GB2592918A

GB2592918A - A packaging insulator

Info

Publication number: GB2592918A
Application number: GB2003378.3A
Authority: GB
Inventors: Belshaw Jonathan; Gammage Mark
Original assignee: Macfarlane Group UK Ltd
Current assignee: Macfarlane Group UK Ltd
Priority date: 2020-03-09
Filing date: 2020-03-09
Publication date: 2021-09-15
Also published as: GB202003378D0

Abstract

A cardboard blank for forming a packaging insulator, the blank comprising at least two elongate body portions 2,4,6 arranged in parallel with one another, and at least one hinge 8 integrally formed with the body portions such that the adjacent body portions are separate from one another but may be folded relative to one another about a longitudinal axis. Each body portion 2,4,6 is divided into a plurality of body panels by fold lines 10,10’,10’’ extending laterally across the body portion. A method of forming a packaging insulator, a cardboard packaging insulator, and a packaging container comprising the cardboard packaging insulator are also provided.

Description

A PACKAGING INSULATOR

Field of the Invention

The present invention relates to the field of packaging. More specifically the present invention relates to insulators, which are placed in packaging in order that the contents of the packaging remain within a desired temperature range for a prolonged period of time.

Background of the Invention

It is known to place insulators in packaging in order to protect temperature sensitive items. Such insulators may reflect cold inwardly in order to keep the contents of packaging at a particular temperature, and/or reflect heat outwardly from the packaging for the same purpose. Examples of commonly used insulators are expanded polystyrene (EPS) and high density polyethylene (HDPE) foam. These materials are usually formed in panels to line a container or package and have low thermal conductivity so they perform well as insulators. However the growth of plastics waste and the associated harm caused to the environment is now a major concern. EPS, HDPE and similar plastics-based insulators are not easily recycled and few companies are engaged in such recycling. This means that the vast majority of plastics-based insulators are sent to landfill or burnt, both of which lead to increased environmental pollution.

More environmentally-friendly insulators have been introduced with a view to replacing these harmful plastics-based insulators. However, such non-plastic insulators are more expensive than EPS and HDPE, are difficult to recycle, and/or have much less effective insulating properties. For example, sheep's wool contained in plastic wrapping has been proposed but it is expensive and the wool needs to be removed from the wrapping before recycling can take place. Even then, whilst the wrapping may be recycled the wool is not usually disposed of in an environmentally-friendly way unless it is placed on a compost heap, which few consumers are likely to have.

Another solution is to line the containers with paper pads. These pads are much easier to recycle as they are accepted in kerbside recycling bins, but their thermal insulating properties are poor due to the thin padding used. It is also not especially straightforward to adapt insulation made from such pads if more or less thermal conductivity is required (e.g. to reflect use in different seasons and/or geographical locations), or different sizes are to be provided.

It is an aim of the present invention to obviate or mitigate one or more of the aforementioned disadvantages of existing packaging insulators.

Summary of the Invention

According to a first aspect of the invention there is provided a cardboard blank for forming a packaging insulator, the blank comprising: at least two elongate body portions arranged in parallel with one another; at least one hinge integrally formed with the body portions such that the adjacent body portions are separate from one another but may be folded relative to one another about a longitudinal axis; and wherein each body portion is divided into a plurality of body panels by fold lines extending laterally across the body portion.

Each body portion may be divided into three body panels.

The blank has a thickness T and comprises X body portions, and wherein the body portions may be arranged in parallel sequentially such that each subsequent body portion has first and second ends which each extend a longitudinal distance D beyond respective first and second ends of the preceding body portion, where DaT(X-1).

The at least one hinge may be frangible.

Each fold line may comprise a plurality of fold perforations extending across the body portion.

The blank may be formed from corrugated cardboard having a flute direction, and wherein the fold lines may be perpendicular to the flute direction. Each body portion includes a first body panel having a free end, and the first body panel may have an indentation in the free end.

Alternatively, the blank may be formed from corrugated cardboard having a flute direction, and wherein the fold lines may be parallel to the flute direction.

