WO2019113453A1

WO2019113453A1 - Insulated package and method

Info

Publication number: WO2019113453A1
Application number: PCT/US2018/064489
Authority: WO
Inventors: Craig L. LENART; Robert C. Cheich; Dennis J. Wagner
Original assignee: Ranpak Corp.
Priority date: 2017-12-08
Filing date: 2018-12-07
Publication date: 2019-06-13

Abstract

An insulated, double-wall bag (10) includes an insulating material (20) sandwiched between inner (14) and outer (12) layers. The inner and outer layers may be made of a suitable sheet material, such as kraft paper. The inner (14) and outer (12) layers may, when necessary for moisture protection, be provided with a water-resistant liner or water- resistant coatings. The insulating material (20) may be fully retained between the outer bag and the inner bag, such that the insulating material cannot be accessed absent a disassembly or destruction of one or both of the inner bag or the outer bag. The materials and coatings added to this product can be processed in standard curbside recycling programs with no additional actions required by the end user to separate the components of the bag.

Description

INSULATED PACKAGE AND METHOD

Related Applications

This application claims the benefit of U.S. Provisional Patent Application No. 62/596,551 , filed December 8, 2017.

Field of the Invention

The present invention relates to an insulated package for short-term temperature-control delivery.

Background

Ready-to-use, one-way packages for shipping and delivery, such as padded envelopes, are known. Items to be shipped are placed in the container, mailed or otherwise shipped to the buyer, and discarded following removal of the items. These packages generally have a relatively small internal volume, however, so for larger items a cardboard box and associated dunnage materials provide a durable shipping container as a preferable alternative.

To date, though, no known ready-to-use packages that provide thermal insulation are available in the marketplace for larger items.

Summary

The present invention provides a ready-to-use package for one-way shipping and delivery that provides thermal insulation and is readily recyclable, including, in some embodiments, no disassembly being required by the recipient prior to recycling The package is composed of materials that are recyclable, reusable, and composed of a renewable resource, namely, paper.

The following paragraphs paraphrase the claims.

More particularly, the present invention provides a container for temperature- controlled transport that includes an outer bottom wall with an outer perimeter, and one or more outer side walls attached to and extending upwardly from the perimeter of the outer bottom wall, an inner liner layer having one or more inner side walls defining interiorly thereof an interior volume for receiving one or more articles for temperature-controlled transport, and a cellulose insulation material interposed between the outer side walls and the inner side walls.

The outer side walls may be made of a single-ply cellulose sheet, and the cellulose sheet may have an outer surface exposed to the exterior and an inner surface in contact with the cellulose insulation material.

Upper edge portions of the inner side walls may be joined to upper edge portions of the outer side walls to contain the cellulose insulation material between the inner side walls and the outer side walls.

The container also or alternatively may be configured for erection from a flat configuration to an expanded configuration taking up a larger volume than the flat configuration.

The cellulose insulation material may be connected to respective adjacent inner and outer side walls.

The cellulose insulation material also may have variable thickness.

The cellulose insulation material may be fully retained between the inner liner layer and one or more of the outer bottom wall and one or more of the outer side walls.

The inner liner layer and the outer liner layer may be attached to one another at a plurality of spaced apart locations.

Portions of the cellulose insulation material interposed between the outer side walls and the inner side walls may be separated from one another by one or more attachment locations of the inner liner layer to the outer liner layer.

The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and annexed drawings setting forth in detail certain illustrative embodiments of the invention, these embodiments being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.

Brief Description of the Drawings

FIG. 1 is a schematic perspective view of an exemplary package provided in accordance with the present invention.

FIG. 2 is a schematic cross-sectional view of a portion of the package of FIG.

1 .

Detailed Description

As mentioned above, the present invention provides a ready-to-use package for one-way shipping and delivery that provides thermal insulation. The package may be composed of materials that are recyclable, reusable, and composed of a renewable resource, namely, paper. The package preferably is readily recyclable as a unit, meaning that the recipient does not have to disassemble all, or potentially any in some embodiments, of the components of the package to prepare it for recycling.

