Gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages

Abstract

A gas-filled insulating packaging material, and gas-filed insulating packaging envelope made therefrom, includes a low-emitting internal film material. Outer pouch layers encapsulate the low-emitting internal film material including on a bottom side and a top side of the low-emitting internal film material. The outer pouch layers are configured to be inflatable via an air cushion machine. The outer pouch layers are sealed on a sealed side and unsealed on an open side prior to inflation and subsequently sealable on the open side after inflation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit to U.S. Provisional Patent Application No. 63 / 664,239 filed on Jun. 26, 2024, entitled GAS-FILLED INSULATING PACKAGING MATERIAL WITH A LOW EMITTING ALUMINIZED FILM INTERNAL STRUCTURE CONFIGURED FOR COLD CHAIN PACKAGES, which is incorporated by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a way to cheaply and effectively insulate cold chain packages in a way that can be quickly implemented by manufacturers and end users.BACKGROUND

[0003] Generally speaking, cold chain packaging is the practice of shipping goods from one destination to another and maintaining the goods at or below a desired temperature to keep the goods cold. As such, cold chain packaging technology is designed and configured to enable various industries to transport goods at or below a desired temperature. As an example, cold chain packaging for the food industry allows for safely transporting meats, seafood, and poultry at temperatures below 40 degrees Fahrenheit to inhibit bacterial growth and contamination. Dairy products, meanwhile, must be kept below 45 degrees Fahrenheit to preserve freshness. Fruits and vegetables also have specific temperature requirements to minimize spoilage, maintain flavor, and prevent skin damage and bruising. As another example, the pharmaceutical industry depends on cold chain packaging to provide cold shipping solutions to supply sorely needed medications, such as vaccines, which are highly prone to spoiling if they are exposed to temperatures even a few degrees higher than what's required to be effective. Other medical products, such as blood, biologics and medical devices, as well as chemicals used in industry, must also be stored at consistently low temperatures to be safe and useful.

[0004] Cold chain packaging generally includes some form of insulating materials or devices added around the goods being shipped inside of a package or box that the goods are shipped inside of. Insulating packaging materials help industries manage the cold chain needs of their products. Insulating packaging materials used today may include insulated box liners, pouches, and pallet covers, to gel packs and other phase change materials, also known as PCMs, molded designs like expanded polystyrene containers, or EPS containers. Insulating packaging materials may be designed in various sizes or shapes configured for various cold chain products.

[0005] One problem that the instant disclosure recognizes is the environmental impacts of these known insulating packaging materials. This may be especially true for EPS containers, like foam coolers, that are infamously known as bad for the environment. As such, it is clearly desirable to provide insulating packaging materials that are less harmful to the environment.

[0006] Another problem that the instant disclosure recognizes is the ease of use, the weight, and costs associated with utilizing known insulating packaging materials. As such, it is clearly desirable to provide insulating packaging material that is easier and more economical to use.

[0007] One known easy to use, light weight and economical shipping product solution is air cushion packaging. Air cushion packaging is a type of packaging solution that has become increasingly popular in recent years. It is designed to protect goods from damage during shipping and storage, while also providing a cost-effective solution. Air cushion packaging is a form of protective packaging that utilizes air bags or cushioning materials to protect goods during shipping and storage. The air cushion packaging is designed to absorb impacts and vibrations, which helps to reduce the risk of damage to the goods during transit. Air cushion packaging is a cost-effective solution that can help to reduce the risk of damage to goods during shipping and storage. Additionally, air cushion packaging is lightweight and easy to store, which helps to reduce the amount of storage space needed.

[0008] Air bags are the most common type of air cushion packaging. They are made from a durable plastic material and usually feature an inflatable design. U.S. Pat. No. 8,627,637, incorporated herein in its entirety, discloses one of the first machines for the manufacture of air pillows that is configured for forming air pillows where a drive means draws tube material from a roll along rollers and an injector means injects air into an interior space between two opposing sheets of tube material, and a sealing means seals the two opposing sheets together with the injected air entrapped in the interior space therebetween. U.S. Pat. No. 10,850,906, incorporated herein in its entirety, discloses a more modern air cushion machine and method that is commonly used to inflate such air bags for air cushion packaging materials.

[0009] Air bags can be used to protect a wide range of goods, from electronics to furniture. They are also available in a variety of sizes and shapes, making them suitable for a wide range of products. However, standard air bags cannot be used in cold chain packaging as they provide little to no insulating properties. As such, the instant disclosure recognizes the need to provide an air cushion or air back packaging material that provides the same ease of use, light weight design, and cost effectiveness while also providing insulating properties for cold chain packaging.

[0010] The instant disclosure may be designed to address at least certain aspects of the problems or needs discussed above by providing gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages.SUMMARY

[0011] The present disclosure may solve the aforementioned limitations of the currently available cold chain packaging materials and technology, by providing gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages. The gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages and a gas-filled insulating packaging envelope made therefrom, may generally include a low-emitting internal film material and outer pouch layers. The outer pouch layers may encapsulate the low-emitting internal film material including on a bottom side and a top side of the low-emitting internal film material. The outer pouch layers may be configured to be inflatable via an air cushion machine. The outer pouch layers may be sealed on a sealed side and unsealed on an open side prior to inflation and subsequently sealable on the unsealed side after inflation to create the gas-filled insulating packaging envelope.

[0012] One feature of the disclosed gas-fillable insulating packaging material may be that the low-emitting internal film material can include a thermal emissivity of less than 0.1. In select embodiments, the low-emitting internal film material may include a thermal emissivity of less than 0.05. In select possibly preferred embodiments, the low-emitting internal film material may include a thermal emissivity of 0.03 or approximately 0.03. In select possibly most preferred embodiments, the low-emitting internal film material of the gas-fillable insulating packaging material may include an aluminized surface with the thermal emissivity of 0.03.

[0013] Another feature of the disclosed gas-fillable insulating packaging material may be that the low-emitting internal film material can include a multilayered internal film structure. The multilayered internal film structure may include at least one low-emissivity surface on each layer of the multilayered internal film structure. In select embodiments, the at least one low-emissivity surface on each of the layers of the multilayered internal film structure may include an aluminized surface with a thermal emissivity of 0.03. The multilayered internal film structure may include or be made from various materials, including, but not limited to, polymer sheets, paper sheets, biodegradable material sheets, the like, and any other desired thin sheet of material. In select possibly preferred embodiments, the multilayered internal film structure of the disclosed gas-filled insulating packaging material may include polymer sheets that can include an aluminized surface on each layer of the polymer sheets forming the multilayered internal film structure.

[0014] Another feature of the disclosed gas-fillable insulating packaging material may be that the multilayered internal film structure can be configured to expand when the outer pouch layers are inflated to create an insulating structure with spacing for internal air gaps therein. In select embodiments, the multilayered internal film structure may include a bonding layer configured to bond adjacent layers of the multilayered internal film structure and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers. In select embodiments, the bonding layer may create an alternating bonding pattern between the adjacent layers of the multilayered internal film structure and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers. The alternating bonding pattern of the bonding layer may be configured for creating the spacing for the internal air gaps. Wherein, when the outer pouch layers are inflated, the multilayered internal film structure with the alternating bonding pattern may be configured to expand into a voided or honeycomb type internal structure of the low-emitting internal film material. In select embodiments, the voided or honeycomb type internal structure created by the multilayered internal film structure may be in a transverse orientation. The alternating bonding patterns of the bonding layer may include any means or methods for bonding the adjacent layers and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers, including, but not limited to, adhesive bonding, heat weld bonding, embossing, taping, the like, and / or combinations thereof. In select possibly preferred embodiments of the disclosed gas-filled insulating packaging material, the multilayered internal film structure may include an alternating adhesive bonding pattern between adjacent layers of the multilayered internal film structure and to the top side and the bottom side of the multilayered internal film structure to the outer pouch layers.

[0015] In select embodiments of the disclosed gas-fillable insulating packaging material, a carrier layer may be included. The carrier layer may connect the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. In select embodiments, the carrier layer may include a thin, heat sealable polymer adhered to the top side and the bottom side of the low-emitting film internal structure and the outer pouch layers through various forms of bonding, including, but not limited to, adhesive, heat sealing, the like, and / or a combination thereof.

[0016] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be formed in an elongated roll of the gas-fillable insulating packaging material. Wherein, in select embodiments, the low-emitting internal film material may be offset an offset distance from the open side of the outer pouch layers. In select embodiments, the outer pouch layers may be comprised of a heat weldable film. Wherein, the heat weldable film of the outer pouch layers may be configured to be inflatable via the air cushion machine, whereby the heat weldable film of the outer pouch layers are sealed on the sealed side and unsealed on the open side prior to inflation and subsequently sealable on the unsealed side after inflation. Wherein, the elongated roll of the gas-fillable insulating packaging material may be configured to be inflated from the unsealed side of the roll in line via the air cushion machine.

[0017] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for cold chain packages.

[0018] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for providing a way to insulate cold chain packages in a way that can be implemented by manufacturers and end users using known technology (air cushion machines or the like).

[0019] Another feature of the disclosed gas-fillable insulating packaging material may be that it does not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (air cushion machine or the like).

[0020] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for structurally supporting products in cold chain packages in transit with the same utility and versatility as known packaging cushioning technology, but also adds the ability to thermally insulate comparably with existing cold chain packaging options including, but not limited to, expanded polystyrene containers (i.e. Styrofoam coolers).

[0021] In another aspect, the instant disclosure embraces a gas-filled insulating packaging envelope generally made from the disclosed gas-fillable insulating packaging material in any of the embodiments and / or combination of embodiments shown and / or described herein. The gas-filled insulating packaging envelope may thus generally include the low-emitting film internal structure with the outer pouch layers. The outer pouch layers may encapsulate the low-emitting film internal structure including on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure. A carrier layer may be included that connects the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. A gas, including but not limited to air, may be sealed inside of the outer pouch layers. Wherein the gas may be pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create the voided or honeycomb type internal structure of the low-emitting film internal structure thereby creating an insulating structure with spacing for internal air gaps therein.

[0022] In another aspect, the instant disclosure embraces a cold chain package with the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of the cold chain package. As such, the disclosed cold chain package may generally include a box (like a cardboard box or the like) with an inside with a bottom surface, a top surface, a front surface, a back surface, a left surface, and a right surface. At least one gas-filled insulating packaging envelope may be included inside of the box in any of the embodiments and / or combination of embodiments shown and / or described herein. As such, each of the gas-filled insulating packaging envelopes positioned in the box may generally include the low-emitting film internal structure and the outer pouch layers. The outer pouch layers may encapsulate the low-emitting film internal structure including on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure. A carrier layer may be included that connects the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. A gas, including, but not limited to air, may be sealed inside of the outer pouch layers. Wherein, the gas may be pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create a voided or honeycomb type internal structure of the low-emitting film internal structure with spacing for internal air gaps therein. The at least one gas-filled insulating packaging envelope may be positioned in the inside of the box on at least one of the bottom surface, the top surface, the front surface, the back surface, the left surface, and / or the right surface. In select possibly preferred embodiments of the disclosed cold chain package, the gas-filled insulating packaging envelopes may be positioned inside of the box on all of the internal surface, including the bottom surface, the top surface, the front surface, the back surface, the left surface, and the right surface.

[0023] In another aspect, the instant disclosure embraces a method of insulating a cold chain package with the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of the cold chain package. As such, the disclosed method of insulating a cold chain package may generally include: providing the disclosed gas-fillable insulating packaging material in any of the embodiments and / or combination of embodiments shown and / or described herein; and inflating the disclosed gas-fillable insulating packaging material with an air cushion machine thereby creating a plurality of the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein. With these gas-filled insulating packaging envelopes created, the disclosed method of insulating a cold chain package may then include positioning at least one of the created gas-filled insulating packaging envelopes on the inside of a box, like on the bottom surface, the top surface, the front surface, the back surface, the left surface, and / or the right surface. In select possibly preferred embodiments of the disclosed method of insulating a cold chain package, the gas-filled insulating packaging envelopes may be positioned inside of the box on all of the internal surface, including the bottom surface, the top surface, the front surface, the back surface, the left surface, and the right surface.

