GB2602835A

GB2602835A - A thermally insulative liner for use in packaging

Info

Publication number: GB2602835A
Application number: GB2100646.5A
Authority: GB
Inventors: Coles Christopher; Foyster Daniel
Original assignee: Anglian Bespoke Corrugated and Packaging Ltd
Current assignee: Anglian Bespoke Corrugated and Packaging Ltd
Priority date: 2021-01-18
Filing date: 2021-01-18
Publication date: 2022-07-20
Also published as: GB202100646D0

Abstract

An insulating liner for packaging formed of multiple walls; where the internal 111 and external 112 surfaces of each wall are hingedly 131 attached to each other. The external wall may also be hingedly 132 attached to the external wall 113 of an adjacent wall. The base and cover can be provided separately and identical and four walls can be provided as two identical pairs. Ideally the initial panel has cellular material sandwiched between two sheets and each hinge comprises a slit in one sheet and the cellular material; with the final sheet being folded to form a living hinge. Ideally all folds/slits hinges defining the side walls are parallel and on the same side of the initial panel. Some inner panels can be shorter than others to permit tessellation. The cellular material can comprise honeycombs or elongate prisms. The lining elements can be place in an outer box 600 and a product placed within them.

Description

A THERMALLY INSULATIVE LINER FOR USE IN PACKAGING

FIELD OF THE INVENTION

The present invention relates to thermally insulative packaging and thermally insulating liners for packaging.

BACKGROUND

User-assembled, or 'flat-pack', packaging is used in a variety of industries as a cost-effective and logistically straightforward solution to the problem of packaging and transporting goods.

In many applications, it is desirable to provide flat-pack packaging which packs in a space-efficient manner prior to assembly but nevertheless forms a robust and well-supported structure upon assembly. Such applications include, for example, the packaging of white goods, construction materials, and furniture.

In many applications, it is desirable to provide flat-pack packaging which provides said improved thermal insulation while also being relatively lightweight. Such applications include, for example, the distribution of food by a courier, or the distribution of goods on large scales, the logistical implications of which motivate even minor reductions in packaging weight, for example that of white goods, construction materials, and medical supplies.

In many applications, it is desirable to provide packaging which provides improved thermal insulation. For example, it is desirable in some applications to improve the heat retention of the goods packaged therein, thereby to house goods at a desired temperature above that of the ambient surroundings. Such applications include, for example, the distribution of perishable goods, hot or cooked foodstuffs, construction materials, and medical supplies.

Alternatively, it is desirable in other applications to mitigate heat transfer to the goods enclosed within the packaging, thereby to house goods at a desired temperature below that of the ambient surroundings. Such applications -2 -include, for example, the distribution of perishable goods, cold or raw foodstuffs, construction materials, and medical supplies.

SUMMARY OF THE INVENTION

The present inventors have realised that some conventional flat-pack packaging is difficult and costly to manufacture, or susceptible upon assembly to fatigue and breakage under heavy load, or of cumbersome and logistically challenging weight, or insufficiently thermally insulating upon assembly for many applications, or prone to incomplete assembly and accidental spillage, breakage or undesirable cooling/heating, or environmentally unsustainable to manufacture or dispose of, or combinations thereof.

Specifically, flat-pack packaging formed predominantly of flat sheet material may provide insufficient robustness and thermal insulation for many applications.

For some applications, flat-pack packaging formed predominantly of fluted or corrugated sheets may provide sub-optimal thermal insulation (since air can enter and exit the open-ended cavities defined by the flutes) and limited rigidity.

The present inventors have therefore recognised that it is desirable to provide flat-pack packaging which is simultaneously cost-effective to manufacture and distribute, sufficiently robust to mitigate the likelihood of packaging fatigue or breakage under load, sufficiently lightweight to minimise the cost of transit, and sufficiently thermally insulating to improve the longevity of perishable or heat-sensitive goods enclosed therein. It is more desirable still that such packaging be formed entirely of environmentally sustainable materials.

In a first aspect, there is provided a thermally insulative liner for packaging, the thermally insulative liner comprising a plurality of walls defining an internal volume. Each wall comprises a first segment and a second segment.

For each wall, the first segment is hingedly attached to the second segment -3 -such that the first segment and the second segment are configured to rotate relative to each other. The second segments together define an external surface of the thermally insulative liner. The first segments together define an internal surface of the thermally insulative liner and are respectively disposed between the internal volume and the respective second segments.

The respective first segments of the thermally insulative liner may together entirely bound the internal volume, such that all portions of respective second segments are separated from the internal volume by a portion of a respective first segment.

One or more of the walls may form a lower boundary of the internal volume, thereby to form a base of the thermally insulative liner.

One or more of the walls may form an upper boundary of the internal volume, thereby to form a cover of the thermally insulative liner.

The respective second segment of each wall may be hingedly attached to the respective second segment of at least one other wall of the plurality of walls.

The thermally insulative liner may comprise: a first part; a second part separate from the first part; a third part separate from the first and second parts; and a fourth part separate from the first, second and third parts. The third part may form a base. The fourth part may form a cover. The first part may form two or more sidewalls extending between the base and the cover. The second part may form two or more further sidewalls extending between the base and the cover.

The first part may be identical to the second part.

The third part may be identical to the fourth part.

For one or both of the first part and the second part, the first segment of a first wall of the two or more walls belonging to said part may be a first segment of said part. For one or both of the first part and the second part, the second segment of the first wall may be a second segment of said part. For one or both of the first part and the second part, the first segment of a second wall of -4 -the two or more walls belonging to said part, the second wall being a wall other than the first wall, may be a fourth segment of said part. For one or both of the first part and the second part, the second segment of the second wall may be a third segment of said part. For one or both of the first part and the second part, a length of the first segment of said part, in a direction from the hinged attachment of the first segment to a distal end therefrom, may be different from a length of the fourth segment of said part in a direction from the hinged attachment of the fourth segment to a distal end therefrom.

Each of the respective first and second segments of the walls may comprise a cellular structure comprising a plurality of substantially sealed cells.

The cellular structure may be a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.

Each cellular structure may be sandwiched between a respective first layer and a respective second layer.

Each respective hinged attachment may be formed by a slit through the cellular structure and only one of the first layer and the second layer.

All of the slits of at least one of the first, second, third and fourth parts may be substantially parallel to each other.

The insulative liner may comprise one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.

In a second aspect, there is provided thermally insulative packaging comprising outer packaging defining an outer packaging internal volume, and a thermally insulative liner located within the outer packaging internal volume of the outer packaging. The thermally insulative liner is in accordance with any preceding aspect. The outer packaging may be a box comprising: a box base, a plurality of box sidewalls extending from the base, the plurality of box sidewalls defining a box opening to the outer packaging internal volume, the box opening -5 -being opposite to the box base, and a box cover configured to cover the box opening. The base of the thermally insulative liner may be disposed against the box base. The cover of the thermally insulative liner may be disposed between the box cover and the enclosed volume of the thermally insulative liner. Each of the walls of the thermally insulative liner other than the base and the cover may be disposed against a respective one of the plurality of box sidewalls.

When the box cover is arranged to cover the box opening, the box cover and the cover of the thermally insulative liner may be spaced apart, thereby to define a cavity therebetween In a third aspect, there is provided a method of assembling thermally insulative packaging, the method comprising: providing outer packaging, the outer packaging defining an outer packaging internal volume, and inserting a thermally insulative liner into the outer packaging internal volume. The thermally insulative liner is in accordance with any preceding aspect.

The method may comprise inserting the third part into the outer packaging internal volume such that the base of the thermally insulative liner is disposed against a base of the outer packaging, and inserting the first part into the outer packaging internal volume such that: each of the respective second and third segments of the first part is disposed against a respective wall of the outer packaging; and each of the respective first, second, third, and fourth segments of the first part is substantially perpendicular to the base of the thermally insulative liner. The method may further comprise inserting the second part into the outer packaging internal volume such that: each of the respective second and third segments of the second part is disposed against a respective sidewall of the outer packaging; and each of the respective first, second, third, and fourth segments of the second part is substantially perpendicular to the base of the thermally insulative liner.

The method may further comprise, thereafter, inserting goods into the internal volume of the thermally insulative liner.