Package generally, benefits and advantages

Referring now to FIG. 1 , an exemplary ready-to-use package 10, also herein referred to as a container or a bag, provided by the invention includes an outer bag 12 having a bottom wall and one or more upright side walls bounding the bottom wall and extending upward from a common side of the bottom wall. The side walls cooperate with the bottom wall to define an enclosed volume. For filling purposes, one side of the package, such as a top side, opposite the bottom wall, may be open. For transport and delivery, however, the open end of the package typically will be closed to secure the items in the package and to maintain a more uniform internal temperature environment.

In some embodiments, the outer bag 12, also herein referred to as an outer layer, may include a top wall attached to an edge of at least one of the side walls, such that the top wall may be an extension of one of the side walls, extending upward from the common side of the bottom wall to a height that is a greater distance than a corresponding height of another side wall. A pre-formed fold line or crease may be present and may visually separate the top wall from the at least one of the side walls.

Outer bag, shape and materials

The outer bag 12 is made of a single-ply recyclable material suitable for protecting the contents during handling, transport, and weather. Consequently, the outer bag may be made of a durable material, such as a heavy basis-weight paper, for example, fifty-pound kraft paper. Other alternatives include paperboard, press board, cardboard, or other recyclable sheet materials. The material may be stiff or flexible. The outer bag 12 may have a round or rectangular cross-sectional shape, and any of the bottom, top, or side walls may be planar or have a predefined shape. Fold lines may be pre-formed in the outer bag to facilitate storage and transport of the bag in a flat configuration and to facilitate erection to an expanded configuration that occupies a larger volume than the flat configuration when ready for use. The outer bag 12 may be provided with a protective coating, for example a water-resistant coating such as wax or other recyclable-material coating, to resist damage from handling, transport, and weather.

Inner bag

Within the outer bag 12, the ready-to-use package provided by the invention includes an inner bag 14, also herein referred to as an inner liner layer. The inner bag 14 is smaller than the outer bag 12 and is configured to be supported spaced from the outer bag 12. For example, when expanded, the inner bag 14 may have a smaller footprint than the outer bag 12. The inner bag 14 defines interiorly thereof an interior volume 16 for receiving one or more articles. The inner bag 14 includes a number of side walls that extend upwardly relative to the bottom wall of the outer bag 12. Where suitable, the inner bag 14 may include a number of side walls that is less than, equal to, or greater than the number of side walls of the outer bag 12.

The inner bag 14 may or may not include an inner bag bottom wall from which the inner bag side walls extend upwardly. Where the inner bag 14 does include a bottom wall, the inner bag side walls extend upwardly from the bottom wall. Where the inner bag does not include a bottom wall, portions of the inner bag side walls, such as bottom portions, may be attached to one or both of the bottom wall of the outer bag 12 or the side walls of the outer bag 12. For example, bottom portions of the inner bag side walls may be attached to bottom portions of the outer bag side walls on an internally facing side of the outer bag side walls.

In some embodiments, an inner bag side wall may be attached to the outer bag at two or more locations which are spaced apart from one another. For example, both a top portion and a bottom portion of the inner side walls may be attached to corresponding top and bottom portions of the outer side walls. In other embodiments, inner and outer bag walls may be attached to one another at a plurality of locations to form two or more pockets between the inner and outer bag walls that are spaced from one another by the attached locations. Accordingly, one or more walls of the inner bag 14 may be spaced from, such as inwardly spaced from, one or more corresponding walls of the outer bag 12, such as forming a pocket between the inner bag 14 and the outer bag 12 for receipt of an insulating material therein.

The inner bag 14 and the outer bag 12 may be attached by any suitable manner, such as adhesive, mechanical fasteners such as staples, etc.