[0024] The foregoing illustrative summary, as well as other exemplary objectives and / or advantages of the disclosure, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present apparatuses, systems and methods will be better understood by reading the disclosure with reference to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

[0026] FIG. 1 is a perspective view of an air cushion machine according to the prior art;

[0027] FIG. 2 is a perspective view of the disclosed gas-filled insulating packaging envelope made from the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages;

[0028] FIG. 3 is a side view of the gas-filled insulating packaging envelope from FIG. 2;

[0029] FIG. 4 is a perspective cross-sectional schematic view of the gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages showing the film layers as it presents in its inflated state to create the voided or honeycomb type internal structure;

[0030] FIG. 5 is a partially disassembled perspective view of the gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages showing an expanded cross section of the multilayered internal film structure, with the raised bands representing either adhesive or a heat seal pattern connecting the layers;

[0031] FIG. 6 is a cross-sectional diagram view of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages encompassing the layers of the disclosed product;

[0032] FIG. 7 shows a schematic view of a basic construction of an idealized manufacturing line according to select embodiments of the instant disclosure for the internal multilayered low-emissivity structure, as well as the carrier film liner layer, and the outer liner for creating the disclosed gas-fillable insulating packaging material;

[0033] FIG. 8 shows a top schematic view of the disclosed gas-fillable insulating packaging material according to select embodiments of the instant disclosure showing the carrier layer adhered to the multilayered internal layers prior to the cutting stage shown in FIG. 7;

[0034] FIG. 9 shows a top schematic view of the disclosed gas-fillable insulating packaging material according to select embodiments of the instant disclosure showing the assembled product prior to its final inflation;

[0035] FIG. 10A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width;

[0036] FIG. 10B shows a schematic top view of a 16-inch section of the film from FIG. 10A with a 16-inch length and a 11.5-inch width;

[0037] FIG. 10C shows a schematic top view of a 10.5-inch section of the film from FIG. 10A with a 10.5-inch length and a 11.5-inch width;

[0038] FIG. 10D shows a schematic view of a first adhesive pattern for the 16-inch section of the film shown in FIG. 10B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.5 inch end adhesive strips;

[0039] FIG. 10E shows a schematic view of a second adhesive pattern for the 16-inch section of the film shown in FIG. 10B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and a 5.125-inch spacing at the end;

[0040] FIG. 10F shows a schematic view of a first adhesive pattern for the 10.5-inch section of the film shown in FIG. 10C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween;

[0041] FIG. 10G shows a schematic view of a second adhesive pattern for the 10.5-inch section of the film shown in FIG. 10C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 2.125 inch spacing at both ends;

[0042] FIG. 10H shows a schematic view of the film from FIG. 10A showing the pattern for a 16-inch section of the film from FIG. 10B, a 10.5-inch section of the film from FIG. 10C, and another 16-inch section of the film from FIG. 10B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset at the bottom inflatable side;

[0043] FIG. 10I shows a schematic view of the film and adhesive layering for the film from FIG. 10H with the first adhesive pattern for the 16-inch section of the film from FIG. 10D or the first adhesive pattern for the 10.5-inch section of the film from FIG. 10F, and the second adhesive pattern for the 16-inch section of the film from FIG. 10E or the second adhesive pattern for the 10.5-inch section of the film from FIG. 10G;

[0044] FIG. 11A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 47.5-inch length and a 12-inch width;

[0045] FIG. 11A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width;

[0046] FIG. 11B shows a schematic top view of a 15-inch section of the film from FIG. 11A with a 15-inch length and a 8.5-inch width;

[0047] FIG. 11C shows a schematic top view of a 11.5-inch section of the film from FIG. 11A with a 11.5-inch length and a 8.5-inch width;

[0048] FIG. 11D shows a schematic view of a first adhesive pattern for the 15-inch section of the film shown in FIG. 11B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.125-inch spacing on each end;

[0049] FIG. 11E shows a schematic view of a second adhesive pattern for the 15-inch section of the film shown in FIG. 11B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween;

[0050] FIG. 11F shows a schematic view of a first adhesive pattern for the 11.5-inch section of the film shown in FIG. 11C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.5-inch spacing on each end;

[0051] FIG. 11G shows a schematic view of a second adhesive pattern for the 11.5-inch section of the film shown in FIG. 11C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.375-inch adhesive strips at both ends;

[0052] FIG. 11H shows a schematic view of the film from FIG. 11A showing the pattern for a 15-inch section of the film from FIG. 11B, a 11.5-inch section of the film from FIG. 11C, and another 15-inch section of the film from FIG. 11B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset at the bottom inflatable side;

[0053] FIG. 11I shows a schematic view of the film and adhesive layering for the film from FIG. 11H with the first adhesive pattern for the 15-inch section of the film from FIG. 11D or the first adhesive pattern for the 11.5-inch section of the film from FIG. 11F, and the second adhesive pattern for the 15-inch section of the film from FIG. 11E or the second adhesive pattern for the 11.5-inch section of the film from FIG. 11G;

[0054] FIG. 12 is a perspective view of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure being filled by an air cushion machine;

[0055] FIG. 13 is an environmental perspective view of a cold chain package box according to select embodiments of the instant disclosure with the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure positioned on all sides of the inside of the cold chain package box;

[0056] FIG. 14 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing thermal profile over time with temperature in degrees Celsius vs. elapsed time in hours;

[0057] FIG. 15 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested EPS container and the tested gas-filled insulating packaging material unit with temperature in degrees Celsius vs. elapsed time in hours;

[0058] FIG. 16 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing product temperature inside the tested EPS container vs. inside the disclosed gas-filled insulating packaging material unit with temperature in degrees Celsius vs. elapsed time in hours;

[0059] FIG. 17 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested EPS container and the tested EPS product with temperature in degrees Celsius vs. elapsed time in hours; and

[0060] FIG. 18 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested gas-filled insulating packaging material unit and the tested gas-filled insulating packaging material with temperature in degrees Celsius vs. elapsed time in hours.

[0061] It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed disclosure.DETAILED DESCRIPTION

[0062] Referring to FIG. 1, an air cushion machine 1 is shown according to the prior art from, namely, from U.S. Pat. No. 10,850,906, incorporated herein in its entirety. As shown in FIG. 1, air cushion machine 1 may be a more modern air cushion machine that is commonly used to inflate air bags for air cushion packaging materials, air pillows, the like, etc. Air cushion machine 1 generally includes a pulling assembly 2 configured to pull a roll of film material through the air cushion machine 1. Air injector assembly 4 is configured to inject air (or any other gas) into the film material as it is being pulled through air cushion machine 1. Once the air is injected into the film material, heat sealing assembly 3 is configured to seal the open side of the film material to seal the air inside of the film material for creating the air cushion packaging materials, air pillows, the like, etc. An operator interface 5 is included for generally operating air cushion machine 1 such as turning air cushion machine 1 on and off, supplying air cushion machine 1 with various inputs, and for receiving various outputs from air cushion machine 1. Air cushion machine 1, or the like, may be utilized in filling the disclosed gas-filled insulating packaging material 10 with a low emitting aluminized film internal structure 26 configured for cold chain packages 82.

[0063] Referring now to FIGS. 2-18, in describing the exemplary embodiments of the present disclosure, specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

[0064] Referring to FIGS. 2-18, the present disclosure may solve the aforementioned limitations of the currently available cold chain packaging technology by providing the disclosed gas-filled insulating packaging material 10 with low emitting aluminized film internal structure 26 configured for cold chain packages 82. Gas-filled insulating packaging material 10 (see FIGS. 4-12) with low emitting aluminized film internal structure 26 configured for cold chain packages 82 and gas-filled insulating packaging envelope 84 (see FIGS. 2-3, 12 and 13) made therefrom, may generally include low-emitting internal film material 12 and outer pouch layers 14. Outer pouch layers 14 may encapsulate low-emitting internal film material 12 including on bottom side 16 and top side 18 of low-emitting internal film material 12. Outer pouch layers 14 may be configured to be inflatable via air cushion machine 1, or the like. Outer pouch layers 14 may be sealed on sealed side 20 and unsealed on open side 21 prior to inflation and subsequently sealable on open side 21 after inflation to create gas-filled insulating packaging envelope 84.

[0065] One feature of the disclosed gas-fillable insulating packaging material10 may be that the low-emitting internal film material 12 can include a low thermal emissivity 22. Emissivity 22 may be the value given to materials based on the ratio of heat emitted compared to a perfect black body, on a scale from zero to one. A black body would have an emissivity of 1 and a perfect reflector would have a value of 0. Low emissivity 22 (low e or low thermal emissivity), as used herein, may refer to a surface condition that emits low levels of radiant thermal (heat) energy. All materials absorb, reflect, and emit radiant energy according to Planck's law but here, the primary concern is a special wavelength interval of radiant energy, namely thermal radiation of materials. Thermal insulation materials are typically fabricated from aluminum foil with a variety of core materials such as low-density polyethylene foam, polyethylene bubbles, fiberglass, or similar materials. When aluminum foil is used as the facing material, reflective thermal insulation can stop 97% of radiant heat transfer. In select embodiments of the disclosed gas-fillable insulating packaging material, low-emitting internal film material 12 may have thermal emissivity 22 of less than 0.1. In select possibly more preferred embodiments, low-emitting internal film material 12 may include thermal emissivity 22 of less than 0.05. In select possibly most preferred embodiments, low-emitting internal film material 12 may include thermal emissivity 22 of 0.03 or approximately 0.03. In other select possibly most preferred embodiments, low-emitting internal film material 12 of gas-fillable insulating packaging material 10 may include aluminized surface 24 with thermal emissivity 22 of 0.03 (or approximate thereto).

[0066] Another feature of gas-fillable insulating packaging material 10 may be that low-emitting internal film material 12 can include multilayered internal film structure 26 (see FIGS. 4-7, and 10-11). Multilayered internal film structure 26 may include at least one low-emissivity surface 28 on one of the layers 30 of multilayered internal film structure 26. In select embodiments, multilayered internal film structure 26 may include at least one low-emissivity surface 28 on each of the layers 30 of multilayered internal film structure 26. In select embodiments, the at least one low-emissivity surface 28 on each of the layers 30 of multilayered internal film structure 26 may include aluminized surface 24 with thermal emissivity of 0.03 (or approximate thereto), like a metalized polyester (MPET) film material. However, the disclosure is not so limited, and the at least one low-emissivity surface 28 on one or more or all of layers 30 of multilayered internal film structure 26 may include any other desired surface material with low thermal emissivity 22. Multilayered internal film structure 26 may include or be made from various sheets of materials 32, including, but not limited to, polymer sheets 34, paper sheets 35, biodegradable material sheets 36, the like, and any other desired thin sheet 38 of material. In select possibly preferred embodiments, multilayered internal film structure 26 of gas-filled insulating packaging material 10 may include polymer sheets 34 that can include aluminized surface 24 on each layer 30 of polymer sheets 34 forming multilayered internal film structure 26. Addition and / or subtraction of internal media layers 30 of multilayered internal film structure 26 may adjust an insulation value provided by gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom.

[0067] Another feature of gas-fillable insulating packaging material 10 may be that multilayered internal film structure 26 can be configured to expand when outer pouch layers 14 are inflated to create insulating structure 40 with spacing 48 for internal air gaps 50 therein. In select embodiments, multilayered internal film structure 26 may include bonding layer 42 configured to bond adjacent layers 30 of multilayered internal film structure 26 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. In select embodiments, bonding layer 42 may create alternating bonding pattern 44 (see FIGS. 5 and 10-11) between adjacent layers 30 of multilayered internal film structure 26 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. Alternating bonding pattern 44 of bonding layer 42 may be configured for creating spacing 48 for internal air gaps 50 for creating insulating structure 40 within gas-filled insulating packing envelopes 84 created from gas-fillable insulating packaging material 10. Wherein, when outer pouch layers 14 are inflated, multilayered internal film structure 26 with alternating bonding pattern 44 may be configured to expand into voided or honeycomb type internal structure 52 of low-emitting internal film material 12. In select embodiments, voided or honeycomb type internal structure 52 created by multilayered internal film structure 26 may be in transverse orientation 54, as shown in the Figures. Transverse orientation 54 of voided or honeycomb type internal structure 52 may allow gas 85 inflated into gas-fillable insulating packaging material 10 to fill internal air gaps 50 within voided or honeycomb type internal structure 52. As such, transverse orientation 54 of voided or honeycomb type internal structure 52 may be to assist with inflation and allow air to penetrate all structures. However, the disclosure is not so limited and voided or honeycomb type internal structure 52 may be provided in a machine direction orientation by providing holes, apertures, slits, the like, etc. through layers 30 of multilayered internal film structure 26. Alternating bonding patterns 44 of bonding layer may include any means or methods for bonding adjacent layers 30 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14, including, but not limited to, adhesive bonding 56, heat weld bonding 58, embossing 60, taping 62, the like, and / or combinations thereof. In select possibly preferred embodiments of gas-filled insulating packaging material 10, multilayered internal film structure 26 may include alternating adhesive bonding pattern 66 between adjacent layers 30 of multilayered internal film structure 26 and to top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. In other select embodiments, film or film is not removed from the internal baffle media of multilayered internal film structure 26, and the entire envelope of gas-fillable insulating packaging material 10 may receive a lateral heat seal across all layers to envelop the pouch prior to inflation.

