Package insulation

Abstract

The present disclosure concerns insulation systems for temperature-controlled shipping applications. A packaging insulation system comprises a first insulating element, a second insulating element discontinuous with the first insulating element, and a third insulating element discontinuous with the first and second insulating elements. The insulating elements are arranged to enclose a three dimensional volume, with the first insulating element defining three sides of the volume, the second insulating element defining two sides, and the third insulating element defining one side. The insulating elements may be contained within encapsulation envelopes comprising poly film or kraft paper. A hinge gap formed between insulating elements facilitates payload loading by allowing a top insulating element to pivot away from the enclosed volume while remaining connected to an adjacent insulating element. Methods of assembling and loading such systems are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 791,072, filed Apr. 18, 2025, which is hereby incorporated by reference in its entirety.FIELD OF INVENTION

[0002] The present disclosure relates to insulated packaging systems for temperature-controlled shipping, and more particularly to packaging insulation systems comprising multiple discontinuous insulating elements configured to enclose a three dimensional volume within a shipping container while facilitating payload loading operations.BACKGROUND

[0003] Temperature-controlled shipping has become increasingly important across various industries, including pharmaceuticals, biotechnology, food services, and other sectors that require products to be maintained within specific temperature ranges during transit. Many products, such as medications, vaccines, biological samples, and perishable food items, can be rendered ineffective, unsafe, or unusable if exposed to temperatures outside their required storage conditions.

[0004] Insulated packaging systems are commonly used to maintain temperature control during shipping. These systems typically include insulation materials positioned within shipping containers to create a thermal barrier between the contents and the external environment. Cooling elements, such as gel packs or phase change materials, may be placed within the insulated space to help maintain desired temperatures throughout the shipping duration.

[0005] Conventional insulated packaging configurations often present challenges during the payload loading process. When loading temperature-sensitive contents into an insulated container, workers or automated systems may need to access the interior space while ensuring that insulation coverage is maintained on all sides of the enclosed volume. Some existing configurations can hinder the loading process by obstructing access to the payload space or by requiring complex manipulation of insulation components.

[0006] Additionally, multi-piece insulation systems may present difficulties in maintaining proper alignment and fit within shipping containers. As illustrated in FIG. 5, conventional insulation configurations comprising multiple disconnected insulating elements may require additional handling steps during assembly and payload loading operations. Insulation panels that do not closely correspond to the internal geometry of the shipping container may leave gaps or areas of reduced thermal protection. Furthermore, loose or unsecured insulation components may shift during handling or transit, potentially compromising the thermal performance of the packaging system.

[0007] There is a general need for insulated packaging systems that can provide effective thermal protection while also facilitating efficient payload loading operations. Improvements in insulation kit configurations that address the balance between thermal performance and ease of use during the packing process may benefit various temperature-controlled shipping applications.SUMMARY

[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0009] Disclosed herein are packaging insulation systems configured for temperature-controlled shipping applications. The disclosed systems utilize multiple discontinuous insulating elements that can be arranged to enclose a three dimensional volume within a shipping container. In various configurations, the insulating elements may be contained within encapsulation envelopes and may incorporate features such as hinge gaps that facilitate payload loading operations while maintaining thermal protection. Methods of assembling and loading such packaging insulation systems are also disclosed.

[0010] Certain examples concern a packaging insulation system comprising a first insulating element, a second insulating element discontinuous with the first insulating element, and a third insulating element discontinuous with the first insulating element and the second insulating element, wherein the first insulating element, the second insulating element, and the third insulating element are arranged to enclose a three dimensional volume, such that the first insulating element defines three sides of the three dimensional volume, the second insulating element defines two sides of the three dimensional volume, and the third insulating element defines one side of the three dimensional volume.

[0011] Certain examples concern a method of cold chain packaging comprising preparing a first insulation panel by folding a first insulating element into first, second, and third connected sections, preparing a second insulation panel by folding a second insulating element into first and second connected sections, inserting the first and second connected sections of the second insulation panel into a container such that the first connected section of the second insulation panel overlaps a bottom portion of the container, inserting the first, second, and third connected sections of the first insulation panel into the container such that the first, second, and third connected sections of the second insulation panel and the second connected section of the first insulation panel define a partially enclosed container space with a top opening, and inserting a third insulating element into the container such that the third insulating element closes the top opening of the partially enclosed container space.

