US20050241978A1 - Shipping container for temperature-sensitive products using semi-rigid or flexible foam - Google Patents
Shipping container for temperature-sensitive products using semi-rigid or flexible foam Download PDFInfo
- Publication number
- US20050241978A1 US20050241978A1 US11/120,615 US12061505A US2005241978A1 US 20050241978 A1 US20050241978 A1 US 20050241978A1 US 12061505 A US12061505 A US 12061505A US 2005241978 A1 US2005241978 A1 US 2005241978A1
- Authority
- US
- United States
- Prior art keywords
- foam
- box
- package
- temperature
- securing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000006260 foam Substances 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 239000000853 adhesive Substances 0.000 claims description 2
- 230000001070 adhesive effect Effects 0.000 claims description 2
- 230000004888 barrier function Effects 0.000 claims description 2
- 231100000252 nontoxic Toxicity 0.000 claims description 2
- 230000003000 nontoxic effect Effects 0.000 claims description 2
- -1 polyethylene Polymers 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 229920002635 polyurethane Polymers 0.000 claims description 2
- 239000004814 polyurethane Substances 0.000 claims description 2
- 238000009413 insulation Methods 0.000 claims 4
- 238000005452 bending Methods 0.000 claims 1
- 239000004794 expanded polystyrene Substances 0.000 description 8
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920006328 Styrofoam Polymers 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000003197 gene knockdown Methods 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 239000008261 styrofoam Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3848—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation semi-rigid container folded up from one or more blanks
- B65D81/3858—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation semi-rigid container folded up from one or more blanks formed of different materials, e.g. laminated or foam filling between walls
Definitions
- the field of invention relates to containers or packages, used for temperature-sensitive products and method of producing the same.
- EPS expanded polystyrene
- EPS is often sold under the STYROFOAM trademark.
- Vacuum panels are semi-rigid porous board wrapped in plastic film and sealed after the air inside the board has been reduced to create a vacuum.
- Other vacuum panel constructions use rigid boards. The disadvantages of these systems are that they are expensive to produce, they take up a great deal of space, and therefore increase the shipping cost.
- the EPS molded container as well as the EPS lined corrugated box and the vacuum panel lined box configuration containers all must be shipped fully assembled to the user.
- a container or package for shipping temperature-sensitive products with superior insulating properties and that can be shipped flat to the end user comprises an unassembled corrugated box to which is secured a rectangular sheet of either semi-rigid or flexible foam (from here onward called “foam”, that has three parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the corrugated box is assembled, yet shipped flat.
- FIG. 1 is a perspective view of a semi-rigid or flexible foam sheet shaped to the present invention.
- FIG. 2 is a perspective view of an assembled corrugated box with the shaped sheet of foam inside the box, all four sides, top and bottom.
- a shipping container or package for temperature-sensitive products that can ship flat comprises an unassembled box laid flat, to which is secured a rectangular sheet of insulating “foam,” as the term is herein defined, that has had three parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the box is assembled, yet shipped flat.
- the apparatus, and the method of making the shipping container or package are described as follows.
- a sheet of insulating foam 10 is provided.
- the foam can be closed or open cell type foam.
- the sheet is first cut the desired thickness, length and width. The length and width will correspond to the inside dimensions of the box to be used.
- the preferred box 12 is a corrugated cardboard box. Then the ends 10 a , 10 b of the sheet will be cut at an angle with an appropriate cutter. Three grooves will also be cut or formed, using an appropriate cutter, corresponding to the folding lines of the corrugated box. Each groove will be cut to an appropriate angle depending on foam thickness, depth and width of box.
- Angle pairs namely 10 a , 10 b , and 10 c , 10 d , and 10 e , 10 f , and 10 g , 10 h should have included angles that add up to approximately 90 degrees or less so that they fit together.
- the sheet 10 After the sheet 10 is formed, it is secured to an unfolded, knock-down, unassembled corrugated box.
- the securing is preferably done with adhesive, but other securing such as clips or other methods can be used that are well known in the art.
- the assembly can be shipped at this state, dramatically lowering the shipping cost.
- the use of foam also contributes to its low cost.
- the corrugated box 12 is then folded and the ends are secured so that it can be used to transport temperature-sensitive products.
