. More specifically, in the illustrated embodiment of the exemplary container 10, the receptacle 12 is constructed from six insulating panels 20. Alternatively, the receptacle 12 may have any known configuration for forming such a receptacle 12, and thus may have any number of panels 20 as needed based on the configuration.

[0016] (0030) One embodiment of an exemplary biodegradable insulation panel 20 is shown in more detail in FIG. 2, which shows a cross-sectional view of the components of the panel 20. The panel 20, as shown, includes a panel box 30, a plurality of pellets 32 (also referred to herein as "packing peanuts" and "packing pellets") disposed within the panel box 30, and a film 34 disposed around the box 30. In certain alternative embodiments, the panel 20 can have biodegradable lightweight kraft paper (not shown) disposed within the box 30 such that the pellets 32 are disposed within the kraft paper. Alternatively, instead of kraft paper, the additional laminate or substrate can be any lightweight packaging laminate or substrate having properties similar to kraft paper.

[0017] (0031) In one embodiment, the panel box 30 is made from biodegradable E-flute corrugated cardboard. More specifically, the panel box 30 can be made from 32ECT or 200# E-flute corrugated cardboard. Alternatively, the panel box 30 can be made from any biodegradable material that has the rigidity of corrugated cardboard.

[0018] (0032) According to certain embodiments, the biodegradable pellets 32 are made from cornstarch. Alternatively, the pellets 32 can be made from other plant-based materials, such as any other known plant-based starch. During the process of making the pellets, the raw materials (which include cornstarch or other plant-based starch as a significant component) are converted into a dry resin, and the resin is then extruded into pellets 32. According to various embodiments, the process for making the pellets 32 is a known process. Alternatively, the biodegradable pellets 32 are commercially available pellets that fall within the parameters described herein.

[0019] (0033) In certain embodiments, the pellets 32 herein have a generally cylindrical shape. Alternatively, the pellets 32 can have any known shape for such packing peanuts 32. Each of the pellets 32 can have a diameter ranging from about 0.75 inches (1.905 cm) to about 0.9 inches (2.286 cm) and a height ranging from about 0.5 inches (1.27 cm) to about 1.5 inches (3.81 cm). Alternatively, each of the pellets 32 has a diameter of about 0.75 inches (1.905 cm) and a height of about 1.25 inches (3.175 cm). Each of the pellets 32 has a tensile strength of about 0.4 lb / ft 3 (6.41 kg / m 3 ) ~ approx. 0.5lb / ft 3 (8.17 kg / m 3 ) Each of the pellets 32 may have a weight ranging from about 0.12 grams to about 0.19 grams. Alternatively, each of the pellets 32 may have a weight of about 0.15 grams.

[0020] (0034) In some iterations, the panel box 30 can accommodate about 300 to about 500 grams of pellets 32. In certain embodiments, the box 30 can accommodate about 353 grams of pellets 32. In certain other embodiments, the box 30 can accommodate about 486 grams of pellets 32. Alternatively, the panel box 30 can accommodate about 300 to about 400 grams of pellets 32. In a further alternative, the amount of pellets 32 depends on the size of the box 30. In certain embodiments, the box 30 can accommodate pellets 32 at a ratio of about 1.5 to about 4.0 lbs of pellets per cubic foot of volume. In other embodiments, the box 30 can accommodate pellets 32 at a ratio of about 2.5 lbs to about 3.7 lbs of pellets per cubic foot of volume. In a further alternative, this ratio is based on the ratio of about 1.64 x 10 -5 m 3) and in certain embodiments, this ratio is approximately 0.4 to 1.0 grams of pellets 32 per cubic inch (1.64 x 10 -5 m 3 ) can be approximately 0.66 to 0.97 grams of pellets 32.

[0021] (0035) The film 34 can be a commercially available biodegradable shrink wrap 34, such as Bi-Olefin 2.0 or Oxo-Biodegradable Shrink Film 60 Gauge. Alternatively, the shrink wrap 34 can be any known biodegradable shrink wrap for use in packaging. The shrink wrap 34 can provide a fluid seal such that the contents of the panel 20 (including the pellets 32 and the panel box 30) are fluidly sealed from external or ambient air and moisture. Thus, the shrink wrap 34 and resulting fluid seal can prevent moisture generated by the contents of the container 10 (such as any ice packs, phase change materials, and / or payload items) from reaching the pellets 32. Alternatively, the film 34 can be made from any known material having similar properties.