One or more of the body panels may include visual perforations arranged to provide visual indications of how to form the blank into the insulation layer.

According to a second aspect of the present invention there is provided a method of forming a packaging insulator, comprising: providing a sheet of cardboard; cutting the cardboard sheet so as to form a blank in accordance with the first aspect of the invention; folding the at least two body portions about the at least one hinge so as to form a stack of body portions; and folding the body panels about their respective fold lines such that each body panel of a body portion lies perpendicular to an adjacent body panel of that body portion.

The step of folding the three body panels may form a substantially U-shaped insulator.

According to a third aspect of the invention there is provided a cardboard packaging insulator comprising: at least two separate elongate body portions arranged in a stack; at least one hinge integrally formed with adjacent body portions and connecting the body portions to one another; and wherein each body portion is divided into a plurality of body panels by fold lines extending laterally across the body portion, each body panel of a body portion lying substantially perpendicular to an adjacent body panel of that body portion.

Each body portion may be divided into three panels such that the insulator is substantially U-shaped.

Each body portion has a thickness T and the insulator comprises X body portions, and wherein the body portions may be arranged sequentially atop one another in the stack such that each subsequent body portion in the upward direction has first and second ends which each lie a longitudinal distance D inwardly of respective first and second ends of the body portion below, where DT(X-1).

The at least one hinge may be frangible.

The insulator may be formed from corrugated cardboard having a flute direction, and wherein the fold lines may be perpendicular to the flute direction. Each body portion includes a first body panel having a free end, and the first body panel may have an indentation in the free end.

Alternatively, the insulator may be formed from corrugated cardboard having a flute direction, and wherein the fold lines are parallel to the flute direction.

One or more of the body panels may include visual perforations arranged to provide visual indications of how to form the insulator.

According to a fourth aspect of the invention there is provided a packaging container comprising at least one packaging insulator according to the third aspect of the invention.

The packaging container may comprise first and second packaging insulators formed from corrugated cardboard having a flute direction, wherein the fold lines of the first packaging insulator are perpendicular to the flute direction and the fold lines of the second insulator are parallel to the flute direction.

Brief Description of the Drawings

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the following drawings: Figures 1 and 2 show blanks for forming a first embodiment of a packaging insulator; Figures 3 and 4 show blanks for forming a second embodiment of a packaging insulator; Figures 5 and 6 show blanks for forming a third embodiment of a packaging insulator; and Figure 7 shows how a packaging insulator is formed from the blanks of the first embodiment.

Detailed Description of the Drawings

Figures 1 and 2 show blanks for forming first and second insulators which are in accordance with a first embodiment of the present invention. This first embodiment of insulator has three layers. The blanks are cut from corrugated cardboard, preferably using a die cutting machine. The second insulator shown in Figure 2 has been rotated anti-clockwise through 90 degrees compared with the first insulator in Figure 1, but the same orientation terminology ("longitudinal"; "lateral", etc) is used for both.

The cardboard is cut in such a way that three elongate body portions 2,4,6 are formed lying in parallel with one another, with the first and second body portions 2,4 separated by a first longitudinal cut line 3, and the second and third body portions 4,6 separated by a second longitudinal cut line 5. The cut lines 3,5 do not extend all of the way along the blank. Instead, the cardboard is cut such that each cut line 3,5 is divided into a number of distinct parts which are separated from one another by solid portions of the cardboard. A small lateral cut 7 is formed where each of the cut lines 3,5 meet these solid cardboard portions, such that each portion of each cut line ends with a T-shape cut. Each solid portion of cardboard has a short (e.g. 10mm) perforation 9 cut therein, where the perforation is co-axial with the respective cut line 3,5.