[0012] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0013] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0014] FIG. 1 illustrates a perspective view of a package comprising an insulation system according to some aspects of the present disclosure.

[0015] FIG. 2 illustrates a perspective view of the insulation system according to FIG. 1.

[0016] FIG. 3A illustrates a perspective view of the insulation system according to FIG. 1, in an alternative configuration.

[0017] FIG. 3B illustrates a cross-sectional schematic view of an insulation panel, according to aspects of the present disclosure.

[0018] FIG. 3C illustrates a cross-sectional schematic view of an insulation panel, according to aspects of the present disclosure.

[0019] FIG. 4 illustrates sequential views of an assembly and payload loading process for a packaging insulation system, according to aspects of the present disclosure.

[0020] FIG. 5 illustrates a conventional three-piece packaging insulation system for comparison purposes, according to aspects of the present disclosure.

[0021] FIG. 6 illustrates a perspective view of a production method for manufacturing insulation material, according to aspects of the present disclosure.DETAILED DESCRIPTIONGENERAL TERMS

[0022] The following explanations of terms are provided to better describe the present disclosure and to guide those of ordinary skill in the art in the practice of the present disclosure. As used herein, “comprising” means “including” and the singular forms “a” or “an” or “the” include plural references unless the context clearly dictates otherwise. The term “or” refers to a single element of stated alternative elements or a combination of two or more elements unless the context clearly indicates otherwise.

[0023] As used herein, the terms proximal and distal refer to direction along an attached object having a free end, relative to the point of attachment. Particularly, when an object is attached at one end, the end of the attachment is the proximal end, and the free end is the distal end. The direction along the object towards the point of attachment is the proximal direction. The direction along the object towards the free end is the distal direction.

[0024] Unless explained otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and compounds similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and compounds are described below. The compounds, methods, and examples are illustrative only and not intended to be limiting, unless otherwise indicated. Other features of the disclosure are apparent from the following detailed description and the claims.

[0025] Unless otherwise indicated, all numbers expressing quantities of components, percentages, temperatures, times, and so forth, as used in the specification or claims are to be understood as being modified by the term “about.” Accordingly, unless otherwise indicated, implicitly or explicitly, the numerical parameters set forth are approximations that can depend on the desired properties sought and / or limits of detection under standard test conditions / methods. When directly and explicitly distinguishing embodiments from discussed prior art, the embodiment numbers are not approximates unless the word “about” is recited. Furthermore, not all alternatives recited herein are equivalents.Introduction to the Disclosed Technology

[0026] The present disclosure relates to packaging insulation systems designed for temperature-controlled shipping applications. The disclosed systems utilize multiple discontinuous insulating elements that are arranged to enclose a three dimensional volume within a shipping container, providing thermal protection for temperature-sensitive contents such as pharmaceuticals, biological samples, and perishable food items. In one configuration, a first insulating element defines three sides of the enclosed volume, a second insulating element defines two sides, and a third insulating element defines one side, with the insulating elements being physically distinct from one another. In another configuration, a first insulating element defines four lateral walls, while second and third insulating elements define the bottom and top of the enclosed volume, respectively. The insulating elements may be contained within encapsulation envelopes, sometimes called sleeves, comprising poly film or kraft paper materials, and may incorporate sustainable materials such as pre-consumer textile remnants, plant fiber, or polyester.

[0027] A feature of certain disclosed configurations is a hinge gap formed between insulating elements, which facilitates payload loading operations. The hinge gap allows a top insulating element to pivot away from the enclosed volume to provide full access during loading while remaining connected to an adjacent insulating element through an encapsulation envelope or connecting member. This configuration enables the top insulating element to rest back during the payload loading process without hindering pack-out operations, and to be returned to close the top opening after loading is complete. Methods of assembling and loading such packaging insulation systems are also disclosed, including folding insulating elements into connected sections, inserting the panels into a container, loading payload contents, and closing the insulated space for transit.Aspects of the Disclosed Technology

[0028] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0029] According to some aspects of the present disclosure, a packaging insulation system 100 may be configured for use with a package 102, as shown in FIG. 1. The packaging insulation system 100 may comprise a first insulating element 104, a second insulating element 106, and a third insulating element 108. The first insulating element 104, the second insulating element 106, and the third insulating element 108 may each be discontinuous with the others. In some aspects, the first insulating element 104, the second insulating element 106, and the third insulating element 108 may be physically distinct from one another, with any connection between the insulating elements being provided by an encapsulation material rather than by direct contact between the insulating elements themselves.