The outer bag and the inner bag are each composed of a sheet material that is recyclable, reusable, and composed of a renewable resource, such as paper but may be composed of different materials or material weights. Kraft paper is an exemplary material for use in the package provided by the invention. The inner bag may be provided with a water-resistant coating, such as wax or other recyclable-material coating to resist damage from condensation. The height, width, or length dimensions of the package may be independently adjusted to provide packages suitable for shipping the desired product. Insulating material

The package further includes an insulating material 20 between the outer bag 12 and the inner bag 14, preferably an insulating material that also is recyclable, re usable, and composed of a renewable resource. An exemplary insulating material is a cellulose insulation material, and may include loose fill cellulose materials, shredded cellulose materials, crumpled cellulose materials, expanded cellulose fibers, tissue paper, creped paper, crumpled paper pads, expanded slit-sheet stock material, provided in one or more layers, etc. The cellulose may include cotton fibers. The cellulose insulating material may be provided as a single layer or in multiple layers, with different materials or densities of material in different layers or in different portions of the bag. An exemplary cellulose material includes paper or paper fluff. Paper fluff is a cellulose material that has been hammer milled, and which is referred to in the industry alternatively as paper fluff or fluff pulp. Typical insulation

thicknesses may include 0.5 inch (1.27 cm), 0.75 inch (1.9 cm), 1 inch (2.54 cm), 1.5 inch (3.81 cm), or similar.

The cellulose insulating material may include paper packaging materials, such as cushioning pads or other protective pads. These pads may be positioned between the walls of the outer bag and the inner bag to provide separation and air pockets that provide insulating capabilities.

Ideally, the insulating material 20 may be fully retained between the outer bag 12 and the inner bag 14, such that the insulating material 20 cannot be accessed absent a disassembly or destruction of one or both of the inner bag 14 or the outer bag 12. For example, the inner bag 14 may be sealed to the outer bag 12 about a periphery of the open end of the package. In particular, upper edge portions of the inner side walls may be joined to upper edge portions of the outer side walls to contain the cellulose insulation material between the inner side walls and the outer side walls.

Where the inner bag 14 and outer bag 12 are attached to one another at a plurality of spaced apart locations, insulating material 20 may be retained between the inner bag 14 and the outer bag 12 in the pockets formed between the inner bag 14 and the outer bag 12.

Each of the top, bottom, and one or more sides of the package 10 may generally have a uniform or same maximum thickness, for example as measured at a center of the top, bottom, and one or more sides. In some embodiments, any of the top, bottom, or one or more sides may have a different thickness than the other of the top, bottom, or other of the one or more sides. In some embodiments, insulating material 20 may be omitted from one or more of the top, bottom, or one or more sides of the package 10, but from less than all of the top, bottom, and one or more sides.

In some embodiments, the walls of the inner and outer bags and the cellulose insulating material may be provided in the form of pre-formed panels that can be joined together to provide the insulating container.

Closure

A closure mechanism may be provided for closing the open end of the package 10, such as by bringing opposing sides of the open end together to form multiple layers and then folding the multiple layers several times and securing the folded portions in place, such as with staples or an adhesive product. For example, a double-sided adhesive tape may be pre-positioned on an outer side wall of the package with a removable release liner covering the adhesive tape until ready for use. The means for closing the package 10 is not limited to use of double-sided tape. A flexible metal element, such as is commonly used to close coffee bags, may be a suitable alternative in some situations. Mechanical clips may be another suitable alternative. In some embodiments, the top side of the outer bag 12 may overlap one or more of the side walls when the open end of the package 10 is closed, at least partially sealing the internal volume 16 from an environment external to the package 10.

Ideally, the insulating material 20 and closure mechanism for the package 10 provide temperature control for a period in the range of about one hour to about twenty-four hours or more for perishable products which need to either remain below (cold) or above (hot) a predetermined temperature. An added source of heating or cooling may be provided in the package 10, such as in the interior volume 16 with the items being delivered to help maintain the desired temperature. In some

embodiments, the added source may be provided between the inner bag 14 and the outer bag 12. The desired temperature may be a minimum or a maximum

temperature or an average temperature, for example. The items being shipped additionally or alternatively may be pre-heated or pre-cooled to help maintain the desired temperature within the package 10.