The method may further comprise, thereafter: closing, by the cover of the thermally insulative liner, the opening of the thermally insulative liner, and -6 -closing, by a cover of the outer packaging, an opening to the outer packaging internal volume.

In a further aspect, there is provided a thermally insulative liner for use in packaging, the thermally insulative liner comprising a plurality of walls defining an internal volume. Each wall comprises an inner sheet and an outer sheet. For each wall, the inner sheet is hingedly attached to the outer sheet such that the inner and outer sheets are configured to rotate relative to each other. The outer sheets define an external surface of the thermally insulative liner. The inner sheets define an internal surface of the thermally insulative liner and are to disposed between the internal volume and the outer sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic illustration (not to scale) showing a perspective view of a first part of a thermally insulative liner for packaging; Figure 2 is a schematic illustration (not to scale) showing a perspective view of a second part of the thermally insulative liner for packaging; Figure 3 is a schematic illustration (not to scale) showing a perspective view of a third part of the thermally insulative liner for packaging; Figure 4 is a schematic illustration (not to scale) showing a perspective view of a fourth part of the thermally insulative liner for packaging; Figure 5 is a process flow chart showing certain steps of a process for assembling the thermally insulative liner in a box; Figure 6 is an exploded perspective view showing assembly of the thermally insulative liner within the box; Figure 7 is a schematic illustration (not to scale) of a side view cross section of the third part of the thermally insulative liner within the box; Figure 8 is a schematic illustration (not to scale) of a side view cross section of the first part and the third part of the thermally insulative liner within the box; -7 -Figure 9 is a schematic illustration (not to scale) of a side view cross section of the first, second and third parts of the thermally insulative liner within the box; Figure 10 is a schematic illustration (not to scale) of a side view cross section of the fully formed thermally insulative liner within the box; Figure 11 is a schematic illustration (not to scale) of a side view cross section of a further fully formed thermally insulative liner within a box; and Figure 12 is a schematic illustration (not to scale) of a side-view cross section of yet another fully formed thermally insulative liner within a box.

DETAILED DESCRIPTION

It will be appreciated that relative terms such as above and below, horizontal and vertical, top and bottom, front and back, and so on, are used herein merely for ease of reference to the Figures, and these terms are not limiting as such, and any two differing directions or positions and so on may be implemented rather than truly above and below, horizontal and vertical, top and bottom, and so on.

Figure 1 is a schematic illustration (not to scale) showing a perspective view of a first part of a thermally insulative liner for packaging.

In this embodiment, the first part 100 is an elongate sheet of material comprising a first core 102 sandwiched between a first layer 104 and a second layer 106 opposing the first layer 104.

In this embodiment, the first part 100 is divided into a first plurality of segments 111-114 by a first plurality of substantially parallel slits 121-123.

Specifically, the first part 100 is divided into a first segment 111, a second segment 112, a third segment 113, and a fourth segment 114 by the first plurality of slits 121-123. Each of the segments 111, 112, 113, 114 is separated from an adjacent segment by a respective slit.

In this embodiment, the first layer 104 and the second layer 106 of each of the segments 111-114 are substantially parallel to each other. -8 -

In this embodiment, each slit of the first plurality of slits 121-123 is a slit or cut spanning the entire width of each of the first core 102 and one of the first layer 104 and the second layer 106, in a direction substantially perpendicular to the direction in which the first layer 104 and the second layer 106 longitudinally extend. Thus, each slit of the first plurality of slits 121-123 may be considered to be a transverse slit.

Specifically, in this embodiment, a first slit 121 separates the first segment 111 from the second segment 112. The first slit 121 is a slit or cut through the second layer 106 and the first core 102, and not through the first layer 104. The first slit 121 defines a first hinge 131. The first segment 111 and second segment 112 are hingedly connected at the first hinge 131 formed by the first layer 104. The hinged connection is such that the second segment 112 may rotate, from a position in which the second segment 112 is parallel to and aligned with the first segment 111, in a first direction relative to the first segment 111 about a first rotation axis 141.

In this embodiment, a second slit 122 separates the second segment 112 from the third segment 113. The second slit 122 is a slit or cut through the second layer 106 and the first core 102, and not through the first layer 104. The second slit 122 defines a second hinge 132. The second segment 112 and third segment 113 are hingedly connected at the second hinge 132 formed by the first layer 104. The hinged connection is such that the third segment 113 may rotate, from a position in which the third segment 113 is parallel to and aligned with the second segment 112, in the first direction relative to the second segment 112 about a second rotation axis 142.

In this embodiment, a third slit 123 separates the third segment 113 from the fourth segment 114. The third slit 123 is a slit or cut through the second layer 106 and the first core 102, and not through the first layer 104. The third slit 123 defines a third hinge 133. The third segment 113 and fourth segment 114 are hingedly connected at the third hinge 133 formed by the first layer 104. The hinged connection is such that the fourth segment 114 may rotate, from a position in which the fourth segment 114 is parallel to and aligned with the third -g -segment 113, in the first direction relative to the third segment 113 about a third rotation axis 143.

In this embodiment, each segment of the first plurality of segments 111114 comprises a sandwiched arrangement of the first core 102, the first layer 104, and the second layer 106.

In this embodiment, the first core 102 of each segment is a honeycomb core, i.e. is formed of a honeycomb arrangement of material, for example a honeycomb arrangement of cellulose fibre, for example paper, or for example cardboard. The honeycomb arrangement includes prismatic or columnar cavities defined by partitioning walls.

In this embodiment, the first layer 104 and second layer 106 of each segment are flat sheets of material, for example flat sheets of cellulose fibre, for example flat sheets of paper, or for example flat sheets of cardboard. In the sandwiched arrangement of this embodiment, the first layer 104 and the second layer 106 of each segment abut, and lie substantially perpendicular to, the partitioning walls of the honeycomb first core 102. The first layer 104 and second layer 106 of each segment are closures of the prismatic or columnar cavities within the honeycomb first core 102 of each segment.

Figure 2 is a schematic illustration (not to scale) showing a perspective view of a second part of the thermally insulative liner for packaging.

In this embodiment, the second part 200 is an elongate sheet of material comprising a second core 202 sandwiched between a third layer 204 and a fourth layer 206 opposing the third layer 204. As will be clear from the below description, the second part 200 may be an identical copy of the first part 100.

In other embodiments, the second part 200 may have one or more dimensions which are different from those of the first part 100.

In this embodiment, the second part 200 is divided into a second plurality of segments 211-214 by a second plurality of substantially parallel slits 221-223. Specifically, the second part 200 is divided into a fifth segment 211, a sixth 30 segment 212, a seventh segment 213, and an eighth segment 214 by the -10 -second plurality of slits 221-223. Each of the segments 211, 212, 213, 214 is separated from an adjacent segment by a respective slit.

In this embodiment, the third layer 204 and the fourth layer 206 of each of the segments 211-214 extend in substantially parallel directions.

In this embodiment, each slit of the second plurality of slits 221-223 is a slit or cut spanning the entire width of each of the second core 202 and one of the third layer 204 and the fourth layer 206, in a direction substantially perpendicular to the direction in which the third layer 204 and the fourth layer 206 longitudinally extend. Thus, each slit of the second plurality of slits 221-223 may be considered to be a transverse slit.

Specifically, in this embodiment, a fourth slit 221 separates the fifth segment 211 from the sixth segment 212. The fourth slit 221 is a slit or cut through the third layer 204 and the second core 202, and not through the fourth layer 206. The fourth slit 221 defines a fourth hinge 231. The fifth segment 211 and sixth segment 212 are hingedly connected at the fourth hinge 231 formed by the fourth layer 206. The hinged connection is such that the sixth segment 212 may rotate, from a position in which the sixth segment 212 is parallel to and aligned with the fifth segment 211, in a second direction relative to the fifth segment 211 about a fourth rotation axis 241, the second direction being opposite to the first direction.