These solid portions dividing up the cut lines 3,5 form hinges 8, which are thus integral with the body portions 2,4,6 and allow the body portions 2,4,6 to be folded relative to one another about folding axes which run along the cut lines 3,5. The perforations 9 in each hinge 8 weaken the hinges such that they are frangible, i.e the hinges are designed to break relatively easily once the blank has served its purpose. This contributes to the blank being easy to break up for recycling. The blank comprises at least one integral hinge for each pair of adjacent body portions, but as seen in Figures 1 and 2 in this preferred embodiment there are a pair of hinges between each body portion.

Each body portion 2,4,6 is divided into three body panels by a pair of fold lines 10,10,10" which extend transversely across each body portion. The fold lines 10,10',10" are preferably formed by a series of perforations cut into the cardboard.

These perforations may be "10 x 10" perforations, where a small cut of 10mm is followed by a solid 10mm length of uncut cardboard, and then another 10mm cut, and then another 10mm of solid cardboard, this sequence repeated across the whole body portion. Thus, the blank shown in Figures 1 and 2 has a total of nine body panels formed therein.

A first body panel 2A,4A,6A of each body portion 2,4,6 may in use form a lid of the insulator. In this case the lateral free edge of each first body panel 2A,4A,6A may have an indentation 13 which will act as a finger hold when the insulator is in use in a container.

When the blank is cut it may include perforations on the surface of one or more of the body panels, where those perforations act as visual indicators 18 for assembling the insulator and/or to identify a first insulator from a second insulator. As shown in Figures 1 and 2 these indicators 18 may include an "0" and/or an arrow, which are intended to indicate the order in which to fold the panels onto each other when assembling the insulator.

As can also be seen, the blank is cut such that each body portion running from left to right is longer than the preceding body portion. This means that first and second ends of the second (middle) body portion 4 each extend a certain distance D beyond the respective first and second ends of the first (left) body portion 2. Similarly, the first and second ends of the third (right) body portion 6 extend the same distance D beyond the first and second ends of the second body portion 4. The distance D is dictated by the thickness T of the cardboard and the number of layers X present in the insulator, where D T(X-1). The number of body portions in the blank dictates the number of layers of the insulator. As will be explained in more detail below, this staggering of the body portions ensures that a pair of insulators can be snuggly fitted together inside of a packaging container.

As can be seen in Figure 1, the transverse fold lines 10,10,10" are cut to run perpendicular to the direction of the flute 100 of the cardboard. This again ensures that the first body panels 2A,4A,6A acting as the lids do not become detached when folded relative to the remainder of the respective body portion. If the fold lines ran parallel to the flute then repeated opening and closing of the insulator lid would result in the lid detaching from the remainder of the insulator.

There are only a couple of small differences between the first insulator shown in Figure 1 and the second insulator shown in Figure 2. Firstly, there are no finger indentations in the first body panels 2A,4A,6A of the second insulator, as the first panels of the second insulator do not serve as a lid. Secondly, the blank for the second insulator is cut such that the fold lines 10,10%10" are parallel to the direction of the flute 100. The flute directions of the first and second insulator are selected so that they run substantially vertically when placed in a packaging container. This ensures the optimal compression strength for the insulators.

The first and second insulators are cut so as to fit within a standardised cuboidal packaging container. As a non-limiting example, the required dimensions for the insulators to fit within a 340mm x 340mm x 340mm cube container will be described, where the cardboard from which the insulator is cut is 7mm thick. In the first insulator shown in Figure 1, each body panel 6A,6B,6C of the third (right) body portion 6 would be 340mm x 340mm, as this body portion will form the outside wall of the insulator when formed. The body panels 4A,4B,4C of the second body portion 4 would all be 340mm wide, but their lengths would vary. The middle panel 4B would be 324mm, that is it is 8mm shorter at either end than the equivalent middle panel 6B of the third body portion 6. The first and third panels 4A,4C would also both be 8mm shorter than their third body portion equivalents at 332mm. These variations mean that the second body portion 4 is a total of 16mm shorter at both ends than the third body portion 6. The distance D referred to above is therefore 16mm in this example.