The package 10, and the illustrated embodiment also may be described as an insulated, double-wall bag 10 with an insulating material 20 sandwiched between the inner and outer layers 14 and 12. The inner and outer layers 14 and 12 may be made of a suitable sheet material, such as kraft paper, as mentioned above. Then inner and outer layers 14 and 12 may, when necessary for moisture protection, be provided with a water-resistant liner or water-resistant coatings. The insulating material 20 may be fully retained between the outer bag 12 and the inner bag 14, such that the insulating material 20 cannot be accessed absent a disassembly or destruction of one or both of the inner bag 14 or the outer bag 12. The materials and coatings added to this product can be processed in standard curbside recycling programs with no additional actions required by the end user to separate the components of the bag 10.

The present invention also may provide a method of forming the insulated package 10. The inner bag 14 may be received into an internal volume of the outer bag 12, with the inner bag 14 being at least partially internally spaced from the outer bag 12. Insulating material 20 may be interposed between at least some of the walls of the inner and outer bags 14 and 12, such as between side walls of the inner bag 14 and side walls of the outer bag 12. Portions of the inner bag 14 and the outer bag 12 having the insulating material disposed therebetween may be attached to one another, such as to fully seal the insulating material 20 between the inner bag 14 and the outer bag 12. After insertion of an article into the interior volume 16 of the inner bag 14, the top wall of the package 10 may be closed relative to one or more of the sides or bottom of the package 10, to protect the article from an external environment and to insulate the article.

In summary, the present invention provides an insulated, double-wall bag 10 that includes an insulating material 20 sandwiched between inner and outer layers 14 and 12. The inner and outer layers 14 and 12 may be made of a suitable sheet material, such as kraft paper. The inner and outer layers 14 and 12 may, when necessary for moisture protection, be provided with a water-resistant liner or water- resistant coatings. The insulating material 20 may be fully retained between the outer bag 12 and the inner bag 14, such that the insulating material 20 cannot be accessed absent a disassembly or destruction of one or both of the inner bag 14 or the outer bag 12. The materials and coatings added to this product can be processed in standard curbside recycling programs with no additional actions required by the end user to separate the components of the bag 10.

Although the invention has been shown and described with respect to a certain illustrated embodiment or embodiments, equivalent alterations and

modifications will occur to others skilled in the art upon reading and understanding the specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated embodiment or embodiments of the invention.

Claims

1. A container for temperature-controlled transport, comprising:

an outer bag having an outer bottom wall with an outer perimeter, and one or more outer side walls attached to and extending upwardly from the perimeter of the outer bottom wall;

an inner liner layer having one or more inner side walls defining interiorly thereof an interior volume for receiving one or more articles for temperature- controlled transport; and

a cellulose insulation material interposed between the outer side walls and the inner side walls.

2. A container as set forth in claim 1 or any other claim, wherein the outer side walls are made of a single-ply cellulose sheet, and the cellulose sheet has an outer surface exposed to the exterior and an inner surface in contact with the cellulose insulation material.

3. A container as set forth in claim 1 or any other claim, wherein the outer bag and the inner liner layer include paper.

4. A container as set forth in claim 1 or any other claim, wherein the container is configured for erection from a flat configuration to an expanded configuration taking up a larger volume than the flat configuration.

5. A container as set forth in claim 1 or any other claim, wherein the cellulose insulation material is connected to respective adjacent inner and outer side walls.

6. A container as set forth in claim 1 or any other claim, wherein the cellulose insulation material has a uniform thickness.

7. A container as set forth in claim 1 or any other claim, wherein the cellulose insulation material is fully retained between the inner liner layer and one or more of the outer bottom wall and one or more of the outer side walls.

8. A container as set forth in claim 1 or any other claim, wherein the inner liner layer includes a bottom wall from which the inner side walls extend upwardly.

9. A container as set forth in claim 1 or any other claim, wherein at least one of the outer bag and the inner liner layer includes a water-resistant coating.

10. A container as set forth in claim 1 or any other claim, wherein the insulation material includes paper.

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