Specifically, in this embodiment, a fifth slit 222 separates the sixth segment 212 from the seventh segment 213. The fifth slit 222 is a slit or cut through the third layer 204 and the second core 202, and not through the fourth layer 206. The fifth slit 222 defines a fifth hinge 232. The sixth segment 212 and seventh segment 213 are hingedly connected at the fifth hinge 232 formed by the fourth layer 206. The hinged connection is such that the seventh segment 213 may rotate, from a position in which the seventh segment 213 is parallel to and aligned with the sixth segment 212, in the second direction relative to the sixth segment 212 about a fifth rotation axis 242.

Specifically, in this embodiment, a sixth slit 223 separates the seventh segment 213 from the eighth segment 214 The sixth slit 223 is a slit or cut through the third layer 204 and the second core 202, and not through the fourth layer 206. The sixth slit 223 defines a sixth hinge 233. The sixth segment 212 and seventh segment 213 are hingedly connected at the sixth hinge 233 formed by the fourth layer 206. The hinged connection is such that the eighth segment 214 may rotate, from a position in which the eighth segment 214 is parallel to and aligned with the seventh segment 213, in the second direction relative to the seventh segment 213 about a sixth rotation axis 243.

In this embodiment, each segment of the second plurality of segments 211-214 comprises a sandwiched arrangement of the second core 202, the third layer 204, and the fourth layer 206.

In this embodiment, the second core 202 of each segment is a honeycomb core, i.e. is formed of a honeycomb arrangement of material, for example a honeycomb arrangement of cellulose fibre, for example paper, or for example cardboard. The honeycomb arrangement includes prismatic or columnar cavities defined by partitioning walls.

In this embodiment, the third layer 204 and fourth layer 206 of each segment are flat sheets of material, for example flat sheets of cellulose fibre, for example flat sheets of paper, or for example flat sheets of cardboard. In the sandwiched arrangement of this embodiment, the third layer 204 and the fourth layer 206 of each segment abut, and lie substantially perpendicular to, the partitioning walls of the honeycomb second core 202. The third layer 204 and fourth layer 206 of each segment are closures of the prismatic or columnar cavities within the honeycomb second core 202 of each segment.

The first part 100 and second part 200 may therefore be considered to be of identical construction, i.e. to be formed of elongate sheets of the same sandwiched arrangement of core and layers.

In this embodiment, a length of the first part 100 in a direction perpendicular to the rotation axes 141-143 is approximately 96m. In other embodiments, the length may be, for example, between 50cm and 150cm, for example between 70cm and 120cm, for example between 90cm and 100cm. A height of the first part 100 in a direction parallel to the rotation axes 141-143 is -12 -approximately 19.5cm. In other embodiments, the height may be, for example, between 5cm and 40cm, for example between 10cm and 30cm. A width of the first part 100 in a direction from the first layer 104 to the second layer 106, i.e. in a direction perpendicular to that of the length and height of the first part 100, is approximately 1.7cm. In other embodiments, the width may be, for example, between 1cm and 4cm, for example between 1.5cm and 2cm.

In this embodiment, the first segment 111 of the first part 100 has a length in a direction perpendicular to the rotation axes 141 -1 43 less than that of the fourth segment 114 of the first part 100.

In this embodiment, the fifth segment 211 of the second part 200 has a length in a direction perpendicular to the rotation axes 241-243 greater than that of the eighth segment 214 of the second part 200 In this embodiment, the second part 200 may be an identical copy of the first part 100. However, in other embodiments, the second part 200 may have one or more dimensions which are different to those of the first part 100.

Figure 3 is a schematic illustration (not to scale) showing a perspective view of a third part of the thermally insulative liner for packaging.

In this embodiment, the third part 300 is an elongate sheet of material comprising a third core 302 sandwiched between a fifth layer 304 and a sixth layer 306 opposing the fifth layer 304.

In this embodiment, the third part 300 is divided into a ninth segment 311 and a tenth segment 312 by a seventh slit 321.

In this embodiment, the fifth layer 304 and the sixth layer 306 of each of the ninth segment 311 and the tenth segment 312 extend in substantially parallel directions.

In this embodiment, the seventh slit 321 is a slit or cut spanning the entire width of each of the third core 302 and the sixth layer 306.

Specifically, in this embodiment, the seventh slit 321 is a slit or cut through the sixth layer 306 and the third core 302, and not through the fifth layer 304. The seventh slit 321 defines a seventh hinge 331. The ninth segment 311 -13 -and tenth segment 312 are hingedly connected at the seventh hinge 331 formed by the fifth layer 304. The hinged connection is such that the tenth segment 312 may rotate, from a position in which the tenth segment 312 is parallel to and aligned with the ninth segment 311, in the first direction relative to the ninth segment 311 about a seventh rotation axis 341.

In this embodiment, each of the ninth segment 311 and the tenth segment 312 comprises a sandwiched arrangement of the third core 302, the fifth layer 304, and the sixth layer 306.

In this embodiment, the third core 302 of each segment is a honeycomb core, i.e. is formed of a honeycomb arrangement of material, for example a honeycomb arrangement of cellulose fibre, for example paper, or for example cardboard. The honeycomb arrangement includes prismatic or columnar cavities defined by partitioning walls.

In this embodiment, the fifth layer 304 and sixth layer 306 of each segment are flat sheets of material, for example flat sheets of cellulose fibre, for example flat sheets of paper, or for example flat sheets of cardboard. In the sandwiched arrangement of this embodiment, the fifth layer 304 and the sixth layer 306 of each segment abut, and lie substantially perpendicular to, the partitioning walls of the honeycomb third core 302. As such, the fifth layer 304 and sixth layer 306 of each segment may be considered to be closures of the prismatic or columnar cavities within the honeycomb third core 302 of each segment.

Figure 4 is a schematic illustration (not to scale) showing a perspective view of a fourth part of the thermally insulative liner for packaging.

In this embodiment, the fourth part 400 is an elongate sheet of material comprising a fourth core 402 sandwiched between a seventh layer 404 and an eighth layer 406 opposing the seventh layer 404. As will be clear from the below description, the fourth part 400 may be an identical copy of the third part 300. In other embodiments, the fourth part 400 may have one or more dimensions which are different to those of the third part 300.

-14 -In this embodiment, the fourth part 400 is divided into an eleventh segment 411 and a twelfth segment 412 by an eighth slit 421.

In this embodiment, the seventh layer 404 and the eighth layer 406 of each of the eleventh segment 411 and the twelfth segment 412 extend in substantially parallel directions.

In this embodiment, the eighth slit 421 is a slit or cut spanning the entire width of each of the fourth core 402 and the eighth layer 406.

Specifically, in this embodiment, the eighth slit 421 is a slit or cut through the eighth layer 406 and the fourth core 402, and not through the seventh layer 404. The eighth slit 421 defines an eighth hinge 431. The eleventh segment 411 and twelfth segment 412 are hingedly connected at the eighth hinge 431 formed by the seventh layer 404. The hinged connection is such that the twelfth segment 412 may rotate, from a position in which the twelfth segment 412 is parallel to and aligned with the eleventh segment 411, in the first direction relative to the eleventh segment 411 about an eighth rotation axis 441.

In this embodiment, each of the eleventh segment 411 and the twelfth segment 412 comprises a sandwiched arrangement of the fourth core 402, the seventh layer 404, and the eighth layer 406.

In this embodiment, the fourth core 402 of each segment is a honeycomb core, i.e. is formed of a honeycomb arrangement of material, for example a honeycomb arrangement of cellulose fibre, for example paper, or for example cardboard. The honeycomb arrangement includes prismatic or columnar cavities defined by partitioning walls.

In this embodiment, the seventh layer 404 and eighth layer 406 of each segment are flat sheets of material, for example flat sheets of cellulose fibre, for example flat sheets of paper, or for example flat sheets of cardboard. In the sandwiched arrangement of this embodiment, the seventh layer 404 and the eighth layer 406 of each segment abut, and lie substantially perpendicular to, the partitioning walls of the honeycomb fourth core 402. As such, the seventh layer 404 and eighth layer 406 of each segment may be considered to be -15 -closures of the prismatic or columnar cavities within the honeycomb fourth core 402 of each segment.

The third part 300 and fourth part 400 may therefore be considered to be of identical construction, i.e. to be formed of elongate sheets of the same 5 sandwiched arrangement of core and layers.