The middle panel 2B of the first body portion 2 would be 308mm, which again is 8mm shorter at either end than the middle panel 4B of the second body portion 4. The first and third panels 2A,2C would also both be 8mm shorter than their second body portion equivalents at 324mm. These variations mean that the first body

B

portion 2 is a total of 16mm shorter at both ends than the second body portion 4, which as we see above is also 16mm shorter at both ends than the third body portion 6.

In the second insulator shown in Figure 2, each body portion 2',4',6' is 300mm wide but the lengths of each body portion and their respective body panels vary. In this non-limiting example, the specific dimensions of the second insulator are dictated by the size of the packaging container (340mm x 340mm x 340mm), and also the need for the second insulator to fit inside the container along with the first insulator, as shown in Figure 7(e) and described further below. This means that with a three layer first insulator where each layer is approximately 7mm thick the body portions 2',4'6' of the second insulator are dimensioned so as to allow 20mm either side to allow the roughly 21mm (3 layers x 7mm) thick first insulator to fit with the second insulator in the packaging container. In the third body portion 6' the first and third panels 6A',6C' are each 320mm long, and thus both 20mm shorter than the 340mm long second panel 6B' so as to also allow sections of the 20-21mm thick first insulator to fit with the second insulator in the container.

The middle body panel 68' of the third body portion is 340mm long, whereas the first and third body panels 6A',6C' are both 320mm long. The middle panel 4B' of the second body portion 4' would be 324mm, which means it is 8mm shorter at either end than the equivalent middle panel 63' of the third body portion 6'. The first and third panels 4A',4C' would also both be 8mm shorter than their third body portion equivalents at 312mm. These variations mean that the second body portion 4' is a total of 16mm shorter at both ends than the third body portion 6'. The distance D referred to above is therefore 16mm in this example.

The middle panel 2B' of the first body portion 2' would be 308mm, which again is 8mm shorter at either end than the middle panel 48' of the second body portion 4'.

The first and third panels 2A',2C' would also both be 8mm shorter than their second body portion equivalents at 304mm. These variations mean that the first body portion 2' is a total of 16mm shorter at both ends than the second body portion 4', which as we see above is also 16mm shorter at both ends than the third body portion 6'.

Figures 3 and 4 show blanks for forming first and second insulators which are in accordance with a second embodiment of the present invention. This second embodiment of insulator has two layers. The blanks are cut from corrugated cardboard, preferably using a die cutting machine. The second insulator shown in Figure 4 has been rotated anti-clockwise through 90 degrees compared with the first insulator in Figure 3, but the same orientation terminology ("longitudinal"; "lateral", etc) is used for both.

The cardboard is cut in such a way that two elongate body portions 22,24 are formed lying in parallel with one another, with the first and second body portions separated by a longitudinal cut line 23. The cut line 23 does not extend all of the way along the blank. Instead, the cardboard is cut such that the cut line 23 is divided into a number of distinct parts which are separated from one another by solid portions of the cardboard. A small lateral cut 27 is formed where the cut line 23 meets these solid cardboard portions, such that each portion of each cut line ends with a T-shape cut.

Each solid portion of cardboard has a short (e.g. 10mm) perforation 29 cut therein, where the perforation is co-axial with the cut line 23.

These solid portions dividing up the cut line 23 form hinges 28, which are thus integral with the body portions 22,24 and allow the body portions to be folded relative to one another about a folding axis which runs along the cut line 23. The perforations 29 in each hinge 28 weaken the hinges such that they are frangible, i.e the hinges are designed to break relatively easily once the blank has served its purpose. This contributes to the blank being easy to break up for recycling. The blank comprises at least one integral hinge for the adjacent body portions, but as seen in Figures 3 and 4 in this preferred embodiment there are a pair of hinges between the body portions 22,24.

Each body portion 22,24 is divided into three body panels by a pair of fold lines 30,30' which extend transversely across each body portion. The fold lines 30,30' are preferably formed by a series of "10 x 10" perforations in the same manner as those of the first embodiment. The blanks shown in Figures 3 and 4 have a total of six body panels formed therein.

