US20220169435A1

US20220169435A1 - Thermal protection packaging

Info

Publication number: US20220169435A1
Application number: US17/432,421
Authority: US
Inventors: David J. Wiemann; Paul C. Haschke; Timothy L. MCCARTHY; William T. MCDONNELL
Original assignee: WestRock Shared Services LLC
Current assignee: WestRock Shared Services LLC
Priority date: 2019-02-19
Filing date: 2020-02-19
Publication date: 2022-06-02
Also published as: US20200262636A1

Abstract

A blank for forming an insulated carton including a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis an end tab hingedly attached to the central portion of the second side panel, wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier which has a higher thermal radiation reflectance than an under-lying layer for energy-insulating the interior space of the carton.

Description

This application claims priority to U.S. Non-Provisional application Ser. No. 16/279,282 filed on Feb. 19, 2019, and U.S. Non-Provisional application Ser. No. 16/791,228 filed on Feb. 14, 2020, which are hereby incorporated by reference in their entirety.

BACKGROUND

Technological Field

The present disclosure relates to insulating blanks for marking cartons and inserts for insulating cartons, and more particularly to blanks and inserts having a reflective barrier.

Description of Related Art

A variety of devices are known in the art for providing thermal protection to products being shipped.
The conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for containers to minimize energy transfer with the outside. There also remains a need in the art for such containers to be economically viable, reusable, and recyclable. The present disclosure may provide a solution for at least one of these remaining challenges.