[0030] According to some aspects of the present disclosure, the first insulating element 104, the second insulating element 106, and the third insulating element 108 may be arranged to enclose a three dimensional volume 110 within the package 102. In some cases, the first insulating element 104 may define three sides of the three dimensional volume 110. The second insulating element 106 may define two sides of the three dimensional volume 110. The third insulating element 108 may define one side of the three dimensional volume 110. In such a configuration, the first insulating element 104 may form an insulating barrier for three lateral walls of the package 102, the second insulating element 106 may form an insulating barrier for a bottom portion and a back wall of the package 102, and the third insulating element 108 may form an insulating barrier for a top portion of the three dimensional volume 110.

[0031] With continued reference to FIG. 1, the package 102 may be a shipping container, such as a corrugated shipper box. The packaging insulation system 100 may be sized and configured to closely correspond to the internal geometry of the package 102. In some aspects, the packaging insulation system 100 may be engineered to achieve a fit lining the bottom, walls, and top of the package 102. Cooling elements 120 may be positioned within the three dimensional volume 110 to maintain temperature control during shipping. The packaging insulation system 100 may be used for temperature-controlled shipping applications, including pharmaceutical shipping, biotechnology product shipping, food services, and other applications requiring products to be maintained within specific temperature ranges during transit.

[0032] According to some aspects of the present disclosure, a first encapsulation envelope 112 may contain the first insulating element 104 to form a first insulation panel 114, as shown in FIGS. 3A through 3C. A second encapsulation envelope 116 may contain both the second insulating element 106 and the third insulating element 108 to form a second insulation panel 118. The first encapsulation envelope 112 and the second encapsulation envelope 116 may each comprise a material configured to enclose and protect the insulating elements contained therein.

[0033] In some aspects, the first encapsulation envelope 112 may comprise poly film material. The poly film material may provide a moisture barrier and structural containment for the first insulating element 104. In some cases, the first encapsulation envelope 112 may comprise kraft paper material. The kraft paper material may provide a sustainable encapsulation option while maintaining structural integrity of the first insulation panel 114. As disclosed herein, the second encapsulation envelope 116 may also comprise poly film material or kraft paper material, for substantially the same benefits.

[0034] With continued reference to FIGS. 3A through 3C, the second encapsulation envelope 116 may enclose both the second insulating element 106 and the third insulating element 108 within a single encapsulation structure. In some aspects, the second encapsulation envelope 116 may comprise a first compartment and a second compartment divided by a divider portion of the second encapsulation envelope 116. The second insulating element 106 may be disposed in the first compartment of the second encapsulation envelope 116, and the third insulating element 108 may be disposed in the second compartment of the second encapsulation envelope 116. The divider portion may separate the second insulating element 106 and the third insulating element 108 while maintaining both insulating elements within the second encapsulation envelope 116.

[0035] While the examples shown in FIGS. 3A-3C depict an insulation system 100 in which the insulating elements 104, 106, 108 are encapsulated, it will be appreciated that in some aspects of the present disclosure, the packaging insulation system 100 may be provided in non-encapsulated form. In such configurations, the first insulating element 104, the second insulating element 106, and the third insulating element 108 may be provided without encapsulation envelopes. The non-encapsulated form may offer versatility for different application requirements where encapsulation is not desired or where the insulating elements are configured to be used without additional encapsulation materials. In such non-encapsulated examples, there may still be one or more connecting elements that retain the various insulating elements (104, 106, 108) in relation to one another. For example, there may exist a connecting member that extends between the second insulating element 106 and the third insulating element 108, allowing the third insulating element 108 to remain connected with the second insulating element 106, even when the third insulating element 108 is folded away from the opening into the enclosed three dimensional volume 110 of the insulated package.

[0036] According to some aspects of the present disclosure, a hinge gap 122 may be formed between the second insulating element 106 and the third insulating element 108 as shown in FIG. 2. The hinge gap 122 may separate the second insulating element 106 from the third insulating element 108 while maintaining a relationship between the second insulating element 106 and the third insulating element 108, either through inclusion in the same second encapsulation envelope 116, or by a connecting member spanning the hinge gap 122 in the case of a non-encapsulated insulating system. In some aspects, the hinge gap 122 may comprise a portion of the second encapsulation envelope 116 that extends between the second insulating element 106 and the third insulating element 108 without containing insulation material.

