AU2016253391A1

AU2016253391A1 - A liner

Info

Publication number: AU2016253391A1
Application number: AU2016253391A
Authority: AU
Inventors: Teck Soon TAN; Khar San TEH; Kah Wei YAM
Original assignee: San Miguel Yamamura Woven Products Sdn Bhd
Current assignee: San Miguel Yamamura Woven Products Sdn Bhd
Priority date: 2015-04-23
Filing date: 2016-04-14
Publication date: 2017-10-26
Anticipated expiration: 2036-04-14
Also published as: MY194568A; AU2016253391B2; TWI667178B; CN107531007A; NZ736076A; TW201702154A; WO2016171539A1; CN107531007B

Abstract

There is disclosed a liner (10) for protecting goods against damage from condensation. The liner (10) comprises a breathable material (20) having a breathable layer (30), wherein the breathable material allows vapour to transfer across the material but inhibits the transfer of liquids.

Description

A Liner

Field of the Invention

The invention relates to liners for protecting goods against water and/ or heat damage. Examples of such liners include, but are not limited to, liners for storage containers, such as shipping or freight containers. The liners could also be in the form of covers to protect goods, such as tarpaulins.

Background of the Invention

During transportation of goods by sea, air or land, the goods are inevitably subjected to variations in environmental conditions. For example, during shipment the temperature inside a freight container may increase to over 70°C when the container is subjected to direct sunlight. In order to mitigate the increase in temperature affecting the goods in the container, containers may be designed to have an insulating liner inside the container.

The container liners are designed to, among other things, avoid heat transfer by convection, and are therefore made from materials that prevent air passing through. However, when shipping products such as, for example, foodstuffs and oleochemicals with high moisture content, water condensation can occur inside the liner. Condensation occurs due to either the external temperature being too low or the relative humidity inside the liner being too high. Because the condensate is trapped inside the container liner spoilage of the products and mold growth can occur.

In order to reduce the problem of water condensing on the inside of the liner water absorbers, such as desiccant, are used, but desiccant has a limited water absorption capacity. Non-moisture generating materials can be used in

Lhe freight containers, such as dried wooden, plastic or paper pallets, to help minimise moisture content inside the liner, but water content contained in the goods themselves cannot necessarily be minimised.

Another option is to use a refrigerated container, which can control the temperature and relative humidity. However, this is a very expensive option.

The present invention was developed in light of the above problems.

Summary of the Invention

The invention provides a liner for protecting goods against damage from condensation, comprising: a breathable material having a breathable layer, wherein the breathable material allows vapour to transfer across the material but inhibits the transfer of liquids.

By providing a breathable material that allows vapour to transfer across the breathable material the liner is able to allow moisture on one side of the liner to pass to a dryer side of the liner rather than condensing on the high humidity side of the liner. In addition, as the breathable material also inhibits the transfer of liquids across the breathable material the liner is also able to protect goods from water damage.

In some embodiments the breathable layer has a water vapour transmission rate between 50g/m2/day and 5,000g/m2/day. In more preferred embodiments the water vapour transmission rate of the breathable material is approximately 1,000g/m2/day.

In some embodiments the breathable material can withstand a hydrostatic pressure of 250 mm or greater. In one example, the breathable material can withstand a hydrostatic pressure of 1,000 mm or greater.

In some embodiments the water vapour transfers across the breathable layer by diffusing through the polymer matrix of the breathable layer. By providing a breathable layer that allows diffusion through the polymer matrix of the breathable layer it is possible to have a breathable material without the material being porous at a micro or macro level to physically allow vapour to transfer across the breathable layer.

In other embodiments the vapour physically transfers across the breathable layer. By providing a breathable layer that physically allows vapour to transfer across the breathable layer a large range of materials may be used to make the breathable layer. For example, the breathable layer could have micropores that allow vapour to transfer across the breathable layer. In other embodiments the breathable layer has perforations that allow vapour to transfer across the breathable layer.

In some embodiments the breathable layer is attached to a support layer. The support layer may act to protect and reinforce the breathable layer. In a preferred embodiment the water vapour transmission rate of the breathable layer is the same as or less than a water vapour transmission rate of the support layer. By having a breathable layer with a water vapour transmission rate that is the same as or less than a water vapour transmission rate of the support layer the breathable layer acts as the principle barrier for moisture transfer.

In some embodiments the support layer is a non-woven layer. In further embodiments the breathable material comprises a second non-woven layer, the breathable layer being located between the two non-woven layers.

In other embodiments the support layer is a woven fabric layer. In further embodiments the breathable material comprises a second woven fabric layer, the breathable layer being located between the two woven fabric layers. By having the breathable layer between two woven fabric layers the breathable layer is well protected by the two woven fabric layers .