[0022] (0036) The resulting insulating panel 20 can have a thickness T (identified by the letter "T" in FIG. 2) ranging from about 1 inch (2.54 cm) to about 4 inches (10.16 cm). Alternatively, the panel 20 can have a thickness T ranging from about 2.75 inches (6.985 cm) to about 3.5 inches (8.89 cm). The thickness T of the panel 20 is considered to be along its narrowest dimension, while the length and width of the panel 20 are considered to be along two directions along the major plane perpendicular to the thickness T. The length and width of the various panel 20 embodiments herein can be any dimensions required for the size of the resulting shipping container. In the exemplary embodiment shown, the panel 20 has a length of about 16 inches (40.64 cm) and a width of about 14 inches (35.56 cm). In some embodiments, the panel 20 may have a length of about 14.5 inches (36.83 cm) and a width of about 12.5 inches (31.75 cm).

[0023] (0037) The resulting panel 20, according to certain implementations, may have a thermal conductivity coefficient ranging from about 0.03 Watts per meter Kelvin ("W / mK") to about 0.09 W / mK, and in some particular embodiments, may have a thermal conductivity coefficient ranging from about 0.036 W / mK to about 0.042 W / mK.

[0024] (0038) In one embodiment, various panel 20 embodiments herein can be made using the following process or method 40, as shown in FIG. 3A. As a first step in method 40, pellets 32 are added to the interior of the panel box 30 (step 42). In certain embodiments, the panel box 30 may be placed within a first mold (not shown in FIG. 3A), a second mold (also not shown in FIG. 3A) may be placed within the panel box 30, and the second mold is then filled with the above-mentioned amount of pellets 32. Once the pellets 32 are placed within the panel box 30, they are compressed (step 44). More specifically, the pellets 32 are compressed with a compression of greater than about 3.5 pounds per square inch (“psi”) (0.02 MPa) applied to the pellets 32 to compress them into a pellet layer having a thickness of about half the intended total thickness T of the panel 20. The compressed pellets 32 may expand over time to fill the volume within the panel box 30. Thus, if the target thickness of the panel 20 is about 3.5 inches (8.89 cm), the pellets 32 are compressed to a thickness of about 1.75 inches (4.445 cm) in some embodiments. Alternatively, the pellets 32 can be compressed to any known thickness to achieve desired thermal insulation properties, or to achieve specific impact protection qualities, or both.

[0025] (0039) Once the desired thickness is achieved, the compression pressure is released and the cavity of the panel box 30 is closed by closing (step 46) a lid or flap on the box 30. Once the box 30 is closed, a film layer 34 (e.g., shrink wrap 34) is placed around the panel box 30 to encapsulate the box 30 within the wrap 34 (step 48). In certain embodiments, heat may then be applied to the panel box 30 and / or the film layer (wrap 34) to shrink the wrap 34, thereby fluidly sealing the box 30 within the wrap 34.

[0026] (0040) Alternatively, any known process can be used to add the pellets 32 to the panel box 30, compress the pellets 32, and enclose the panel box 30 in the wrap 34.

[0027] (0041) An exemplary alternative process for forming or manufacturing the insulating panel 20 of the present disclosure may include one or more of the following steps, which are described and illustrated as process or method 140 with respect to the flowchart shown in FIG. 3B and with reference to FIGS. 11A-11C and 13A-13C.

[0028] (0042) Step 142 may include providing a first mold for use in compressing the pellets 32. In some embodiments, a hollow rectangular mold 202 (see, e.g., the exemplary mold 202 in FIGS. 12A-12C and 13A-13C) may be used as a compression chamber for compressing the pellets 32. The size of the mold 202 varies depending on the desired size and thickness of the insulation panel 20 to be formed. For example, in some embodiments, the mold 202 may have interior dimensions of 11.5 inches (29.21 cm) x 11.5 inches (29.21 cm) x 1.7 inches (4.318 cm) (interior dimensions) to produce an insulation panel 20 having dimensions of 11.75 inches (29.845 cm) x 11.75 inches (29.845 cm) x 2.0 inches (5.08 cm).