[0068] In select embodiments of gas-fillable insulating packaging material 10, carrier layer 51 or carrier film layer 51 may be included. Carrier layer 51 may connect top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. In select embodiments, carrier layer 51 may include a thin, heat sealable polymer 74 adhered to top side 18 and bottom side 16 of low-emitting film internal structure 26 and outer pouch layers 14 through various forms of bonding, including, but not limited to, adhesive 76, heat sealing 78, the like, and / or a combination thereof.

[0069] As best shown in FIG. 12, another feature of gas-fillable insulating packaging material 10 may be that it can be formed in elongated roll 68 of gas-fillable insulating packaging material 10. Wherein, in select embodiments, low-emitting internal film material 12 may be offset the offset distance 70 (see FIGS. 10H, 11H and 12) from open side 21 of outer pouch layers 14. In select embodiments, outer pouch layers 14 may be comprised of heat weldable film 72. Wherein, heat weldable film 72 of outer pouch layers 14 may be configured to be inflatable via air cushion machine 1 (or the like), whereby heat weldable film 72 of outer pouch layers 14 may be sealed on sealed side 20 and unsealed on open side 21 prior to inflation and subsequently sealable on open side 21 or unsealed side 21 after inflation. Wherein, elongated roll 68 of gas-fillable insulating packaging material 10 may be configured to be inflated from open side 21 or unsealed side 21 of elongated roll 68 in line, including, but not limited to, via air cushion machine 1 (or the like). Heat weldable film 72 of outer pouch layers 14 may be, but is not limited to, a polyethylene (PE) film.

[0070] Referring to FIG. 13, another feature of gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom, may be that they can be designed and configured for cold chain packages 82. Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may be designed and configured for providing a way to insulate cold chain packages 82 in a way that can be implemented by manufacturers and end users using known technology (like via air cushion machine 1, or the like). Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (like air cushion machine 1 or the like). Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may be designed and configured for structurally supporting products in cold chain packages 82 in transit with the same utility and versatility as known packaging cushioning technology, but also adds the ability to thermally insulate comparably with existing cold chain packaging options including, but not limited to, expanded polystyrene containers (i.e. Styrofoam coolers). See testing results in FIGS. 14-18

[0071] Referring specifically to FIGS. 2-3, 12 and 13, in another aspect, the instant disclosure embraces gas-filled insulating packaging envelope 84 (may also be referred to as a pillow, bag, the like, etc.). Gas-filled insulating packaging envelopes 84 may generally be made from the disclosed gas-fillable insulating packaging material 10 in any of the embodiments and / or combination of embodiments shown and / or described herein. Gas-filled insulating packaging envelope 84 may thus generally include low-emitting film internal structure 26 with outer pouch layers 14. The outer pouch layers 14 may encapsulate low-emitting film internal structure 26 including on bottom side 16 of low-emitting film internal structure 26 and top side 18 of low-emitting film internal structure 26. Carrier layer 51 or carrier film layer 51 may be included that connects top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. Gas 85, including but not limited to air, may be sealed inside of outer pouch layers 14. Wherein, gas 85 may be pressurized inside of outer pouch layers 14 for expanding outer pouch layers 14 thereby separating bottom side 16 from top side 18 of low-emitting film internal structure 26 to create voided or honeycomb type internal structure 52 of low-emitting film internal structure 26 thereby creating insulating structure 40 with spacing 48 for internal air gaps 50 therein.

[0072] Referring specifically to FIG. 13, in another aspect, the instant disclosure embraces cold chain package 82 with the disclosed gas-filled insulating packaging envelope 84 in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of cold chain package 82. As such, cold chain package 82 may generally include box 86 (like a cardboard box, plastic container, or the like) with inside 88 with bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98. At least one gas-filled insulating packaging envelope 84 may be included inside of box 86 in any of the embodiments and / or combination of embodiments shown and / or described herein. In select embodiments, each gas-filled insulating packaging envelope 84 may be sized and configured to cover each surface inside of box 86. However, the disclosure is not so limited, and cold chain package 82 may include multiple gas-filled insulating packaging envelopes 84 on each surface inside of box 86. Each gas-filled insulating packaging envelope 84 positioned in box 86 may generally include low-emitting film internal structure 26 and outer pouch layers 14. Outer pouch layers 14 may encapsulate low-emitting film internal structure 26 including on bottom side 16 of low-emitting film internal structure 26 and top side 18 of low-emitting film internal structure 26. Carrier layer 51 or carrier film layer 51 may be included that connects top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. Gas 85, including, but not limited to air, may be sealed inside of outer pouch layers 14. Wherein, gas 85 may be pressurized inside of outer pouch layers 14 for expanding outer pouch layers 14 thereby separating bottom side 16 from top side 18 of low-emitting film internal structure 26 to create voided or honeycomb type internal structure 52 of low-emitting film internal structure 26 with spacing 48 for internal air gaps 50 therein. The at least one gas-filled insulating packaging envelope 84 may be positioned in inside 88 of box 86 on at least one of bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and / or right surface 98. In select possibly preferred embodiments of cold chain package 82, gas-filled insulating packaging envelopes 84 may be positioned inside of box 86 on all of the internal surface, including bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98. This possibly preferred embodiment of cold chain package 82 with gas-filled insulating packaging envelopes 84 positioned inside of box 86 on all of the internal surfaces was used in testing to get the results shown in FIGS. 14-18.

[0073] In another aspect, the instant disclosure embraces a method of insulating cold chain package 82 with the disclosed gas-filled insulating packaging envelope 84 in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of cold chain package 82. As such, the disclosed method of insulating cold chain package 82 may generally include: providing the disclosed gas-fillable insulating packaging material 10 in any of the embodiments and / or combination of embodiments shown and / or described herein; and inflating the disclosed gas-fillable insulating packaging material 10 with air cushion machine 1 (or the like) thereby creating a plurality of the disclosed gas-filled insulating packaging envelopes 84 in any of the embodiments and / or combination of embodiments shown and / or described herein. With these gas-filled insulating packaging envelopes 84 created, the disclosed method of insulating cold chain package 82 may then include positioning at least one of the created gas-filled insulating packaging envelopes 84 on inside 88 of box 86, like on bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and / or right surface 98. In select possibly preferred embodiments of the disclosed method of insulating cold chain package 82, gas-filled insulating packaging envelopes 84 may be positioned inside of box 86 on all of the internal surface, including bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98.

[0074] Referring specifically to FIG. 4, a sketch of the gas-fillable insulating packaging material 10 is shown showing the internal structure 26 with layers 30 of low-emitting internal film material 12. The sketch shown in FIG. 4 may present material 10 in its inflated state to create the voided or honeycomb type internal structure 52 with spacing 48 for internal air gaps 50. The areas represented by the filled lines is the internal baffle material, this material can be made of many materials, both reflective and unreflective, though reflective films offer the best thermal performance, there could be various reasons to exclude aluminized reflective films from various layers of the product. This baffle material, or multilayered internal film structure 26, can be assembled in various ways including through adhesives 76, tapes 62, heat sealing 78, and other methods and the widths of the bands can vary. The widths of the internal air gaps 50 can also vary, although it is most ideal to have a 0.01-0.5 (0.1 is ideal) inch gap as that range allows for the most efficient air gap 50 width, as convection currents are unable to form in those widths. The outer pouch material, or outer pouch layers 14, can be made of any flat material polymer, cellulose, paper etc. Offset distance 70 denotes that the inner baffle material (multilayered internal structure 26) is offset from the seal by some offset distance 70. This is only applicable on open side 21 that is receiving the final seal and is inflated, but can be both sides for aesthetic / material cost purposes. This is to allow the air or gas 85 to enter the baffle material (multilayered internal structure 26), while also allowing the final seal to be effective.

[0075] Referring specifically to FIG. 5, an expanded cross section of the web structure or multilayered internal film structure 26 is shown, with the raised bands of bonding layer 42 representing either adhesive 76 or heat seal 78 pattern connecting layers 30.

[0076] Referring specifically to FIG. 6, a diagram of the cross-section of gas-fillable insulating packaging material 10 is shown. Outer heat sealable layer of film layers 14 must be impermeable to gases. Carrier layer 51, which may also be made of a heat sealable layer 78, can be made considerably thinner than outer layers 14. Low-emissivity internal film material 12 layers can range in quantity depending on the situation and required insulation.

[0077] Referring specifically to FIG. 7, an embodiment of a method of forming or manufacturing gas-fillable insulating packaging material 10 is shown. However, the disclosure is not so limited and gas-fillable insulating packaging material 10 may be made by other means and / or method of forming or manufacturing gas-fillable insulating packaging material 10. Individual low-emissivity films may be used for low-emitting internal film material 12 used to create the multilayered internal film structure 26 created with this method. Adhesives 76 are shown as being applied between each layer of low-emitting internal film material 12 with an adhesive applicator to apply the repetitive alternating adhesive bonding pattern 44 or alternating adhesive bonding pattern 66. Film windower or cut pattern 41 may be used to apply a selective cut pattern into the internal multilayered structure 26 in order to allow heat sealing at a later stage. Carrier film layer 51 is shown in position to adhere to one or both sides (top side 18 and / or bottom side 16) of internal multilayered structure 26 after the internal multilayered structure 26 is windowed with film windower or cut pattern 41. Cutting process 71 is shown to remove the edges of the conjoined carrier layer 51 and internal multilayered structure 26 to remove the excess web and allow the area lateral to the film direction to be heat sealed completely and the internal layer encompassed. Heat sealable outer liner 72 is shown for outer pouch layers 14. This layer will usually be wrapped around the structure in a known process to remove the need to heat seal that edge, however it can also be laid in two layers and heat sealed on sealed side 20. In select possibly preferred embodiments, heat sealable outer liner 72 for outer pouch layers 14 may be a heat sealable polymer layer, as is commonly used with air cushion machines like air cushion machine 1. However, the disclosure is not so limited, and heat sealable outer liner 72 of outer pouch layers 14 may be made from other heat sealable materials, like biodegradable films, papers coated to make them somewhat heat sealable, the like, etc.

[0078] Referring specifically to FIG. 8, a top view of gas-fillable insulating packaging material 10 is shown after being created with the method in FIG. 7. 8.1 represents all layers at this stage in the process, both the carrier layer 51, as well as the internal multilayered structure 26. 8.2 represents the sections where only the carrier layer 51 remains, as the multilayered internal structure 26 has been removed due to the windowing process done via film windower or cut pattern 41 of FIG. 7. 8.3 represents the cuts that will be made in stage 71 shown in FIG. 7 to ensure that the internal multilayered structure 26 will not impede the heat sealing to be done.

[0079] Referring specifically to FIG. 9, another top view of gas-fillable insulating packaging material 10 is shown after being created with the method in FIG. 7 and the windowing process has been done via film windower or cut pattern 41. Regions 9.1 represent the regions where all layers of the design remain. Regions 9.2 represent the regions where only the carrier layer(s) 51 and the outer pouch layers 14 remain. This region 9.2 may be subject to heat sealing and perforation dependent on the needs of the final packaging design. Region 9.3 represents the area where only the outer film 14 is left. Area 9.4 represents an exaggerated representation of the edge that will most likely be folded over itself and not need a heat seal (sealed side 20). Region 9.5 represents open side 21 with the edge that will require the final heat seal once inflated, and that will be inflated via air cushion machine 1 (or the like) at the end users destination. Referring now specifically to FIGS. 10-11, an embodiment of an A-B liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. The dimensions shown in these figures are only meant to be examples to illustrate various alternating layers and alternating bonding patterns for the instant disclosure, and the disclosure is clearly not limited thereto. It is noted that it has been discovered that with the right films, a heat seal can be applied through all layers 30 (like 11 layers 30) of gas-fillable insulating packaging material 10, and that removes the need to remove panels from the design, i.e. this embodiment would remove the need for the windowing process via film windower or cut pattern 41.