In this embodiment, a length of the third part 300 in a direction perpendicular to the rotation axis 341 is approximately 45cm. In other embodiments, the length may be, for example, between 20cm and 70cm, for example between 30cm and 60cm, for example between 40cm and 50cm. A height of the third part 300 in a direction parallel to the rotation axis 341 is approximately 33.5cm. In other embodiments, the height may be, for example, between 10cm and 60cm, for example between 20cm and 50cm. A width of the third part 300 in a direction from the fifth layer 304 to the sixth layer 306, i.e. in a direction perpendicular to that of the length and height of the third part 300, is approximately 1.7cm. In other embodiments, the width may be, for example, between 1cm and 4cm, for example between 1.5cm and 2cm.

In this embodiment, the ninth segment 311 of the third part 300 has a length in a direction perpendicular to the rotation axis 341 equal to that of the tenth segment 312.

In this embodiment, the eleventh segment 411 of the fourth part 400 has a length in a direction perpendicular to the rotation axis 441 equal to that of the twelfth segment 412.

In this embodiment, the fourth part 400 may be an identical copy of the third part 300. In other embodiments, the fourth part 400 may have one or more dimensions which are different to those of the third part 300.

Figure 5 is a process flow chart showing steps of a process 500 for assembling the thermally insulative liner in a box.

It should be noted that certain of the process steps depicted in the flowchart of Figure 5 and described above may be omitted, or such process 30 steps may be performed in differing order to that presented above and shown in -16 -Figure 5. Furthermore, although all the process steps have, for convenience and ease of understanding, been depicted as discrete temporally-sequential steps, some of the process steps may nevertheless in fact be performed simultaneously or in a temporally-overlapping manner, at least to some extent.

The below description of Figure 5 refers to Figure 6, which is a schematic illustration (not to scale) showing assembly of the thermally insulative liner in the box.

At step s502, the box 600 is provided. The box 600 comprises a base 602 and side walls 604. The side walls extend from the base 602. The sidewalls 604 define an opening 606 opposite to the base 602. The box 600 further comprises closing flaps 608 at the ends of the sidewalls 604 opposite the base 602 At step s504, the third part 300 is inserted into the box 600 via the opening 606 (as depicted by arrows in Figure 6).

Upon insertion of the third part 300 into the box 600, the ninth segment 311 of the third part 300 abuts, and lies substantially flush with, the base 602 of the box 600. That is to say that the ninth segment 311 substantially covers a top surface of the base 602 of the box 600.

In this embodiment, the ninth segment 311 is hingedly attached, at the seventh hinge 331, to the tenth segment 312. The tenth segment 312 may be rotated about the seventh axis 341 by approximately 180 degrees in the first direction relative to the ninth segment 311, such that the tenth segment 312 lies substantially flush with the ninth segment 311. In this position, the tenth segment 312 lies on top of, i.e. above, the ninth segment 311. Thus, the ninth segment 311 and tenth segment 312 may together be considered to form a double-layered segment covering the base 602 of the box 600. The term 'double-layered segment' refers, here and hereinafter, to an arrangement of two respective segments wherein one segment abuts, and lies substantially flush with, the other segment, thereby to form an arrangement consisting of back-to-back sandwiched structures, i.e. a double-layered segment.

-17 -Execution of step s504 results in the configuration of Figure 7, which is a schematic illustration (not to scale) of a side view cross section of the third part 300 of the thermally insulative liner within the box 600.

At step s506, the first and second parts 100, 200 are inserted, simultaneously or sequentially, into the box 600 via the opening 606 (as depicted by further arrows in Figure 6).

In this embodiment, the third segment 113 is hingedly attached, at the third hinge 133, to the fourth segment 114. The fourth segment 114 may be rotated about the third axis 143 by approximately 180 degrees in the first direction relative to the third segment 113, such that the fourth segment 114 lies substantially flush with the third segment 113.

In this embodiment, the second segment 112 is hingedly attached, at the second hinge 132, to the third segment 113. The third segment 113 may be rotated about the second axis 142 by approximately 90 degrees in the first direction relative to the second segment 112, such that the third segment 113 lies substantially perpendicular to the second segment 112.

In this embodiment, the first segment 111 is hingedly attached, at the first hinge 131, to the second segment 112. The second segment 112 may be rotated about the first axis 141 by approximately 180 degrees in the first direction relative to the first segment 111, such that the second segment 112 lies substantially flush with the first segment 111.

Insertion of the first part 100 only provides the configuration shown in Figure 8, which is a schematic illustration (not to scale) of a side view cross section of the first part 100 and the third part 300 of the thermally insulative liner within the box 600. In this configuration, the first part 100 may be considered to be in a folded configuration.

At step s506, the first part 100 is inserted in the folded configuration such that a respective lower surface of each of the first, second, third and fourth segments 111, 112, 113, 114 abuts, and lies substantially flush with, the tenth segment 312 of the third part 300. Each of the second segment 112 and the third segment 113 abuts, and lies substantially flush with, a respective one of -18 -the sidewalls 604 of the box 600. That is to say that each of the second and third segments 112, 113 substantially covers a respective inner surface of one of the sidewalls 604 of the box 600.

Thus, as shown in Figures 6 and 8, the first and second segments 111, 112 may be considered to form a respective double-layered segment substantially covering a respective inner surface of one of the sidewalls 604 of the box 600. The third and fourth segments 113, 114 may also be considered to form a respective double-layered segment substantially covering a respective inner surface of another of the sidewalls 604 of the box 600.

Thus, in this embodiment, following execution of step s506, the first part substantially covers, with respective double-layered segments, two of the sidewalls 604 of the box 600.

As illustrated in Figures 6 and 8, when the first part is in the folded configuration, an end surface of the first segment 111 opposite the first hinge 131 abuts the fourth segment 114. In some embodiments, this abutment tends to hinder rotation of the first and fourth segments 111, 114 relative to, respectively, the second and third segments 112, 113. Specifically, in some embodiments, friction between the first segment 111 and the fourth segment 114 tends to hinder subsequent rotation of the first segment 111 relative to the second segment 112. Specifically, obstruction of the arc of rotation of the fourth segment 114 by an end portion of the first segment 111 opposite the first hinge 131 tends to hinder subsequent rotation of the fourth segment 114 relative to the third segment 113. Thus, in some embodiments, the first part 100 tends to maintain the folded configuration once folded. Confinement of the first part 100 within the volume defined by the sidewalls 604 of the box 600 also serves to keep the first part 100 in the folded configuration within the box 600.

In this embodiment, the fifth segment 211 is hingedly attached, at the fourth hinge 231, to the sixth segment 212. The sixth segment 212 may be rotated about the fourth axis 241 by approximately 180 degrees in the second direction relative to the fifth segment 211, such that the sixth segment 211 lies substantially flush with the fifth segment 211.

-19 -In this embodiment, the sixth segment 212 is hingedly attached, at the fifth hinge 232, to the seventh segment 213. The seventh segment 213 may be rotated about the fifth axis 242 by approximately 90 degrees in the second direction relative to the sixth segment 212, such that the seventh segment 213 lies substantially perpendicular to the sixth segment 212.

In this embodiment, the seventh segment 213 is hingedly attached, at the sixth hinge 233, to the eighth segment 214. The eighth segment 214 may be rotated about the sixth axis 243 by approximately 180 degrees in the second direction relative to the seventh segment 213, such that the eighth segment 214 lies substantially flush with the seventh segment 213.

Execution of step s506 provides the configuration shown in Figure 9, which is a schematic illustration (not to scale) of a side view cross section of the first, second and third parts 100, 200, 300 of the thermally insulative liner within the box 600. In this configuration, the second part 200 may also be considered to be in a folded configuration.

At step s506, the second part 200 is inserted in the folded configuration such that a respective lower surface of each of the fifth, sixth, seventh and eighth segments 211, 212, 213, 214 abuts, and lies substantially flush with, the tenth segment 312 of the third part 300. Each of the sixth segment 212 and the seventh segment 213 abuts, and lies substantially flush with, a respective one of the sidewalls 604 of the box 600. That is to say that each of the sixth and seventh segments 112, 113 substantially covers a respective inner surface of one of the sidewalls 604 of the box 600.

