Abstract:
An insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial, pre-consumer card waste. The insulation layer may be characterized by a lack of any wrapping material. The insulation layer may be manufactured using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven material for providing consistent density throughout the insulation layer. The insulation layer may include a natural fiber lamination layer on an outer surface of the insulation layer. The insulation layer may be biodegradable in an anaerobic environment.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATIONS 
       [0001]    This application is a PCT application tracing priority to United States Provisional Application having Ser. No. 62/338,136 filed on May 18, 2016. Application number 62/338,136 is herein expressly incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD AND BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to the field of containers and to the field of insulated containers. More particularly, the present invention relates to the field of insulated shipping containers utilizing sustainable materials including recycled post-industrial, pre-consumer natural fiber. The containers according to the present invention may be used in transporting and storing objects which may be at a temperature that is different from the temperature outside the container. 
         [0003]    Temperature sensitive products need to be transported from time to time. For instance, certain medications may need to be kept cool relative to temperatures outside of the container. In other instances, food may need to be kept warm relative to temperatures outside of the container. As a result of these needs, packaging has been designed to maintain an internal temperature according the requirements of the product. Some packaging may utilize electro-mechanical devices such as refrigeration, heat exchangers, or heat sinks in order to provide a required steady temperature. Other packaging may utilize foams, plastics, and other polymers along with cool packs, water ice, or dry ice in order to maintain the required temperature environment inside the packaging. 
         [0004]    However, many of these packages and devices are expensive and heavy (as with the refrigeration and heat sinks) or are harmful to the environment (as with some refrigeration and also the foams and plastics) or both. Because of these problems, some have devised products which may be made from post-consumer waste such as recycled cotton gathered from used clothing. However, these products may be prone to contamination from yarn dies, applied chemicals, and other contaminants which the clothing may have acquired during the period of use. The post-consumer material must be cleaned and shredded ahead of reprocessing, however, this process does not eliminate yarn dies and the possibility of contaminants. Most post-consumer waste retains a blue colorization after processing. Therefore, because of the contamination and residual colorization issues these products require that any insulation manufactured from post-consumer cotton be wrapped in another material such as plastic. This use of plastic and other barriers undermines the environmental incentive for using a recycled product by posing additional environmental concerns. It may also further add to the manufacturing costs. 
         [0005]    Accordingly, there is a long felt need in the art for a packaging material which affords safe transportation of temperature sensitive materials, which has a consistent density, which maintains an in internal temperature relative an external temperature, which is efficiently and economically manufactured, which is lightweight, and which minimizes negative impacts to the environment. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    The present invention is an insulated shipping container which affords safe transportation of temperature sensitive products, which has a consistent density, which maintains an in internal temperature relative to an external temperature, which is efficiently and economically manufactured, which is lightweight, and which minimizes negative impacts to the environment. 
         [0007]    The present invention utilizes post-industrial, pre-consumer cotton waste. Post-industrial, pre-consumer cotton waste may include fiber material gleaned and/or trimmed as part of cotton manufacturing, and converting process. 
         [0008]    Such fiber material, collected from the manufacturing process, may contain small pieces of cotton seed pods and stems removed as part of the manufacturing process. These fiber materials have not been converted into finished products (such as clothing or other fabrics). Thus, the present invention is directed to an insulated shipping container utilizing unwrapped cotton waste as the thermal insulating layer. 
         [0009]    However, the invention is not limited only to waste generated from a single manufacturing or converting process. As such, post-industrial, pre-consumer waste may be from raw cotton processing, cotton yarn manufacturing, cotton fabric manufacturing and related processes such as carding, airlay, garneting, and other similar methods Of manufacturing. 
         [0010]    According to one aspect of the invention, the use of polyethylene film wrapped around pads manufactured from cotton waste can be eliminated. No wrapping is required by the present invention and exposed fibers alone can be utilized. Because the fibers are pre-consumer, according to the present invention, the risk of cross contamination from post-consumer recycled products is eliminated. 