[0080] Referring specifically to FIGS. 10A-10I, an embodiment of an A-liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. FIG. 10A shows a schematic top view of Film-A 100 used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width. This Film-A 100 may be, but is not limited to, a 36 gauge polyethylene (PE) film that can be used as outer pouch layers 14. FIG. 10B shows a schematic top view of Film-A16 102 with a 16-inch length and a 11.5-inch width. Film-A16 102 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 10C shows a schematic top view of Film-A10 104 with a 10.5-inch length and a 11.5-inch width. Film-A10 104 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 10D shows a schematic view of a first A-16 adhesive bonding pattern 106 for Film-A16 102 shown in FIG. 10B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.5 inch end adhesive strips positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10E shows a schematic view of second A-16 adhesive pattern 107 for Film-A16 102 shown in FIG. 10B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and a 5.125-inch spacing at the end positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10F shows a schematic view of a first A-10 adhesive pattern 108 for Film-A10 104 shown in FIG. 10C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10G shows a schematic view of a second A-10 adhesive pattern 110 for Film-A10 104 shown in FIG. 10C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 2.125 inch spacing at both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10H shows a schematic view of Film-A 100 from FIG. 10A showing the pattern for inserting 16-inch section Film-A16 102 from FIG. 10B, a 10.5-inch section of Film-A10 from FIG. 10C, and another 16-inch section of Film-A16 102 from FIG. 10B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset distance 79 at the bottom inflatable side (open side 21). FIG. 10I shows a schematic view of the film and adhesive layering for material 10 created from FIG. 10H with the first A-16 adhesive bonding pattern 106 for the 16-inch section of the film from FIG. 10D or the first A-10 adhesive pattern 108 for the 10.5-inch section of the film from FIG. 10F, and the second A-16 adhesive pattern 107 for the 16-inch section of the film from FIG. 10E or the second A-10 adhesive pattern 110 for the 10.5-inch section of the film from FIG. 10G.

[0081] Referring specifically to FIGS. 11A-11I, an embodiment of a B-liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. FIG. 11A shows a schematic top view of Film-B 112 used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 47.5-inch length and a 12-inch width. This Film-B 112 may be, but is not limited to, a 36 gauge polyethylene (PE) film that can be used as outer pouch layers 14. FIG. 11B shows a schematic top view of Film-B15 114 with a 15-inch length and a 8.5-inch width. Film-B15 112 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 11C shows a schematic top view of Film-B11 116 with a 11.5-inch length and an 8.5-inch width. Film-B11 116 may also be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 11D shows a schematic view of a first B-15 adhesive bonding pattern 118 for Film-B15 114 shown in FIG. 11B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.125 inch end spacing positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11E shows a schematic view of second B-15 adhesive pattern 120 for Film-B15 114 shown in FIG. 11B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween and at the ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11F shows a schematic view of a first B-11 adhesive pattern 122 for Film-B11 116 shown in FIG. 11C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween and 0.5 inch end spacing on both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11G shows a schematic view of a second B-11 adhesive pattern 124 for Film-B11 116 shown in FIG. 11C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.375 inch spacing at both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11H shows a schematic view of Film-B 112 from FIG. 11A showing the pattern for inserting 15-inch section of Film-B15 114 from FIG. 11B, a 11.5-inch section of Film-B11 from FIG. 11C, and another 15-inch section of Film-B15 114 from FIG. 11B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset distance 79 at the bottom inflatable side (open side 21). FIG. 11I shows a schematic view of the film and adhesive layering for material 10 created from FIG. 11H with the first B-15 adhesive bonding pattern 118 for the 15-inch section of the film from FIG. 11D or the first B-11 adhesive pattern 122 for the 11.5-inch section of the film from FIG. 11F, and the second B-15 adhesive pattern 120 for the 15-inch section of the film from FIG. 11E or the second B-11 adhesive pattern 124 for the 11.5-inch section of the film from FIG. 11G.Test Results

[0082] Referring now to FIGS. 13-17, to assess the thermal performance of gas-filled insulating packaging material 10, a comparative study was conducted using a standard EPS cooler and a unit with gas-filled insulating packaging material 10 (like cold chain package 82, as shown in FIG. 13). Thermocouples and a CSZ Environmental Chamber were utilized to run the ISTA 7E 72 Hour Heat Thermal Qualification Test Sequence. The EPS and containers with gas-filled insulating packaging material 10 were loaded with 6.98 pounds of ice and a store-bought tuna product. Two thermocouples were installed in each unit: one positioned in direct contact with the tuna to monitor product temperature, and the other placed against the interior sidewall and suspended freely within the container to capture internal package conditions. To ensure clear identification during data collection, thermocouple wires were labeled as follows: chamber: temperature in the environmental chamber; package: internal thermocouple in the EPS cooler; pack 2: internal thermocouple in the unit with gas-filled insulating packaging material 10; product 1: tuna product in the EPS cooler; and product 2: tuna product in the unit with gas-filled insulating packaging material 10.

[0083] The ISTA 7E 72-hour heat temperature profile was utilized, with a control thermocouple placed within the CSZ environmental chamber to log chamber temperature throughout the test. The experiment was conducted over a 72-hour period, during which temperature data for the products, internal container environments, and environmental chamber were continuously recorded.

[0084] Referring to FIGS. 13-17, the post test results shows that units with gas-filled insulating packaging material 10 outperformed the EPS cooler in maintaining lower temperatures throughout the test. Both the internal package temperature and the product temperature remained lower in the unit with gas-filled insulating packaging material 10 compared to the EPS cooler unit, particularly in the first 50 hours. Summary plots were constructed to display temperature and elapsed time, as shown in FIGS. 13-17.

[0085] In sum, the present disclosure of gas-filled insulating packaging material 10 with low emitting aluminized internal film material 12 of multilayered internal film structure 26 configured for cold chain packages 82 may be directed to a way to cheaply and effectively insulate cold chain packages 82 in a way that can be quickly implemented by manufacturers and end users. The disclosed gas-filled insulating packaging material 10 may include a multilayered internal structure 26 that utilizes at least one low-emissivity surface 28 (aluminized film surface 24 or the like) on each layer 30. An outer pouch layer 14 may be included to encapsulate the multilayered internal film structure 26. The internal multilayered polymer film structure 26 (the multilayered structure can also be made of paper, biodegradable materials, or any other thin sheet) may be joined via an alternating adhesive pattern 66 to produce voided or honeycomb structure 52 when inflated (this structure can also be produced by other methods of attachment such as heat welding, embossing, taping etc.). The outer layer 14 may encompass a heat weldable film, that is inflated by use of a machine similar to a pillow pack machine (see FIG. 1) common in the packaging industry. The inner structure 26 can have its adhesive pattern altered to accommodate different sizes, structures to accommodate the desired packaging dimensions from the end user. A carrier layer 51 of necessarily thin, heat sealable polymer (likely identical to the outer layer 14 in material) may be adhered to the internal multilayered structure 26 through adhesive, and the outer layer 14 through either adhesive, heat sealing or both.

[0086] In use, gas-filled insulating packaging material 10 with low emitting aluminized internal film material 12 of multilayered internal film structure 26 configured for cold chain packages 82 offers manufacturers the ability to cheaply insulate cold chain products to their end user using known technology. It does not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (pillow pack machine, like shown in FIG. 1). Gas-filled insulating packaging material 10 may be able to structurally support products in transit with the same utility and versatility as known packaging air cushioning technology, but it adds the ability to thermally insulate comparably with existing cold chain packaging options such as Styrofoam.

[0087] In the specification and / or figures, typical embodiments of the disclosure have been disclosed. The present disclosure is not limited to such exemplary embodiments. The use of the term “and / or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

[0088] The foregoing description and drawings comprise illustrative embodiments. Having thus described exemplary embodiments, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present disclosure. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein but is limited only by the following claims.

Examples

Embodiment Construction

[0062]Referring to FIG. 1, an air cushion machine 1 is shown according to the prior art from, namely, from U.S. Pat. No. 10,850,906, incorporated herein in its entirety. As shown in FIG. 1, air cushion machine 1 may be a more modern air cushion machine that is commonly used to inflate air bags for air cushion packaging materials, air pillows, the like, etc. Air cushion machine 1 generally includes a pulling assembly 2 configured to pull a roll of film material through the air cushion machine 1. Air injector assembly 4 is configured to inject air (or any other gas) into the film material as it is being pulled through air cushion machine 1. Once the air is injected into the film material, heat sealing assembly 3 is configured to seal the open side of the film material to seal the air inside of the film material for creating the air cushion packaging materials, air pillows, the like, etc. An operator interface 5 is included for generally operating air cushion machine 1 such as turning ...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit to U.S. Provisional Patent Application No. 63 / 664,239 filed on Jun. 26, 2024, entitled GAS-FILLED INSULATING PACKAGING MATERIAL WITH A LOW EMITTING ALUMINIZED FILM INTERNAL STRUCTURE CONFIGURED FOR COLD CHAIN PACKAGES, which is incorporated by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a way to cheaply and effectively insulate cold chain packages in a way that can be quickly implemented by manufacturers and end users.BACKGROUND

[0003] Generally speaking, cold chain packaging is the practice of shipping goods from one destination to another and maintaining the goods at or below a desired temperature to keep the goods cold. As such, cold chain packaging technology is designed and configured to enable various industries to transport goods at or below a desired temperature. As an example, cold chain packaging for the food industry allows for safely transporting meats, seafood, and poultry at temperatures below 40 degrees Fahrenheit to inhibit bacterial growth and contamination. Dairy products, meanwhile, must be kept below 45 degrees Fahrenheit to preserve freshness. Fruits and vegetables also have specific temperature requirements to minimize spoilage, maintain flavor, and prevent skin damage and bruising. As another example, the pharmaceutical industry depends on cold chain packaging to provide cold shipping solutions to supply sorely needed medications, such as vaccines, which are highly prone to spoiling if they are exposed to temperatures even a few degrees higher than what's required to be effective. Other medical products, such as blood, biologics and medical devices, as well as chemicals used in industry, must also be stored at consistently low temperatures to be safe and useful.

[0004] Cold chain packaging generally includes some form of insulating materials or devices added around the goods being shipped inside of a package or box that the goods are shipped inside of. Insulating packaging materials help industries manage the cold chain needs of their products. Insulating packaging materials used today may include insulated box liners, pouches, and pallet covers, to gel packs and other phase change materials, also known as PCMs, molded designs like expanded polystyrene containers, or EPS containers. Insulating packaging materials may be designed in various sizes or shapes configured for various cold chain products.

[0005] One problem that the instant disclosure recognizes is the environmental impacts of these known insulating packaging materials. This may be especially true for EPS containers, like foam coolers, that are infamously known as bad for the environment. As such, it is clearly desirable to provide insulating packaging materials that are less harmful to the environment.

[0006] Another problem that the instant disclosure recognizes is the ease of use, the weight, and costs associated with utilizing known insulating packaging materials. As such, it is clearly desirable to provide insulating packaging material that is easier and more economical to use.

[0007] One known easy to use, light weight and economical shipping product solution is air cushion packaging. Air cushion packaging is a type of packaging solution that has become increasingly popular in recent years. It is designed to protect goods from damage during shipping and storage, while also providing a cost-effective solution. Air cushion packaging is a form of protective packaging that utilizes air bags or cushioning materials to protect goods during shipping and storage. The air cushion packaging is designed to absorb impacts and vibrations, which helps to reduce the risk of damage to the goods during transit. Air cushion packaging is a cost-effective solution that can help to reduce the risk of damage to goods during shipping and storage. Additionally, air cushion packaging is lightweight and easy to store, which helps to reduce the amount of storage space needed.

[0008] Air bags are the most common type of air cushion packaging. They are made from a durable plastic material and usually feature an inflatable design. U.S. Pat. No. 8,627,637, incorporated herein in its entirety, discloses one of the first machines for the manufacture of air pillows that is configured for forming air pillows where a drive means draws tube material from a roll along rollers and an injector means injects air into an interior space between two opposing sheets of tube material, and a sealing means seals the two opposing sheets together with the injected air entrapped in the interior space therebetween. U.S. Pat. No. 10,850,906, incorporated herein in its entirety, discloses a more modern air cushion machine and method that is commonly used to inflate such air bags for air cushion packaging materials.