SUMMARY

A blank for forming an insulated carton includes a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis, an end tab hingedly attached to the central portion of the second side panel, and wherein at least one surface of the blank includes a reflective barrier for energy-insulating the interior space of the carton and the blank defines an interior space of a carton when folded along each hinged attachment. Each of the panels can be different lengths, each of the panels can be of equal widths.
The flap of each panel can be indirectly attached to at one flap of an adjacent panel. The flap of the front panel and the at least one flap of the rear panel can be rectangle shaped, and the at the flap of the first side panel and the flap of the second side panel can be trapezoid shaped.
The end tab can include a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.
The reflective barrier can face the interior space and an outwardly facing surface of the end tab which does not include a reflective barrier can be attached to the reflective barrier of the front panel when the carton is erected. It is also conceived that the end tab can be located on the outside of the carton when assembled.
An insulating insert for a carton includes a frontal layer, including a reflective barrier for energy-insulating the interior space of a carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer, and a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert, wherein the top side and the bottom side each include at least one notch and at least one tab for mating with a second insert or third insert.
The at least one tab of the top side can include two tabs aligned asymmetrically with respect to a length of the top side and the at least one tab of the bottom side can include two tabs aligned asymmetrically with respect to a length thereof. The at least one notch of the top side can also include two notches symmetrically disposed along a length of the top side and the at least one notch of the bottom side can include two notches symmetrically disposed along a length of the bottom side.
A second insert can be detachably attached to a side of the first insert, wherein when the second insert can be detached and the rear layer of the first insert can abuts the rear layer of the second insert. The tabs of the two inserts can be of unequal height.
The reflective barrier of the insert can face an interior space defined if the insert is joined with another five inserts, it is also considered that the reflective barrier faces away from the interior space. The at least one tab of the bottom side of the first insert can interlock with the at least one notch of the top side of the second insert.
A system of inserts for insulating a carton includes a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier, for energy-insulating the interior space of the carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer. The top, bottom, a frontal, a rear, first side, and second side inserts define an interior space when the top, bottom, a frontal, a rear, first side, and second side inserts are mated together. Each of the top, bottom, a frontal, a rear, first side, and second side inserts include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert includes two tabs configured for mating with two notches of a frontal insert and the bottom side of the top insert includes two tabs configured for mating with notches of a rear insert, wherein the frontal insert and the rear insert are wider than the top insert and the bottom insert.
The reflective barrier of the embodiments mentioned above can include an optical density greater than 2.0, can include metalized polyester, and can be laminated to the insert.
The system can further include a thermal regulating device to be placed on the inside of the carton. The thermal regulating device can include an insulated envelope configured to contain a thermal element therein to reduce thermal transfer between the thermal element and the contents of the carto. The insulated envelope can include an outer liner and an insulating material disposed within the outer liner. An amount of the insulating material can be selected to control temperature of the outer liner and/or rate of heat transfer to the thermal element.
In certain embodiments, the liner can include natural and/or synthetic materials, e.g., at least one of paper, a board, a plastic, or nylon. For example, the liner can be a flexible paper liner (e.g., kraft liner). Any other suitable material is contemplated herein.
In certain embodiments, the insulating material can be natural and/or synthetic materials, e.g. cellulose insulation, recycled cellulose insulation, plastic, PET, Styrofoam, etc. For example, the insulating material can be fluff pulp. Any other suitable insulating material is contemplated herein.
In certain embodiments, the thermal regulating device can include the thermal element. For example, the thermal element can be dry ice (e.g., a brick of dry ice disposed within the envelope). Any other suitable thermal element is contemplated herein. In certain embodiments, the envelope can be configured to control a location of where sublimated gas escapes.
The envelope can be configured such that a time to about 31 degrees C. internal temperature of the carton containing the envelope having two pounds of dry ice disposed in the envelope when the carton is consistently exposed to about 40.6 degrees C. is greater than 18 hours.
In accordance with at least one aspect of this disclosure, a package can include a first volume for storing an item to be shipped, and a second volume divided from the first volume by at least one wall, the second volume configured to retain a thermal element to reduce an amount of dead space surrounding the thermal element. The package can include the thermal element (e.g., as disclosed above). In certain embodiments, the second volume is configured to reduce sublimation of the dry ice brick.
A method can include insulating a thermal element within an insulated package, placing the insulated package within the carton to regulate a temperature within the carton for at least a predetermined amount of time. The thermal element can be dry ice, for example. Placing the insulated package can include placing the insulated package at a bottom of the carton. The method can include any other suitable method(s) and/or portions thereof.
In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured such that a time to about 31 degrees C. internal temperature of a carton containing the envelope having two pounds of dry ice disposed in the envelope when the shipping package is consistently exposed to about 40.6 degrees C. is greater than 18 hours.
In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured to contain a thermal element, the thermal regulating device comprising an R factor of greater than about 0.001 ft²·° F.·h/BTU and less than about 10 ft²·° F.·h/BTU. For example, the thermal element can be at least one of dry ice, a gel pack, or a heat source.
In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured to contain a thermal element, the device having a substantially linear gravimetric slope of greater than about −0.19 lbs-dry-ice/hour at an atmospheric temperature of 73 degrees F. In certain embodiments, the gravimetric slope can be about −0.085 lbs-dry-ice/hour at an atmospheric temperature of 73 degrees F. The gravimetric slope in a cooler exposed to 73 degrees F is about −0.067 lbs-dry-ice/hour.
These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject invention appertains will readily understand how to make and use the devices and methods of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;

FIG. 1a is a perspective view of portion la of FIG. 1, showing the reflective layer of the blank.

FIG. 1b is a perspective view of a carton formed from the blank of FIG. 1, showing a carton with open flaps;

FIG. 2 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;

FIG. 2a is a perspective view of portion 2 a of FIG. 2, showing the reflective layer of the blank;

FIG. 2b is a perspective view of a carton formed from the blank of FIG. 2, showing a carton with open flaps;

FIG. 3 is an exploded view of insulating inserts for a carton;

FIG. 4 is a partially exploded view of the insulating inserts of FIG. 5, showing being placed in the carton;

FIG. 5 is a perspective view of an insulating insert of FIG. 3, showing the insert in a pre-folded stage;

FIG. 5a is a perspective view of a detail 5A of FIG. 5, showing connection of the two portions of the insert;

FIG. 5b is a perspective view of an insulating insert of FIG. 5, showing the insert in a folded stage;

FIG. 5c is a perspective view of a detail 5C of FIG. 5b , showing connection of the two portions of the insert;

FIG. 6 is a perspective view of an insulating insert of FIG. 3, showing an insert in a pre-folded stage;