In some embodiments the liner further comprises a breathable reflective material attached to the breathable material. By having a breathable reflective material attached to the breathable material the liner is able to reduce the transfer of heat across the liner by reflecting the radiant heat. This allows the liner to reduce the fluctuations in temperature experienced by the goods due to varying ambient conditions during transportation, which can lead to goods being damaged.

In preferred embodiments the breathable reflective material is perforated. In more preferred embodiments the breathable reflective material is attached to the breathable material by an adhesive layer. The adhesive layer is preferably discontinuous so as to stay free of the perforated openings in the breathable material and breathable reflective material.

The invention also provides a container liner comprising a plurality of panels joined together to form a full or partial enclosure for storing goods, wherein at least a portion of at least one of the panels comprises a liner as described above to define a breathable panel.

By providing a container liner with a plurality of panels joined together it is possible to fully enclose goods within the container liner. This has the advantage of providing a barrier between the goods and the ambient conditions, while also allowing vapour to transfer across at least a portion of at least one of the panels (i.e. a breathable panel).

In some embodiments of the container liner at least one of the panels that is not a breathable panel has an outer layer of reflective material. In a preferred embodiment all of the panels of the container liner comprise an outer layer of reflective material. By providing a reflective material on all of the panels of the container liner the ability to reflect radiant heat is maximised.

In a more preferred embodiment of the container liner a top panel is the breathable panel. By having the top panel of the container liner breathable the transfer of moisture from inside the container liner to outside the container liner is aided, as the warmer moist air will naturally rise to the top of the container liner.

In a more preferred embodiment the container liner is attached to an inside of a shipping container such that there is an air gap between, on the one hand, the top panel, side panels, end panel and door panel, and on the other hand, the interior walls of the shipping container. By providing an air gap between a panel of the container liner and a wall of the shipping container the panel of the container liner is able to avoid heat transfer to the panel by conduction.

In a preferred embodiment the container liner is attached to an inside of a shipping container so as to avoid water accumulation at the top panel. Avoiding water accumulation helps to maintain water vapour transmission rate of the breathable layer.

The invention still further provides a container liner comprising a plurality of panels joined together to form a full or partial enclosure for storing goods, wherein at least a portion of a top panel comprises a breathable material having a breathable layer, wherein the breathable material allows vapour to transfer across the material but inhibits the transfer of liquids; and wherein the top panel includes a hanging assembly that lifts the top panel to form an apex and at least one sloping side to assist in draining condensed water from the top panel.

In a preferred embodiment the hanging assembly includes a plurality of lifting mechanisms provided along a length of the top panel. The lifting mechanisms can be provided along a midpoint of the top panel, or may be provided anywhere off-centreline between the midpoint and the edge where side walls meet the top panel.

The lifting mechanisms may be sewn into, or adhered to, or otherwise attached to the top panel. In one embodiment the lifting mechanisms are magnets located in pouches provided along the length of the top panel. In other embodiments the lifting mechanisms can be hooks, double-side adhesive tape and/or an apex frame to which the top panel is hooked on.

Brief Description of the Drawings

An embodiment, incorporating all aspects of the invention, will now be described by way of example only with reference to the accompanying drawings in which;

Figure la is a cross-sectional view of a portion of a liner;

Figure lb is an isometric view of the portion of the liner in Figure la;

Figure lc is a cross-sectional view of the portion of the liner in Figure la showing vapour transfer across the portion of the liner;

Figures 2a to 2c are views of a portion of another liner, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 3a to 3c are views of a portion of another liner, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 4a to 4c are views of the portion of the liner in Figures la to lc with an additional support layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 5a to 5c are views of the portion of the liner in Figures 2a to 2c with an additional support layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 6a to 6c are views of the portion of the liner in Figures 3a to 3c with an additional layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc

Figure 7a is a cross-sectional view of the liner portion of the in Figures 4a to 4c with a reflective layer;

Figure 7b is an isometric view of the portion of the liner in Figure 7a;

Figure 7c is a cross-sectional view of the portion of the liner in Figure 7a showing vapour transfer across the portion of the liner and reflected radiant heat;

Figures 8a to 8c are views of the portion of the liner in Figures la to lc with a reflective layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 9a to 9c are views of the portion of the liner in Figures 5a to 5c with a reflective layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figures 10a to 10c are views of the portion of the liner in Figures 2a to 2c with a reflective layer, shown in corresponding views to the views of the portion of the liner in Figures la to lc;

Figure 11a is a cross-sectional view of a portion of the liner with a two reflective layers;

Figure lib is an isometric view of the portion of the liner in Figure 11a;

Figure 11c is a cross-sectional view of the portion of the liner in Figure 11a showing vapour transfer across the portion of the liner and reflected radiant heat;

Figure 12a is a cross-sectional view of a portion of a liner with a reflective layer;

Figure 12b is an isometric view of the portion of the liner in Figure 12a;

Figure 12c is a cross-sectional view of the portion of the liner in Figure 12a showing vapour transfer across the liner and reflected radiant heat;

Figure 13 is an isometric sketch of a container liner;

Figure 14a is a flow chart of a method for making a breathable material; and

Figure 14b a diagram of the lamination process for making a breathable material;

Figure 15 is an isometric schematic view of a liner in accordance with another embodiment;

Figure 16A is an end section view of the liner illustrated in Figure 15; and

Figure 16B is an enlarged view of area A illustrated in Figure 16A.