[0009] Air bags can be used to protect a wide range of goods, from electronics to furniture. They are also available in a variety of sizes and shapes, making them suitable for a wide range of products. However, standard air bags cannot be used in cold chain packaging as they provide little to no insulating properties. As such, the instant disclosure recognizes the need to provide an air cushion or air back packaging material that provides the same ease of use, light weight design, and cost effectiveness while also providing insulating properties for cold chain packaging.

[0010] The instant disclosure may be designed to address at least certain aspects of the problems or needs discussed above by providing gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages.SUMMARY

[0011] The present disclosure may solve the aforementioned limitations of the currently available cold chain packaging materials and technology, by providing gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages. The gas-filled insulating packaging material with a low emitting aluminized film internal structure configured for cold chain packages and a gas-filled insulating packaging envelope made therefrom, may generally include a low-emitting internal film material and outer pouch layers. The outer pouch layers may encapsulate the low-emitting internal film material including on a bottom side and a top side of the low-emitting internal film material. The outer pouch layers may be configured to be inflatable via an air cushion machine. The outer pouch layers may be sealed on a sealed side and unsealed on an open side prior to inflation and subsequently sealable on the unsealed side after inflation to create the gas-filled insulating packaging envelope.

[0012] One feature of the disclosed gas-fillable insulating packaging material may be that the low-emitting internal film material can include a thermal emissivity of less than 0.1. In select embodiments, the low-emitting internal film material may include a thermal emissivity of less than 0.05. In select possibly preferred embodiments, the low-emitting internal film material may include a thermal emissivity of 0.03 or approximately 0.03. In select possibly most preferred embodiments, the low-emitting internal film material of the gas-fillable insulating packaging material may include an aluminized surface with the thermal emissivity of 0.03.

[0013] Another feature of the disclosed gas-fillable insulating packaging material may be that the low-emitting internal film material can include a multilayered internal film structure. The multilayered internal film structure may include at least one low-emissivity surface on each layer of the multilayered internal film structure. In select embodiments, the at least one low-emissivity surface on each of the layers of the multilayered internal film structure may include an aluminized surface with a thermal emissivity of 0.03. The multilayered internal film structure may include or be made from various materials, including, but not limited to, polymer sheets, paper sheets, biodegradable material sheets, the like, and any other desired thin sheet of material. In select possibly preferred embodiments, the multilayered internal film structure of the disclosed gas-filled insulating packaging material may include polymer sheets that can include an aluminized surface on each layer of the polymer sheets forming the multilayered internal film structure.

[0014] Another feature of the disclosed gas-fillable insulating packaging material may be that the multilayered internal film structure can be configured to expand when the outer pouch layers are inflated to create an insulating structure with spacing for internal air gaps therein. In select embodiments, the multilayered internal film structure may include a bonding layer configured to bond adjacent layers of the multilayered internal film structure and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers. In select embodiments, the bonding layer may create an alternating bonding pattern between the adjacent layers of the multilayered internal film structure and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers. The alternating bonding pattern of the bonding layer may be configured for creating the spacing for the internal air gaps. Wherein, when the outer pouch layers are inflated, the multilayered internal film structure with the alternating bonding pattern may be configured to expand into a voided or honeycomb type internal structure of the low-emitting internal film material. In select embodiments, the voided or honeycomb type internal structure created by the multilayered internal film structure may be in a transverse orientation. The alternating bonding patterns of the bonding layer may include any means or methods for bonding the adjacent layers and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers, including, but not limited to, adhesive bonding, heat weld bonding, embossing, taping, the like, and / or combinations thereof. In select possibly preferred embodiments of the disclosed gas-filled insulating packaging material, the multilayered internal film structure may include an alternating adhesive bonding pattern between adjacent layers of the multilayered internal film structure and to the top side and the bottom side of the multilayered internal film structure to the outer pouch layers.

[0015] In select embodiments of the disclosed gas-fillable insulating packaging material, a carrier layer may be included. The carrier layer may connect the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. In select embodiments, the carrier layer may include a thin, heat sealable polymer adhered to the top side and the bottom side of the low-emitting film internal structure and the outer pouch layers through various forms of bonding, including, but not limited to, adhesive, heat sealing, the like, and / or a combination thereof.

[0016] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be formed in an elongated roll of the gas-fillable insulating packaging material. Wherein, in select embodiments, the low-emitting internal film material may be offset an offset distance from the open side of the outer pouch layers. In select embodiments, the outer pouch layers may be comprised of a heat weldable film. Wherein, the heat weldable film of the outer pouch layers may be configured to be inflatable via the air cushion machine, whereby the heat weldable film of the outer pouch layers are sealed on the sealed side and unsealed on the open side prior to inflation and subsequently sealable on the unsealed side after inflation. Wherein, the elongated roll of the gas-fillable insulating packaging material may be configured to be inflated from the unsealed side of the roll in line via the air cushion machine.

[0017] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for cold chain packages.

[0018] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for providing a way to insulate cold chain packages in a way that can be implemented by manufacturers and end users using known technology (air cushion machines or the like).

[0019] Another feature of the disclosed gas-fillable insulating packaging material may be that it does not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (air cushion machine or the like).

[0020] Another feature of the disclosed gas-fillable insulating packaging material may be that it can be designed and configured for structurally supporting products in cold chain packages in transit with the same utility and versatility as known packaging cushioning technology, but also adds the ability to thermally insulate comparably with existing cold chain packaging options including, but not limited to, expanded polystyrene containers (i.e. Styrofoam coolers).

[0021] In another aspect, the instant disclosure embraces a gas-filled insulating packaging envelope generally made from the disclosed gas-fillable insulating packaging material in any of the embodiments and / or combination of embodiments shown and / or described herein. The gas-filled insulating packaging envelope may thus generally include the low-emitting film internal structure with the outer pouch layers. The outer pouch layers may encapsulate the low-emitting film internal structure including on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure. A carrier layer may be included that connects the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. A gas, including but not limited to air, may be sealed inside of the outer pouch layers. Wherein the gas may be pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create the voided or honeycomb type internal structure of the low-emitting film internal structure thereby creating an insulating structure with spacing for internal air gaps therein.

[0022] In another aspect, the instant disclosure embraces a cold chain package with the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of the cold chain package. As such, the disclosed cold chain package may generally include a box (like a cardboard box or the like) with an inside with a bottom surface, a top surface, a front surface, a back surface, a left surface, and a right surface. At least one gas-filled insulating packaging envelope may be included inside of the box in any of the embodiments and / or combination of embodiments shown and / or described herein. As such, each of the gas-filled insulating packaging envelopes positioned in the box may generally include the low-emitting film internal structure and the outer pouch layers. The outer pouch layers may encapsulate the low-emitting film internal structure including on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure. A carrier layer may be included that connects the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers. A gas, including, but not limited to air, may be sealed inside of the outer pouch layers. Wherein, the gas may be pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create a voided or honeycomb type internal structure of the low-emitting film internal structure with spacing for internal air gaps therein. The at least one gas-filled insulating packaging envelope may be positioned in the inside of the box on at least one of the bottom surface, the top surface, the front surface, the back surface, the left surface, and / or the right surface. In select possibly preferred embodiments of the disclosed cold chain package, the gas-filled insulating packaging envelopes may be positioned inside of the box on all of the internal surface, including the bottom surface, the top surface, the front surface, the back surface, the left surface, and the right surface.

[0023] In another aspect, the instant disclosure embraces a method of insulating a cold chain package with the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of the cold chain package. As such, the disclosed method of insulating a cold chain package may generally include: providing the disclosed gas-fillable insulating packaging material in any of the embodiments and / or combination of embodiments shown and / or described herein; and inflating the disclosed gas-fillable insulating packaging material with an air cushion machine thereby creating a plurality of the disclosed gas-filled insulating packaging envelope in any of the embodiments and / or combination of embodiments shown and / or described herein. With these gas-filled insulating packaging envelopes created, the disclosed method of insulating a cold chain package may then include positioning at least one of the created gas-filled insulating packaging envelopes on the inside of a box, like on the bottom surface, the top surface, the front surface, the back surface, the left surface, and / or the right surface. In select possibly preferred embodiments of the disclosed method of insulating a cold chain package, the gas-filled insulating packaging envelopes may be positioned inside of the box on all of the internal surface, including the bottom surface, the top surface, the front surface, the back surface, the left surface, and the right surface.

[0024] The foregoing illustrative summary, as well as other exemplary objectives and / or advantages of the disclosure, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present apparatuses, systems and methods will be better understood by reading the disclosure with reference to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

[0026] FIG. 1 is a perspective view of an air cushion machine according to the prior art;

[0027] FIG. 2 is a perspective view of the disclosed gas-filled insulating packaging envelope made from the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages;

[0028] FIG. 3 is a side view of the gas-filled insulating packaging envelope from FIG. 2;

[0029] FIG. 4 is a perspective cross-sectional schematic view of the gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages showing the film layers as it presents in its inflated state to create the voided or honeycomb type internal structure;

[0030] FIG. 5 is a partially disassembled perspective view of the gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages showing an expanded cross section of the multilayered internal film structure, with the raised bands representing either adhesive or a heat seal pattern connecting the layers;

[0031] FIG. 6 is a cross-sectional diagram view of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a low emitting aluminized film internal structure configured for cold chain packages encompassing the layers of the disclosed product;

[0032] FIG. 7 shows a schematic view of a basic construction of an idealized manufacturing line according to select embodiments of the instant disclosure for the internal multilayered low-emissivity structure, as well as the carrier film liner layer, and the outer liner for creating the disclosed gas-fillable insulating packaging material;

[0033] FIG. 8 shows a top schematic view of the disclosed gas-fillable insulating packaging material according to select embodiments of the instant disclosure showing the carrier layer adhered to the multilayered internal layers prior to the cutting stage shown in FIG. 7;

[0034] FIG. 9 shows a top schematic view of the disclosed gas-fillable insulating packaging material according to select embodiments of the instant disclosure showing the assembled product prior to its final inflation;

[0035] FIG. 10A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width;

[0036] FIG. 10B shows a schematic top view of a 16-inch section of the film from FIG. 10A with a 16-inch length and a 11.5-inch width;

[0037] FIG. 10C shows a schematic top view of a 10.5-inch section of the film from FIG. 10A with a 10.5-inch length and a 11.5-inch width;

[0038] FIG. 10D shows a schematic view of a first adhesive pattern for the 16-inch section of the film shown in FIG. 10B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.5 inch end adhesive strips;

[0039] FIG. 10E shows a schematic view of a second adhesive pattern for the 16-inch section of the film shown in FIG. 10B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and a 5.125-inch spacing at the end;

[0040] FIG. 10F shows a schematic view of a first adhesive pattern for the 10.5-inch section of the film shown in FIG. 10C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween;

[0041] FIG. 10G shows a schematic view of a second adhesive pattern for the 10.5-inch section of the film shown in FIG. 10C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 2.125 inch spacing at both ends;

[0042] FIG. 10H shows a schematic view of the film from FIG. 10A showing the pattern for a 16-inch section of the film from FIG. 10B, a 10.5-inch section of the film from FIG. 10C, and another 16-inch section of the film from FIG. 10B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset at the bottom inflatable side;

[0043] FIG. 10I shows a schematic view of the film and adhesive layering for the film from FIG. 10H with the first adhesive pattern for the 16-inch section of the film from FIG. 10D or the first adhesive pattern for the 10.5-inch section of the film from FIG. 10F, and the second adhesive pattern for the 16-inch section of the film from FIG. 10E or the second adhesive pattern for the 10.5-inch section of the film from FIG. 10G;

[0044] FIG. 11A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 47.5-inch length and a 12-inch width;

[0045] FIG. 11A shows a schematic top view of the film used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width;

[0046] FIG. 11B shows a schematic top view of a 15-inch section of the film from FIG. 11A with a 15-inch length and a 8.5-inch width;

[0047] FIG. 11C shows a schematic top view of a 11.5-inch section of the film from FIG. 11A with a 11.5-inch length and a 8.5-inch width;

[0048] FIG. 11D shows a schematic view of a first adhesive pattern for the 15-inch section of the film shown in FIG. 11B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.125-inch spacing on each end;

[0049] FIG. 11E shows a schematic view of a second adhesive pattern for the 15-inch section of the film shown in FIG. 11B with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween;

[0050] FIG. 11F shows a schematic view of a first adhesive pattern for the 11.5-inch section of the film shown in FIG. 11C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.5-inch spacing on each end;