A first body panel 22A,24A of each body portion 22,24 may in use form a lid of the insulator. In this case the lateral free edge of each first body panel 22A,24A may have an indentation 33 which will act as a finger hold when the insulator is in use in a container.

When the blank is cut it may include perforations on the surface of one or more of the body panels, where those perforations act as visual indicators 38 for assembling the insulator. As shown in Figures 3 and 4 these indicators 38 may include an "0" and/or an arrow, which are intended to indicate the order in which to fold the panels onto each other when assembling the insulator.

As can also be seen, the blank is cut such that first and second ends of the second body portion 24 each extend a certain distance D beyond the respective first and second ends of the first body portion 22. The distance D is dictated by the thickness T of the cardboard and the number of layers X present in the insulator, where D T(X-1).

As in the first embodiment, the transverse fold lines 30,30' in the first insulator of Figure 3 are cut to run perpendicular to the direction of the flute 100 of the cardboard. There are no finger indentations in the first body panels 22A,24A of the second insulator shown in Figure 4, as the first panels of the second insulator do not serve as a lid. The blank for the second insulator is cut such that the fold lines 30,30' are parallel to the direction of the flute 100. Otherwise, the remainder of the features of the first insulator shown in Figure 3 are present in the second insulator of Figure 4.

Figures 5 and 6 show blanks for forming first and second insulators which are in accordance with a third embodiment of the present invention. This third embodiment of insulator has four body portions and hence four layers. The blanks are cut from corrugated cardboard, preferably using a die cutting machine. The second insulator shown in Figure 6 has been rotated anti-clockwise through 90 degrees compared with the first insulator in Figure 5, but the same orientation terminology ("longitudinal"; "lateral", etc) is used for both.

The cardboard is cut in such a way that four elongate body portions 42,44,46,48 are formed lying in parallel with one another, with each pair of adjacent body portions separated by a longitudinal cut line 53,55,57. Each adjacent pair of body portions is also connected together via at least one integral hinge 58 of the type already described above with reference to the first and second embodiments.

Each body portion 42,44,46,48 is divided into three body panels by a pair of fold lines 60,60,60,60-which extend transversely across each body portion. The fold lines are preferably formed by a series of perforations cut into the cardboard. These perforations may be "10 x 10" perforations as already described above. The blanks shown in Figures 5 and 6 each have a total of twelve body panels formed therein.

A first body panel 42A,44A,46A,48A of each body portion may in use form a lid of the first insulator. In this case the lateral free edge of each first body panel may have an indentation 73 which will act as a finger hold when the insulator is in use in a container.

When the blank is cut it may include perforations on the surface of one or more of the body panels, where those perforations act as visual indicators 78 for assembling the insulator. As shown in Figures 5 and 6 these indicators 78 may include an "0" and/or an arrow, which are intended to indicate the order in which to fold the panels onto each other when assembling the insulator.

As can also be seen, the blank is cut such that each body portion running from left to right (when viewed in Figure 5) is longer than the preceding body portion. This means that first and second ends of the successive body portions 44,46,48 each extend a certain distance D beyond the respective first and second ends of the preceding adjacent body portion. The distance D is dictated by the thickness T of the cardboard and the number of layers X present in the insulator, where D T(X-1).

The number of body portions in the blank dictates the number of layers of the insulator. As will be explained in more detail below, this staggering of the body portions ensures that a pair of insulators can be snuggly fitted together inside of a packaging container.

As in the first insulators of the preceding embodiments, the transverse fold lines 60,60',60",60" are cut to run perpendicular to the direction of the flute 100 of the cardboard. The blank for the second insulator is cut such that the fold lines 60,60',60",60" are parallel to the direction of the flute 100.

Industrial Applicability

The manner in which packaging insulators are formed from the blanks described above will now be explained, with reference to the steps set out in Figure 7. For the purposes of this explanation three layer insulators formed from the blanks of the first embodiment will be used. However the method also applies to insulators having fewer or more layers, such as those of the second and third embodiments.