[0037] According to some aspects of the present disclosure, the hinge gap 122 may allow the third insulating element 108 to pivot away from the enclosed three dimensional volume 110 to provide full access during payload loading operations. As shown in FIG. 2, the third insulating element 108 may be folded back relative to the second insulating element 106 while remaining connected to the second insulating element 106 through the second encapsulation envelope 116. The second encapsulation envelope 116 may secure the third insulating element 108 during the payload loading process, such that the third insulating element 108 remains supported and attached even when the third insulating element 108 is folded away from the opening into the enclosed three dimensional volume 110.

[0038] With continued reference to FIG. 2, the hinge gap 122 may allow the third insulating element 108 to rest back during the payload loading process without hindering pack-out operations. In some aspects, the configuration of the hinge gap 122 may facilitate manual or robotic payload loading by providing unobstructed access to the enclosed three dimensional volume 110 while the third insulating element 108 is in the folded-back position.

[0039] According to some aspects of the present disclosure, the third insulating element 108 may be returned to rest on the top edges of the first insulating element 104 and the second insulating element 106 to form a top insulation barrier. In such a configuration, the third insulating element 108 may nest in place against the top edges of the first insulating element 104 and the second insulating element 106, forming an insulation seal as the panels meet perpendicular to one another. The third insulating element 108 may seal against the walls defined by the first insulating element 104 while connecting against the top edges of the first insulating element 104 and the second insulating element 106. Thermal performance of the packaging insulation system 100 may be secured with the closure of the package 102.

[0040] Referring now to FIGS. 3A through 3C, the detailed structure of a first insulation panel 114 and a second insulation panel 118 is described according to some aspects of the present disclosure. The first insulation panel 114 may comprise a first insulating element 104 contained within a first encapsulation envelope 112. The second insulation panel 118 may comprise a second insulating element 106 and a third insulating element 108 contained within a second encapsulation envelope 116.

[0041] According to some aspects of the present disclosure, the second encapsulation envelope 116 may comprise a first compartment and a second compartment divided by a divider portion of the second encapsulation envelope 116. The second insulating element 106 may be disposed in the first compartment of the second encapsulation envelope 116. The third insulating element 108 may be disposed in the second compartment of the second encapsulation envelope 116. The divider portion of the second encapsulation envelope 116 may separate the second insulating element 106 from the third insulating element 108 while maintaining both the second insulating element 106 and the third insulating element 108 within a single encapsulation structure. In some aspects, the divider portion may correspond to a hinge gap 122 that allows the third insulating element 108 to pivot relative to the second insulating element 106.

[0042] With continued reference to FIGS. 3A through 3C, the compartmentalized structure of the second encapsulation envelope 116 may secure the third insulating element 108 during payload loading operations. The second encapsulation envelope 116 may maintain the third insulating element 108 in connection with the second insulating element 106 even when the third insulating element 108 is folded away from an opening into an enclosed three dimensional volume 110. The first compartment and the second compartment of the second encapsulation envelope 116 may each provide containment and protection for the respective insulating elements disposed therein.

[0043] According to some aspects of the present disclosure, the first insulating element 104 may have a first length, the second insulating element 106 may have a second length, and the third insulating element 108 may have a third length. The first length may be greater than the second length, and the second length may be greater than the third length. In some aspects, the dimensional relationships between the first insulating element 104, the second insulating element 106, and the third insulating element 108 may correspond to the internal geometry of a package 102. The first insulating element 104, having the first length, may be configured to define three sides of the enclosed three dimensional volume 110. The second insulating element 106, having the second length, may be configured to define two sides of the enclosed three dimensional volume 110. The third insulating element 108, having the third length, may be configured to define one side of the enclosed three dimensional volume 110.

[0044] In some aspects of the present disclosure, the second insulating element 106 and the third insulating element 108 may have a substantially equal thickness. The substantially equal thickness of the second insulating element 106 and the third insulating element 108 may facilitate uniform thermal protection across the surfaces defined by the second insulation panel 118. In some cases, the first insulating element 104 may also have a thickness that corresponds to the thickness of the second insulating element 106 and the third insulating element 108 to provide consistent thermal barrier properties throughout the packaging insulation system 100.