- the sheet 10 fits snugly in the corrugated box 12 using this system.
- a semi-rigid or flexible foam top 14 and bottom 16 are also provided to fit snugly to the top and bottom of the box 12 .
- the foam ranges from soft to semi-rigid, based on the density of foam used.
- the system is ideal for shipments weighing less than 65 pounds, which is also the limit for couriers like Fed Ex, UPS and the U.S. Postal Service. Insulating a box in this way is capable of keeping its contents cold for between 24 to 48 hours.
- the preferred thickness of the foam is between one (1) and three (3) inches, depending upon the product, temperature to be maintained and size of shipping container or package.
- foam instead of foam, other materials that meet the important criteria can be used.
- the criteria are that it must be: 1) adequate in terms of thermal barrier capability; 2) stiff enough to hold its shape inside the corrugated box; 3) resistant to moisture and dirt; 4) non-toxic; 5) low cost; and 6) flexible enough to conform to the shape of the corrugated box and for the joints to seal tightly.
- Polyurethane and polyethylene are examples of suitable materials.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Packages (AREA)
Abstract
A shipping container or package for temperature-sensitive products that can ship in a collapsed or flat configuration made up of an unassembled corrugated container or box, laid flat to which is secured a rectangular sheet of semi-rigid or flexible foam that has had three (3) parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the container or box is assembled, yet shipped flat.
Description
- 1. Field of Invention
- The field of invention relates to containers or packages, used for temperature-sensitive products and method of producing the same.
- 2. Description of the Related Art
- When shipping or distributing temperature-sensitive products the typical material used is expanded polystyrene (“EPS”), either in the form of a molded container or an EPS lined corrugated box. EPS is often sold under the STYROFOAM trademark. When more temperature protection is required, the EPS is replaced by vacuum panels. Vacuum panels are semi-rigid porous board wrapped in plastic film and sealed after the air inside the board has been reduced to create a vacuum. Other vacuum panel constructions use rigid boards. The disadvantages of these systems are that they are expensive to produce, they take up a great deal of space, and therefore increase the shipping cost. The EPS molded container as well as the EPS lined corrugated box and the vacuum panel lined box configuration containers all must be shipped fully assembled to the user.
- Other packaging methods for temperature-sensitive can get very complex and therefore very expensive for both the package and the shipping cost. One example of such complex methods is disclosed in U.S. Pat. No. 6,192,703, which is not admitted to being prior art by its mention in this Background section. The '703 patent discloses an insulating vacuum panel and method for making the same. It does not teach any way of making a vacuum panel assembly to a package in a flat state, and therefore must also be shipped fully assembled to the user.
- What is needed, therefore, is a shipping container or package for temperature-sensitive products, with equal to or improved insulating properties to those of existing products, but costs less to produce and that may be shipped flat or collapsed (un-assembled) to the user which will save a considerable amount of money.
- A container or package for shipping temperature-sensitive products with superior insulating properties and that can be shipped flat to the end user, comprises an unassembled corrugated box to which is secured a rectangular sheet of either semi-rigid or flexible foam (from here onward called “foam”, that has three parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the corrugated box is assembled, yet shipped flat. These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, claims, and accompanying drawings.
-
FIG. 1 is a perspective view of a semi-rigid or flexible foam sheet shaped to the present invention. -
FIG. 2 is a perspective view of an assembled corrugated box with the shaped sheet of foam inside the box, all four sides, top and bottom. - A shipping container or package for temperature-sensitive products that can ship flat comprises an unassembled box laid flat, to which is secured a rectangular sheet of insulating “foam,” as the term is herein defined, that has had three parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the box is assembled, yet shipped flat. The apparatus, and the method of making the shipping container or package, are described as follows.