[0029] (0043) Step 144 may include placing a layer of kraft paper 160 at the bottom of the mold 202. As previously mentioned, other materials having similar properties to kraft paper may be used, such as certain laminates. Preferably, layer 160 is formed from biodegradable and / or renewable materials.

[0030] (0044) Step 146 may include placing pellets 32 on the kraft paper 160 in the mold 202 to fill the mold 202. The pellets 32 may be cornstarch pellets or other plant-based or biodegradable materials.

[0031] (0045) Step 148 may include applying steam or mist to the interior of the mold 202 while the pellets 32 are being filled to achieve some level of bonding between the pellets 32. In some embodiments, steam / mist may be applied at high pressure while the cornstarch pellets are being filled into the mold to achieve a desired level of bonding between the pellets 32. In some embodiments, the steam pressure and temperature should be at least 50 psi (0.34 MPa) and 212°F (100°C). The application of steam (particularly steam under pressure or high-pressure steam) during the pellet filling step (step 146) may facilitate the adhesion of the pellets 32 to one another within the formed pellet layer 162 (see FIGS. 11B and 11C) after a subsequent compression step (described below).

[0032] (0046) Step 150 may include, for example, placing a second layer of kraft paper 160 over the pellets 32 after the mold is filled with the pellets 32. Using sheets of kraft paper 160 above and below (e.g., on both major surfaces) the layer of pellets 32 may help prevent the compressed pellet layer 162 (to be formed in step 152) from sticking to the press plate or press base as the pellets are being compressed.

[0033] (0047) Step 152 may include compressing the pellets 32 in a mold to form a pellet layer 162 (see FIGS. 11B and 11C). The amount of compression of the pellets 32 may be determined based on the desired thickness of the insulation panel 20 (e.g., a typical amount of compression ranges from about 0.5 times the thickness of the panel 20 to 0.75 times the thickness of the panel 20 to allow the insulation panel 20 to expand back to the desired resulting panel size (e.g., after the compression pressure is released)). The pellet layer 162 resembles a "sandwich" of compressed pellets 32 between top and bottom layers of kraft paper 160 after the compression step (step 152).

[0034] (0048) Step 154 ​​may include releasing the compressive pressure applied to the pellets 32 and the kraft paper 160. This may include, for example, reducing or removing the amount of compressive pressure applied between the press plates of the press.

[0035] (0049) Step 156 may include placing the compressed pellet layer 162 inside the panel box 30 (e.g., inside the cardboard enclosure of the panel box 30) and sealing the enclosure (e.g., sealing a lid or flap of the panel box 30 with an adhesive such as glue). Figures 13A-13C illustrate the use of an outer mold 202 to hold the shape of the panel box 30 while placing the pellet layer 162 inside the panel box 30, according to some embodiments.

[0036] (0050) Step 158 may include wrapping the panel box 30 in a film 34 (e.g., biodegradable shrink wrap or a fluid-resistant material) or leaving it as is, depending on the application or intended use of the particular shipping container 10 being formed (e.g., if humidity is a concern, the panel box 30 may be wrapped using biodegradable shrink wrap 34 or wax paper 34; in some cases, it may be acceptable to use an unwrapped insulation panel 20 if the duration of transport within the shipping container 10 is less than 48 hours).

[0037] (0051) The term "about" indicates a variation of about 10% of the dimensions set forth herein. Additionally, various terms such as "top," "bottom," "vertical," and "side" may be used herein, but it should be understood that these terms refer to the relative positioning of components under the assumption that the opening to any of the containers / boxes herein is at the top, and do not necessarily refer to the orientation relative to gravity; during use or assembly, any container embodiment herein may be oriented on its side or upside down relative to gravity.

[0038] (0052) Various biodegradable shipping container embodiments disclosed or contemplated herein can be used to transport cold chain products using environmentally friendly materials that help reduce environmental pollution and / or environmental footprint. Additionally, various embodiments herein can provide structural support to prevent damage from any external impact while maintaining a safe temperature zone for any payload item.

[0039] (0053) In certain embodiments, the various container iterations disclosed or contemplated herein are designed to maintain payload articles at temperatures ranging from about 2°C to about 8°C for at least 48 hours. [Example]

[0040] (0054) An embodiment of an insulated shipping container having the dimensions described above with respect to FIG. 1 was tested under various external conditions to determine whether the container could maintain a payload item at a target temperature for a desired period of time.