Thus, as shown in Figures 6 and 9, the fifth and sixth segments 211, 212 may together be considered to form a respective double-layered segment substantially covering a respective inner surface of one of the sidewalls 604 of the box 600. The seventh and eighth segments 213, 214 may also together be considered to form a respective double-layered segment substantially covering a respective inner surface of another of the sidewalls 604 of the box 600. Thus, in this embodiment, following execution of step s506, each of the first part 100 -20 -and the second part 200 substantially covers, with respective double-layered segments, two of the sidewalls 604 of the box 600, thereby to line the box 600.

As illustrated in Figures 6 and 9, when the first part 100 is in the folded configuration, an end surface of the eighth segment 214 opposite the sixth hinge 233 abuts the fifth segment 211. This abutment tends to hinder rotation of the fifth and eighth segments 211, 214 relative to, respectively, the sixth and seventh segments 212, 213. Specifically, friction between the fifth segment 211 and the eighth segment 214 tends to hinder subsequent rotation of the eighth segment 214 relative to the seventh segment 213. Specifically, obstruction of the arc of rotation of the fifth segment 211 by an end portion of the eighth segment 214 distal from the sixth hinge 233 tends to hinder rotation of the fifth segment 211 relative to the sixth segment 212. Thus, the second part 200 tends to maintain the folded configuration once folded. Confinement of the second part 200 within the volume defined by the sidewalls 604 of the box 600 also serves to keep the second part 200 in the folded configuration within the box 600.

Thus, the majority of the opening 606 of the box 600 tends to be unobstructed, thereby to facilitate the packing of goods within the packaging. This tends to be particularly beneficial for assembly line packing of goods.

Optionally, following step s506, the packaging may be filled with goods.

Examples of such goods include, but are not limited to, food, medical supplies, or construction materials.

In this embodiment, following step s506, respective portions of each of the first and second parts 100, 200 abut respective portions of the other of the first and second parts 100, 200. Specifically, in this embodiment, the first, second and third parts 100, 200, 300 of the thermally insulative liner together define boundaries of a liner volume. More specifically, the lower boundary of the liner volume is defined by the tenth segment 312. More specifically, the liner volume is further bounded by the first, fourth, fifth, and eighth segments 111, 114, 211, 214 of the liner.

-21 -At step s508, the fourth part 400 is inserted into the box 600 via the opening 606 (as depicted by further arrows in Figure 6).

Upon insertion of the fourth part 400 into the box 600, the eleventh segment 411 of the fourth part 400 abuts, and lies substantially flush with, respective top surfaces of the segments of the first and second parts 100, 200 positioned within the box 600. That is to say that the eleventh segment 411 defines an upper boundary of the liner volume. Thus, the liner volume may be considered to be an enclosed volume bounded by the first, fourth, fifth, eighth, tenth, and eleventh segments 111, 114, 211, 214, 312, 411 of the thermally insulative liner. Accordingly, the liner volume bounded by the first, second, third and fourth parts 100, 200, 300, 400 when the thermally insulative liner is fully formed within the box is hereinafter referred to as the enclosed volume of the liner.

In the embodiment, the eleventh segment 411 is hingedly attached, at the eighth hinge 431, to the twelfth segment 412. The twelfth segment 412 may be rotated about the eighth axis 441 by approximately 180 degrees in the first direction relative to the eleventh segment 411, such that the twelfth segment 412 lies substantially flush with the eleventh segment 411. In this position, the twelfth segment 412 lies on top of, i.e. above, the eleventh segment 411. Thus, the eleventh segment 411 and twelfth segment 412 may together be considered to form a double-layered segment which is a cover to the thermally insulative liner disposed within the box 600.

Thus, following step s508, the thermally insulative liner may be considered to be fully formed, i.e. to define an enclosed volume therewithin.

Execution of step s508 provides the configuration of Figure 10, which is a schematic illustration (not to scale) of a side view cross section of the fully formed thermally insulative liner within the box 600.

Advantageously, the weight of the fourth part 400 of the thermally insulative liner acting on the first and second parts 100, 200 upon which the fourth part 400 rests tends to further impede the unfolding of the respective parts 100, 200 from their folded configurations. More specifically, increased -22 -friction at the respective top and bottom surfaces of the first and second parts 100, 200 which abut, respectively, the fourth and third parts 400, 300 tends to further impede the unfolding of the respective parts 100, 200 from their folded configurations.

At step s510, the box 600 is closed is closed and sealed. In particular, the closing flaps 608 are aligned and sealed together, thereby to form a unitary box lid. Specifically, the closing flaps 608 of the box 600 are rotated relative to the sidewalls 604 to which they adjoin, thereby to form the unitary box lid of the box 600. (Exemplary rotation of one of the closing flaps 608 relative to the sidewalls 604 is depicted by an arrow in Figure 10.) Following step s510, the box 600 encloses a box volume within which the fully formed thermally insulative liner is disposed. In other words, a fully lined box is formed.

Thus, a process 500 for assembling the thermally insulative liner in a box is provided In some embodiments, the unitary box lid formed by the closing flaps 608 contacts, and lies substantially flush with, the twelfth segment 412 of the fourth part 400 forming the cover of the thermally insulative liner. As such, in some embodiments, the fourth part 400 forming the cover of the thermally insulative liner is substantially covered by an inner, i.e. lower, surface of the unitary box lid.

In other embodiments, however, a height of the box 600 is greater than a height of the fully formed thermally insulative liner, so as to define a cavity between the fourth part 400 of the liner and the unitary box lid.

Figure 11 is a schematic illustration (not to scale) of a side view cross section of such a further embodiment of the thermally insulative liner within the box 600. More specifically, Figure 11 shows the configuration of the packaging following execution of the process 500. The cavity 610 defined between the twelfth segment 412 of the fourth part 400 of the liner and the unitary box lid tends to provide improved thermal insulation to the packaging. More specifically, the air within the cavity 610 tends to further reduce the rate of heat -23 -transfer between the enclosed volume of the thermally insulative liner and the unitary box lid of the box 600. The longevity of perishable goods, such as foodstuffs and medical supplies, enclosed within the thermally insulative liner thus tends to be further improved.

The cavity 610 may be used as additional storage space for goods, separate from the possibly temperature-sensitive goods within the enclosed volume of the thermally insulative liner.

Figure 12 is a schematic illustration (not to scale) of a side view cross section of yet another embodiment of the thermally insulative liner within the o box 600. More specifically, the fourth part 400 of the thermally insulative liner of this embodiment further comprises a thirteenth segment 413, a fourteenth segment 414, and a fifteenth segment 415.

In this embodiment, the ninth slit is a slit or cut spanning the entire width of each of the fourth core 402 and the seventh layer 404.

Specifically, in this embodiment, the ninth slit is a slit or cut through the seventh layer 404 and the fourth core 402, and not through the eighth layer 406. The ninth slit defines a ninth hinge 432. The twelfth segment 412 and thirteenth segment 413 are hingedly connected at the ninth hinge 432 formed by the eighth layer 406. The hinged connection is such that the thirteenth segment 413 may rotate, from a position in which the thirteenth segment 413 is parallel to and aligned with the twelfth segment 412, in the second direction relative to the twelfth segment 412 about a ninth rotation axis parallel to the eighth rotation axis 441.

In this embodiment, the tenth slit is a slit or cut spanning the entire width 25 of each of the fourth core 402 and the eighth layer 406.

Specifically, in this embodiment, the tenth slit is a slit or cut through the eighth layer 406 and the fourth core 402, and not through the seventh layer 404. The tenth slit defines a tenth hinge 433. The thirteenth segment 413 and fourteenth segment 414 are hingedly connected at the tenth hinge 433 formed by the seventh layer 404. The hinged connection is such that the fourteenth segment 414 may rotate, from a position in which the fourteenth segment 414 is -24 -parallel to and aligned with the thirteenth segment 413, in the first direction relative to the thirteenth segment 413 about a tenth rotation axis parallel to the eighth rotation axis 441.

In this embodiment, the eleventh slit is a slit or cut spanning the entire 5 width of each of the fourth core 402 and the seventh layer 404.

Specifically, in this embodiment, the eleventh slit is a slit or cut through the seventh layer 404 and the fourth core 402, and not through the eighth layer 406. The eleventh slit defines an eleventh hinge 434. The fourteenth segment 414 and fifteenth segment 415 are hingedly connected at the eleventh hinge 10 434 formed by the eighth layer 406. The hinged connection is such that the fifteenth segment 415 may rotate, from a position in which the fifteenth segment 415 is parallel to and aligned with the fourteenth segment 414, in the second direction relative to the fourteenth segment 414 about an eleventh rotation axis parallel to the eighth rotation axis 441.

In this embodiment, each of the thirteenth segment 413, fourteenth segment 414 and fifteenth segment 415 comprises a sandwiched arrangement of the fourth core 402, the seventh layer 404, and the eighth layer 406.

In this and other embodiments, the thirteenth, fourteenth and fifteenth segments 413, 414, 415 together form a concertina-shaped handle 450 of the thermally insulative liner. Specifically, in the closed configuration of Figure 12, the thirteenth, fourteenth and fifteenth segments 413, 414, 415 abut, and lie flush with, each other, above the eleventh segment 411 and the twelfth segment 412 of the fourth part 400. Subsequent movement of one or more of the segments forming the handle 450 away from the enclosed volume of the thermally insulative liner causes the twelfth segment 412, being hingedly attached to the handle 450, to also move up and away from the enclosed volume of liner. Further movement of one or more of the segments forming the handle 450 away from enclosed volume causes movement of the eleventh segment 411, being hingedly attached to the twelfth segment 412 at the eighth hinge 431, up and away from the enclosed volume, thereby to remove the cover of, i.e. open, the liner.

-25 -In this embodiment, the handle may be used, for example, to open the liner. This tends to ease and speed packing/unpacking, and additionally tends to reduce or eliminate the need to handle the eleventh and twelfth segments 411, 412 during opening, thereby to reduce wear and tear or damage of the eleventh and twelfth segments 411, 412. In particular, it is especially advantageous to reduce the wear and tear or damage of the eleventh and twelfth segments 411, 412 where they provide a predominant fraction of the thermally insulative effect, i.e. when it is desirable to mitigate, in particular, heat transfer across a top wall of the packaging, as is the case when packaging 1 heated goods (for example, hot food).

In this embodiment, when the thermally insulative liner is in the closed configuration of Figure 12, the thirteenth, fourteenth and fifteenth segments 413, 414, 415 abut, and lie flush with, each other. In this and other embodiments, the segments of the handle 450 are sized such that the handle 450 extends across the cavity 610, from the cover of the liner to the unitary box lid formed by the closing flaps 608. The handle supportingly contacts the unitary box lid. While maintaining a thermally insulative cavity, this tends advantageously to provide increased strength to the unitary box lid of the box 600, in particular allowing separate boxes to be stacked without damage to the box 600 and the thermally insulative liner and goods therein. The risk of spillages or breakages due to inverting, jostling, or otherwise mishandling the box during assembly or transit also tends to be reduced. The contents of the cavity 610 also tend to be protected, as a crushing or impacting of said contents by parts of the thermally insulative liner upon inversion of the box tends to be prevented.

In the above embodiment, the fourth part 400 comprises thirteenth, fourteenth and fifteenth segments 413, 414, 415, thereby to form a handle 450 of the cover for opening the packaging. However, in other embodiments, the handle may be formed of more of a different number of segments, for example one segment, for example two segments, or for example four segments.

In the above embodiment, the segments forming the handle of the thermally insulative liner, i.e. the segments of the fourth part which are stacked above the twelfth segment 412 when the thermally insulative liner is in the -26 -closed configuration (as in Figure 12), do not extend far from the sidewall 604 along a direction parallel to the unitary box lid of the box 600. Thus, in the above embodiment, the volume of the cavity 610 tends to be maximised. In other embodiments, however, the length of one or more of the segments forming the handle 450 may be increased so as to provide a handle 450 which extends more than halfway from one sidewall 604 to another sidewall 604 when the thermally insulative liner is in the closed configuration. In such embodiments, the thermally insulative liner tends to reinforce or support the closing flaps of the box. Thus, a want for the box 600 or other outer packaging of the packaging to be particularly robust or reinforced tends to be reduced.

This tends to allow for reduced cost of manufacture of the box or other outer packaging.

An advantage of the above-described thermally insulative liner is that, when the thermally insulative liner is fully formed, the third and fourth parts 300, 400 cover respective bottom and top surfaces of the first and second parts 100, 200 at which the first and second cores 102, 202, are otherwise exposed. This tends to reduce wear and tear or damage of the first and second cores 102, 202, thereby to improve the robustness and longevity of the first and second parts 100, 200. In particular, it is advantageous to preserve the structural integrity of the first and second parts 100, 200 so that they may remain upright in place under the force of their own weight (and that of the fourth part 400).

As detailed below, it is an advantage of the above-described thermally insulative liner that the sandwiched arrangement of layers forming each segment of the thermally insulative liner tends to provide improved thermal insulation.

In the above embodiments, the first, second, third, fourth, fifth, sixth, seventh and eighth layers 104, 106, 204, 206, 304, 306, 404, 406 of each segment may be considered to be closures of the prismatic or columnar cavities within the honeycomb core of the respective segment. The entrance or exit of air from the honeycomb cavities is thus inhibited. This tends to greatly reduce the rate of heat transfer along the prismatic or columnar cavities of the honeycomb core. Thus, the thermally insulative liner having a sandwiched -27 -arrangement of material layers tends to provide for improved thermal insulation of the packaging.

In particular, in the above embodiments, the sandwiched arrangement of material layers within each segment of the thermally insulative liner tends to reduce a rate of heat transfer across the segment. Thus, a rate of heat transfer between the enclosed volume of the thermally insulative liner and the base 602 and sidewalls 604 of the box 600 tends to be reduced. The longevity of perishable goods, such as foodstuffs and medical supplies, enclosed within thus tends to be improved.

In particular, in the above embodiments, when the thermally insulative liner is in the closed configuration, the sandwiched arrangement of material layers within each of the eleventh and twelfth segments 411, 412 tends to reduce a rate of heat transfer between the enclosed volume of the liner and the unitary box lid of the box 600. The longevity of perishable goods, such as foodstuffs and medical supplies, enclosed within thus tends to be further improved.

In the above embodiments, each of the first, second, third, and fourth parts 100, 200, 300, 400 comprises one or more double-layered segments. Each double-layered segment substantially covers a respective inner surface of the box 600. Specifically, the third part 300 forms a double-layered segment which substantially covers an inner surface of the base 602 of the box 600. The first part 100 forms two double-layered segments which substantially cover respective inner surfaces of two adjoined sidewalls of the sidewalls 604 of the box 600. The second part 200 forms two double-layered segments which substantially cover respective inner surfaces of a further two adjoined sidewalls of the sidewalls 604 of the box 600. The further two adjoined sidewalls of the sidewalls 604 are opposite the two adjoined sidewalls of the sidewalls 604 whose respective inner surfaces are substantially covered by the first part 100. The fourth part 400 forms a double-layered segment which is a cover to the liner, the cover being disposed between the enclosed volume of the liner and an inner surface of the unitary box lid of the box 600.

-28 -Thus, when the box 600 is lined, each inner surface of the box 600 is advantageously provided with a respective double-layered segment of the thermally insulative liner. More specifically, the provision, at each inner surface of the box, of a double-layered liner wall tends to improve the thermally insulative effect of the liner to a greater extent than if a single-layered liner wall of the same thickness was used. Thus, the double-layering of segments at each inner surface of the box 600 tends to further reduce a rate of heat transfer between the enclosed volume of the liner and the box 600. The longevity of perishable goods, such as foodstuffs and medical supplies, enclosed within thus tends to be further improved.

In the above embodiments, following execution of step s506 of the process 500, each of the first part 100 and the second part 200 substantially covers, with respective double-layered segments, two of the sidewalls 604 of the box 600, thereby to line the sidewalls 604. Each double-layered segment substantially covering a sidewall 604 may be considered to comprise a respective first segment and a respective second segment.

In the above embodiments, following execution of step s504 of the process 500, the third part 300 substantially covers, with a double-layered segment, the base 602 of the box 600, thereby to line the base 602. The double-layered segment substantially covering the base 602 may be considered to comprise a respective first segment and a respective second segment.