- Turning to
FIG. 1 , a sheet of insulatingfoam 10, is provided. The foam can be closed or open cell type foam. The sheet is first cut the desired thickness, length and width. The length and width will correspond to the inside dimensions of the box to be used. Thepreferred box 12 is a corrugated cardboard box. Then theends - After the
sheet 10 is formed, it is secured to an unfolded, knock-down, unassembled corrugated box. The securing is preferably done with adhesive, but other securing such as clips or other methods can be used that are well known in the art. The assembly can be shipped at this state, dramatically lowering the shipping cost. The use of foam also contributes to its low cost. - Turning to
FIG. 2 , thecorrugated box 12 is then folded and the ends are secured so that it can be used to transport temperature-sensitive products. One can see that thesheet 10 fits snugly in thecorrugated box 12 using this system. A semi-rigid orflexible foam top 14 andbottom 16 are also provided to fit snugly to the top and bottom of thebox 12. - The foam ranges from soft to semi-rigid, based on the density of foam used. The system is ideal for shipments weighing less than 65 pounds, which is also the limit for couriers like Fed Ex, UPS and the U.S. Postal Service. Insulating a box in this way is capable of keeping its contents cold for between 24 to 48 hours. The preferred thickness of the foam is between one (1) and three (3) inches, depending upon the product, temperature to be maintained and size of shipping container or package.
- Major benefits of this system of the present invention besides the ability to be shipped flat is the substantial reduction in both delivery time and cost. Compared with the making of an Expanded Polystyrene (EPS) container which requires an expensive fabricating mold. The mold average cost is $40,000.00, and a typical fabrication time is 4 (four) to 8 (eight) weeks from order to delivery. In contrast, the foam can be cut to any desired shape, on demand, with no capital invested in molds. The present invention saves both time and money.
- Instead of foam, other materials that meet the important criteria can be used. The criteria are that it must be: 1) adequate in terms of thermal barrier capability; 2) stiff enough to hold its shape inside the corrugated box; 3) resistant to moisture and dirt; 4) non-toxic; 5) low cost; and 6) flexible enough to conform to the shape of the corrugated box and for the joints to seal tightly. Polyurethane and polyethylene are examples of suitable materials.
- While there have been described what are present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is, therefore, aimed to cover all such changes and modifications as fall within the true spirit and scope of the invention.
Claims (20)
1. A package for temperature-sensitive products comprising:
an outside box;
a first rectangular piece of foam insulation, wherein two opposite sides of said rectangular piece are mitered at angles that add up to 90? or less, and wherein three notches whose angles add up to 90? or less, are formed in the insulation parallel to the mitered sides;
a top panel of foam insulation; and
a bottom panel of foam insulation, wherein the first piece, top panel, and bottom panel are sized to fit inside the outside box when assembled.
2. The package of claim 1 , wherein the foam is selected according to the criteria that the material must have adequate thermal barrier capability; the material must be stiff enough to hold its shape inside the box; the material must be resistant to moisture and dirt; the material must be non-toxic; the material must have low cost relative to EPS and vacuum bags; and the material must be flexible enough to conform to the shape of the box and for box joints to seal tightly.
3. The package of claim 1 , wherein the foam is made of a material selected from the group consisting of closed cell foam and open cell foam.
4. The package of claim 1 , the foam having a thickness between 1 inch and 3 inches.
5. The package of claim 1 , wherein the thickness of the foam is calculated to maintain the temperature of package contents below ambient temperature for at least 24 hours.
6. The package of claim 1 , wherein the thickness of the foam is calculated to maintain the temperature of package contents below ambient temperature for at least 24 hours.
7. The package of claim 1 , wherein the outside box is made of corrugated cardboard.
8. The package of claim 1 , wherein the gross weight of the package is less than 65 pounds.
9. The package of claim 1 , wherein the box and the foam are secured to each other.
10. The package of claim 9 , wherein the box and foam are secured to each other by at least one mechanism taken from the group consisting of adhesive and clips.
11. The package of claim 1 , wherein the foam is disposed upon the box, both in a flat position for shipping.
12. The package of claim 1 , wherein the foam is made of at least one selected from the group consisting of polyurethane and polyethylene.
13. A method of making a package for temperature-sensitive products comprising the steps of:
providing a laid-out and unassembled box, having pre-formed folds;
providing insulating foam of a selected thickness;
cutting a rectangle out of the foam substantially the same size as four linear sides of the box;
cutting three parallel folding notches in the foam at angles adding up to about 90?or less; and
cutting two opposite ends of the rectangle parallel to the notches at angles that add up to 90?; and
securing the foam to the box.
14. The method of claim 13 , wherein the securing step is at least one taken from the group consisting of adhering and clipping.