The steps of Figure 7 show the forming of the second insulator of the first embodiment from the blank shown in Figure 2. Firstly, referring to Figure 7(a), the second body panel 4' is rotated clockwise about a longitudinal axis defined by the second cut line 5. At the same time, the first body panel 2' is rotated in the opposite rotational direction about a longitudinal axis defined by the first cut line 3. Rotation of both body panels 2,4' relative to each other and the third body panel 6' is effected by the hinges 8 lying on each cut line 3,5. This folding results in the first, second and third panels 2',4',6' being stacked upon on another as shown in Figure 7(b).

Referring now to Figure 7(c), the next step is to fold all of the third body panels 20',40',60' about 90 degrees about their respective fold lines 10,10,10" relative to the second body panels 2B',4B',6B'. As described above, the second panels 2B',4B',6B' are successively shorter than each other. In the non-limiting dimensions described above for 7mm thick cardboard the second panel 2B' of the first body portion 2' is 8mm shorter at either end than the second panel 4B' of the second body portion 4', and the same with the second panel 4B' of the second body portion relative to the second body panel 6B' of the third body portion 6'. This results in the fold lines 10,10',10" of the body portions 2',4',6' being offset by 8mm relative to each other, and this allows the third panels 20',40',60' to remain flush with each other and to all lie at substantially 90 degrees to the second panels 2B',4B',6B' when folded up.

The substantially perpendicular second and third panels are then all folded about the fold lines 10,10',10" between the first panels 2A',4A',6A' and the second panels 2B',4B',6B' to form a substantially C-or U-shaped insulator, which can be seen in Figure 7(d). Again the offset of these fold lines allows the second panels 2B',4B',6B' to remain flush with each other and to all lie at substantially 90 degrees relative to the first panels 2A',4A',6A' when folded.

Once both the first and second insulators have been formed in this way they can be inserted into a packaging container 100, as shown in Figure 7(e). In Figure 7(e) the first insulator has already been formed into an L-shape and inserted into the container 100. This results in the outermost third panel 6C of the third body portion 6 lying upon the base of the container 100 with the other third panels 2C,4C stacked upon the third panel 6C. The second panels 2B,4B,6B lie at substantially 90 degrees to the third panels 2C,4C,6C in the container 100, with the second panel 6B contacting an internal side wall of the container. The first panels 2A,4A,6A forming the lid remain substantially co-planar with the second panels 23,43,6B for the time being to allow the second insulator to be inserted into the container 100.

With the first insulator in place the now U-shaped second insulator can also be inserted into the container. As can be seen in Figure 7(e), the second insulator is rotated 90 degrees relative to the first insulator and then inserted until it contacts the third panels 2C,4C,6C of the first insulator at the base of the container 100. This results in the outermost panels 6A',6B',6C' belonging to the third body panel 6' lying against the three internal side walls of the container 100 which are not already covered by the first insulator. Once the second insulator is in place, the container can be filled with the contents which are to be temperature-controlled. Then the first panels 2A,4A,6A of the first insulator forming the lid are folded down so as to lie substantially perpendicular to the second panels 2B,4B,6B thus enclosing the contents of the container 100. The container 100 can then be sealed and transported to a desired destination with the contents kept within a desired temperature range.

The insulators of the present invention are formed from 100% recyclable material, which can be disposed of in standard kerbside recycling. The frangible hinges of the insulators mean that little effort is required to separate the body portions for recycling. Whilst corrugated cardboard is the preferred material for the insulators, non-corrugated cardboard may also be used.

Any packaging manufacturer should be able to set up the tooling to form the blanks thereby ensuring that the insulators can be produced local to the produce, thus further reducing the environmental impact of the insulators.

The insulators can be formed with greater or fewer layers/body portions depending on the temperature control requirements, time of year and geographical location.

Although each body portion preferably comprises three body panels other configurations are possible. For example, each body portion may comprise four body panels defined by three respective fold lines.