[0045] As further shown in FIGS. 3A through 3C, the first encapsulation envelope 112 may enclose the first insulating element 104 in a single compartment configuration. The first insulation panel 114 may be configured for insertion into a package 102 such that the first insulating element 104 forms an insulating barrier for multiple lateral walls of the package 102. The first encapsulation envelope 112 may provide structural containment for the first insulating element 104 during handling and assembly operations.

[0046] According to some aspects of the present disclosure, at least one insulating element of the first insulating element 104, the second insulating element 106, and the third insulating element 108 may comprise pre-consumer textile remnants. In some aspects, the pre-consumer textile remnants may comprise upcycled pre-consumer textile remnants. The upcycled pre-consumer textile remnants may be USDA BioPreferred Certified. The use of upcycled pre-consumer textile remnants may provide sustainable insulation material for the packaging insulation system 100.

[0047] In some aspects, at least one insulating element of the first insulating element 104, the second insulating element 106, and the third insulating element 108 may comprise plant fiber. The plant fiber may comprise plant fiber blends. In some cases, the plant fiber blends may be USDA BioPreferred Certified. The plant fiber material may provide thermal barrier properties while incorporating sustainable material compositions.

[0048] According to some aspects of the present disclosure, at least one insulating element of the first insulating element 104, the second insulating element 106, and the third insulating element 108 may comprise polyester. In some aspects, the polyester may comprise 100% polyester material. The polyester material may provide thermal insulation properties for the packaging insulation system 100.

[0049] With continued reference to FIGS. 1 through 4, the insulating elements of the packaging insulation system 100 may comprise nonwoven insulation material. The nonwoven insulation material may be engineered to provide thermal protection for temperature-controlled shipping applications. In some aspects, the packaging insulation system 100 may incorporate sustainable materials in one or more of the first insulating element 104, the second insulating element 106, and the third insulating element 108.

[0050] Also disclosed herein are methods of preparing and loading a package containing the insulation systems disclosed herein.

[0051] According to some aspects of the present disclosure, a method of cold chain packaging may be performed using the packaging insulation system 100, as shown in FIG. 4. The method may comprise preparing a first insulation panel 114 and a second insulation panel 118 for insertion into a container, such as a package 102.

[0052] According to some aspects of the present disclosure, preparing the first insulation panel 114 may comprise folding a first insulating element 104 into first, second, and third connected sections. The first, second, and third connected sections of the first insulating element 104 may be configured to form an insulating barrier for three lateral walls of the package 102. In some aspects, the first insulating element 104 may be enclosed within a first encapsulation envelope 112 prior to folding.

[0053] With continued reference to FIG. 4, preparing the second insulation panel 118 may comprise folding a second insulating element 106 into first and second connected sections. The first and second connected sections of the second insulating element 106 may be configured to form an insulating barrier for a bottom portion and a back wall of the package 102. In some aspects, the second insulating element 106 and a third insulating element 108 may be enclosed within a second encapsulation envelope 116. The second insulating element 106 and the third insulating element 108 may be separated from each other by a hinge gap 122 within the second encapsulation envelope 116.

[0054] According to some aspects of the present disclosure, the method may comprise inserting the first and second connected sections of the second insulation panel 118 into the package 102 such that the first connected section of the second insulation panel 118 overlaps a bottom portion of the package 102. The method may further comprise inserting the first, second, and third connected sections of the first insulation panel 114 into the package 102 such that the first, second, and third connected sections of the first insulation panel 114 and the second connected section of the second insulation panel 118 define a partially enclosed container space with a top opening. As further shown in FIG. 4, the method may comprise inserting the third insulating element 108 into the package 102 such that the third insulating element 108 closes the top opening of the partially enclosed container space, thereby forming an enclosed three dimensional volume 110, as shown in panel (a) of FIG. 4.

[0055] According to some aspects of the present disclosure, loading the package 102 may comprise clearing the top opening of the enclosed three dimensional volume 110 by moving the third insulating element 108 away from the top opening. The hinge gap 122 may allow the third insulating element 108 to pivot away from the enclosed three dimensional volume 110 to provide full access during payload loading operations. In some aspects, the third insulating element 108 may rest back during the payload loading process without hindering pack-out operations. The second encapsulation envelope 116 may secure the third insulating element 108 during the payload loading process such that the third insulating element 108 remains supported and attached even when the third insulating element 108 is folded away from the opening into the enclosed three dimensional volume 110.