Detailed Description of an Embodiment of the Invention

Figures 1 to 3 show a liner 10 that can be used to protect goods from water damage. The liner 10 has a breathable material 20 that allows water vapour to pass through to mitigate condensation on the side of the liner 10 that the goods are located but inhibits the transfer of water or other liquid across the material to the goods' side. The breathable material 20 has a breathable layer 30. The breathable material allows vapour to transfer across the material but inhibits, as much as possible, the transfer of water across the material.

It will be understood that the term 'liner' includes liners that are formed for substantially surrounding goods, such as shipping container liners, as well as other liners that are substantially sheet-like, such as tarpaulins and covers. The term 'liner' therefore includes items such as pallet covers, tarpaulins, temporary storage tents and container liners.

As shown in Figures 1 to 3, the breathable layer 30 is laminated to a support layer 40. The support layer 40 provides a substrate on which the breathable layer 30 is supported. The support layer 40 works to protect and reinforce the breathable layer 30. The support layer therefore has adequate tensile strength and tear resistance to support and protect the breathable layer 30.

It will be understood that the support layer is a preferred feature, and that the breathable material will function without the support layer to allow vapour to transfer across the breathable material but inhibit, as much as possible, the transfer of liquid across the breathable material.

The breathable layer 30 is designed to be the same or less breathable than the support layer 40. In this way water vapour is able to move more easily (or at the same rate) through the support layer 40 than the breathable layer 30, resulting in the breathable layer 30 acting as the principle barrier for moisture transfer. In other words, the breathable layer 30 has water vapour transmission rate that is the same or less than the support layer 40.

The breathable layer 30 of the breathable material 20 may be made of a diffusive material, such as a diffusive film (i.e. a film capable of molecular diffusion), through which vapour chemically diffuses. Alternatively, the breathable layer may be porous to varying degrees so that at a micro or macro level the layer is structured to physically allow vapour to transfer across the layer.

In Figures 1(a) to 1(c) the breathable layer 30 is made from a diffusive material, such as a diffusive film. The diffusive film may be a monolithic film capable of molecular diffusion. The diffusive film may be a breathable film such as a thermoplastic elastomer (TPE), for example thermoplastic polyurethane (TPU). The diffusive film allows moisture to pass through the polymeric layer by adsorption the surface of a high humidity side of the breathable layer 30, followed by dissolving and diffusing through the polymer matrix of the breathable layer 30, and finally by desorption on the surface of the low humidity side of the breathable layer 30. That is, the water vapour transfers across the breathable layer by diffusing through the polymer matrix of the breathable layer. This mechanism is reversible to allow transfer in both directions across the breathable layer and depends on water vapour partial pressure of the two sides of the diffusive film.

As shown in Figures 2(a) to 2(c), the breathable layer 30 could instead be a microporous breathable film. The microporous breathable film has micropores 31. The micropores 31 are created by stretching polymer film, for example polypropylene (PP) or polyethylene (PE), impregnated with inorganic fillers, for example calcium carbonate, to create the microporous structure. The microporous breathable film may be combined with other more porous layers to create a microporous layer with the desired physical properties.

The micropores are smaller than water droplets, hence water cannot penetrate through the microporous layer unless sufficient pressure is applied across the structure.

However, the micropores are bigger than water vapour and air molecules, hence water vapour and air can physically pass through the microporous layer. For example, depending on the material, micropores of approximately 0.01 to 4.00 micron in diameter may be used.

Alternatively, as shown in Figures 3(a) to 3(c), the breathable layer 30 could instead have larger pores, or access channels for the vapour to pass through, and specifically the plastic film could include perforations 32 extending from one surface 33 of the layer 30 to the opposite surface 34 on the other side of the layer 30.

The perforations 32 may be made by using a variety of methods, such as heated or non-heated spikes, heated or non-heated needles, or laser beams. The diameter of the perforations will vary according to the perforation technique used. In general, water, water vapour and air can pass through perforations, however, materials with lower surface energy than the surface tension of water are used to prevent water from flowing through the perforations by capillary action.

Alternatively, the perforations may be made sufficiently small in dimension that transfer of liquids, including water, is prevented or inhibited. For example, depending on the material, perforations of up to approximately 800 micron in diameter may be used, so long as the perforated material has a lower surface energy than water.