[0041] (0055) To achieve overall shipping container performance, the test methodology was divided into four different test parameters / environments: (1) hot and humid conditions, (2) summer conditions, (3) winter conditions, and (4) consistency in summer conditions. For hot and humid weather conditions, a constant temperature (+26 to +27°C) was applied for the entire duration with a relative humidity greater than 92%. The summer environment utilized the ISTA7D summer environment parameters, while the winter environment utilized the ISTA7D winter environment parameters. The consistency test compared three identical insulated containers using the ISTA7D summer environment parameters.

[0042] (0056) As shown in Figure 4, for testing, two 500 ml standard water bottles 50A, 50B were used as payload items 24 within each container 10. More specifically, the two bottles 50A, 50B were placed within the payload box 22 along with three temperature sensors and data loggers 52A, 52B, 52C arranged as shown that were used to measure the temperature throughout the payload box 22. More specifically, one data logger 52A was placed on top of bottle 50B, another data logger 52B was placed between the two bottles 50A, 50B, and another data logger 52C was placed below bottle 50A.

[0043] (0057) All tests were conducted in a standard environmental chamber. Prior to each test, water bottles 50A, 50B, data loggers 52A-C, and soft packs 28 were preconditioned in a refrigerator at +2 to +8°C for at least 48 hours before testing began. For summer weather tests, all hard packs 26 were preconditioned at -21 to -27°C for at least 96 hours before testing began, while all soft packs 28 were preconditioned at +2 to +8°C for at least 48 hours before testing began. For winter weather tests, all soft packs 28 and hard packs 26 were preconditioned at +2 to +8°C for at least 48 hours before testing began. Additionally, the containers under test were stored in a controlled room temperature and humidity environment prior to testing.

[0044] (0058) (result) The summer performance test results are provided in the graph shown in FIG. 5. From the graph, it is clear that all temperature readings from data loggers 52A-C within payload box 22 were between +2 and +8°C for at least a 55-hour duration. In the graph, black curve 64 represents the ambient temperature, red line 152A represents the temperature near the top surface of payload product 24 (e.g., data collected from top data logger 52A located at the top of bottle 50B in FIG. 4), yellow line 152B represents the temperature at the center of payload item 24 (e.g., data collected from center data logger 52B located between bottles 50A and 50B in FIG. 4), and green line 152C represents the temperature near the bottom surface of payload product 24 (e.g., data collected from bottom data logger 52C, shown in FIG. 4 as being directly below bottle 50A). Durations are recorded for time periods of 0 hours (start of test), 24 hours, 48 ​​hours, and 55 hours. Data prior to time 0 represents the pre-test storage period 62 of the payload product or item 24 .

[0045] (0059) The winter performance test results are provided in the graph shown in FIG. 6. As shown in the graph, all data logger readings within the payload box 22 were between +2 and +8°C for a duration of at least 48 hours. As noted above, the black curve 64 represents the ambient temperature, the red line 152A represents the temperature near the top surface of the payload product 24 (e.g., data collected from the top data logger 52A), the yellow line 152B is the temperature at the center of the payload product 24 (e.g., data collected from the center data logger 52B), and the green line 152C is the temperature near the bottom surface of the payload product 24 (e.g., data collected from the bottom data logger 52C). Data prior to 0 hours represents the pre-test storage period 62 of the payload product 24.

[0046] (0060) The results of the hot and humid weather test are given in Figure 7. In this test, only the central data logger 52B was used. As shown, the data logger in the payload box 22 read between +2 and +8°C for a duration of at least 56 hours. In this graph, the black line 64 represents the ambient temperature, and the red line 152B represents the central temperature (e.g., data collected from the central data logger 52B).