15. The method of claim 13 , wherein cutting the three folding notches are positioned to align with the pre-formed folds of the box.
16. The method of claim 13 , further comprising the step of aligning the edges of the rectangular foam to the edges of the box before securing them.
17. The method of claim 13 , further comprising the step of bending each corner of the unassembled box and securing the edges to form a cube.
18. The method of claim 17 , further comprising the step of providing a rectangular piece of insulating foam for the top of the box and a rectangular piece of insulating foam for the bottom of the box.
19. The method of claim 18 , further comprising the step of securing a box top and a box bottom onto the box with the foam top and foam bottom enclosed.
20. The method of claim 13 , wherein the cutting step is performed with a mitering tool.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/120,615 US20050241978A1 (en) | 2004-05-03 | 2005-05-03 | Shipping container for temperature-sensitive products using semi-rigid or flexible foam |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US52147604P | 2004-05-03 | 2004-05-03 | |
US11/120,615 US20050241978A1 (en) | 2004-05-03 | 2005-05-03 | Shipping container for temperature-sensitive products using semi-rigid or flexible foam |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050241978A1 true US20050241978A1 (en) | 2005-11-03 |
Family
ID=35185987
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/120,615 Abandoned US20050241978A1 (en) | 2004-05-03 | 2005-05-03 | Shipping container for temperature-sensitive products using semi-rigid or flexible foam |
Country Status (1)
Country | Link |
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US (1) | US20050241978A1 (en) |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090319395A1 (en) * | 2007-12-13 | 2009-12-24 | Kitaru Innovations Inc. | Method of selling and shipping a product utilizing the internet |
US20100001056A1 (en) * | 2007-12-13 | 2010-01-07 | Kitaru Innovations Inc. | Method and apparatus for making, shipping and erecting boxes |
GB2513106A (en) * | 2013-03-22 | 2014-10-22 | Peli Cool Logistics Ltd | Packaging |
US9272811B1 (en) | 2014-09-12 | 2016-03-01 | Sonoco Development, Inc. | Temperature controlled pallet shipper |
WO2016048770A1 (en) * | 2014-09-26 | 2016-03-31 | Pelican Biothermal, Llc | Bolt-on thermal insulating panel and thermally insulated shipping container employing same |
WO2016066251A3 (en) * | 2014-10-27 | 2016-06-23 | Va-Q-Tec Ag | Box-type transport container |
US9938066B2 (en) | 2014-09-12 | 2018-04-10 | Sonoco Development, Inc. | Temperature controlled pallet shipper |
US9981797B2 (en) | 2015-04-20 | 2018-05-29 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US10266332B2 (en) | 2015-05-04 | 2019-04-23 | Pratt Corrugated Holdings, Inc. | Adjustable insulation packaging |
US10329080B1 (en) | 2018-05-08 | 2019-06-25 | Lincoln Global, Inc. | Welding consumable packaging |
USD874268S1 (en) | 2018-05-04 | 2020-02-04 | Pratt Corrugated Holdings, Inc. | Mechanically secured box |
US10807761B2 (en) | 2018-03-01 | 2020-10-20 | Pratt Corrugated Holdings, Inc. | Fastener-free packaging |
US20210341340A1 (en) * | 2020-05-04 | 2021-11-04 | Carrier Corporation | System and method for monitoring a container environment |
US20220153505A1 (en) * | 2020-11-18 | 2022-05-19 | Westrock Shared Services, Llc | Cold chain barrier wall packaging system |
US20220219848A1 (en) * | 2019-06-29 | 2022-07-14 | Zhejiang University | Preservation method for room temperature logistics of fresh pork |
US12025508B2 (en) * | 2021-04-26 | 2024-07-02 | Carrier Corporation | System and method for monitoring a container environment |
-
2005
- 2005-05-03 US US11/120,615 patent/US20050241978A1/en not_active Abandoned