[0051] FIG. 11G shows a schematic view of a second adhesive pattern for the 11.5-inch section of the film shown in FIG. 11C with 2-inch wide adhesive strips with 2.25-inch wide spacing therebetween, and 0.375-inch adhesive strips at both ends;

[0052] FIG. 11H shows a schematic view of the film from FIG. 11A showing the pattern for a 15-inch section of the film from FIG. 11B, a 11.5-inch section of the film from FIG. 11C, and another 15-inch section of the film from FIG. 11B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset at the bottom inflatable side;

[0053] FIG. 11I shows a schematic view of the film and adhesive layering for the film from FIG. 11H with the first adhesive pattern for the 15-inch section of the film from FIG. 11D or the first adhesive pattern for the 11.5-inch section of the film from FIG. 11F, and the second adhesive pattern for the 15-inch section of the film from FIG. 11E or the second adhesive pattern for the 11.5-inch section of the film from FIG. 11G;

[0054] FIG. 12 is a perspective view of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure being filled by an air cushion machine;

[0055] FIG. 13 is an environmental perspective view of a cold chain package box according to select embodiments of the instant disclosure with the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure positioned on all sides of the inside of the cold chain package box;

[0056] FIG. 14 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing thermal profile over time with temperature in degrees Celsius vs. elapsed time in hours;

[0057] FIG. 15 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested EPS container and the tested gas-filled insulating packaging material unit with temperature in degrees Celsius vs. elapsed time in hours;

[0058] FIG. 16 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing product temperature inside the tested EPS container vs. inside the disclosed gas-filled insulating packaging material unit with temperature in degrees Celsius vs. elapsed time in hours;

[0059] FIG. 17 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested EPS container and the tested EPS product with temperature in degrees Celsius vs. elapsed time in hours; and

[0060] FIG. 18 is a line graph of the insulating properties of the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure showing the testing chamber vs. the tested gas-filled insulating packaging material unit and the tested gas-filled insulating packaging material with temperature in degrees Celsius vs. elapsed time in hours.

[0061] It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed disclosure.DETAILED DESCRIPTION

[0062] Referring to FIG. 1, an air cushion machine 1 is shown according to the prior art from, namely, from U.S. Pat. No. 10,850,906, incorporated herein in its entirety. As shown in FIG. 1, air cushion machine 1 may be a more modern air cushion machine that is commonly used to inflate air bags for air cushion packaging materials, air pillows, the like, etc. Air cushion machine 1 generally includes a pulling assembly 2 configured to pull a roll of film material through the air cushion machine 1. Air injector assembly 4 is configured to inject air (or any other gas) into the film material as it is being pulled through air cushion machine 1. Once the air is injected into the film material, heat sealing assembly 3 is configured to seal the open side of the film material to seal the air inside of the film material for creating the air cushion packaging materials, air pillows, the like, etc. An operator interface 5 is included for generally operating air cushion machine 1 such as turning air cushion machine 1 on and off, supplying air cushion machine 1 with various inputs, and for receiving various outputs from air cushion machine 1. Air cushion machine 1, or the like, may be utilized in filling the disclosed gas-filled insulating packaging material 10 with a low emitting aluminized film internal structure 26 configured for cold chain packages 82.

[0063] Referring now to FIGS. 2-18, in describing the exemplary embodiments of the present disclosure, specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

[0064] Referring to FIGS. 2-18, the present disclosure may solve the aforementioned limitations of the currently available cold chain packaging technology by providing the disclosed gas-filled insulating packaging material 10 with low emitting aluminized film internal structure 26 configured for cold chain packages 82. Gas-filled insulating packaging material 10 (see FIGS. 4-12) with low emitting aluminized film internal structure 26 configured for cold chain packages 82 and gas-filled insulating packaging envelope 84 (see FIGS. 2-3, 12 and 13) made therefrom, may generally include low-emitting internal film material 12 and outer pouch layers 14. Outer pouch layers 14 may encapsulate low-emitting internal film material 12 including on bottom side 16 and top side 18 of low-emitting internal film material 12. Outer pouch layers 14 may be configured to be inflatable via air cushion machine 1, or the like. Outer pouch layers 14 may be sealed on sealed side 20 and unsealed on open side 21 prior to inflation and subsequently sealable on open side 21 after inflation to create gas-filled insulating packaging envelope 84.

[0065] One feature of the disclosed gas-fillable insulating packaging material10 may be that the low-emitting internal film material 12 can include a low thermal emissivity 22. Emissivity 22 may be the value given to materials based on the ratio of heat emitted compared to a perfect black body, on a scale from zero to one. A black body would have an emissivity of 1 and a perfect reflector would have a value of 0. Low emissivity 22 (low e or low thermal emissivity), as used herein, may refer to a surface condition that emits low levels of radiant thermal (heat) energy. All materials absorb, reflect, and emit radiant energy according to Planck's law but here, the primary concern is a special wavelength interval of radiant energy, namely thermal radiation of materials. Thermal insulation materials are typically fabricated from aluminum foil with a variety of core materials such as low-density polyethylene foam, polyethylene bubbles, fiberglass, or similar materials. When aluminum foil is used as the facing material, reflective thermal insulation can stop 97% of radiant heat transfer. In select embodiments of the disclosed gas-fillable insulating packaging material, low-emitting internal film material 12 may have thermal emissivity 22 of less than 0.1. In select possibly more preferred embodiments, low-emitting internal film material 12 may include thermal emissivity 22 of less than 0.05. In select possibly most preferred embodiments, low-emitting internal film material 12 may include thermal emissivity 22 of 0.03 or approximately 0.03. In other select possibly most preferred embodiments, low-emitting internal film material 12 of gas-fillable insulating packaging material 10 may include aluminized surface 24 with thermal emissivity 22 of 0.03 (or approximate thereto).

[0066] Another feature of gas-fillable insulating packaging material 10 may be that low-emitting internal film material 12 can include multilayered internal film structure 26 (see FIGS. 4-7, and 10-11). Multilayered internal film structure 26 may include at least one low-emissivity surface 28 on one of the layers 30 of multilayered internal film structure 26. In select embodiments, multilayered internal film structure 26 may include at least one low-emissivity surface 28 on each of the layers 30 of multilayered internal film structure 26. In select embodiments, the at least one low-emissivity surface 28 on each of the layers 30 of multilayered internal film structure 26 may include aluminized surface 24 with thermal emissivity of 0.03 (or approximate thereto), like a metalized polyester (MPET) film material. However, the disclosure is not so limited, and the at least one low-emissivity surface 28 on one or more or all of layers 30 of multilayered internal film structure 26 may include any other desired surface material with low thermal emissivity 22. Multilayered internal film structure 26 may include or be made from various sheets of materials 32, including, but not limited to, polymer sheets 34, paper sheets 35, biodegradable material sheets 36, the like, and any other desired thin sheet 38 of material. In select possibly preferred embodiments, multilayered internal film structure 26 of gas-filled insulating packaging material 10 may include polymer sheets 34 that can include aluminized surface 24 on each layer 30 of polymer sheets 34 forming multilayered internal film structure 26. Addition and / or subtraction of internal media layers 30 of multilayered internal film structure 26 may adjust an insulation value provided by gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom.

[0067] Another feature of gas-fillable insulating packaging material 10 may be that multilayered internal film structure 26 can be configured to expand when outer pouch layers 14 are inflated to create insulating structure 40 with spacing 48 for internal air gaps 50 therein. In select embodiments, multilayered internal film structure 26 may include bonding layer 42 configured to bond adjacent layers 30 of multilayered internal film structure 26 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. In select embodiments, bonding layer 42 may create alternating bonding pattern 44 (see FIGS. 5 and 10-11) between adjacent layers 30 of multilayered internal film structure 26 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. Alternating bonding pattern 44 of bonding layer 42 may be configured for creating spacing 48 for internal air gaps 50 for creating insulating structure 40 within gas-filled insulating packing envelopes 84 created from gas-fillable insulating packaging material 10. Wherein, when outer pouch layers 14 are inflated, multilayered internal film structure 26 with alternating bonding pattern 44 may be configured to expand into voided or honeycomb type internal structure 52 of low-emitting internal film material 12. In select embodiments, voided or honeycomb type internal structure 52 created by multilayered internal film structure 26 may be in transverse orientation 54, as shown in the Figures. Transverse orientation 54 of voided or honeycomb type internal structure 52 may allow gas 85 inflated into gas-fillable insulating packaging material 10 to fill internal air gaps 50 within voided or honeycomb type internal structure 52. As such, transverse orientation 54 of voided or honeycomb type internal structure 52 may be to assist with inflation and allow air to penetrate all structures. However, the disclosure is not so limited and voided or honeycomb type internal structure 52 may be provided in a machine direction orientation by providing holes, apertures, slits, the like, etc. through layers 30 of multilayered internal film structure 26. Alternating bonding patterns 44 of bonding layer may include any means or methods for bonding adjacent layers 30 and top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14, including, but not limited to, adhesive bonding 56, heat weld bonding 58, embossing 60, taping 62, the like, and / or combinations thereof. In select possibly preferred embodiments of gas-filled insulating packaging material 10, multilayered internal film structure 26 may include alternating adhesive bonding pattern 66 between adjacent layers 30 of multilayered internal film structure 26 and to top side 18 and bottom side 16 of multilayered internal film structure 26 to outer pouch layers 14. In other select embodiments, film or film is not removed from the internal baffle media of multilayered internal film structure 26, and the entire envelope of gas-fillable insulating packaging material 10 may receive a lateral heat seal across all layers to envelop the pouch prior to inflation.

[0068] In select embodiments of gas-fillable insulating packaging material 10, carrier layer 51 or carrier film layer 51 may be included. Carrier layer 51 may connect top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. In select embodiments, carrier layer 51 may include a thin, heat sealable polymer 74 adhered to top side 18 and bottom side 16 of low-emitting film internal structure 26 and outer pouch layers 14 through various forms of bonding, including, but not limited to, adhesive 76, heat sealing 78, the like, and / or a combination thereof.

[0069] As best shown in FIG. 12, another feature of gas-fillable insulating packaging material 10 may be that it can be formed in elongated roll 68 of gas-fillable insulating packaging material 10. Wherein, in select embodiments, low-emitting internal film material 12 may be offset the offset distance 70 (see FIGS. 10H, 11H and 12) from open side 21 of outer pouch layers 14. In select embodiments, outer pouch layers 14 may be comprised of heat weldable film 72. Wherein, heat weldable film 72 of outer pouch layers 14 may be configured to be inflatable via air cushion machine 1 (or the like), whereby heat weldable film 72 of outer pouch layers 14 may be sealed on sealed side 20 and unsealed on open side 21 prior to inflation and subsequently sealable on open side 21 or unsealed side 21 after inflation. Wherein, elongated roll 68 of gas-fillable insulating packaging material 10 may be configured to be inflated from open side 21 or unsealed side 21 of elongated roll 68 in line, including, but not limited to, via air cushion machine 1 (or the like). Heat weldable film 72 of outer pouch layers 14 may be, but is not limited to, a polyethylene (PE) film.

[0070] Referring to FIG. 13, another feature of gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom, may be that they can be designed and configured for cold chain packages 82. Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may be designed and configured for providing a way to insulate cold chain packages 82 in a way that can be implemented by manufacturers and end users using known technology (like via air cushion machine 1, or the like). Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (like air cushion machine 1 or the like). Gas-fillable insulating packaging material 10 and gas-filled insulating packaging envelope 84 made therefrom may be designed and configured for structurally supporting products in cold chain packages 82 in transit with the same utility and versatility as known packaging cushioning technology, but also adds the ability to thermally insulate comparably with existing cold chain packaging options including, but not limited to, expanded polystyrene containers (i.e. Styrofoam coolers). See testing results in FIGS. 14-18

[0071] Referring specifically to FIGS. 2-3, 12 and 13, in another aspect, the instant disclosure embraces gas-filled insulating packaging envelope 84 (may also be referred to as a pillow, bag, the like, etc.). Gas-filled insulating packaging envelopes 84 may generally be made from the disclosed gas-fillable insulating packaging material 10 in any of the embodiments and / or combination of embodiments shown and / or described herein. Gas-filled insulating packaging envelope 84 may thus generally include low-emitting film internal structure 26 with outer pouch layers 14. The outer pouch layers 14 may encapsulate low-emitting film internal structure 26 including on bottom side 16 of low-emitting film internal structure 26 and top side 18 of low-emitting film internal structure 26. Carrier layer 51 or carrier film layer 51 may be included that connects top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. Gas 85, including but not limited to air, may be sealed inside of outer pouch layers 14. Wherein, gas 85 may be pressurized inside of outer pouch layers 14 for expanding outer pouch layers 14 thereby separating bottom side 16 from top side 18 of low-emitting film internal structure 26 to create voided or honeycomb type internal structure 52 of low-emitting film internal structure 26 thereby creating insulating structure 40 with spacing 48 for internal air gaps 50 therein.