[0047] (0061) After conducting the above tests for various simulated weather conditions, a consistency test was conducted to verify the overall performance of the insulated container 10. For this test, three identical containers were prepared and filled with the same ice packs, the same phase change material, and the same payload product. The ambient weather conditions selected for this test were the ISTA7D summer profile. Figures 8, 9, and 10 show temperature readings from the top, middle, and bottom data loggers 52A-52C, respectively, for different boxes among the three separate boxes. In other words, Figure 8 is a plot of the top data logger 52A for each of the three separate containers, Figure 9 is a plot of the middle data logger 52B for each of the three separate containers, and Figure 10 is a plot of the bottom data logger 52C for each of the three separate containers. Note that the readings in each of the three graphs are very similar, meaning that the three separate insulated containers performed consistently. For each container, the top data logger 52A recorded temperatures within the desired temperature range for at least 55 hours, the middle data logger 52B recorded temperatures within the desired range for at least 56 hours, and the bottom data logger 52C recorded temperatures within the desired range for at least 53 hours. As a result, it can be concluded that the performance of the insulated containers can be verified for the minimum allowable duration (48 hours).

[0048] (0062) 14A-14C illustrate a series of alternative arrangements of components forming a shipping container 10 according to embodiments of the present disclosure. For example, FIGS. 14A and 14B illustrate the use of different numbers of hard and soft icepacks 26, 28, as well as different positions of the icepacks 26, 28. The embodiments shown in FIGS. 14B and 14C illustrate the additional use of cardboard separators 27, for example, positioned relative to the payload box or payload sleeve 22 according to some embodiments. In FIG. 14C, no hard icepacks 26 are used. In such embodiments, the use of cardboard separators 27 may provide additional structural support and / or thermal insulation in combination with the use of soft icepacks 28. The shipping container 10 of FIGS. 14A and 14B also illustrates the use of an inner box 29, according to some embodiments, which may be useful for providing additional structural support and / or thermal insulation between the receptacle 12 and the payload box 22. Other possible arrangements of the aforementioned components of the shipping container 10 will be apparent to those skilled in the art and are contemplated by the present disclosure.

[0049] (0063) It is contemplated that various aspects, features, processes, and operations from various embodiments may be used in any of the other embodiments unless expressly stated otherwise. The particular operations illustrated may be implemented by a computer executing a computer program product on a non-transitory computer-readable storage medium, where the computer program product includes instructions that cause a computer to perform one or more of the operations or issue commands to other devices to perform one or more operations.

[0050] (0064) While the present disclosure has been illustrated and described in detail in the drawings and the foregoing description, it is to be understood that this is to be considered illustrative in character and not restrictive, that only certain exemplary embodiments have been shown and described, and that all changes and modifications within the spirit of the disclosure are desired to be protected. The use of words such as "preferable," "preferably," "preferred," or "more preferred" as used in the above description indicates that the feature so described may be more desirable, but it should nevertheless be understood that it may not be necessary, and embodiments lacking it may be contemplated as being within the scope of the present disclosure, the scope of which is defined by the following claims. When reading the claims, the use of words such as "a," "an," "at least one," or "at least one portion" does not intend that the claim be limited to a single item unless specifically stated otherwise in the claim. The term "of" can mean an association or connection with another item, as well as belonging to or connecting to other items as informed by the context in which it is used. Terms such as "coupled to," "coupled with," and the like include indirect connections and connections, and further include direct connections or connections, but do not require direct connections or connections unless expressly stated otherwise. When the terms "at least a portion" or "a portion" are used, an item can include a portion or all of the item unless specifically stated otherwise. Unless expressly stated otherwise, the terms "or" and "and / or" in a list of two or more list items can imply each individual listed item or a combination of the listed items. Unless expressly stated otherwise, the transitional phrase "having" is an open-ended term and has the same meaning as the transitional phrase "comprising."

[0051] (0065) The above-described embodiments of the present invention are intended to be merely exemplary, and numerous variations and modifications will be apparent to those skilled in the art. Such variations and modifications are intended to be within the scope of the various embodiments.

Claims

1. 1. An insulating panel for a shipping container, comprising: (a) a panel box comprising corrugated cardboard; (b) a plurality of biodegradable pellets disposed within the panel box; (c) a film disposed around the panel box; Equipped with The plurality of biodegradable pellets disposed within the panel box are compressed at a pressure ranging from about 3 pounds per square inch (0.02 MPa) to about 4 pounds per square inch (0.03 MPa).

2. 10. The insulating panel of claim 1, wherein the plurality of biodegradable pellets disposed within the panel box are compressed at a pressure of approximately 3.5 pounds per square inch (0.02 MPa).

3. The insulating panel of claim 1 , further comprising a lining disposed within the panel box, the plurality of biodegradable pellets being disposed within the lining.

4. 4. The insulation panel of claim 3, wherein the lining comprises an upper layer of kraft paper and a lower layer of kraft paper, and the plurality of biodegradable pellets are disposed between the upper layer of kraft paper and the lower layer of kraft paper.

5. The insulating panel of claim 1 , wherein the plurality of biodegradable pellets are formed from a plant-based material.

6. 6. The insulation panel of claim 5, wherein the plurality of biodegradable pellets are generally cylindrical, each having a diameter ranging from about 0.5 inches (1.27 cm) to about 1.0 inches (2.54 cm) and a height ranging from about 1.0 inches (2.547 cm) to about 2.0 inches (5.08 cm).

7. The plurality of biodegradable pellets compressed within the panel box are compressed to a density of approximately 1.5 pounds per cubic foot (24.03 kg / m ３ ) to about 4.0 pounds per cubic foot (64.07 kg / m ３ 6. The insulating panel of claim 5, having a density in the range of 0.15 to 0.55 mm.

8. The insulating panel of claim 1 , wherein the film comprises biodegradable shrink wrap.

9. 10. The insulation panel of claim 8, wherein the biodegradable shrink wrap is heated to form a fluid seal around the periphery of the insulation panel.

10. 1. A method of manufacturing an insulating panel for a shipping container, comprising: placing a plurality of biodegradable pellets within a panel box; compressing the plurality of biodegradable pellets at a pressure in the range of about 3 pounds per square inch (0.02 MPa) to about 4 pounds per square inch (0.03 MPa) so that the panel box and the plurality of biodegradable pellets are compressed to an initial thickness that is less than a desired final thickness of the insulation panel; Releasing the pressure from compressing the plurality of biodegradable pellets; placing a film around the panel box; A method comprising:

11. 11. The method of claim 10, wherein the pressure is about 3.5 pounds per square inch (0.02 MPa).

12. The method of claim 10 , wherein the panel box and the plurality of biodegradable pellets are compressed to the initial thickness, the initial thickness being approximately half of the desired final thickness.

13. The method of claim 10, further comprising using at least one die while compressing the plurality of biodegradable pellets.

14. 11. The method of claim 10, further comprising placing at least one sheet of kraft paper within the panel box prior to compressing the plurality of biodegradable pellets.

15. 1. A method of manufacturing an insulating panel for a shipping container, comprising: preparing a first mold having a substantially rectangular shape; placing a first layer of kraft paper at the bottom of the first mold; placing a plurality of biodegradable pellets over the first layer of kraft paper in the first mold; applying steam to the plurality of biodegradable pellets in the first mold; placing a second layer of kraft paper over the plurality of biodegradable pellets in the first mold; applying a compressive pressure to the first mold to compress the plurality of biodegradable pellets between the first layer of kraft paper and the second layer of kraft paper, thereby forming a compressed pellet layer comprising the plurality of biodegradable pellets and the first and second layers of kraft paper; placing the compressed pellet layer within a panel box; A method comprising:

16. The method of claim 15 further comprising placing a film layer around the perimeter of the panel box.

17. 17. The method of claim 16, wherein the film layer comprises a shrink wrap layer for forming a fluid seal around the periphery of the panel box.

18. 17. The method of claim 16, further comprising sealing the panel box before placing the film layer.

19. 1. An insulated shipping container comprising:

1. A receptacle comprising at least four insulating panels arranged to form an interior cavity for holding one or more payload items to be transported, each of said at least four insulating panels comprising: A panel box, a plurality of packing pellets compressed within the panel box, the plurality of packing pellets being formed from a biodegradable material; a receptacle comprising: one or more ice packs; a payload box for holding the one or more payload items to be transported; outer cardboard box, Equipped with the interior cavity of the receptacle is sized and configured to accommodate the payload box and the one or more ice packs; the outer cardboard box is sized and configured to accommodate the receptacle located within the outer cardboard box; At least the receptacle, the payload box, and the outer cardboard box of the insulated shipping container are formed from biodegradable or renewable materials. Insulated shipping container.

20. 20. The insulated shipping container of claim 19, wherein the at least four insulating panels further comprise a shrink wrap layer disposed around an exterior surface of the panel box, and the plurality of packing pellets are compressed between a first layer of kraft paper and a second layer of kraft paper to form the pellet layer before the pellet layer is disposed within the panel box.

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