         [0011]    Alternatively, a natural fiber lamination may be applied to surfaces in order to provide a smoother surface wherein images and indicia may be applied. The elimination of poly wrap may provide an environmental benefit and also be a cost saving measure. The entirety of the insulation layer, whether including fibers alone or also including the laminated layer is biodegradable in anaerobic environments. 
         [0012]    According to one embodiment of the invention, the insulating layer may have applied to it one or more natural fiber lamination layers. The natural fiber lamination layer may be applied to an outer surface of the insulating layer which may be a contact surface. In some embodiments, the natural fiber lamination layer may be applied to only one surface or may be applied to two surfaces but need not be applied to side edge surfaces. 
         [0013]    According to one embodiment of the invention, an insulated container may include a rigid container surrounding an insulation layer formed from a post-industrial cotton waste. The insulation layer may be characterized by a lack of any wrapping material. 
         [0014]    According to another embodiment of the invention, the rigid container may be made from cardboard. 
         [0015]    According to another embodiment of the invention, the rigid container may be made from plastic. The plastic may be a reusable plastic. 
         [0016]    According to another embodiment of the invention, the insulation layer may include a pair of interlocking C-shaped members forming an enclosed cube shaped cavity. The interior of the cube may form an interior portion of the insulated container. 
         [0017]    According to another embodiment of the invention, the interlocking C-shaped members, referred to as an “A” and a “B” pad, may have a top portion which is integrally and hingedly formed in the member for providing access to an interior portion of the insulated container. 
         [0018]    According to a method of practicing the invention, an insulated container may be manufactured by providing a rigid container and providing a quantity of post-industrial cotton waste. This post-industrial cotton waste may then be processed into a fiber sheet. The sheet made from the waste may be formed using a variety of converting processes including, carding, airlay, and needle punch to achieve a specified thickness and density. Next, the sheet may be cut into rectangular sections. A pair of sections may be arranged to form interlocking C-shaped members, The pair of sections, referred to as an “A” pad and a “B” pad, may then be placed into the rigid container. 
         [0019]    According to another aspect of the method, the method may further include the step of laminating a natural fiber lamination layer to the fiber sheet. 
         [0020]    According to another aspect of the method, the cotton waste includes cotton waste generated from one or more of cotton processing, cotton manufacturing, and/or cotton converting. 
         [0021]    According to another aspect of the method, the insulation layer is capable of maintaining a constant internal temperature for 48 hours where three 500 ML and two 250 ML IV bags are cooled by four 24 oz frozen ice packs placed at the top and bottom below a payload. 
         [0022]    According to another aspect of the method, the insulation layer is biodegradable in an anaerobic environment. 
         [0023]    According to another aspect of the invention, both the rigid container and the pair of sections of the insulation layer may be provided to an end user in sheet form and may be assembled into the insulated container by the end user. 
         [0024]    According to another embodiment of the invention, the insulated container may include an insulation layer formed from a post-industrial, pre-consumer cotton waste, a rigid cardboard container surrounding the insulation layer, and a natural fiber lamination layer applied to a contact surface of the insulation layer. According to such an embodiment, the cotton waste may include cotton waste generated from one or more of cotton processing, cotton manufacturing, and/or cotton converting. According to such an embodiment, the insulation layer may be biodegradable in an anaerobic environment. According to such an embodiment, the insulation layer may be capable of maintaining a constant internal temperature for 48 hours where three 500 ML and two 250 ML IV bags are cooled by four 24 oz frozen ice packs placed at the top and bottom below a payload. 