[0072] Referring specifically to FIG. 13, in another aspect, the instant disclosure embraces cold chain package 82 with the disclosed gas-filled insulating packaging envelope 84 in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of cold chain package 82. As such, cold chain package 82 may generally include box 86 (like a cardboard box, plastic container, or the like) with inside 88 with bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98. At least one gas-filled insulating packaging envelope 84 may be included inside of box 86 in any of the embodiments and / or combination of embodiments shown and / or described herein. In select embodiments, each gas-filled insulating packaging envelope 84 may be sized and configured to cover each surface inside of box 86. However, the disclosure is not so limited, and cold chain package 82 may include multiple gas-filled insulating packaging envelopes 84 on each surface inside of box 86. Each gas-filled insulating packaging envelope 84 positioned in box 86 may generally include low-emitting film internal structure 26 and outer pouch layers 14. Outer pouch layers 14 may encapsulate low-emitting film internal structure 26 including on bottom side 16 of low-emitting film internal structure 26 and top side 18 of low-emitting film internal structure 26. Carrier layer 51 or carrier film layer 51 may be included that connects top side 18 and bottom side 16 of low-emitting film internal structure 26 to outer pouch layers 14. Gas 85, including, but not limited to air, may be sealed inside of outer pouch layers 14. Wherein, gas 85 may be pressurized inside of outer pouch layers 14 for expanding outer pouch layers 14 thereby separating bottom side 16 from top side 18 of low-emitting film internal structure 26 to create voided or honeycomb type internal structure 52 of low-emitting film internal structure 26 with spacing 48 for internal air gaps 50 therein. The at least one gas-filled insulating packaging envelope 84 may be positioned in inside 88 of box 86 on at least one of bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and / or right surface 98. In select possibly preferred embodiments of cold chain package 82, gas-filled insulating packaging envelopes 84 may be positioned inside of box 86 on all of the internal surface, including bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98. This possibly preferred embodiment of cold chain package 82 with gas-filled insulating packaging envelopes 84 positioned inside of box 86 on all of the internal surfaces was used in testing to get the results shown in FIGS. 14-18.

[0073] In another aspect, the instant disclosure embraces a method of insulating cold chain package 82 with the disclosed gas-filled insulating packaging envelope 84 in any of the embodiments and / or combination of embodiments shown and / or described herein positioned inside of cold chain package 82. As such, the disclosed method of insulating cold chain package 82 may generally include: providing the disclosed gas-fillable insulating packaging material 10 in any of the embodiments and / or combination of embodiments shown and / or described herein; and inflating the disclosed gas-fillable insulating packaging material 10 with air cushion machine 1 (or the like) thereby creating a plurality of the disclosed gas-filled insulating packaging envelopes 84 in any of the embodiments and / or combination of embodiments shown and / or described herein. With these gas-filled insulating packaging envelopes 84 created, the disclosed method of insulating cold chain package 82 may then include positioning at least one of the created gas-filled insulating packaging envelopes 84 on inside 88 of box 86, like on bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and / or right surface 98. In select possibly preferred embodiments of the disclosed method of insulating cold chain package 82, gas-filled insulating packaging envelopes 84 may be positioned inside of box 86 on all of the internal surface, including bottom surface 90, top surface 92, front surface 93, back surface 94, left surface 96, and right surface 98.

[0074] Referring specifically to FIG. 4, a sketch of the gas-fillable insulating packaging material 10 is shown showing the internal structure 26 with layers 30 of low-emitting internal film material 12. The sketch shown in FIG. 4 may present material 10 in its inflated state to create the voided or honeycomb type internal structure 52 with spacing 48 for internal air gaps 50. The areas represented by the filled lines is the internal baffle material, this material can be made of many materials, both reflective and unreflective, though reflective films offer the best thermal performance, there could be various reasons to exclude aluminized reflective films from various layers of the product. This baffle material, or multilayered internal film structure 26, can be assembled in various ways including through adhesives 76, tapes 62, heat sealing 78, and other methods and the widths of the bands can vary. The widths of the internal air gaps 50 can also vary, although it is most ideal to have a 0.01-0.5 (0.1 is ideal) inch gap as that range allows for the most efficient air gap 50 width, as convection currents are unable to form in those widths. The outer pouch material, or outer pouch layers 14, can be made of any flat material polymer, cellulose, paper etc. Offset distance 70 denotes that the inner baffle material (multilayered internal structure 26) is offset from the seal by some offset distance 70. This is only applicable on open side 21 that is receiving the final seal and is inflated, but can be both sides for aesthetic / material cost purposes. This is to allow the air or gas 85 to enter the baffle material (multilayered internal structure 26), while also allowing the final seal to be effective.

[0075] Referring specifically to FIG. 5, an expanded cross section of the web structure or multilayered internal film structure 26 is shown, with the raised bands of bonding layer 42 representing either adhesive 76 or heat seal 78 pattern connecting layers 30.

[0076] Referring specifically to FIG. 6, a diagram of the cross-section of gas-fillable insulating packaging material 10 is shown. Outer heat sealable layer of film layers 14 must be impermeable to gases. Carrier layer 51, which may also be made of a heat sealable layer 78, can be made considerably thinner than outer layers 14. Low-emissivity internal film material 12 layers can range in quantity depending on the situation and required insulation.

[0077] Referring specifically to FIG. 7, an embodiment of a method of forming or manufacturing gas-fillable insulating packaging material 10 is shown. However, the disclosure is not so limited and gas-fillable insulating packaging material 10 may be made by other means and / or method of forming or manufacturing gas-fillable insulating packaging material 10. Individual low-emissivity films may be used for low-emitting internal film material 12 used to create the multilayered internal film structure 26 created with this method. Adhesives 76 are shown as being applied between each layer of low-emitting internal film material 12 with an adhesive applicator to apply the repetitive alternating adhesive bonding pattern 44 or alternating adhesive bonding pattern 66. Film windower or cut pattern 41 may be used to apply a selective cut pattern into the internal multilayered structure 26 in order to allow heat sealing at a later stage. Carrier film layer 51 is shown in position to adhere to one or both sides (top side 18 and / or bottom side 16) of internal multilayered structure 26 after the internal multilayered structure 26 is windowed with film windower or cut pattern 41. Cutting process 71 is shown to remove the edges of the conjoined carrier layer 51 and internal multilayered structure 26 to remove the excess web and allow the area lateral to the film direction to be heat sealed completely and the internal layer encompassed. Heat sealable outer liner 72 is shown for outer pouch layers 14. This layer will usually be wrapped around the structure in a known process to remove the need to heat seal that edge, however it can also be laid in two layers and heat sealed on sealed side 20. In select possibly preferred embodiments, heat sealable outer liner 72 for outer pouch layers 14 may be a heat sealable polymer layer, as is commonly used with air cushion machines like air cushion machine 1. However, the disclosure is not so limited, and heat sealable outer liner 72 of outer pouch layers 14 may be made from other heat sealable materials, like biodegradable films, papers coated to make them somewhat heat sealable, the like, etc.

[0078] Referring specifically to FIG. 8, a top view of gas-fillable insulating packaging material 10 is shown after being created with the method in FIG. 7. 8.1 represents all layers at this stage in the process, both the carrier layer 51, as well as the internal multilayered structure 26. 8.2 represents the sections where only the carrier layer 51 remains, as the multilayered internal structure 26 has been removed due to the windowing process done via film windower or cut pattern 41 of FIG. 7. 8.3 represents the cuts that will be made in stage 71 shown in FIG. 7 to ensure that the internal multilayered structure 26 will not impede the heat sealing to be done.

[0079] Referring specifically to FIG. 9, another top view of gas-fillable insulating packaging material 10 is shown after being created with the method in FIG. 7 and the windowing process has been done via film windower or cut pattern 41. Regions 9.1 represent the regions where all layers of the design remain. Regions 9.2 represent the regions where only the carrier layer(s) 51 and the outer pouch layers 14 remain. This region 9.2 may be subject to heat sealing and perforation dependent on the needs of the final packaging design. Region 9.3 represents the area where only the outer film 14 is left. Area 9.4 represents an exaggerated representation of the edge that will most likely be folded over itself and not need a heat seal (sealed side 20). Region 9.5 represents open side 21 with the edge that will require the final heat seal once inflated, and that will be inflated via air cushion machine 1 (or the like) at the end users destination. Referring now specifically to FIGS. 10-11, an embodiment of an A-B liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. The dimensions shown in these figures are only meant to be examples to illustrate various alternating layers and alternating bonding patterns for the instant disclosure, and the disclosure is clearly not limited thereto. It is noted that it has been discovered that with the right films, a heat seal can be applied through all layers 30 (like 11 layers 30) of gas-fillable insulating packaging material 10, and that removes the need to remove panels from the design, i.e. this embodiment would remove the need for the windowing process via film windower or cut pattern 41.

[0080] Referring specifically to FIGS. 10A-10I, an embodiment of an A-liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. FIG. 10A shows a schematic top view of Film-A 100 used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 48.5-inch length and a 15-inch width. This Film-A 100 may be, but is not limited to, a 36 gauge polyethylene (PE) film that can be used as outer pouch layers 14. FIG. 10B shows a schematic top view of Film-A16 102 with a 16-inch length and a 11.5-inch width. Film-A16 102 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 10C shows a schematic top view of Film-A10 104 with a 10.5-inch length and a 11.5-inch width. Film-A10 104 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 10D shows a schematic view of a first A-16 adhesive bonding pattern 106 for Film-A16 102 shown in FIG. 10B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.5 inch end adhesive strips positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10E shows a schematic view of second A-16 adhesive pattern 107 for Film-A16 102 shown in FIG. 10B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and a 5.125-inch spacing at the end positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10F shows a schematic view of a first A-10 adhesive pattern 108 for Film-A10 104 shown in FIG. 10C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10G shows a schematic view of a second A-10 adhesive pattern 110 for Film-A10 104 shown in FIG. 10C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 2.125 inch spacing at both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 10H shows a schematic view of Film-A 100 from FIG. 10A showing the pattern for inserting 16-inch section Film-A16 102 from FIG. 10B, a 10.5-inch section of Film-A10 from FIG. 10C, and another 16-inch section of Film-A16 102 from FIG. 10B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset distance 79 at the bottom inflatable side (open side 21). FIG. 10I shows a schematic view of the film and adhesive layering for material 10 created from FIG. 10H with the first A-16 adhesive bonding pattern 106 for the 16-inch section of the film from FIG. 10D or the first A-10 adhesive pattern 108 for the 10.5-inch section of the film from FIG. 10F, and the second A-16 adhesive pattern 107 for the 16-inch section of the film from FIG. 10E or the second A-10 adhesive pattern 110 for the 10.5-inch section of the film from FIG. 10G.