FIG. 6a is a perspective view of an insulating insert of FIG. 6, showing the insert in a folded stage;

FIG. 7 is a perspective view of an insulating insert of FIG. 3, showing an untabbed insert in a pre-folded stage;

FIG. 7a is a perspective view of an insulating insert of FIG. 7, showing the insert in a folded stage;

FIG. 8 is a perspective view of an embodiment of the carton of FIG. 1b in accordance with this disclosure, showing an embodiment of an envelope in accordance with this disclosure disposed within a shipping package having a thermally reflective layer;

FIG. 9 is a perspective view of the embodiment of an envelope of FIG. 1b , shown open at an end thereof and having a thermal element and an insulating material disposed therein;

FIG. 9a is a cross-sectional view of the embodiment of FIG. 9;

FIG. 9b is a cross-sectional view of the embodiment of FIG. 9, shown having a larger thermal element and little to no dead space;

FIG. 10 is a perspective view of an embodiment of a package for containing a thermal element in accordance with this disclosure;

FIG. 11a is a perspective view of an embodiment of a package for containing a thermal element in accordance with this disclosure; and

FIG. 11b is a cross-sectional side view of an embodiment of a shipping packaged in accordance with this disclosure, shown having the package of FIG. 11a disposed therein.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject invention. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a blank for forming an insulated carton in accordance with the invention is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of blanks for forming an insulated carton in accordance with the invention, or aspects thereof, are provided in FIGS. 2-11 b, as will be described. The systems of the invention can be used to increase the insulation of cartons, reduce production costs, and provide better temperature control of shipments.
Referring to FIGS. 1-1 b, a blank 100 for forming an insulated carton includes a front panel 102 hingedly attached to a first side panel 104, the first side panel 104 hingedly attached to a rear panel 106, the rear panel 106 hingedly attached to a second side panel 108 along a longitudinal axis 110 of the blank 100, wherein each panel 102-108 includes a central portion 1020, 1040, 1060, 1080 disposed between and hingedly attached to at least one flap 1021, 1041, 1061, 1081, arranged transverse to the longitudinal axis 110, an end tab 112 hingedly attached to the central portion 1080 of the second side panel 108, and wherein at least one surface of the blank includes a reflective barrier 114, for energy-insulating the interior space the carton, and the blank 100 defines an interior space 116 of a carton when folded along each hinged attachment. The reflective barrier 114 has a higher thermal radiation reflectance than an underlying layer. The reflective barrier 114 attached to the underlying layer by an adhesive. The reflective barrier 114 or film is applied such that it can be removed as a whole or partially. The ability to remove ensures that end-of-the-line users are able to remove the reflective barrier 114 and discard or recycle the carton properly. The reflective barrier 114 uses an adhesive such that it can be peeled off by hand at room temperature and does not require any machinery to so. The following adhesives are considered: formulated water based copolymer emulsions, formulated water based acrylic polymer emulsions, formulated water based vinyl acrylic copolymer emulsions, formulated water based styrene acrylic copolymer emulsions, formulated water based acrylate polymer emulsions, formulated water based pressure sensitive polymer emulsions, formulated water based polyvinyl acetate copolymer emulsions, formulated water based poly(vinyl acetate: vinyl alcohol) emulsions, formulated water based poly(vinyl acetate: ethylene) emulsions, formulated water based rubber polymer and rubber copolymer emulsions, formulated water based styrene butadiene rubber emulsions, formulated water based neoprene dispersions, formulated water based urethane dispersions, solvent based formulations including the polymers previously named, liquid polyurethane adhesives, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt adhesives, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.
The reflective barrier 114 of the embodiments mentioned above include an optical density greater than 2.0, can include metalized polyester, and can also be laminated to the insert. The reflective barrier 114 can include a starting point that enables a user to peel away the reflective barrier 114. The reflective barrier 114 can include a corner that does not include the adhesive and is not attached to the underlying layer. This corner is grabbed and can be used as the start point for peeling away the reflective barrier.
It is further conceived that the reflective barrier 114 can be removed as a whole or in pieces. The reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely in order to make the carton available for recycling and other processing. However, as recycling technology changes and adapts, less of the reflective barrier needs to be removed. The reflective barrier 114 can be attached such that it is substantially, a majority, is removable from the underlying layer. The reflective barrier 114 can include perforations or other divisions that split the layer into multiple parts ensuring that each of the parts can be removed smoothly. The reflective barrier 114 is meant to be removed such that the underlying layer is not damaged or disturbed. When the reflective barrier 114 is removed no more than 10% of the underlying layer need to be disturbed, or removed along with the reflective barrier.
Each of the panels can be different lengths L1-L4, each of the panels can be of equal widths W1. The lengths L1-L4 of the flaps vary in order to accommodate the thickness of the reflective barrier 114. The flap of each panel can be indirectly attached to a flap of an adjacent panel, each of the panels being rectangular.
The reflective barrier 114 can face the interior space 116 and an outwardly facing surface 115 of the end tab 112 which does not include a reflective barrier can be attached to the reflective barrier 114 of the front panel 102 when the carton is erected. The reflective barrier 114, can be used for both keeping energy within the carton and for keeping excess energy from entering from the outside. Also, the panels 102-108 of the blank 100 are folded in such a way so as to minimize the airflow into and out of the carton. The carton can be airtight when folded properly.
Referring to FIGS. 2-2 b, the flaps of the front panel 2021, 2022 and the at flaps of the rear panel 2061, 2062 can be rectangle shaped, and the flaps of the first side panel 2041, 2042 and the flaps of the second side panel 2081, 2082 can be trapezoidal shaped. The end tab 212 can include a central portion 2120 disposed between and hingedly attached to two opposing flaps 2121, 2122 arranged transverse to the longitudinal axis 210. Panels 202 and 206 can be approximately the equal lengths, and panels 204 and 208 can be approximately equal lengths. All panels 202-208 can include differing lengths. The flap of each panel can be at least partially directly attached to a flap of an adjacent panel. It is also conceived that the end tab 212 can be located on the outside of the carton when assembled.
Referring to FIGS. 3 and 4, system of inserts for insulating a carton includes a top insert 302, a bottom insert 304, a frontal insert 306, a rear insert 308, a first side insert, and a second side insert 312. The top 302, the bottom 304, the frontal 306, the rear 308, the first side 310, and the second side 312 inserts define an interior space when the inserts 302-312 are mated together. Each of the top 302, bottom 304, a frontal 306, a rear 308, first side 310, and second side inserts 312 include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert 3021 includes two tabs 320 configured for mating with two notches 322 of a frontal insert 306 and the bottom side 3023 of the top insert 302 includes two tabs 324 configured for mating with two notches 326 of a rear insert 306, wherein the frontal insert 306 and the rear insert 308 are wider than the top insert 302 and the bottom insert 304. The two side inserts 310, 312 can be without locking features. The two side inserts 310, 312 can be shorter than the front 306 and rear 308 inserts, and be less wide than then top 302 and bottom 304 inserts. The tabs 320, 324 and notches 322 of the two inserts are of unequal height, allowing the insert to be locked mated together without a tab 320, 324 protruding past a notch 322.
Referring to FIGS. 5-7 a, each inset includes a frontal layer including a reflective barrier 314 attached to a middle layer 315 including at least one layer of corrugated cardboard and attached to a rear layer 316. The top side of the insert shown in FIG. 5-5 c includes two tabs 320 aligned asymmetrically with respect to a length L9 of the top side. The insert shown in FIG. 5-5 c corresponds to the top 302 and bottom 304 inserts of FIG. 3. The insert shown in FIG. 6-6 a includes two notches 322 symmetrically disposed along a length L12. The insert shown in FIG. 6-6 a corresponds to the front 306 and rear 308 inserts of FIG. 3 The insert shown in FIG. 7-7 a does not include notches, tabs, or other locking features. The insert shown in FIG. 7-7 b corresponds to the first side 310 and the second side 312 inserts of FIG. 3. It is also conceived that the inserts can be arranged to form an interior space without being interlocked by the tabs and notches. The inserts can fit together and be further held in place by the carton.
Referring further to FIGS. 5-7 b a second insert 303 is detachably attached to a side of the first insert 302. The second insert 303 can be attached at a first side. The second insert 307 can be attached at a bottom side. The second insert 303 can be identical to the first insert 302. The second insert 303 is folded such that the rear layer 316 of the first insert 302 abuts the rear layer 316 of the second insert 303. The reflective barrier 314 of each first insert faces the interior space 401, and the reflective barrier 314 of each second insert 303 faces away from the interior space 401. This arrangement ensures that energyloss and gain are limited to the interior space 401. When assembled, the inserts minimize airflow into and out of the interior space. It is also conceived that the reflective barrier 314 faces the exterior, to provide further energy efficiency. The interior space can be airtight when folded the inserts are assemble properly.
It is also considered that the insert system can include a pair of inserts each covering three sides of the insert system. In this embodiment each of the inserts is “C-shaped.” Each insert would include three panels hingedly attached to each other. After a first insert was placed within the carton, the second insert would also be inserted and coupled. These inserts can also couple with each other using the tabbed system described above. This system simplifies assembly by mistake proofing the process by eliminating four assembly steps.
Referring to FIGS. 8 and 9, a package 1100, 1200 can include a thermal regulating device 1101, for example. A thermal regulating device 1101 can include an insulated envelope 1101 a configured to contain a thermal element 1303 therein to reduce thermal transfer between the thermal element 1303 and the atmosphere (e.g., air in a shipping package). The insulated envelope 1101 a can include an outer liner 1105 and an insulating material 1107 disposed within the outer liner 1105. An amount of the insulating material 1107 can be selected to control temperature of the outer liner 1105 and/or a rate of heat transfer to the thermal element 1303 (e.g., from the atmosphere). For example, an amount of insulation in an envelope for ambient applications may be more than for frozen applications, for example (e.g., to ensure sufficient cooling action). As used herein, the term “envelope” can be any suitable enclosure, e.g., a flexible pouch, a rigid box, and/or any other suitable structure.
The liner 1105 can include any suitable natural and/or synthetic materials. For example, in certain embodiments, the liner 1105 can include at least one of paper (e.g., kraft), a board (e.g., paperboard, corrugate), a plastic (a flexible plastic, corrugate), or nylon. For example, the liner 1105 can be a flexible paper liner (e.g., kraft liner) or any other thin sheet material. Any other suitable material is contemplated herein. A thickness of the liner 1105 can be selected to control heat transfer to produce a certain loss of thermal power of the thermal element, for example.
In certain embodiments, the insulating material 1107 can be natural and/or synthetic materials, e.g. cellulose insulation, recycled cellulose insulation, plastic, PET, Styrofoam, etc.
For example, the insulating material 1107 can be fluff pulp (e.g., nonwoven cellulose fibers), e.g., as shown in FIG. 9. For example, embodiments can include a fibrous material as the insulating layer, cellulose fiber insulation, and the liner can be one or more of kraft liner, plastic (e.g., bubble wrap), nylon, and/or corrugated outer casing/liner. Any other suitable insulating material is contemplated herein.
In certain embodiments, the envelope 1101 a can have a pouch shape, e.g., as shown. In certain embodiments, the envelope 1101 a can have individually sized components (e.g., tearable pouches to select a number of thermal packages to use in a given shipping package to control a temperature of the shipping package).
In certain embodiments, the thermal regulating device 1101 can include the thermal element 1303. For example, the thermal element 1303 can be dry ice (e.g., a brick of dry ice disposed within the envelope 1101 a). Any other suitable thermal element 1303 is contemplated herein (e.g., a cold pack, a chemical heater). It is contemplated that each envelope 1101 a and/or each portion thereof can be sold including a fixed amount of dry ice (e.g., in a freezer) and/or can include a metric printed thereon for a user to determine how many envelopes 1101 a or portions thereof to use to achieve a desired cooling effect (temperature and/or length of cooling time below a certain temperature) for a standardized volume of packaging.
In certain embodiments, the envelope 1101 a can be configured to control a location of where sublimated gas escapes (e.g., one or more holes on the bottom of the envelope 1101 a). As shown, the envelope 1101 a can form at least one opening at an end thereof. The at least one opening can be enclosed using any suitable tape, adhesive, or any other suitable enclosure.
The envelope 1101 a can be configured such that a time to about 31 degrees C/87.8° F. internal temperature of a shipping container 1109, 1209 (e.g., a corrugate box, an insulated box) containing the envelope 1101 a having two pounds of dry ice disposed in the envelope when the shipping package (e.g., when enclosing the envelope 1101 a) is consistently exposed to about 40.6 degrees C/105° F. is greater than 18 hours. This is an unexpectedly longer time to failure than traditional packages. As shown in FIG. 1, the shipping container 1109 can include thermal insulation and/or an inner thermal reflective layer 1211. In such a case, the time to about 31 degrees C/87.8° F. can be greater than 24 hours (e.g., 28 hours or more).
In certain embodiments, the thermal regulating device 1101 can include an R value greater than about 0.001 ft²·° F.·h/BTU and less than about 10 ft²·° F.·h/BTU. Any suitable R value to allow a controlled thermal transfer from the thermal regulating device 1101 to a package (e.g., to hold the package at a desired temperature), for example, is contemplated herein. For example, an R value above that of basic plastic sheet packaging (of negligible R value of about 0) for dry ice, and below the R value of a vacuum flask.
As described above, as shown in FIG. 8, in certain embodiments of the outer liner can be composed of an outer kraft liner with an inner fiber-based fiberized layer. Embodiments of a package 1100, 1200 and/or the envelope 1101 a can be a drop-in cooling agent inside a shipping package. In certain embodiments, the package 1100, 1200 can include the shipping container 1109, 1209 having the envelope 1101 a disposed therein. In certain embodiments, the package 1100, 1200 can be the envelope 1101 a alone. FIG. 9 shows an opening of the envelope 1101 a composed of an outer kraft liner with an inner fiber-based fiberized layer encompassing dry ice. As disclosed above, the envelope 1101 a can be sealed from the top by an adhesive, for example. Certain embodiments can be completely sealed, e.g., where not using subliming coolant, but can have some gas path or permeability to allow gas to escape (e.g., to avoid expansion of the envelope). Any suitable arrangement is contemplated herein.
Referring to FIG. 10, and alternative design for an encasement material is shown that can be used as both the encasement layer as well as full or partial insulation within a shipping package. A first C-pad 1401 (e.g., having 3 panels) and a second C-pad (e.g., having a fourth flap configured to fold over a middle panel) can be folded and inserted into a shipping package to provide insulation and retain the thermal element. For example, the extra flap on the second C-pad 403 can fold over and cover a dry ice brick to sandwich the dry ice brick. This extra flap can be adhered, taped, or otherwise attached or sealed to the other panels of the second C-pad to retain and/or seal in the thermal element and reducing or eliminating dead space. This assembly can then be inserted into the shipping container, for example.
Referring to FIGS. 11a and 11 b, a four panel design of encasement material can be used as both the encasement layer as well as full or partial insulation within a shipper, for example. The embodiment of FIG. 11a can be similar to the embodiment of FIG. 4, but instead of a T-shaped structure, the C-pad can have a fourth flap in a line (e.g., with panels 1, 2, 3, and 4, which can be folded over and attached to cover and retain the thermal element. Any other suitable assembly is contemplated herein. Embodiments of a package can include any suitable materials, coatings, and/or components as appreciated by those having ordinary skill in the art for any suitable application (e.g., food transport, medicine transport, etc.).
A method can include insulating a thermal element within an insulated package, placing the insulated package within a shipping container to regulate a temperature within the shipping container for at least a predetermined amount of time. The thermal element can be dry ice, for example. Placing the insulated package can include placing the insulated package at a bottom of the shipping container. The method can include any other suitable method(s) and/or portions thereof.
As described above, embodiments can provide a target temperature based on amount of insulation and/or other thermal properties of material surrounding the thermal element. Embodiments control the flow of heat to/from the coolant/heater to the surrounding package volume. The thermal packaging for a thermal element can be selected (e.g., more or less insulation, thickness of liner, holes in liner and/or insulation) to provide a predetermined heat transfer between the thermal element and the package volume to produce a predetermined temperature range or value in the package volume. Embodiments can reduce heat transfer to the thermal element and greatly extend the life of the thermal element to cool or heat a shipping package volume to the desired temperature range or value.
The methods and systems of the present disclosure, as described above and shown in the drawings, provide for an insulating system with superior properties including increased energy conservation. While the apparatus a of the subject disclosure have been showing and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and score of the subject disclosure.

Claims

What is claimed is:

1. A blank for forming an insulated carton comprising:

a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis;

an end tab hingedly attached to the central portion of the second side panel; and

wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton.

2. The blank of claim 1, wherein the reflective barrier is attached to the underlying layer by an adhesive.

3. The blank of claim 2, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

4. The blank of claim 2, wherein the reflective barrier is substantially removable from the underlying layer.

5. The blank of claim 2, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

6. The blank of claim 1, wherein each of the panels are different lengths.

7. The blank of claim 1, wherein each of the panels are equal widths.

8. The blank of claim 1, wherein the at least one flap of each panel is indirectly attached to the at least one flap of an adjacent panel.

9. The blank of claim 1, wherein the at least one flap of the front panel and the at least one flap of the rear panel are rectangular, and the at least one flap of the first side panel and the at least one flap of the second side panel are trapezoidal.

10. The blank of claim 1, wherein the end tab includes a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.

11. The blank of claim 1, wherein the reflective barrier is configured to face the interior space when the carton is erected.

12. The blank of claim 11, wherein an outwardly facing surface of the end tab does not include a reflective barrier and is attached to the reflective barrier of the front panel.

13. An insulating insert for a carton comprising:

a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer; and

a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert.

14. The insert of claim 13, wherein the reflective barrier is at least partially removably attached to the underlying layer by an adhesive.

15. The insert of claim 14, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

16. The insert of claim 14, wherein the reflective barrier is substantially removable from the underlying layer.

17. The insert of claim 14, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

18. The insert of claim 14, wherein the adhesive includes a formulated water emulsion, a formulated water dispersion, a solvent based formulation, liquid polyurethane, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.

19. The insert of claim 13, wherein the top side and the bottom side each include at least one notch and at least one tab configured for mating with a second insert.

20. The insert of claim 13, wherein the at least one tab of the top side includes two tabs aligned asymmetrically with respect to a length thereof and the at least one tab of the bottom side includes two tabs aligned asymmetrically with respect to a length thereof.

21. The insert of claim 13, wherein the at least one notch of the top side includes two notches symmetrically disposed along a length thereof and the at least one notch of the bottom side includes two notches symmetrically disposed along a length thereof.

22. The insert of claim 13, further comprising a second insert detachably attached to a side thereof, wherein when the second insert is detached and the rear layer of the first insert abuts the rear layer of the second insert.

23. The insert of claim 22, wherein the tabs of the two inserts are of unequal height.

24. The insert of claim 13, wherein the reflective barrier of the insert faces an interior space defined by the insert being joined with another five inserts.

25. The insert of claim 13, wherein the reflective barrier of the insert faces away from an interior space by the insert being joined with another five inserts.

26. The insert of claim 25, wherein the at least one tab of the bottom side interlocks with the at least one notch of the top side.

27. A system of inserts for insulating a carton comprising:

a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer;

the top, bottom, a frontal, a rear, first side, and second side inserts defining an interior space when mated together;

wherein each of the top, bottom, a frontal, a rear, first side, and second side inserts includes a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof.

28. The system of claim 27, wherein the reflective barrier is at least partially removably attached to the underlying layer by an adhesive.

29. The system of claim 28, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

30. The system of claim 28, wherein the reflective barrier is substantially removable from the underlying layer.

31. The system of claim 28, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

32. The blank of claim 1, wherein the reflective barrier includes an optical density greater than 2.0.

33. The insert of claim 13, wherein the reflective barrier includes a polyester film.

34. The blank of claim 1, wherein the adhesive includes a formulated water emulsion, a formulated water dispersion, a solvent based formulation, liquid polyurethane, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.