Examples of materials suitable for providing a perforated breathable layer include polypropylene (PP), polyethylene (PE) or polyethylene terephthalate (PET). The perforated plastic film allows moisture to pass through the physical holes of the layer/ material. It will be understood that a large range of materials may be used to create a perforated breathable layer and, as a result, perforated embodiments described herein may not require a support layer. This is because a perforated breathable layer may be less fragile than the diffusive film and microporous breathable layers, reducing the level of protection and support required for the perforated breathable layer. It will also be noted that while perforated embodiments may be particularly suited to not requiring a support layer, the diffusive film and microporous embodiments may also function without a support layer.

The support layer 40 provides a substrate on which the breathable layer 30 is supported. The support layer 40 also protects and reinforces the breathable layer 30. The support layer therefore has adequate tensile strength and tear resistance to support and protect the breathable layer 30. The support layer may be a woven or non-woven material that is breathable in order to also allow vapour/moisture to pass through. As the degree of water vapour transmission rate is dictated by the breathable layer 30, the support layer 40 will have the same or a greater water vapour transmission rate than the breathable layer 30.

The breathability of the support layer may be a result of a characteristic of the material used, eg. a thermoplastic elastomer that relies on chemical diffusion to 'breathe' or the support layer could include micropores or perforations as discussed below.

The support layer 40 of the breathable material 20 in Figures 1 and 2 is made from a non-woven material and specifically polypropylene (PP) in this embodiment. Alternatively, the support layer could be made from non-woven polyethylene terephthalate (PET), non-woven polyethylene (PE).

Where the support layer 40 is made of a woven fabric, the support layer could be made of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyamide (Nylon), fibre glass and cotton.

Referring to the embodiment in Figures 3(a) to 3(c), as the support layer 40 is also perforated the support layer 40 does not need to be a material that is naturally breathable, as the step of perforating the material inherently makes the support layer breathable. During manufacture of the breathable material in Figures 3(a) to 3(c) the two layer structure is produced and then perforated. In this way both layers are perforated at the same time, making both of the layers breathable. The support layer could therefore be made from non-woven polypropylene (PP), non-woven polyethylene terephthalate (PET), non-woven polyethylene (PE), a woven fabric or a film.

It will be understood that the perforated plastic film breathable layer 30 in Figures 3(a) to 3(b) could be laminated to a non-perforated support layer 40, so long as the support layer 40 was made from a material that is breathable (e.g. PP, PET, PE etc.).

As described above, the breathable layer 30 has water vapour transmission rate that is the same or less than the support layer 40. The following quantities for water vapour transmission rate correspond to using a breathability test method according to American Society for Testing and Materials (ASTM) E96. It is understood that the ASTM E96 is not intended to provide a definition for 'breathable', but is merely a test method which results may differ in some circumstances. In the presently described embodiments the breathable layer 30 has a water vapour transmission rate of between 50g/m2/day and 5,000g/m2/day, preferably a rate of between 500g/m2/day and 2500g/m2/day, and more preferably approximately 1,000 g/m2/day.

Water resistance can also be tested in several ways.

The following quantities for water resistance correspond to using the water column test of American Association of Textile Chemists and Colorists (AATCC) 127. The breathable material 20 is able to withstand a hydrostatic pressure of at least 250 mm and preferably 1,000 mm or greater.

Figures 4(a) to 4(c) and Figure 5(a) to 5(c) show the breathable material of Figures 2(a) to 2(c) and 3(a) to 3(c), respectively, with the addition of another support layer 40A provided on the other side of the layer 30 to the first support layer 40. The second support layer 40A further protects the breathable layer 30 and provides integrity to the whole liner. Figures 4(a) to 4(c) show a breathable layer 30 made from a diffusive film sandwiched between two layers of non-woven polypropylene. Figures 5(a) to 5(c) shows a breathable layer 30 made from a micro-porous breathable film sandwiched between two layers of non-woven polypropylene .

It will be understood that one or both of the layers of non-woven polypropylene could be replaced with any of the materials described above in relation to the support layer. That is, the diffusive film in Figures 4(a) to 4(c), or the micro-porous breathable film in Figures 5(a) to 5(c), could be located between two woven fabric layers, two non-woven layers, or one woven fabric layer and one non-woven layer.

It will also be understood that the perforated breathable layer could also be sandwiched between two support layers.