It is preferred that the embodiments of insulator described herein are used in pairs, with the first and second insulators of each embodiment being inserted into a container in the manner described above. However, the present invention is not limited to use of pairs of insulators in this manner as a single insulator may be inserted into a container so as to provide a degree of insulation.

Modifications and improvements may be incorporated without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS: 2. 3. 4. 5. 7.A cardboard blank for forming a packaging insulator, the blank comprising: at least two elongate body portions arranged in parallel with one another; at least one hinge integrally formed with the body portions such that the adjacent body portions are separate from one another but may be folded relative to one another about a longitudinal axis; and wherein each body portion is divided into a plurality of body panels by fold lines extending laterally across the body portion.
The blank of claim 1, wherein each body portion is divided into three body panels.
The blank of either preceding claim, wherein the blank has a thickness T and comprises X body portions, and wherein the body portions are arranged in parallel sequentially such that each subsequent body portion has first and second ends which each extend a longitudinal distance D beyond respective first and second ends of the preceding body portion, where DT(X-1).
The blank of any preceding claim, wherein the at least one hinge is frangible.
The blank of any preceding claim, wherein each fold line comprises a plurality of fold perforations extending across the body portion.
The blank of any preceding claim, wherein the blank is formed from corrugated cardboard having a flute direction, and wherein the fold lines are perpendicular to the flute direction.
The blank of claim 6, wherein each body portion includes a first body panel having a free end, the first body panel having an indentation in the free end.
The blank of any of claims 1 to 5, wherein the blank is formed from corrugated cardboard having a flute direction, and wherein the fold lines are parallel to the flute direction.
9 The blank of any preceding claim, wherein one or more of the body panels includes visual perforations arranged to provide visual indications of how to form the blank into the insulation layer.
10. A method of forming a packaging insulator, comprising: providing a sheet of cardboard; cutting the cardboard sheet so as to form a blank in accordance with any preceding claim; folding the at least two body portions about the at least one hinge so as to form a stack of body portions; and folding the body panels about their respective fold lines such that each body panel of a body portion lies perpendicular to an adjacent body panel of that body portion.
11. The method of claim 10 when dependent upon claim 2, wherein the step of folding the three body panels forms a substantially U-shaped insulator.
12. A cardboard packaging insulator comprising: at least two separate elongate body portions arranged in a stack; at least one hinge integrally formed with adjacent body portions and connecting the body portions to one another; and wherein each body portion is divided into a plurality of body panels by fold lines extending laterally across the body portion, each body panel of a body portion lying substantially perpendicular to an adjacent body panel of that body portion.
13. The insulator of claim 12, wherein each body portion is divided into three panels such that the insulator is substantially U-shaped.
14. The insulator of claim 12 or claim 13, wherein each body portion has a thickness T and the insulator comprises X body portions, and wherein the body portions are arranged sequentially atop one another in the stack such that each subsequent body portion in the upward direction has first and second ends which each lie a longitudinal distance D inwardly of respective first and second ends of the body portion below, where DT(X-1).
15. The insulator of any of claims 12 to 14, wherein the at least one hinge is frangible.
16. The insulator of any of claims 12 to 15, wherein each fold line comprises a plurality of fold perforations extending across the body portion.
17. The insulator of any of claims 12 to 16, wherein the insulator is formed from corrugated cardboard having a flute direction, and wherein the fold lines are perpendicular to the flute direction.
18. The insulator of claim 17, wherein each body portion includes a first body panel having a free end, the first body panel having an indentation in the free end.
19. The insulator of any of claims 12 to 16, wherein the insulator is formed from corrugated cardboard having a flute direction, and wherein the fold lines are parallel to the flute direction.
20. The insulator of any of claims 12 to 19, wherein one or more of the body panels includes visual perforations arranged to provide visual indications of how to form the insulator.
21. A packaging container comprising at least one packaging insulator according to any of claims 12 to 20
22. The packaging container of claim 21, comprising a first packaging insulator according to claim 17 or claim 18, and a second packaging insulator according to claim 19.