In the above embodiments, following execution of the process 500, the fourth part 400 substantially covers, with a double-layered segment, an opening to the thermally insulative liner. The double-layered segment substantially covering said opening may be considered to comprise a respective first segment and a respective second segment.

In the above embodiments, following execution of the process 500, respective double-layered segments line the box or outer packaging. Thus, the thermally insulative liner may be considered to comprise a base of the thermally insulative liner, a cover of the thermally insulative liner, and sidewalls of the thermally insulative liner. Each of the base, the cover, and the sidewalls of the -29 -thermally insulative liner may be considered a wall of the thermally insulative liner.

In the above embodiments, following execution of process 500, each double-layered segment, which may be considered a wall of the thermally insulative liner, may be considered to comprise an inner sheet and an outer sheet. The inner sheets together completely bound the enclosed volume of the thermally insulative liner. For each double-layered segment or wall of the thermally insulative liner, the respective inner sheet is disposed between the enclosed volume of the thermally insulative liner and the respective outer sheet.

Elongate sheets, formed of the sandwiched arrangement of a core between two opposing layers, such as those used in the present invention each have a greater tensile strength in some directions than others, i.e. an anisotropic tensile strength. This may render individual segments of a liner part prone to breakage or damage under a shearing force in a certain direction. In the above embodiments, the elongate sheets which form the first and second parts 100, 200 are, advantageously, substantially perpendicular to the elongate sheets which form the third and fourth parts 300, 400. Furthermore, each of the first and second parts 100, 200, when in the folded configuration of Figures 6 and 9, comprises substantially perpendicular double-layered segments. Thus, the thermally insulative liner, when fully formed, tends to be provided with improved structural integrity, and tends to be robust under shearing forces in a number of different directions. The risk of spillages, breakages or undesirable heating/cooling of the enclosed goods therefore tends to be reduced. This tends to allow for reduced cost of manufacture and/or assembly of the box or other outer packaging.

Advantageously, the sandwiched arrangement of each segment of the double-layered segments tends to provide packaging with improved thermal insulation without adding restrictive or cumbersome weight to the packaging. More specifically, that many prismatic or columnar cavities of the honeycomb arrangement of the core of each segment provides much of the thermally insulative effect tends to minimise the weight of the liner parts, thereby to provide a lightweight thermally insulative liner.

-30 -In some embodiments, the parts of the thermally insulative liner are sized so as to fit snugly within a corresponding box or outer packaging. A close fit of the fully formed thermally insulative liner within the box 600 tends to advantageously secure the liner within the box. In such embodiments, a close fit 5 of the liner parts 100, 200, 300, 400 within the box 600 may be ensured by slightly oversizing the parts relative to the box dimensions. More specifically, each segment may, at least to some extent, elastically compress in a direction from one layer of the segment towards the opposing layer of the segment. Thus, in such embodiments, when the thermally insulative liner is fully formed 10 within the box 600, each double-layered segment of the first and second liner parts 100, 200 may be elastically compressed through abutment with adjacent double-layered segments. A restoring force from each compressed double-layered segment acts on the adjacent double-layered segment by which it is compressed, and tends thereby to secure, by friction, the position of each double-layered segment relative to adjacent double-layered segments. Thus, in some embodiments, the first and second parts 100, 200 may, by virtue of being manufactured with slightly oversized dimensions relative to the corresponding box 600, be secured within the box 600 following step s506. The third part 300, whose motion within the box is restricted by the first and second parts 100, 200, is thus also secured within the box 600 by oversizing the first and second parts 100, 200 in this manner.

In the above embodiments, the slits of the first plurality of slits 121-124 within the first part 100 are substantially parallel. The slits of the second plurality of slits 221-224 within the second part 200 are also substantially parallel. Thus, the first part 100 and second part 200 of the thermally insulative liner are more easily manufactured by existing methods, and the manufacturing time and cost tends to be reduced.

In the embodiment of Figure 12, the eight slit 421, ninth slit, tenth slit, and eleventh slit are substantially parallel. Thus, the fourth part 400 of the thermally insulative liner of said embodiment is more easily manufactured by existing methods, and the manufacturing time and cost tends to be reduced.

-31 -In the above embodiments, following execution of the process 500, each of the first part and the second part substantially covers, with respective double-layered segments, two of the sidewalls of the box, thereby to line the sidewalls. In other embodiments, however, the first and second parts each substantially cover or line a different number of sidewalls of the box, for example one sidewall, for example three sidewalls, or four example four sidewalls.

In the above embodiments, following execution of the process 500, each of the first part and the second part substantially covers each respective sidewall with a respective double-layered segment. In other embodiments, however, the first and second parts each substantially cover or line each respective sidewall with a multiple-layered segment consisting of a number of layers other than two. For example, each of the first and second parts may cover respective sidewalls with triple-layered segments, or for example quadruple-layered segments.

In the above embodiments, each of the first part and the second part corn prises four segments, thereby to provide respective sidewalls with double-layered segments upon execution of the process 500. In other embodiments, however, the first and second parts may each comprise a different number of segments. For example, each of the first and second parts may comprise five segments, or six segments, or seven segments, or eight segments, thereby to cover each respective sidewall with a multiple-layered segment other than a double-layered segment. The number of segments which form the second part of the liner may be a number associated with the number of segments which form the first part of the liner, such that the liner may fully line every sidewall of a corresponding box with a respective multiple-layered segment.

In the above embodiments, following execution of the process 500, each of the third part and the fourth part substantially covers, with a respective double-layered segment, the base of the box and the opening of the thermally insulative liner, respectively. In other embodiments, however, the third and fourth parts each substantially cover the base of the box and the opening of the thermally insulative liner, respectively, with a multiple-layered segment consisting of a number of layers other than two. For example, each of the third -32 -and fourth parts may cover the base of the box and the opening of the thermally insulative liner, respectively, with triple-layered segments, or for example quadruple-layered segments.

In some of the above embodiments, each of the third part and the fourth part comprises two segments, thereby to provide, respectively, the base and the opening of the liner with double-layered segments upon execution of the process 500. In other embodiments, however, the third and fourth parts may each comprise a different number of segments. For example, each of the third and fourth parts may comprise three segments, or four segments, or five segments, or six segments, thereby to cover each of the base and the opening of the liner with a multiple-layered segment other than a double-layered segment.

Thus, while in the above embodiments each wall of the thermally insulative liner is a double-layered segment, in other embodiments each wall of the thermally insulative liner is a different multiple-layered segment. In other embodiments still, one or more of the walls is a single-layered segment, i.e. is composed of one segment only or is only one segment thick.

In the above embodiments, the box is substantially cuboidal in shape when the closing flaps seal the opening to said box. More specifically, in the above embodiments, the box comprises four sidewalls, a base and a unitary box lid. In other embodiments, however, the box is a different shape. For example, the box may have a different number of sidewalls, for example three sidewalls, five sidewalls, six sidewalls, seven sidewalls, or eight sidewalls. The number of sidewalls of the box may be a number associated with the respective numbers of segments forming the first and second parts.

In the above embodiments, the box comprises substantially planar or flat sidewalls. However, in other embodiments, the box comprises one or more curved sidewalls.

In the above embodiments, the thermally insulative liner defines a 30 substantially cuboidal enclosed volume, upon assembly, in its closed configuration. However, in other embodiments, the first part and the second part -33 -are shaped to define an enclosed volume of a different shape. The shape of the enclosed volume may be a shape associated with the shape of the box, for example the same shape, or a complimentary shape.

In the above embodiments, the parts of the thermally insulative liner are 5 formed of elongate sheets comprising a honeycomb core sandwiched between flat sheet layers. However, in other embodiments, one or more of the parts of the thermally insulative liner are formed of elongate sheets comprising a different arrangement of layers. In some embodiments, the parts of the thermally insulative liner may be formed of elongate sheets comprising layers 10 other than a honeycomb core or flat sheets. In some embodiments, the elongate sheets may comprise a honeycomb core and flat sheets in an arrangement other than a sandwiched arrangement. For example, in some embodiments, the parts of the thermally insulative liner may be formed of elongate sheets comprising corrugated or fluted sheets. For example, in some embodiments, the parts of the thermally insulative liner may be formed of elongate sheets comprising air cavities, solid material, or some other insulative material. For example, in some embodiments, the parts of the thermally insulative liner may be formed of elongate sheets comprising a plurality of honeycomb cores and flat, corrugated, or fluted sheets, the cores and sheets being configured in alternating sandwiched arrangement within the elongate sheet.