Figures 6(a) to 6(c) show the breathable material similar to the breathable material in Figures 3(a) to 3(c). As described above in relation to the breathable material in Figures 3(a) to 3(c), the three layer breathable material shown in Figures 6(a) to 6(c) is produced first, by combining the three layers 40,30, 40A, and then perforating the three layer material. In this way all three layers are perforated at the same time, making all of the layers breathable. By sandwiching breathable layer 30 between two support layers 40, 40A breathable layer 30 is better protected. A reflective material 50 may be provided on one (or both, as shown in Figures 11(a) to 11(c)) sides of the breathable material described above. The reflective material 50 acts to reflect radiant (solar) heat. By having a reflective material 50 applied to the breathable material 20 the liner 10 is able to reduce the transfer of heat across the liner 10 by reflecting the radiant heat. By reducing the in-flow and out-flow of radiant heat energy fluctuations in temperature can be reduced to goods that the liner 10 is protecting. It will be understood that temperature fluctuation during transportation can lead to goods being damaged, especially if there are large fluctuations. The reflective material may be highly reflective in order to reflect a large portion of the radiant heat, thereby further reducing the temperature fluctuations.

Highly reflective is intended to mean an emissivity of less than or equal to 0.2 (corresponding to a reflectivity of equal to or more than 80%). This is the measured emissivity of the perforated reflective material after it has been perforated. By having a reflective material 50 applied to the breathable material 20 the liner 10 is able to reduce the transfer of heat across the liner 10 by reflecting radiant heat.

It will be understood that the reflective material must face an air gap in order to be effective. If the liner 10 is used for covering goods it can be considered that the liner 10 has a 'goods side' and an 'outer side' . The reflective layer may be on either the 'goods side' and/or the 'outer side'. If the reflective material is only applied to a single side of the breathable material then the reflective material is preferably applied to the 'outer side' of the liner 10 as the goods covered by the liner 10 will potentially contact the 'goods side' of the liner 10, removing the air gap in these locations.

Figures 7 to 12 show examples of the breathable material having a perforated reflective material 50 attached to the breathable material 20. The perforated reflective material 50 may be made out of, for example, a reflective foil (with or without protective layer) or a low-emissivity film. The reflective material 50 is perforated in order to allow the reflective material 50 to also be breathable. The water vapour transmission rate of the perforated reflective material 50 is greater than the water vapour transmission rate of the breathable layer 30.

The reflective material 50 may be attached to the breathable material 20 in any suitable way. For example, the reflective material 50 may be attached to the breathable material 20 by a polymer tie layer 60, as shown in Figures 7 to 12, or by an adhesive, such as a spot-pattern adhesive layer. The polymer tie 60 is perforated in order to allow the polymer tie layer 60 to be breathable. The water vapour transmission rate of the perforated polymer tie layer 60 is greater than the water vapour transmission rate of the breathable layer 30. If a spot pattern adhesive is used then the adhesive or hot-melt is only applied to certain area based on the pattern required (i.e. the adhesive does not cover the entire material).

Figures 11 and 12 show a material that is made in a similar way to Figures 3(a) to 3(c) and 6(a) to 6(c), in that the material is produced first and then perforated. In relation to Figures 12(a) to 12(c), layer 30 is attached to reflective material 50 by a polymer tie layer 60. The material is then perforated, thereby perforating all three layers at the same time, making all of the layers breathable. In relation to Figures 11(a) to 11(c), layer 30 is sandwiched between two reflective layers 50, each of the reflective layers being attached to the layer 30 by a polymer tie layer 60. The material is then perforated, thereby perforating all five layers at the same time, making all of the layers breathable. In Ihese examples Ihe breathable layer 30 acts as a support layer.

The breathable material described above may be used to create a number of devices for protecting goods against condensation but also water damage from the ingress of water. For example, the breathable material can be used to make a liner 10, such as a pallet cover or temporary storage tent. The liner 10 could also form at least a portion of at least one panel of a container liner 100 comprising a plurality of panels joined together.

Figure 13 shows a container liner 100 for protecting goods against water damage. The container liner 100 comprises a plurality of panels, namely a top panel 110, a bottom panel 111, two side panels 112, 113, a rear panel 114 and one or more front panels 115. The plurality of panels are joined together to form a full or partial enclosure for storing goods. The top panel 110 of the container liner 100 is made from any of the breathable materials 20 described above.

By having the top panel 110 of the container liner 100 made from the breathable material 20 the transfer of moisture from inside the container liner to outside the container liner is aided, as the warmer moist air will naturally rise to the top panel 110 of the container liner 100.

It will be understood that the container liner 100 will still function if only a portion of the panel 110 is a breathable material. It will be further understood that all of the panels of the container liner 100 could be made from the breathable material. Preferably the top panel 110 is made of the breathable material 20, with the breathable material having a perforated reflective layer on the outside of the breathable material 20. It will be understood that any of the panels of the container liner 100 could be the breathable panel.

It will also be understood that the container liner could be used, for example, in a shipping container, a freight container or cool room.

In use, condensation will occur inside a standard container liner if the external temperature of the container liner is too low, or if the relative humidity inside the container liner is too high. The breathable material 20 acts to prevent condensation on the inside the container liner 100 by allowing water vapour to permeate through the breathable material 20 condense on the walls and roof of the container (not shown). In addition, if condensed water on the walls or roof of the container drips onto the container liner 100 it will be discouraged from transferring through the breathable material as the breathable material allows water vapour to transfer across the material but discourages the transfer of water. It will be understood that the panels that are not breathable will preferably also be made from water resistant materials.

The container liner 100 may have one or more panels that is not a breathable panel having an outer layer of reflective material. Notably, all of the panels may have an outer layer of reflective material, including the breathable panel, in order to increase the thermal insulation of the container liner 100 by reducing the radiant heat. It will be understood that if a panel is not a breathable panel then the reflective layer will not need to be breathable.

It will be understood that the container liner 100 could have one or more panels that is not a breathable panel and does not have an outer layer of reflective material. For example, the bottom of a container liner 100 could be made from a non-breathable, non-reflective material, as there may not be an air gap at the bottom of the container liner 100.

By way of example, if the container liner 100 is installed in a shipping container the reflective material will reduce temperature fluctuation of the space inside the container liner 100. The reflective panels will reflect radiant (solar) heat which may reach the container liner 100 from the containers metal walls and roof. This will help to slow down the increase in temperature inside the container liner. Conversely, when the temperature inside the container liner is higher than external environment, the reflective property of the container liner 100 will retard the out flow of heat energy. Reduction of this in-flow and out-flow of radiant heat energy will help to reduce the temperature fluctuation inside the container liner. It is generally possible to reduce the typical fluctuation of 50 to 55°C experienced in a shipping container to a fluctuation of 20 to 25°C, or less.

If a non-reflective breathable panel is used on the top panel 100 and the other panels still possess the reflective property then the temperature fluctuation inside the container liner 100 will be slightly higher than a container liner with all of the panels having a reflective material, but the temperature fluctuation will be much lower than without the container liner 100.

Additionally, in order to further increase the thermal resistance the container liner 100 may be attached to an inside of a shipping container such that there is an air gap between the top panel, side panels, end panel and door panel of the container liner 100 and the walls of the shipping container, in order to reduce heat transfer from the shipping container to the container liner by conduction. A method for installing a liner in a container is described in Australian Patent 2004201415, which is incorporated herein by reference in its entirety.

To insert the container liner 100 into a container the rear panel 114 is first positioned at the back end of the container. Belts 140, which are attached to the side panels 112, 113 and rear panel 114, are used to retain the container liner 100 in position inside the container.

The container liner 100 is positioned within the container such that an air gap is formed on the long sides and top between the container liner 100 and the container. The reflective surface of the container liner 100 reduces heat transfer by thermal radiation to (or from) the air immediately adjacent to the container liner 100. The air gap between the container and the container liner 100 improves the thermal insulation by minimising conduction from the container liner 100 to the container.

In addition, the container liner 100 may be attached to an inside of a shipping container in such a way to avoid water accumulation at the top panel and to encourage any water accumulation to drain off the top panel to the sides of the shipping container. Avoiding water accumulation helps to prevent water penetrating the breathable layer due to the hydrostatic pressure of sitting water and maintain breathability of the top panel.

Figure 15 illustrates schematically the shape of a container liner 300 having a hanging assembly 350 that lifts the top panel 310 to form an apex 315, and at least one sloping side 320 (two sloping sides are shown in Figure 15) to assist in draining any condensed water from the top panel 310. Figure 16A illustrates in side profile the container liner 300 of Figure 15 inside a shipping container 308 and from which the apex 315 and sloping sides 320 can be clearly seen.

The container liner 300 has its hanging assembly 350 located mid-width of the liner 300 and namely along a centerline length CL of the liner. This arrangement results in a symmetrical triangulated-shaped top panel 310 with sloping sides 320 of equal length. It is understood that other arrangements could be achieved, for example, a non-symmetrical triangulated-shaped top panel. Further still, the hanging assembly may be located along one top edge length of the container liner so that the apex occurs above one side wall 330 and the top panel has one sloping side that slopes towards to the other side wall 330. A number of lifting mechanisms 325 are provided along a length L of the top panel to act as lifting points in the hanging assembly 350. In the embodiment shown in Figures 15, 16A and 16B, the lifting mechanisms 325 are located at fixed points along the centerline CL of the top panel and comprise pouches 335 in which to insert magnets.

In the embodiment shown in these drawings the top panel comprises sections of breathable material that are sewn across the width of the container liner 300. In other described embodiments (such as that illustrated in Figure 13) the breathable material is sewn along the length of the container liner. Accordingly, in the embodiment of Figures 15, 16A and 16B pouches 335 contain magnets are sewn into the seam between sections of breathable material and face the ends of the container. If instead the seams run along the length of the container liner, it is convenient for the pouches to be sewn into the seam and oriented in a perpendicular direction to that shown in Figures 15, 16A and 16B.

As the container liner 300 is installed in the shipping container magnets are inserted into pouches 335 and raised toward the container ceiling 340, which is ferromagnetic, where the lifting mechanisms are attracted to the ceiling and hold the midpoint length of the top panel in an apex against the shipping container ceiling while the remaining part of the top panel slopes away toward the side of the container. The sides of the container liner 300 can be restrained by tethering means, or the like to the upper side corner edges of the container, but at a point that is lower than the apex. The pouches can be sewn into the top panel, for example, along a mid-seam.

Other lifting mechanisms could be used instead of magnets in pouches. This could include double-sided adhesive tape that would be applied continuously, or discretely, along a length of the top panel on one side of the tape while the other side of the tape is adhered to the container ceiling 340.

In yet another example, hooks could be sewn into the top panel and used to hook onto complementary catches fixed along the container ceiling.

In yet another embodiment and as illustrated in Figure 13, loops 150 may be provided along the centre portion of the top panel 110 of the container liner 100, through which a cord 160 is threaded. The cord 160 can be attached to the container so that the centre portion of the top panel 110 is higher than the edges of the top panel 110, thereby reducing the amount of water that can accumulate on the top panel.

The cord 160 may be attached to the container so that the top panel 110 is pulled tight to form a triangular shape when viewed from the front of the container, in order to avoid water accumulating in the space between the centre portion of the top panel 110 and the edge of the top panel 110.

In still a further embodiment, a frame (not shown) could be fixed in tension across the shipping container and against the side walls close to the ceiling. The frame would form an apex when installed and there could be a series of frames located along the length of the container near the ceiling, or at least two at each end of the container, or there could be a single large frame across the entire length of the container ceiling. The top panel would be adapted to hook or thread on to the frames particularly at their apex thereby lifting the top panel to form its own apex. The top panel can be attached to the frame through a rope threaded through loops provided along the top panel, or simply through hooks on the top panel that hook on to the frames.

To enable easy access to the internal part of the container liner one or more of the panels may be openable using a zip or hook and loop fastener, such as Velcro.

The method of making the breathable material described above involves laminating a breathable layer with a support layer to form the breathable material. It will be understood that instead of lamination other methods could be used to make the breathable material described above. For example, the method could use hot pressing, breathable glue, etc.

If the breathable material has a reflective layer the process includes laminating a reflective material to an adhesive layer, perforating the laminated reflective material and adhesive layer, and then laminating the perforated reflective material to the breathable layer and the support layer. It will be understood that instead of laminating the reflective material to an adhesive layer vacuum metalizing could be used to deposit a thin layer of metal coating (e.g. aluminium) onto the breathable layer, in order to create a reflective surface.

Referring to Figure 14a, the step of laminating a reflective material to an adhesive layer may include a third layer, such as a non-woven material. In this case the reflective layer is laminated, for example using extrusion lamination, with a non-woven fabric using an adhesive layer to produce the laminate 201. The laminate is then passed through a perforator to produce a perforated laminate 202. Referring to 14B, the perforated laminate 202 then undergoes a second lamination with the support layer 203 using the breathable layer 204 to produce a final lamination 205 (see also Figure 14B).

It will be understood that if the reflective layer is not desired only the support layer 203 and the breathable layer 204 need to be laminated.

Once the final lamination has been created the breathable material is cut according to the design dimensions required, e.g., 20 ft or 40 ft container. As discussed above, the top panel 110 of a container liner 100 could be made of the breathable material whereas the other panels could be made of a non-breathable material, preferably with a reflective layer. All of the panels are joined together with hooks 120 and belts 130 added in for installation purpose (see Figure 13).

An example of another application of a liner would be to form a pallet cover (not shown). The pallet cover could be used to substantially cover the top and sides of a pallet loaded with goods, effectively enclosing the goods. By having a portion of the pallet cover made from a breathable material the goods on the pallet can be protected from condensation as the moisture that would be trapped by a standard pallet cover would be able to escape through the breathable portion. It will be understood that the pallet cover could be made entirely from a breathable material, and that the pallet cover could also have one or more portions that have a reflective material. In addition, instead of specifically being a pallet cover, the liner could stead be a tarpaulin.

Another application for a liner would be to form a temporary storage tent (not shown). A temporary storage tent would be similar in structure to a container liner, however, it would be a self-supporting structure. A temporary storage tent would also likely have a pitched roof to aid in drainage if the temporary storage tent was exposed to rain. Again, by having one or more portions of the temporary storage tent made from a breathable material moisture that would be trapped by a standard storage tent would be able to escape through the breathable portion.

An advantage of the embodiments described above is that they provide a breathable material to allow vapour to transfer across the material to allow moisture on one side of the liner to pass to a dryer side of the liner, rather than condensing on the high humidity side of the liner. In addition, as the breathable material also inhibits the transfer of liquids across the material the liner is also able to protect goods from water damage.

In addition, for embodiments that allow diffusion through a polymer matrix of the breathable layer, it is possible to have a breathable material without the material being porous at a micro or macro level to physically allow vapour to transfer across the breathable layer.

Claims

Claims:

1. A liner (10) for protecting goods against damage from condensation, comprising: a breathable material (20) having a breathable layer (30), wherein the breathable material allows vapour to transfer across the material but inhibits the transfer of liquids .
2. The liner as claimed in claim 1, wherein the breathable layer (30) has a water vapour transmission rate between 50g/m2/day and 5,000g/m2/day.
3. The liner as claimed in 2, wherein the water vapour transmission rate of the breathable material (20) is approximately 1,000g/m2/day.
4. The liner as claimed in any one of the preceding claims, wherein the breathable material (20) can withstand a hydrostatic pressure of 250 mm or greater.
5. The liner as claimed in claim 4, wherein the breathable material (20) can withstand a hydrostatic pressure of 1,000 mm or greater.
6. The liner as claimed in any one of the preceding claims, wherein the vapour transfers across the breathable layer (30) by diffusing through a polymer matrix of the breathable layer.
7. The liner as claimed in any one of claims 1 to 5, wherein the vapour physically transfers across the breathable layer.
8. The liner as claimed in claim 7, wherein the breathable layer has micropores (31) that allow vapour to transfer across the breathable layer.
9. The liner as claimed in claim 7, wherein the breathable layer has perforations (32) that allow vapour to transfer across the breathable layer.
10. The liner as claimed in any one of the preceding claims, wherein the breathable layer (30) is attached to a support layer (40).
11. The liner as claimed in claim 10, wherein the water vapour transmission rate of the breathable layer (30) is the same as or less than a water vapour transmission rate of the support layer (40).
12. The liner as claimed in claim 10 or claim 11, wherein the support layer (40) is a non-woven layer.
13. The liner as claimed in claim 12, wherein the breathable material comprises a second non-woven layer, the breathable layer being located between the two non-woven layers .
14. The liner as claimed in claim 10 or claim 11, wherein the support layer is a woven fabric layer.
15. The liner as claimed in claim 14, wherein the breathable material comprises a second woven fabric layer, the breathable layer being located between the two woven fabric layers.
16. The liner as claimed in any one of the preceding claims, wherein the liner further comprises a breathable reflective material (50) attached to the breathable material.
17. The liner as claimed in claim 16, wherein the breathable reflective material (50) is perforated.
18. The liner as claimed in claim 16 or claim 17, wherein the breathable reflective material (50) is attached to the breathable material by an adhesive layer.
19. A container liner (100) comprising a plurality of panels (110, 111, 112, 113, 114, 115) joined together to form a full or partial enclosure for storing goods, wherein at least a portion of at least one of the panels comprises a liner (10) as claimed in any one of the preceding claims to define a breathable panel.
20. The container liner as claimed in claim 19, wherein at least one of the panels that is not a breathable panel has an outer layer of reflective material (50).
21. The container liner as claimed in claim 19 or claim 20, wherein all of the panels comprise an outer layer of reflective material (50).
22. The container liner as claimed in any one of claims 19 to 21, wherein a top panel (110) is the breathable panel.
23. The container liner as claimed in any one of claims 19 to 22, wherein the liner (10) is attached to an inside of a shipping container (308) such that there is an air gap between, on the one hand, the top panel (110), side panels (112, 113), end panel (114) and door panel (115), and on the other hand, the interior walls of the shipping container.
24. The container liner as claimed in any one of claims 19 to 23, wherein the container liner (100) is attached to an inside of a shipping container so as to avoid water accumulation at the top panel.
25. A container liner (100) comprising a plurality of panels (110, 111, 112, 113, 114, 115) joined together to form a full or partial enclosure for storing goods, wherein at least a portion of a top panel (110) comprises a breathable material (20) having a breathable layer (30), wherein the breathable material allows vapour to transfer across the material but inhibits the transfer of liquids; and wherein the top panel includes a hanging assembly (350) that lifts the top panel to form an apex (315) and at least one sloping side (320) to assist in draining condensed water from the top panel.
26. The container liner as claimed in claim 25, wherein the hanging assembly includes a plurality of lifting mechanisms (325) provided along a length (L) of the top panel.
27. The container liner as claimed in claim 26, wherein the lifting mechanisms are provided along a midpoint of the top panel.
28. The container liner as claimed in claim 26 or 27, wherein the lifting mechanisms are sewn into, or adhered to, the top panel.
29. The container liner as claimed in any one of claims 26 to 28, wherein the lifting mechanisms are magnets located in pouches provided along the length of the top panel.
30. The container liner as claimed in any one of claims 26 to 28, wherein the lifting mechanisms are hooks, double-side adhesive tape and/or an apex frame to which the top panel is hooked on.