Cited By (31)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100001056A1 (en) * | 2007-12-13 | 2010-01-07 | Kitaru Innovations Inc. | Method and apparatus for making, shipping and erecting boxes |
US9061477B2 (en) | 2007-12-13 | 2015-06-23 | Kitaru Innovations Inc. | Method and apparatus for making, shipping and erecting boxes |
US20090319395A1 (en) * | 2007-12-13 | 2009-12-24 | Kitaru Innovations Inc. | Method of selling and shipping a product utilizing the internet |
GB2513106A (en) * | 2013-03-22 | 2014-10-22 | Peli Cool Logistics Ltd | Packaging |
US9272811B1 (en) | 2014-09-12 | 2016-03-01 | Sonoco Development, Inc. | Temperature controlled pallet shipper |
US9938066B2 (en) | 2014-09-12 | 2018-04-10 | Sonoco Development, Inc. | Temperature controlled pallet shipper |
GB2558682A (en) * | 2014-09-26 | 2018-07-18 | Pelican Biothermal Llc | Bolt-on thermal insulating panel and thermally insulated shipping container employing same |
WO2016048770A1 (en) * | 2014-09-26 | 2016-03-31 | Pelican Biothermal, Llc | Bolt-on thermal insulating panel and thermally insulated shipping container employing same |
GB2558682B (en) * | 2014-09-26 | 2021-09-15 | Pelican Biothermal Llc | Bolt-on thermal insulating panel and thermally insulated shipping container employing same |
CN107148301A (en) * | 2014-10-27 | 2017-09-08 | 瓦克技术股份公司 | Box-like shipping container |
US10766685B2 (en) | 2014-10-27 | 2020-09-08 | Va-Q-Tec Ag | Box-type transport container |
WO2016066251A3 (en) * | 2014-10-27 | 2016-06-23 | Va-Q-Tec Ag | Box-type transport container |
CN107148301B (en) * | 2014-10-27 | 2021-08-10 | 瓦克技术股份公司 | Shipping container and insert |
US10752425B2 (en) | 2015-04-20 | 2020-08-25 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US9981797B2 (en) | 2015-04-20 | 2018-05-29 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US11697543B2 (en) | 2015-04-20 | 2023-07-11 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US11453543B2 (en) | 2015-04-20 | 2022-09-27 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US10633165B2 (en) | 2015-04-20 | 2020-04-28 | Pratt Corrugated Holdings, Inc. | Nested insulated packaging |
US11414257B2 (en) | 2015-05-04 | 2022-08-16 | Pratt Corrugated Holdings, Inc. | Adjustable insulation packaging |
US11834251B2 (en) | 2015-05-04 | 2023-12-05 | Pratt Corrugated Holdings, Inc. | Adjustable insulation packaging |
US10875698B2 (en) | 2015-05-04 | 2020-12-29 | Pratt Corrugated Holdings, Inc. | Adjustable insulation packaging |
US10266332B2 (en) | 2015-05-04 | 2019-04-23 | Pratt Corrugated Holdings, Inc. | Adjustable insulation packaging |
US11440696B2 (en) | 2018-03-01 | 2022-09-13 | Pratt Corrugated Holdings, Inc. | Fastener-free packaging |
US10807761B2 (en) | 2018-03-01 | 2020-10-20 | Pratt Corrugated Holdings, Inc. | Fastener-free packaging |
USD919432S1 (en) | 2018-05-04 | 2021-05-18 | Pratt Corrugated Holdings, Inc. | Mechanically secured box |
USD874268S1 (en) | 2018-05-04 | 2020-02-04 | Pratt Corrugated Holdings, Inc. | Mechanically secured box |
US10329080B1 (en) | 2018-05-08 | 2019-06-25 | Lincoln Global, Inc. | Welding consumable packaging |
US20220219848A1 (en) * | 2019-06-29 | 2022-07-14 | Zhejiang University | Preservation method for room temperature logistics of fresh pork |
US20210341340A1 (en) * | 2020-05-04 | 2021-11-04 | Carrier Corporation | System and method for monitoring a container environment |
US20220153505A1 (en) * | 2020-11-18 | 2022-05-19 | Westrock Shared Services, Llc | Cold chain barrier wall packaging system |
US12025508B2 (en) * | 2021-04-26 | 2024-07-02 | Carrier Corporation | System and method for monitoring a container environment |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: THERMO-CHIEF, INC., MASSACHUSETTS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:TREBLY GROUP, INC.;REEL/FRAME:017864/0783 Effective date: 20060501 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |