WO2014147425A2

WO2014147425A2 - Packaging

Info

Publication number: WO2014147425A2
Application number: PCT/GB2014/050912
Authority: WO
Inventors: Richard Wood; Sean James AUSTERBERRY
Original assignee: Peli Cool Logistics Limited
Priority date: 2013-03-22
Filing date: 2014-03-24
Publication date: 2014-09-25
Also published as: WO2014147425A3; GB2513106A; GB201305308D0

Abstract

Thermally insulating packaging 2 comprises an outer shell 4 made from a foldable sheet material and a plurality of thermal conditioning panels 6 arrangable within the outer shell in a first, erected, configuration to define a payload space for a product and in a second, collapsed configuration. The outer shell 4 is foldable closely to surround the panels 6 in both their first and second configurations.

Description

PACKAGING The present invention relates to packaging and in particular to thermally insulated packaging.

It is frequently desirable to transport goods in a thermally controlled environment. For example, medical materials commonly have to be maintained within a predetermined temperature range during transport. This may include, for example, frozen tissue, which may typically have to be maintained between -15°C and -25°C, and vaccines and pharmaceuticals which may typically have to be maintained at room temperature, for example +15°C to +25°C or at refrigerator temperature, for example +2°C to +8°C.

One form of packaging which has been used in this context comprises an outer container having a cardboard outer body and vacuum insulated panels attached to the outer body. A plurality of removable, interlocking panels containing a phase change material are arranged within the space defined by the vacuum insulated panels to create a payload receiving space. Such phase change panels are available commercially, for example from the Applicant, and an appropriate phase change material is chosen for the particular temperature required. The product is then loaded into the payload space, which is closed by a top phase change panel, and the outer container then closed over the top phase change panel

Once the product has been transported to its destination, the outer container is opened, the top phase change panel removed and the product removed. The packaging may be re-used after appropriate cleaning and re-conditioning of the phase change panels. This is particularly desirable as the packaging components, for example the vacuum insulated panels and the phase change panels are relatively expensive. For this purpose, the whole container may be returned to the manufacturer, which is cumbersome. Also, the outer container is subject to greater wear and tear than the inner, phase change panels, so it is sometimes the case that the outer container cannot be re-used, in which case it may be re-cycled. The phase change panels can, however, still be used, and users are encouraged to return the panels to the package manufacturer for refurbishment. However, this is inconvenient for the user, and many serviceable panels are often simply wasted.

The present invention seeks from one aspect to address this problem. From a first aspect, therefore, the present invention provides thermally insulating packaging comprising: an outer shell made from a foldable sheet material; a plurality of thermal conditioning panels arrangable within the outer shell in a first, erected, configuration to define a payload space for a product and in a second, collapsed configuration, wherein the outer shell is foldable to enclose the panels in both their first and second configurations.

In accordance with this aspect of the invention, therefore, thermal conditioning panels, for example panels containing a phase change material, are arranged within an outer shell of a foldable sheet material in an erected or a collapsed configuration, for example a horizontally stacked configuration. In the erected configuration the outer shell is foldable into a first configuration around the panels to close the packaging and support the panels. In the collapsed configuration, the outer shell is foldable into a second, smaller configuration effectively to form a package around the collapsed panels. This package can then be used to store or transport the panels in their collapsed configuration.

This is advantageous as the same outer shell can be used both to surround and support the panels in their erected configuration and also to transport the "knocked down" panels either from the user back to the manufacturer for re-use or re- conditioning or indeed for transporting the panels to a user from the manufacturer.

The second configuration of the outer shell will be smaller than its first, as the collapsed volume of the panels will be smaller than their erected volume. The outer shell preferably closely surrounds the panels in the respective configurations.

In the case where the outer shell is used to send panels to a user, the user may open the package, remove the panels and reposition the panels in an erected configuration either into the outer shell in which the panels were supplied, or into a similar outer shell, such that the container so formed provides a payload space. In the case where the user returns the panels to the manufacturer for re-use or refurbishment, the user may, upon removing the payload from the thermally isolated chamber formed by the panels, simply reposition the panels in the or a similar outer shell in their collapsed configuration, and fold the outer shell around the collapsed panels. This package may then be shipped back to the manufacturer. To facilitate and encourage this, a return address, for example a pre-paid postage label, may be pre-printed or affixed to the outer shell. Alternatively, the reconfigured package may be used simply to store the panels in a space efficient manner.

From a second aspect, therefore, the invention provides a method of re-using thermally insulating packaging, which packaging comprises a shell of a foldable sheet material and a plurality of thermal conditioning panels arrangable within the shell in a first , erected configuration in which the panels define a payload space and in a second collapsed condition, comprising: opening the packaging; removing the panels from the shell in one of the first or second configurations and replacing the panels in the shell or a similar shell in the other of the first or second

configurations.

The outer shell may then be folded as necessary to enclose the panels in that other configuration.

By "similar" in this context is meant a shell which of the same design. Thus in accordance with the invention, the panels need not be replaced in the very same outer shell as the one from which they were originally removed, but simply in one of the same design.

Typically the shell and the panels will be erectable into a cuboid. Thus for example the package may comprise a cuboidal outer shell and for example six panels erectable within the shell. The panels may, as is known, be provided with interlocking formations, for example chamfered edges to facilitate their erection within the outer shell.

The package can be placed in an outer container to provide additional support and insulation. For example it may be placed in a container as discussed above having an outer body and vacuum insulated panels. However that is not the only possible arrangement. In another arrangement, the package could simply be placed in a pre-formed box, for example a pre-formed insulated foam box. In another embodiment the outer container may comprise an outer body, for example of corrugated board or corrugated plastics and a moulded foam body or panels of insulating foam, for example expanded polystyrene or polyurethane, arranged within the outer box, for example attached to the walls or arranged loose within the box. The components of this outer container are relatively inexpensive (compared to the vacuum insulating panels discussed above) and can easily be recycled.

However it is not essential that the package is arranged within an outer container. The outer shell of the package will provide some support for the thermal

conditioning panels and also some thermal insulation, so the package may be used as a stand-alone package, i.e. one which is not placed within an outer container.

Also, as the package supports the thermal conditioning panels, it may be used to allow the panels to be stored, or cooled or heated to their desired conditioning temperature in the package before the package is placed into an outer container. For example, the panels may be stored or conditioned in either configuration, with or without the product. This will allow, for example, the product to be loaded into the package, thermally conditioned and the package then either placed into the outer container (which is potentially less cumbersome than having to erect the panels in the outer container and then pack the product) for shipping or shipped.

The outer shell is advantageously formed from a corrugated material, for example a corrugated board material or a corrugated plastics material for example Correx^®. This material will provide strength and some insulative properties.

The outer shell may, if desired, incorporate additional thermal insulation material. For example, if the outer shell material is a corrugated material as discussed above, insulating material may be filled in the flutes of the corrugated material to improve its thermal insulation.

As discussed above, the outer shell of the package is formed from a foldable sheet material. This allows the outer shell to be closely received around the panels in their two configurations. In one embodiment, the outer shell may comprise opposed pairs of top flaps, hingedly attached to respective wall panels. The walls panels are of such a height as to extend over the height of the panels in their collapsed configuration. The respective flaps may be of such a height that they will extend substantially over the height of the panels when the panels are in their erected configuration. Moreover, at least one of the pairs of flaps may be formed with one or more intermediate fold lines which will allow an upper portion of that pair of flaps to be folded over the top of the thermal conditioning panels when they are arranged in the erected condition to close the top of the package.

In one embodiment, the respective pairs of flaps may be of the same height and optionally provided with one or more intermediate fold lines, such that both pairs can be folded over the top of the erected panels. However, in a preferred arrangement, the flaps of one pair are shorter than the flaps of the other pair and preferably have no intermediate fold line such that these flaps cannot be folded over the top of the erected thermal conditioning panels. This may make it easier to fold the flaps over the collapsed panels in the other configuration by reducing the number of board thicknesses.

The flaps and/or walls of the outer shell may be provided with suitable tabs, slots or other locking elements means to retain the outer shell in any given configuration, particularly the collapsed configuration.

The invention also extends to a blank for making the outer shell of packaging as described above. Some preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a first embodiment of package in a first configuration; Figure 2 shows the package of Figure 1 in a second configuration;

Figure 3 shows an exploded view of the package of Figure 1 ;

Figure 4 shows a second exploded view of the package of Figure 2; Figure 5 illustrates a blank for making the outer shell of the package of Figures 1 and 2;

Figures 6A to 6G show the stages in the formation of the package and container above;

Figure 7 shows the package of Figure 1 and 2 being received in an outer container; Figure 8 shows a horizontal section through the assembled container of Figure 7;

Figure 9 shows a vertical section through the assembled container of Figure 7; Figure 10 shows a second embodiment of package in a first configuration; Figure 11 shows the package of Figure 10 in a second configuration; Figure 12 shows the package of Figure 10, with its top open; and Figure 13 shows an exploded view of the package of Figure 10.

With reference to Figures 1 to 4, an embodiment of package 2 in accordance with the invention is illustrated which comprises an outer shell 4 of a foldable sheet material and a plurality, in this case six, thermal conditioning panels 6. In this embodiment, the outer shell 4 is made from a foldable corrugated plastics material, for example Correx^®. The panels 6 contain a phase change material, as is known in the art. The panels 6 are square in section and have chamfered edges 8, for reasons discussed below. As illustrated in Figures 3 and 4, the panels 6 are receivable in the outer shell 4 in two configurations.

In the first configuration shown in Figures 1 and 3, the panels 6 are illustrated in an erected condition, in which the panels 6 are closely received in the outer shell 4 and interlock at their chamfered edges 8 to form a cubic, thermally isolated payload chamber 10. In the second configuration, shown in Figures 2 and 4, the panels 6 are in a collapsed, configuration in which they are stacked one upon the other.

The outer shell 4 is made from a blank 12 of foldable corrugated plastics sheet illustrated in Figure 5. The outer shell 4 has a base 14 made up by two bottom flaps 16, four side walls 18, and first and second pairs of opposed top flaps 20, 22 hingedly connected to the upper edges of the side walls 18. The side walls 18 are rectangular and all of substantially the same size. Their width is approximately twice their height, although this may vary depending on the package volume. When erected they provide a square cross section. A glue tab 24 is attached to one of the side walls 18 for hold the outer shell 4 in an erect configuration.

Each flap 20 of the first pair is approximately twice the height of the flaps 22 of the second pair and is formed with an intermediate fold line 26 which is generally aligned with the upper edge 28 of the flaps 22 of the second pair. This splits the flaps 20 into lower and upper portions 30,32.

It will be seen from Figure 1 , in the first configuration, the side walls 8, the lower portions 30 of the longer flaps 20 and the shorter flaps 22 form the sides of the package 2. In addition, the upper portion 32 of each longer flap 20 is folded over the top of the top most panel 6, to form the top of the package 2.

As will be seen from Figure 2, in the second configuration, the side walls 8 form the sides of the package 2 while the shorter flaps 22 and the longer flaps 22 are both folded over the stack of panels 6 to form the top of the package 2. In this configuration, therefore, the package 2 is smaller than the package 2 in the first configuration. The various walls and flaps of the outer shell 4 closely surround the collapsed panels 6. The various stages in the construction and use of the package of Figure 1 will now be described with reference to Figure 6A to 6G.

In the arrangement discussed with reference to Figures 6A to 6C, the package 2 is being used to deliver the panels 6 to a user. Thus as a first step, illustrated in Figure 6A, the manufacturer packs a stack of six panels 6 in a horizontal configuration into an outer shell 4 whose bottom flaps 16 are closed in an appropriate manner. Once the panels 6 are received within the outer shell 4, the shorter flaps 22 are folded over the top most panel 6T as illustrated by arrow A. The longer flaps 20 are then folded sequentially over the shorter flaps 22 as illustrated by arrows B and C in Figure 6B and secured in position either by locking tabs or similar or by separate means such as one or more straps (not shown). The outer shell 4 closely surrounds the collapsed panels 6 in this configuration. In the condition shown in Figure 6C, the package can then be posted to the user.

When received by the user, the user may place the package 2 in a temperature controlled environment in order to condition the panels 6 to the appropriate temperature. When the user wishes to use the package 2, he or she may remove the package 2 from the temperature controlled environment, fold back the flaps 20, 22 and remove the panels 6 from the outer shell 4 and allow the panels 6 to temperature stabilise in accordance with the manufacturer's guidelines.

The panels 6 can then be put back into the outer shell 4 in their erected

configuration as illustrated in Figure 6D. To do this, the flaps 20, 22 are folded to at least an upright position and a bottom panel 6B and four side panels 6S placed within the outer shell 4. The chamfered edges 8 of the panels 6 facilitate their interengagement. Then, as illustrated in Figure 6E and 6F, a product may then be placed within the payload chamber 10 formed by the panels 6, the top panel 6T inserted to close the chamber 10, and the upper portions 32 of the longer flaps 20 then folded over the top of the panel 6T as illustrated by arrows D to close the package 2 as shown in Figure 6G. The outer shell 4 also closely surrounds the erected panels in this configuration.

In this condition, the package 2 may be used to transport the product, if the outer shell 4 and panels 6 provide sufficient strength and thermal insulation for the product. In that event, the flaps 20, 22 may be held in position by suitable tabs, fasteners or external closures such as straps .

When the customer receives the package, he or she may unload the package 2 by reversing the steps above. He or she can then reuse the package 2, should they so wish, or return the panels 6 to the supplier or manufacturer for refurbishment by essentially following the steps described above with reference to Figures 6A to 6C. The panel supplier or manufacturer may offer to pay the customer an agreed sum per panel or panel set in order to encourage their return. To facilitate the return, the package may be provided, either integrally or separately, with a prepaid postage label 34 as illustrated in Figure 2.

However, as discussed above, the package 2 may itself be placed within an outer container to provide additional strength and/or insulation. Figures 7 to 9 illustrate such an embodiment.

With reference to Figure 7, the package 2 is shown being placed into an outer container 36. The outer container 36 comprises a corrugated board or corrugated plastics outer body 38 insider which is received thermal insulation 40. The thermal insulation 40 may comprise vacuum insulated panels as is known in the prior art, but preferably the insulation 40 is a foam or expanded bead material such as expanded polystyrene or polyurethane. Such materials are relatively inexpensive and can be easily recycled.

The insulation 40 may be a pre-shaped component, for example as illustrated in Figures 7 and 9. In this embodiment, the insulation 40 comprises a one piece body portion 42 and a lid 44. The body portion 42 and lid 44 are located relative to each other by means of a tongue and groove or other locating formation 46.

Alternatively, the insulation may comprise one or more panels which are assembled in the outer body 38 in situ.

As illustrated in Figure 7, the closure flaps 48 of the outer body 38 can then be closed over by folding as indicated by arrow E and the container 36 shipped to a customer. When received by the customer, he or she may remove the product from the inner package 2 (with the inner package 2 still arranged within the outer container 36, or after it has been removed therefrom) is removed and send back the entire container to the user or manufacturer. However, it may be simpler and more cost effective to recycle the components of the outer container 36 and return only the panels 6 to the manufacturer. To this end, the customer can pack the panels 6 back into the outer shell 4 of the package 2 (or a similar package) in the collapsed configuration as in the embodiment described above and return the package 2 including the panels 6 to the manufacturer.

In another arrangement, the inner package 2 may be removed from the outer container 36 and then used to transport the product further. For example the container 36 with the inner package 2 could be transported to a depot where the inner package is removed, possibly stored until delivery is required, and then used for that delivery. This may be advantageous as the inner package 2 will not take up as much space on a delivery vehicle as the container 36. This may be useful for local deliveries, for example.

It will be understood from the above that the present invention not only provides a simple form of packaging but an improved system by which potentially expensive thermal conditioning panels may be returned to a manufacturer for refurbishing or reuse. It also allows the panels to be handled and stored more easily, as the panels can be stored or conditioned in sets in the outer shell, rather than individually. In the collapsed configuration, the packaging adopts a smaller size than in the erected configuration, allowing for more efficient storage, handling etc.. In the embodiments described this is facilitated by the formation of appropriate fold lines in the blank 12 of the outer shell 4, facilitating the folding of the outer shell 4 into its erected and collapsed configurations.

It will also be appreciated that changes and modifications may be made to the embodiments described above without departing from the scope of the claims. For example, while a cubic package has been described, other shapes of package are contemplated within the scope of the invention. For example packages with rectangular, rather than square sections are possible. An example of such a package is described with reference to Figures 10 to 13. In this embodiment, the package 2 is rectangular in horizontal cross section with opposed side walls 8a being longer than opposed side walls 8b. The lower portions 30 of the flaps 20 attached to the longer side walls 8a are of such a height that in the erected configuration shown in Figures 10 and 13, the longer sides of the package 2 have substantially the same dimensions as the package base 14. The upper portions 32 of the flaps 20 may be of such a height that they will meet when folded over in the closed configuration shown in Figure 10.

The flaps 22 are of the same height as the lower portions 32 of the flaps 20. In this case, that means that when folded over in the collapsed configuration of the package shown in Figure 11 , they may overlap one another by a small amount as shown.

In this embodiment, the panels 6 will be of different sizes. In particular the top and bottom panels 6T , 6B, and two wall panels 6A are all of the same size, but two wall panels 6C are smaller as they have a shorter width as they will be received along the shorter walls 8b. This is shown quite clearly in Figures 12 and 13.

Apart from these differences, the package 2 can be used in the same manner as described with the reference to the first embodiment.

It will be understood from the above that the invention can be adapted to provide different volumes of different shapes by simply changing the dimensions of the panels and the shell.

Also, while corrugated plastics are preferred as the material of the outer shell of the package and outer container, other foldable sheet materials such as corrugated board may be used.