[0081] Referring specifically to FIGS. 11A-11I, an embodiment of a B-liner system is shown that utilizes multi-layered inflatable laminate structure 26 for creating gas-fillable insulating packaging material 10. FIG. 11A shows a schematic top view of Film-B 112 used for the disclosed gas-filled insulating packaging material according to select embodiments of the instant disclosure with a 47.5-inch length and a 12-inch width. This Film-B 112 may be, but is not limited to, a 36 gauge polyethylene (PE) film that can be used as outer pouch layers 14. FIG. 11B shows a schematic top view of Film-B15 114 with a 15-inch length and a 8.5-inch width. Film-B15 112 may be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 11C shows a schematic top view of Film-B11 116 with a 11.5-inch length and an 8.5-inch width. Film-B11 116 may also be, but is not limited to, a metalized polyester (MPET) film that can be used for each layer 30 of low-emitting internal film material 12 for creating multilayered internal film structure 26. FIG. 11D shows a schematic view of a first B-15 adhesive bonding pattern 118 for Film-B15 114 shown in FIG. 11B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.125 inch end spacing positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11E shows a schematic view of second B-15 adhesive pattern 120 for Film-B15 114 shown in FIG. 11B with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween and at the ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11F shows a schematic view of a first B-11 adhesive pattern 122 for Film-B11 116 shown in FIG. 11C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween and 0.5 inch end spacing on both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11G shows a schematic view of a second B-11 adhesive pattern 124 for Film-B11 116 shown in FIG. 11C with 2-inch wide adhesive strips 76 for adhesive bonding 56 with 2.25-inch wide spacing therebetween, and 0.375 inch spacing at both ends positioned on aluminized surface 24 or low-emissivity surface 28. FIG. 11H shows a schematic view of Film-B 112 from FIG. 11A showing the pattern for inserting 15-inch section of Film-B15 114 from FIG. 11B, a 11.5-inch section of Film-B11 from FIG. 11C, and another 15-inch section of Film-B15 114 from FIG. 11B with 2-inch spacing therebetween, 1-inch offsets on each end and the top, and a 2.5-inch offset distance 79 at the bottom inflatable side (open side 21). FIG. 11I shows a schematic view of the film and adhesive layering for material 10 created from FIG. 11H with the first B-15 adhesive bonding pattern 118 for the 15-inch section of the film from FIG. 11D or the first B-11 adhesive pattern 122 for the 11.5-inch section of the film from FIG. 11F, and the second B-15 adhesive pattern 120 for the 15-inch section of the film from FIG. 11E or the second B-11 adhesive pattern 124 for the 11.5-inch section of the film from FIG. 11G.Test Results

[0082] Referring now to FIGS. 13-17, to assess the thermal performance of gas-filled insulating packaging material 10, a comparative study was conducted using a standard EPS cooler and a unit with gas-filled insulating packaging material 10 (like cold chain package 82, as shown in FIG. 13). Thermocouples and a CSZ Environmental Chamber were utilized to run the ISTA 7E 72 Hour Heat Thermal Qualification Test Sequence. The EPS and containers with gas-filled insulating packaging material 10 were loaded with 6.98 pounds of ice and a store-bought tuna product. Two thermocouples were installed in each unit: one positioned in direct contact with the tuna to monitor product temperature, and the other placed against the interior sidewall and suspended freely within the container to capture internal package conditions. To ensure clear identification during data collection, thermocouple wires were labeled as follows: chamber: temperature in the environmental chamber; package: internal thermocouple in the EPS cooler; pack 2: internal thermocouple in the unit with gas-filled insulating packaging material 10; product 1: tuna product in the EPS cooler; and product 2: tuna product in the unit with gas-filled insulating packaging material 10.

[0083] The ISTA 7E 72-hour heat temperature profile was utilized, with a control thermocouple placed within the CSZ environmental chamber to log chamber temperature throughout the test. The experiment was conducted over a 72-hour period, during which temperature data for the products, internal container environments, and environmental chamber were continuously recorded.

[0084] Referring to FIGS. 13-17, the post test results shows that units with gas-filled insulating packaging material 10 outperformed the EPS cooler in maintaining lower temperatures throughout the test. Both the internal package temperature and the product temperature remained lower in the unit with gas-filled insulating packaging material 10 compared to the EPS cooler unit, particularly in the first 50 hours. Summary plots were constructed to display temperature and elapsed time, as shown in FIGS. 13-17.

[0085] In sum, the present disclosure of gas-filled insulating packaging material 10 with low emitting aluminized internal film material 12 of multilayered internal film structure 26 configured for cold chain packages 82 may be directed to a way to cheaply and effectively insulate cold chain packages 82 in a way that can be quickly implemented by manufacturers and end users. The disclosed gas-filled insulating packaging material 10 may include a multilayered internal structure 26 that utilizes at least one low-emissivity surface 28 (aluminized film surface 24 or the like) on each layer 30. An outer pouch layer 14 may be included to encapsulate the multilayered internal film structure 26. The internal multilayered polymer film structure 26 (the multilayered structure can also be made of paper, biodegradable materials, or any other thin sheet) may be joined via an alternating adhesive pattern 66 to produce voided or honeycomb structure 52 when inflated (this structure can also be produced by other methods of attachment such as heat welding, embossing, taping etc.). The outer layer 14 may encompass a heat weldable film, that is inflated by use of a machine similar to a pillow pack machine (see FIG. 1) common in the packaging industry. The inner structure 26 can have its adhesive pattern altered to accommodate different sizes, structures to accommodate the desired packaging dimensions from the end user. A carrier layer 51 of necessarily thin, heat sealable polymer (likely identical to the outer layer 14 in material) may be adhered to the internal multilayered structure 26 through adhesive, and the outer layer 14 through either adhesive, heat sealing or both.

[0086] In use, gas-filled insulating packaging material 10 with low emitting aluminized internal film material 12 of multilayered internal film structure 26 configured for cold chain packages 82 offers manufacturers the ability to cheaply insulate cold chain products to their end user using known technology. It does not require specialty gasses, or excessive storage space, and only utilizes equipment already common in the industry (pillow pack machine, like shown in FIG. 1). Gas-filled insulating packaging material 10 may be able to structurally support products in transit with the same utility and versatility as known packaging air cushioning technology, but it adds the ability to thermally insulate comparably with existing cold chain packaging options such as Styrofoam.

[0087] In the specification and / or figures, typical embodiments of the disclosure have been disclosed. The present disclosure is not limited to such exemplary embodiments. The use of the term “and / or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

[0088] The foregoing description and drawings comprise illustrative embodiments. Having thus described exemplary embodiments, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present disclosure. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein but is limited only by the following claims.

Examples

Embodiment Construction

[0062]Referring to FIG. 1, an air cushion machine 1 is shown according to the prior art from, namely, from U.S. Pat. No. 10,850,906, incorporated herein in its entirety. As shown in FIG. 1, air cushion machine 1 may be a more modern air cushion machine that is commonly used to inflate air bags for air cushion packaging materials, air pillows, the like, etc. Air cushion machine 1 generally includes a pulling assembly 2 configured to pull a roll of film material through the air cushion machine 1. Air injector assembly 4 is configured to inject air (or any other gas) into the film material as it is being pulled through air cushion machine 1. Once the air is injected into the film material, heat sealing assembly 3 is configured to seal the open side of the film material to seal the air inside of the film material for creating the air cushion packaging materials, air pillows, the like, etc. An operator interface 5 is included for generally operating air cushion machine 1 such as turning ...

Claims

1. A gas-fillable insulating packaging material comprising:a low-emitting internal film material;outer pouch layers that encapsulate the low-emitting internal film material including on a bottom side and a top side of the low-emitting internal film material; andthe outer pouch layers are configured to be inflatable via an air cushion machine, where the outer pouch layers are sealed on a sealed side and unsealed on an open side prior to inflation and subsequently sealable on the open side after inflation.

2. The gas-fillable insulating packaging material of claim 1, wherein the low-emitting internal film material includes a thermal emissivity of less than 0.1.

3. The gas-fillable insulating packaging material of claim 2, wherein the low-emitting internal film material includes the thermal emissivity of less than 0.05.

4. The gas-fillable insulating packaging material of claim 3, wherein the low-emitting internal film material includes the thermal emissivity of 0.03 or approximately 0.03.

5. The gas-fillable insulating packaging material of claim 4, wherein the low-emitting internal film material includes an aluminized surface with the thermal emissivity of 0.03.

6. The gas-fillable insulating packaging material of claim 1, wherein the low-emitting internal film material including a multilayered internal film structure that includes at least one low-emissivity surface on each layer of the multilayered internal film structure.

7. The gas-fillable insulating packaging material of claim 6, wherein the at least one low-emissivity surface on each of the layers of the multilayered internal film structure includes an aluminized surface with a thermal emissivity of 0.03.

8. The gas-fillable insulating packaging material of claim 6, wherein the multilayered internal film structure includes sheets of material selected from a group consisting of: polymer sheets; paper sheets; biodegradable material sheets; and thin sheets.

9. The gas-fillable insulating packaging material of claim 6, wherein the multilayered internal film structure including polymer sheets including an aluminized surface on each layer of the polymer sheets forming the multilayered internal film structure.

10. The gas-fillable insulating packaging material of claim 6, wherein the multilayered internal film structure is configured to expand when the outer pouch layers are inflated to create an insulating structure.

11. The gas-fillable insulating packaging material of claim 10, wherein the multilayered internal film structure including a bonding layer configured to bond adjacent layers of the multilayered internal film structure and to bond the top side and the bottom side of the multilayered internal film structure to the outer pouch layers to create an insulating structure with spacing for internal air gaps therein;the bonding layer creating an alternating bonding pattern between the adjacent layers of the multilayered internal film structure and the top side and the bottom side of the multilayered internal film structure to the outer pouch layers;the alternating bonding pattern of the bonding layer is configured for creating the spacing for the internal air gaps;wherein, when the outer pouch layers are inflated, the multilayered internal film structure with the alternating bonding pattern is configured to expand into a voided or honeycomb type internal structure of the low-emitting internal film material; andwherein, the voided or honeycomb type internal structure is in a transverse orientation.

12. The gas-fillable insulating packaging material of claim 11, wherein the alternating bonding patterns of the bonding layer including bonding of adjacent layers selected from a group consisting of: adhesive bonding; heat weld bonding; embossing; taping; and combinations thereof.

13. The gas-fillable insulating packaging material of claim 10, wherein the multilayered internal film structure including an alternating adhesive bonding pattern between adjacent layers of the multilayered internal film structure and to the top side and the bottom side of the multilayered internal film structure to the outer pouch layers.

14. The gas-fillable insulating packaging material of claim 1 further comprising a carrier layer, the carrier layer is configured to connect the top side and the bottom side of the low-emitting film material of the multilayered internal film structure to the outer pouch layers.

15. The gas-fillable insulating packaging material of claim 14, wherein the carrier layer including a thin, heat sealable polymer adhered to the top side and the bottom side of the low-emitting film material of the multilayered internal film structure and the outer pouch layers through adhesive, heat sealing, or a combination thereof.

16. The gas-fillable insulating packaging material of claim 1 is formed in an elongated roll of the gas-fillable insulating packaging material, wherein:the low-emitting internal film material is offset an offset distance from the open side of the outer pouch layers;the outer pouch layers are comprised of a heat weldable film;wherein the heat weldable film of the outer pouch layers is configured to be inflatable via the air cushion machine, where the heat weldable film of the outer pouch layers are sealed on the sealed side and unsealed on the open side prior to inflation and subsequently sealable on the open side after inflation; andwherein, the elongated roll of the gas-fillable insulating packaging material is configured to be inflated from the open side of the roll in line via the air cushion machine.

17. The gas-fillable insulating packaging material of claim 1 being configured for cold chain packages.

18. The gas-fillable insulating packaging material of claim 1 designed and configured to:provide a way to insulate cold chain packages in a way that can be implemented by manufacturers and end users using known technology;does not require specialty gasses, or excessive storage space, and only utilizes equipment already common in industry;structurally supports products in cold chain packages in transit with the same utility and versatility as known packaging cushioning technology, but also adds an ability to thermally insulate comparably with existing cold chain packaging options including expanded polystyrene containers; orcombinations thereof.

19. A gas-filled insulating packaging envelope comprising:a low-emitting film internal structure;outer pouch layers encapsulating the low-emitting film internal structure on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure;a carrier layer connecting the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers; anda gas sealed inside of the outer pouch layers, wherein the gas is pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create a voided or honeycomb type internal structure of the low-emitting film internal structure thereby creating an insulating structure with spacing for internal air gaps therein.

20. A cold chain package comprising:a box with an inside with a bottom surface, a top surface, a front surface, a back surface, a left surface, and a right surface;at least one gas-filled insulating packaging envelope comprising:a low-emitting film internal structure;outer pouch layers encapsulating the low-emitting film internal structure on a bottom side of the low-emitting film internal structure and a top side of the low-emitting film internal structure;a carrier layer connecting the top side and the bottom side of the low-emitting film internal structure to the outer pouch layers;a gas sealed inside of the outer pouch layers, wherein the gas is pressurized inside of the outer pouch layers for expanding the outer pouch layers thereby separating the bottom side from the top side of the low-emitting film internal structure to create a voided or honeycomb type internal structure of the low-emitting film internal structure thereby creating an insulating structure with spacing for internal air gaps therein; andthe at least one gas-filled insulating packaging material is positioned in the inside of the box on at least one of the bottom surface, the top surface, the front surface, the back surface, the left surface, and / or the right surface.

Images