[0056] With continued reference to FIG. 4, loading the package 102 may further comprise adding one or more package contents 124 to the partially enclosed container space through the unobstructed top opening, as shown in panel (b) of FIG. 4. In some aspects, loading the package 102 may comprise adding one or more cooling elements 120 to the enclosed three dimensional volume 110. The cooling elements 120 may be positioned within the enclosed three dimensional volume 110 to maintain temperature control during shipping.

[0057] According to some aspects of the present disclosure, loading the package 102 may further comprise replacing the third insulating element 108 to close the top opening of the enclosed three dimensional volume 110, as shown in panel (c) of FIG. 4. The third insulating element 108 may rest on the top edges of the first insulating element 104 and the second insulating element 106 to form a top insulation barrier. In such a configuration, the third insulating element 108 may nest in place against the top edges of the first insulating element 104 and the second insulating element 106, forming an insulation seal as the panels meet perpendicular to one another. As shown in panel (d) of FIG. 4, the insulation assembly may be compressed to fit within the package 102. The package 102 may then be closed, as shown in panels (e) and (f) of FIG. 4. Thermal performance of the packaging insulation system 100 may be secured with the closure of the package 102. In some aspects, the package 102 may be closed and taped for transit following the payload loading process.

[0058] For comparison purposes, a conventional packaging insulation system 200 is described with reference to FIG. 5. Conventional packaging insulation systems may comprise three separate, disconnected insulating elements that require additional assembly steps compared to the packaging insulation system 100 described herein.

[0059] As shown in FIG. 5, a conventional packaging insulation system 200 may comprise a first insulating element 202, a second insulating element 206, and a third insulating element 204. In conventional configurations, the first insulating element 202, the second insulating element 206, and the third insulating element 204 are each physically distinct and disconnected from one another, requiring separate handling during assembly.

[0060] In such conventional configurations, the first insulating element 202 may define four lateral walls of a three dimensional volume, the second insulating element 206 may define a bottom side of the three dimensional volume, and the third insulating element 204 may define a top side of the three dimensional volume. Because each insulating element is disconnected from the others, assembly of the conventional packaging insulation system 200 requires handling and positioning each piece separately.

[0061] With continued reference to FIG. 5, assembly of the conventional packaging insulation system 200 requires inserting the second insulating element 206 into a container, then separately inserting the first insulating element 202, and finally positioning the third insulating element 204 at the top. Unlike the packaging insulation system 100 described herein, the conventional system lacks a hinge gap or connecting member between insulating elements, requiring the third insulating element 204 to be completely removed and set aside during payload loading operations.

[0062] In conventional configurations such as the packaging insulation system 200, the third insulating element 204 is not connected with the first insulating element 202 or the second insulating element 206. Because the third insulating element 204 is not connected with the other insulating elements, it must be removed from the packaging insulation system 200 and placed aside to allow for payload loading into the enclosed insulated space. This disconnected configuration may present challenges during pack-out operations, as the third insulating element 204 may be misplaced or may obstruct the work area when set aside.

[0063] In contrast to the packaging insulation system 100 described herein, the conventional packaging insulation system 200 requires additional handling steps during both assembly and payload loading. The hinge gap 122 of the packaging insulation system 100 allows the third insulating element 108 to remain connected during payload loading, whereas the conventional system requires the third insulating element 204 to be completely separated and later retrieved to close the insulated space.

[0064] Also disclosed herein are methods of making package insulation systems, such as those disclosed herein.

[0065] A production method 300 for manufacturing insulation material used in the insulation kits according to various aspects of the present disclosure is described and illustrated in FIG. 6. The production method 300 may comprise processing an insulation material 302 through an encapsulation system to produce encapsulated insulation panels suitable for use in packaging insulation systems.

[0066] According to some aspects of the present disclosure, the production method 300 may comprise feeding a first encapsulation material 304 along a conveyor 310 in a machine direction. The insulation material 302 may be deposited onto the first encapsulation material 304 as the first encapsulation material 304 advances along the conveyor 310. A second encapsulation material 306 may be fed from above and applied over the insulation material 302 as the assembly progresses through the production line. In such a configuration, the insulation material 302 becomes sandwiched between the first encapsulation material 304 and the second encapsulation material 306 as the materials move together along the conveyor 310.

[0067] With continued reference to FIG. 6, a first upper roller 308a and a second upper roller 308b may be positioned to guide and apply the second encapsulation material 306 onto the insulation material 302. The first upper roller 308a may be located on a first side of the assembly, and the second upper roller 308b may be located on a second side of the assembly. As the second encapsulation material 306 passes over the first upper roller 308a and the second upper roller 308b, the rollers may apply downward pressure to bring the second encapsulation material 306 into contact with the insulation material 302 and the first encapsulation material 304. The first upper roller 308a and the second upper roller 308b may facilitate alignment and uniform application of the second encapsulation material 306 across the width of the insulation material 302.

[0068] According to some aspects of the present disclosure, the conveyor 310 may transport the layered assembly of the first encapsulation material 304, the insulation material 302, and the second encapsulation material 306 through successive processing stages. As the assembly advances along the conveyor 310, the first encapsulation material 304 and the second encapsulation material 306 may be joined together along peripheral edges of the insulation material 302 to form an encapsulation envelope. The joining of the first encapsulation material 304 and the second encapsulation material 306 may be accomplished through heat sealing, adhesive bonding, or other suitable joining techniques applied as the materials progress through the production method 300.

[0069] In some aspects, the first encapsulation material 304 and the second encapsulation material 306 may comprise polymer film. When polymer film is used, heat sealing may be applied to fuse the first encapsulation material 304 and the second encapsulation material 306 together in regions surrounding the insulation material 302. In other aspects, the first encapsulation material 304 and the second encapsulation material 306 may comprise kraft paper. When kraft paper is used, adhesive application or heat-activated bonding may join the first encapsulation material 304 and the second encapsulation material 306 together. The production method 300 may enable encapsulation of the insulation material 302 within polymer film or kraft paper depending on the desired encapsulation option for the insulation kits.

[0070] According to some aspects of the present disclosure, the production method 300 may include heat seal and cut pressure adjustments for production of a hinge gap 122 in the second encapsulation envelope 116. During the production process, heat sealing stations may apply heat and pressure to join the first encapsulation material 304 and the second encapsulation material 306 together in regions between adjacent insulating elements where no insulation material 302 is present. The heat seal and cut pressure adjustments may be configured to form the divider portion of the second encapsulation envelope 116 that separates the second insulating element 106 from the third insulating element 108 while maintaining both insulating elements within a single encapsulation structure. Cutting operations may be performed downstream to separate individual encapsulated panels from the continuous production stream. In such configurations, the hinge gap 122 may be formed by sealing the first encapsulation material 304 and the second encapsulation material 306 directly to each other in a region between adjacent insulating elements, creating a flexible connection that allows relative movement between the second insulating element 106 and the third insulating element 108.

[0071] According to some aspects of the present disclosure, the packaging insulation system 100 may be configured for various commercial applications requiring temperature-controlled shipping. With reference to FIG. 1, the packaging insulation system 100 may be configured for cold chain packaging applications where products are maintained within specific temperature ranges during transit.

[0072] In some aspects, the packaging insulation system 100 may be configured for meal kit insulation applications. In meal kit insulation applications, the packaging insulation system 100 may provide thermal protection for perishable food items during delivery to consumers. The first insulating element 104, the second insulating element 106, and the third insulating element 108 may be arranged to enclose the three dimensional volume 110 containing meal kit contents and cooling elements 120 to maintain food freshness during transit.

[0073] According to some aspects of the present disclosure, the packaging insulation system 100 may be configured for pharmaceutical engineered cooler kit applications. In pharmaceutical engineered cooler kit applications, the packaging insulation system 100 may provide thermal protection for medications, vaccines, biological samples, and other pharmaceutical products that require temperature control during shipping. The hinge gap 122 may facilitate payload loading operations for pharmaceutical products by allowing the third insulating element 108 to pivot away from the enclosed three dimensional volume 110 to provide full access during loading of pharmaceutical contents.

[0074] In some aspects, the packaging insulation system 100 may be configured for pharmaceutical cooler and mailer pouch applications. In pharmaceutical cooler and mailer pouch applications, the packaging insulation system 100 may be sized and configured to correspond to the internal geometry of mailer pouches used for pharmaceutical distribution. The first encapsulation envelope 112 and the second encapsulation envelope 116 may provide moisture barrier protection for pharmaceutical products during transit.

[0075] According to some aspects of the present disclosure, the packaging insulation system 100 may be configured for corrugated shipper design applications. As shown in FIG. 1, the package 102 may comprise a corrugated shipper box, and the packaging insulation system 100 may be engineered to achieve a fit lining the bottom, walls, and top of the corrugated shipper box. The first insulation panel 114 and the second insulation panel 118 may be engineered to custom fit inner box dimensions of the corrugated shipper box.

[0076] Although there have been described particular examples of new systems and methods, it is not intended that such references be construed as limitations upon the scope of an invention as disclosed herein, except as set forth in the following claims.

Claims

1. A packaging insulation system, comprising:first insulating element;a second insulating element discontinuous with the first insulating element; anda third insulating element discontinuous with the first insulating element and discontinuous with but coupled to the second insulating element,wherein the first insulating element, the second insulating element, and the third insulating element are arranged to enclose a three dimensional volume, such that the first insulating element defines three sides of the three dimensional volume, the second insulating element defines two sides of the three dimensional volume, and the third insulating element defines one side of the three dimensional volume.

2. The packaging insulation system of claim 1, further comprising a first encapsulation envelope containing the first insulating element to form a first panel and a second encapsulation envelope containing the second insulating element and the third insulating element to form a second panel.

3. The packaging insulation system of claim 2, wherein at least one encapsulation envelope of the first encapsulation envelope and the second encapsulation envelope comprises poly film.

4. The packaging insulation system of claim 2, wherein at least one encapsulation envelope of the first encapsulation envelope and second encapsulation envelope comprises kraft paper.

5. The packaging insulation system of claim 2, wherein:the first insulating element has a first length, the second insulating element has a second length, and the third insulating element has a third length; andthe first length is greater than the second length and the second length is greater than the third length.

6. The packaging insulation system of claim 2, wherein:the second encapsulation envelope comprises a first compartment and a second compartment divided by a divider portion of the second encapsulation envelope; andthe second insulating element is disposed in the first compartment of the second encapsulation envelope and the third insulating element is disposed in the second compartment of the second encapsulation envelope.

7. The packaging insulation system of claim 1, wherein the second insulating element and the third insulating element are connected by a connecting member and spaced apart by a hinge gap spanned by the connecting member.

8. The packaging insulation system of claim 1, wherein at least one insulating element of the first insulating element, the second insulating element, and the third insulating element comprises pre-consumer textile remnants.

9. The packaging insulation system of claim 1, wherein at least one insulating element of the first insulating element, the second insulating element, and the third insulating element comprises plant fiber.

10. The packaging insulation system of claim 1, wherein at least one insulating element of the first insulating element, the second insulating element, and the third insulating element comprises polyester.

11. The packaging insulation system of claim 1, wherein the second insulating element and the third insulating element have a substantially equal thickness.

12. A container including the packaging insulation system of claim 1.

13. (withdrawn, currently amended) A method of producing the packaging insulation system of claim 1, the method comprising:preparing a first insulation panel by folding the first insulating element into first, second, and third connected sections;preparing a second insulation panel by folding the second insulating element into first and second connected sections;inserting the first and second connected sections of the second insulation panel into a container such that the first connected section of the second insulation panel overlaps a bottom portion of the container;inserting the first, second, and third connected sections of the first insulation panel into the container such that the first, second, and third connected sections of the first insulation panel and the second connected section of the second insulation panel define a partially enclosed container space with a top opening;inserting the third insulating element into the container such that the third insulating element closes the top opening of the partially enclosed container space.

14. The method of claim 13, further comprising loading the container by:clearing the top opening of the enclosed container space of the third insulating element; andadding one or more package contents to the partially enclosed container space through the top opening of the enclosed container space.

15. The method of claim 14, wherein loading the container further comprises replacing the third insulating element to close the top opening of the enclosed container space.

16. The method of claim 14, wherein, while loading the container, the third insulation panel is secured by a member connecting the third insulation panel to the second insulation panel.

17. The method of claim 14, wherein loading the container further comprises adding one or more cooling elements to the enclosed container space.

18. The method of claim 13, wherein:preparing the first insulation panel further comprises enclosing the first insulating element in a first encapsulation envelope; andpreparing the second insulation panel further comprises enclosing the second insulating element and the third insulating element in a second encapsulation envelope.

19. The method of claim 18, wherein the second insulation panel and the third insulation panel are separated from each other by a hinge gap.

20. The method of claim 18, wherein:the second encapsulation envelope is divided into a first compartment and a second compartment by a divider portion; andthe second insulating element is disposed within the first compartment and the third insulating element is disposed within the second compartment.

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