Claims

1. Thermally insulating packaging comprising:

an outer shell made from a foldable sheet material;

a plurality of thermal conditioning panels arrangable within the outer shell in a first, erected, configuration to define a payload space for a product and in a second, collapsed configuration;

wherein the outer shell is foldable to enclose the panels in both their first and second configurations, the volume of the folded outer shell being larger in the first configuration than in the second configuration.

2. A method of re-using packaging, which packaging comprises an outer shell of a foldable sheet material and a plurality of thermal conditioning panels arrangable within the shell in a first, erected configuration in which the panels define a payload space and in a second, collapsed configuration, the method comprising: opening the packaging;

removing the panels arranged in one of the first or second configurations from the outer shell; and

replacing the panels in the or a similar outer shell in the other of the first or second configurations.

3. The method of claim 2 further comprising folding the outer shell around the panels in the other of the first and second configurations after replacing the panels, the outer shell having a larger volume in the first configuration than in the second configuration.

4. The method of claim 2 or 3 wherein the package is used to send a recipient panels in the collapsed configuration, and wherein the recipient opens the package, removes the panels and reinserts the panels into the outer shell the erected configuration.

5. The method of claim 2, 3 or 4 wherein the packaging is used to transport a payload arranged within the payload space defined by the panels in the erected configuration, and wherein after removing the payload from the thermally isolated chamber, the panels are replaced in the or a similar outer shell in the collapsed configuration.

6. The method of claim 5 wherein the reconfigured package is sent to a manufacturer for reuse or refurbishment.

7. The method of any of claims 2 to 6 wherein an address label, in particular a pre-paid postage label, is included with or on the package.

8. The method of any of claims 2 to 7 wherein the reconfigured package is used to store, condition or transport the panels.

9. The packaging or method of any preceding claim wherein the outer shell closely surrounds the panels in the first and second configurations.

10. The packaging or method of any preceding claim wherein the outer shell and the panels are erectable into a cuboid.

1 1. The packaging or method of any preceding claim wherein the panels are provided with interlocking formations to facilitate their erection within the outer shell.

12. The packaging or method of any preceding claim wherein the packaging is received in an outer container.

13. The packaging or method of claim 12 wherein the outer container comprises an outer body and a moulded body of insulating material or panels of insulating material arranged within the outer body.

14. The packaging or method of claim 13 wherein the outer body is made from a corrugated board or corrugated plastics material and/ or wherein the insulating material is expanded polystyrene or polyurethane.

15. The method of claims 12, 13 or 14 wherein the thermal conditioning panels are stored, cooled or heated to a desired conditioning temperature in the

packaging.

16. The packaging or method of any preceding claim wherein the outer shell of the packaging is made from a corrugated material.

17. The packaging or method of claim 16 wherein the corrugated material is a corrugated plastics material.

18. The packaging or method of any preceding claim wherein the outer shell incorporates thermal insulation material.

19. The packaging or method of claim 18 as dependent upon claim 16 or 17, wherein insulating material is provided in the flutes of the corrugated material.

20. The packaging or method of any preceding claim wherein:

the outer shell is formed with a plurality of fold lines which permit the outer shell to be folded around the panels in either their erected or collapsed

configurations.

21. The packaging or method of claim 20 wherein:

the outer shell comprises opposed pairs of top flaps, hingedly attached to respective wall panels;

the walls panels are of such a height as to extend over the height of the panels in their collapsed configuration;

the respective flaps are of such a length that they will extend from the wall panels substantially to the height of the panels when the panels are arranged in their erected configuration; and

the flaps of at least one of the pairs of flaps is formed with one or more intermediate fold lines which will allow that pair of flaps to be folded over the top of the thermal conditioning panels when they are arranged in their erected condition.

22. The packaging or method of claim 21 wherein the flaps of one pair are shorter than the flaps of the other pair.

23. The packaging or method of claim 22 wherein the shorter flaps have no intermediate fold lines.

24. The packaging or method of claim 22 or 23 wherein an intermediate fold line of the longer flaps is aligned with the upper edge of the shorter flaps.

25. The packaging or method of any preceding claim wherein the outer shell comprises tabs, slots or other locking elements to retain the outer shell in a chosen configuration.

26. A blank of foldable sheet material for forming the outer shell of the packaging of claim 21 comprising:

a row of wall panels; and

an array of top flaps, hingedly attached to the upper edge of the wall panels, said array comprising a pair of longer flaps and a pair of shorter flaps; wherein: the longer flaps are each formed with an intermediate fold line aligned substantially with the upper edges of the shorter flaps.

27. The blank of claim 26 wherein the shorter flaps have no intermediate fold lines.