         [0025]    According to one embodiment, the term biodegradable may mean that the insulation layer will biodegrade completely within one year or less when subjected to the biodegration dynamics contained in ASTM D 5511 . According to the ASTM D 511  protocol, test reaction mixture consisted of 10% shredded nitrile gloves, 10% Trypticase Soy Broth, 10% Thioglycollate medium, 60% municipal solid waste, and inoculated with concentrated inoculum (1.2×10 6  CFU/ml) of aerobic and anaerobic mixed culture in 0.01 M phosphate buffer at pH 7.2 placed in aerobic and anaerobic glass digesters, and incubated at 37.5°. Positive controls consisted of reaction mixture above with lab-grade cellulose (100%, Aldrich) instead of shredded test sample(s) while negative controls contained EDTA lab-grade (100%, Aldrich) instead of shredded test sample(s) in the test above. Reaction mixture was monitored at least daily, often more frequently, and sampled weekly for CO2 production, trapped in 3 KOH bottles connected in series, over a period of 15 weeks when cumulative CO2 production was observed. Biodegradation was deemed to be positive (passed P test, 95 or &gt;95% biodegradation) or negative (failed test, 5 or &lt;5% biodegradation), based on carbon conversion. Percentages (%), actual observed versus theoretical possible -based on total carbon content- were determined on a dry weight basis. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    Features, aspects and advantages of the present invention are understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which: 
           [0027]      FIG. 1  is a perspective view of a prior art insulated container where the insulating material is expanded polystyrene foam; 
           [0028]      FIG. 2  is a perspective view of a prior art insulated container where the insulating material is enclosed in plastic; 
           [0029]      FIG. 3  is an exploded view of the insulated container in a partially assembled state; 
           [0030]      FIG. 4  is an exploded view of the insulated container in a partially assembled state; 
           [0031]      FIG. 5  is an exploded view of the insulated container in an unassembled state; 
           [0032]      FIG. 6  is an exploded view of the insulated container in a partially assembled state; 
           [0033]      FIG. 7  is an exploded view of the insulated container in a partially assembled state; 
           [0034]      FIG. 8  is an exploded view of the insulated container in a partially assembled state; 
           [0035]      FIG. 9  is an exploded view of the insulated container in a partially assembled state; 
           [0036]      FIG. 10  is an exploded view of the insulated container in a partially assembled state; 
           [0037]      FIG. 11  is a perspective view of the insulated container in an assembled state; 
           [0038]      FIG. 12  is a perspective view of the insulated container in an assembled state; 
           [0039]      FIG. 12A  is sectional view of the insulated container; 
           [0040]      FIG. 13  is an exploded view of the insulated container in a partially assembled state and where the insulation layer does not include the natural fiber lamination; 
           [0041]      FIG. 14  is a heat stress chart; 
           [0042]      FIG. 15  is a heat stress chart; and 
           [0043]      FIG. 16  is a cold stress chart. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0044]      FIG. 1  and  FIG. 2  show prior art insulated containers. In particular,  FIG. 1  shows a prior art insulated container having a rigid foam insulation layer.  FIG. 2  shows a prior art insulated container having an insulation layer which is wrapped in plastic. 
         [0045]    Generally,  FIGS. 3 through 10 , show embodiments of the invention with insulation layer  20  having a natural fiber lamination layer  26  applied to contact surfaces. The contact surfaces are surfaces which may come into contact with contents of the container. Generally,  FIG. 13  shows an alternate embodiment of the invention where there is no natural fiber lamination layer and the fibers of the insulation layer  20  are exposed to the contents of the container. The embodiment utilizing the natural lamination layer  26  may be preferred to the embodiment of  FIG. 13  when a shipper desires that the contents not come into contact with the insulation layer, such as when shipping raw, unwrapped produce. The natural fiber lamination layer  26  is sustainable and is biodegradable. The natural fiber lamination layer  26  thus provides a helpful option to companies seeking a smoother, more consistent surface. The natural fiber lamination layer  26  may be made from a coffee filter paper, kraft paper, and the like. Text and images (not shown) may be printed on the lamination layer  26 . 
         [0046]    Referring to  FIG. 3 , an insulated container  10  is shown in a partially assembled state. The insulated container  10  includes rigid container  50  and insulation layer  20 . The rigid container  50  may be a cardboard box as shown. The insulation layer  20  is made from cotton waste. The cotton waste is processed into a sheet formed using a variety of converting processes including, carding, airlay, and needle punch to form a non-woven sheet. The insulation layer  20  is formed to maintain uniform density and of a thickness optimized for particular applications. 
         [0047]    The sheet may then be cut into rectangles which may be bent into a pair of C-shaped members,  22 ,  24 . The first C-shaped member, referred to as an “A” pad  22  forms lid portion  30  which is connected to back side portion  32  via first hinge portion  31 . Bottom portion  34  is connected to back portion  32  via second hinge portion  33 . 
         [0048]    Similarly, the second C-shaped member, referred to as a “B” pad  24  forms first side portion  40  which is connected to front side portion  24  via hinge  41 . Second side portion  44  is connected to front side portion  24  via hinge portion  43 . 
         [0049]    When assembled, as shown in  FIG. 4 , second C-shaped member  24  fits into a cavity formed by first C-shaped member  22  to form the interlocking C-shapes of the insulation layer  20 . 
         [0050]    As shown in  FIGS. 5   10 , the insulation layer  20  of the insulated container  10  may be assembled by folding respective C-shaped members  22 ,  24 . As shown in  FIG. 5 , the C-shaped members  22 ,  24  may have in unfolded state that is a flat rectangular shape. As shown in  FIGS. 6  .  9 , hinges  31 ,  33  and  41 ,  43  may be formed by folding. These folds separate the portions  30 ,  32 ,  34 ,  40 ,  42 ,  44  of each C-shaped member  22 ,  24 . 
         [0051]      FIG. 11  shows the fully assembled insulated container  10  with the lid of the rigid container  50  open.  FIG. 12  visualized the cross-section A-A which is shown in  FIG. 12A . In particular, the cross section A-A shows the insulation layer  20  inside the rigid container  50 . The natural fiber lamentation layer  26  is shown on the contact surfaces. Importantly, there is no plastic or non-biodegradable layer between the insulation layer  20  and the rigid container  50  as is present in the prior art of  FIG. 2 . That is, there is no additional plastic housing surrounding the insulation layer  20 . Both to the rigid container  50  and the internal cavity of the insulate container. 
         [0052]      FIG. 13  shows the insulated container  10  of  FIGS. 3-12A  but where the natural fiber insulation layer has not been added during the manufacturing process. Accordingly, the cotton waste of the insulation layer  20  is exposed. 
         [0053]    An embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where three 500 ML and two 250 ML IV bags are cooled by four 24 oz frozen ice packs. The ice packs are placed at the top and bottom below the payload.  FIG. 14  shows heat stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV bags. The top line shows the ambient temperature outside the insulated container. The other lines show “wrapped white cotton” “molded 1.5 inch foam” and “unwrapped white cotton.” 
         [0054]    Another embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where six 600 ML IV bags are cooled by four 24 oz frozen ice packs. The ice packs are placed at the top and bottom below the payload.  FIG. 15  shows heat stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV gabs. The top line shows the ambient temperature outside the insulated container. The lower line shows the internal temperature. 
         [0055]    Another embodiment of the invention may be created wherein the container is capable of maintaining a constant internal temperature for 48 hours where six 600 ML IV bags are cooled by two 24 oz frozen ice packs and two 24 oz ambient ice packs. The ice packs are placed at the top and bottom below the payload.  FIG. 16  shows cold stress test results which were recorded by individual data loggers within and outside the test package as well as in proximity to the IV gabs. The top line shows the ambient temperature outside the insulated container. The lower line shows the internal temperature. 
         [0056]    Another embodiment may be created where the insulated container  10  complies with test scope protocol ISTA  7 D such that it maintains temperature above 2° C. and below 8° C., without freezing, in simulated summer/heat stress conditions for a 48 hour distribution cycle. According to the ISTA  7 D test, six 24 oz gel ice packs were added to the insulated container  10  with a payload of six 500 mL IV bags (Lactated Ringer&#39;s Solution USP), conditioned to 3° C. 
         [0057]    Another embodiment may be created where the insulated container  10  complies with test scope protocol ISTA  7 D such that it maintains temperature above 2° C. and below 8° C., without freezing, in simulated winter/cold stress conditions for a 48 hour distribution cycle. According to the ISTA  7 D test, four 24 oz gel ice packs were added to the insulated container  10  with a payload of ten 500 mL IV bags (Lactated Ringer&#39;s Solution USP), condition to 3° C. 
         [0058]    An insulated container  10  according to the invention has been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. It is envisioned that other embodiments may perform similar functions and/or achieve similar results. Any and all such equivalent embodiments and examples are within the scope of the present invention and are intended to be covered by the appended claims.