In the above embodiments, the parts of the thermally insulative liner are formed of elongate sheets of cellulose fibre material, for example paper, or for example card, or for example cardboard. However, in other embodiments, the parts of the thermally insulative liner are formed of elongate sheets of a different material other than cellulose fibre material, for example a composite fibre material, or for example a polymer material. In other embodiments still, the parts of the thermally insulative liner are formed of elongate sheets of, for example, a recycled material, or for example a recyclable material, or for example a biodegradable material, for example wood.

In some embodiments, the honeycomb core of each part may have a thickness, in a direction from one layer of said part to the respective opposing -34 -layer of said part, greater than a respective thickness, in the same direction, of each of said layers. In other embodiments, the honeycomb core of each part may have a thickness, in a direction from one respective layer of said part to the opposing layer of said part, equal to or less than the respective thicknesses, in the same direction, of said layers.

In the above embodiments, the first part and the second part are separately formed, i.e. not unitarily or integrally formed of the same elongate sheet of material. In other embodiments, however, the first part and the second part are unitarily or integrally formed of the same elongate sheet, or of the same material of a different shape or arrangement than that of the above embodiments.

In the above embodiments, the box lined by the thermally insulative liner comprises two closing flaps. However, in other embodiments, the box lined by the thermally insulative liner comprises a different number of closing flaps, for example one, for example three, for example four. In other embodiments still, the box lined by the thermally insulative liner may have no closing flaps, and the unitary box lid may not be formed, or may be formed by a lid or cover separate to the box.

Claims

-35 -CLAIMS1. A thermally insulative liner for packaging, the thermally insulative liner comprising: a plurality of walls defining an internal volume; wherein each wall comprises a first segment and a second segment; for each wall, the first segment is hingedly attached to the second segment such that the first segment and the second segment are configured to rotate relative to each other; the second segments together define an external surface of the thermally insulative liner; and the first segments together define an internal surface of the thermally insulative liner and are respectively disposed between the internal volume and the respective second segments.
2. The thermally insulative liner of claim 1, wherein the respective first segments together entirely bound the internal volume, such that all portions of respective second segments are separated from the internal volume by a portion of a respective first segment.
3. The thermally insulative liner of claim 1 or 2, wherein one or more of the walls forms a lower boundary of the internal volume, thereby to form a base of the thermally insulative liner.
4. The thermally insulative liner of any of the preceding claims, wherein one or more of the walls forms an upper boundary of the internal volume, thereby to form a cover of the thermally insulative liner. -36 -
5. The thermally insulative liner of any of the preceding claims, wherein the respective second segment of each wall is hingedly attached to the respective second segment of at least one other wall of the plurality of walls.
6. The thermally insulative liner in accordance with claims 1-5, wherein the thermally insulative liner comprises: a first part; a second part separate from the first part; a third part separate from the first and second parts; and a fourth part separate from the first, second and third parts; wherein the third pad forms a base; the fourth part forms a cover; the first part forms two or more sidewalls extending between the base and the cover; the second part forms two or more further sidewalls extending between the base and the cover.
7. The thermally insulative liner of claim 6, wherein the first part is identical to the second part.
8. The thermally insulative liner of claim 6 or 7, wherein the third part is identical to the fourth part.
9. The thermally insulative liner of any of claims 6 to 8, wherein, for one or both of the first part and the second part: the first segment of a first wall of the two or more walls belonging to said part is a first segment of said part; -37 -the second segment of the first wall is a second segment of said part; the first segment of a second wall of the two or more walls belonging to said part, the second wall being a wall other than the first wall, is a fourth segment of said part; the second segment of the second wall is a third segment of said part; and a length of the first segment of said part, in a direction from the hinged attachment of the first segment to a distal end therefrom, is different from a length of the fourth segment of said part in a direction from the hinged 10 attachment of the fourth segment to a distal end therefrom.
10. The thermally insulative liner of any of the preceding claims, wherein each of the respective first and second segments of the walls comprises a cellular structure comprising a plurality of substantially sealed cells.
11. The thermally insulative liner of claim 10, wherein the cellular structure is a structure selected from the group of structures consisting of a honeycomb structure and a prismatic columnar structure.
12. The thermally insulative liner of claim 10 or 11, wherein each cellular structure is sandwiched between a respective first layer and a respective second layer.
13. The thermally insulative liner of claim 12, wherein each respective hinged attachment is formed by a slit through the cellular structure and only one of the first layer and the second layer.
14. The thermally insulative liner of claim 13 when dependent on claim 6, wherein all of the slits of at least one of the first, second, third and fourth parts are substantially parallel to each other.
15. The thermally insulative liner of any of claims 1 to 14, wherein the insulative liner comprises one or more materials selected from the group of materials consisting of: a recycled material, a recyclable material, a biodegradable material, paper, card, cardboard, wood, polymer, and a cellulose fibre material.
16. Thermally insulative packaging comprising.outer packaging defining an outer packaging internal volume; and a thermally insulative liner located within the outer packaging internal volume of the outer packaging, the thermally insulative liner being in accordance with any of claims 1 to 15.
17. The thermally insulative packaging of claim 16, wherein: the thermally insulative liner is in accordance with any of claims 5 to 15 when dependent on claims 3 and 4; and the outer packaging is a box comprising: a box base; a plurality of box sidewalls extending from the base, the plurality of box sidewalls defining a box opening to the outer packaging internal volume, the box opening being opposite to the box base; and a box cover configured to cover the box opening; and wherein the base of the thermally insulative liner is disposed against the box base; -39 -the cover of the thermally insulative liner is disposed between the box cover and the enclosed volume of the thermally insulative liner; and each of the walls of the thermally insulative liner other than the base and the cover is disposed against a respective one of the plurality of box sidewalls.
18. The thermally insulative packaging of claim 17, wherein, when the box cover is arranged to cover the box opening, the box cover and the cover of the thermally insulative liner are spaced apart, thereby to define a cavity therebetween.
19. A method of assembling thermally insulative packaging, the method comprising: providing outer packaging, the outer packaging defining an outer packaging internal volume; and inserting a thermally insulative liner into the outer packaging internal volume, the thermally insulative liner being in accordance with any of claims 1 to 15.
20. The method of claim 19, wherein: the thermally insulative liner is in accordance with claim 6 or any of claims 7 to 15 when dependent on claim 6; and the method comprises: inserting the third part into the outer packaging internal volume such that the base of the thermally insulative liner is disposed against a base of the outer packaging; inserting the first part into the outer packaging internal volume such that: -40 -each of the respective second and third segments of the first part is disposed against a respective wall of the outer packaging; and each of the respective first, second, third, and fourth segments of the first part is substantially perpendicular to the base of the thermally insulative liner; inserting the second part into the outer packaging internal volume such that: each of the respective second and third segments of the second part is disposed against a respective sidewall of the outer packaging; and each of the respective first, second, third, and fourth segments of the second part is substantially perpendicular to the base of the thermally insulative liner.
21. The method of claim 20, further comprising, thereafter, inserting goods into the internal volume of the thermally insulative liner.
22. The method of claim 20 or 21, further comprising, thereafter: closing, by the cover of the thermally insulative liner, the opening of the thermally insulative liner; and closing, by a cover of the outer packaging, an opening to the outer packaging internal volume.
23. A thermally insulative liner for use in packaging, the thermally insulative liner comprising: a plurality of walls defining an internal volume; wherein each wall comprises an inner sheet and an outer sheet; -41 -for each wall, the inner sheet is hingedly attached to the outer sheet such that the inner and outer sheets are configured to rotate relative to each other; the outer sheets define an external surface of the thermally insulative liner; and the inner sheets define an internal surface of the thermally insulative liner and are disposed between the internal volume and the outer sheets.