Abstract:
A two component box has a lid and a lower body portion; both the lid and the lower body portion have an interior compartment substantially surrounded by at least one interior wall and at least one exterior wall. At least one interior wall and at least one exterior wall of the lid are attached one to the other by a first connecting portion and at least one interior wall and at least one exterior wall of the lower body portion being attached one to the other by a second connecting portion. Disposed between the at least one interior wall and the at least one exterior wall is a vacuum.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable 
       FIELD OF THE INVENTION 
       [0003]    This invention relates to an insulated box for substantially maintaining the temperature within the box through use of a vacuum. 
       BACKGROUND OF THE INVENTION 
       [0004]    Hauling temperature sensitive freight over long distances or storing it for an extended period of time is problematic in that the freight often times must either be kept cooler or warmer than the outside environment. A total vacuum does not conduct heat nor are there molecules within a vacuum to transfer heat through convection. A container having a vacuum or semi-vacuum significantly improves the insulating qualities of the container. Energy savings are very desirable and there is a need for a container that reduces energy requirements while maintaining a desired temperature range. This need can be filled by the vacuum container of the instant invention as it provides a vacuum chamber or annulus for heightened insulating qualities. 
         [0005]    The instant invention, as disclosed within this application, fills this need. The art referred to and/or described within this application is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists. 
         [0006]    All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety. 
         [0007]    Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below. 
         [0008]    A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    In at least one embodiment, a box can comprise an outer bottom case disposed about a bottom interior set of walls (e.g. having an open side and/or an open top as shown in  FIG. 6 ), an upper interior cover, an upper exterior cover, a front inner panel, and a front outer panel. The outer bottom case can have elongated support struts extending along the outer bottom case from the bottom case floor towards the bottom case top. The bottom interior set of walls can be constructed to have a lip which alone engages the bottom case. In the space between the bottom case and the bottom interior set of walls a vacuum can be produced. A vacuum can also exist in the void spaces between the upper interior cover and the upper exterior cover and between the front inner panel and the front outer panel. The inner compartment of the box can be substantially defined by the bottom interior set of walls and the upper interior cover and the front inner panel. 
         [0010]    In at least one embodiment the front inner panel can be a portion of the bottom interior set of walls and the front outer panel can be a portion of the outer bottom case. 
         [0011]    In at least one embodiment, a vacuum valve can be included and used to create a vacuum within the void spaces. The vacuum valve can be directly engaged to the box such that a void space is in fluid communication with a vacuum pulling device through the vacuum valve. 
         [0012]    In at least one embodiment, a pallet portion can be attached to the bottom of the outer bottom case, the pallet portion having slots spaced and sized for being carried by a forklift. 
         [0013]    In at least one embodiment, insulating material can also fill the void spaces. Insulating material can include an amorphous volcanic glass (e.g. perlite). 
         [0014]    These and other embodiments which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for further understanding of the invention, its advantages and objectives obtained by its use, reference should be made to the drawings which form a further part hereof and the accompanying descriptive matter, in which there is illustrated and described embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0015]    A detailed description of the invention is hereafter described with specific reference being made to the drawing. 
           [0016]      FIG. 1  is a schematic perspective view of an embodiment of the invention. 
           [0017]      FIG. 2  is a schematic perspective view of an embodiment of the invention in cross-section. 
           [0018]      FIG. 2   a  is a cross-sectional view of a wall portion including a valve. 
           [0019]      FIG. 3  is a flat view of a wall of an embodiment of the invention. 
           [0020]      FIG. 3   a  is a cross-sectional view of a wall of an embodiment of the invention. 
           [0021]      FIG. 4  is a perspective view of the outer walls of and embodiment of the invention. 
           [0022]      FIG. 5  is a perspective view of an embodiment of the invention. 
           [0023]      FIG. 6  is a perspective view of an embodiment of the invention. 
           [0024]      FIG. 7  is a perspective view of an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0025]    While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. It should be noted that the term “vacuum” does not indicate that the vacuum be perfect or complete. As used here, a vacuum exists at 200 torrs or less. In some embodiments the vacuum has a substantially lower pressure; in some embodiments the vacuum has a pressure of 1 to 10 −3  torr, in some embodiments the vacuum has a pressure of 10 −3  to 10 −8  torr, and in some embodiments substantially equal to or substantially less than 10 −9  torr. As used herein the term “connecting portion” identifies a portion of the lid and/or lower body portion that connects the panels or walls between which a vacuum is formed. Some examples are part identifiers  29 ,  29 ′, and  32 . 
         [0026]    In the embodiment of  FIG. 1  a perspective view of a box  10  having an inventive vacuum space is illustrated. The box  10  is illustrated in  FIG. 2  in cross-section. In  FIG. 2  the embodied box  10  has a lid  85 , a lower body portion  80 , and a storage space  20 . The lid  85  and/or lower body portion  80  can comprise composite wall(s)  30  having a vacuum between two substantially parallel surfaces. The structure of the composite wall  30  is shown in more detail in  FIG. 2   a  which is a wall portion  40  of the lower body portion  80  of  FIG. 2  and further includes a valve  45  for pulling a vacuum within vacuum space  30   c . In  FIG. 2   a  composite wall  30  is better detailed to illustrate components, namely, interior wall  30   a  and exterior wall  30   b  which are separated by vacuum space  30   c . The lid  85  can have the same components including the valve as shown in  FIG. 2   a . It should be noted that in some embodiments interior wall  30   a  and exterior wall  30   b  are not substantially parallel. 
         [0027]    As shown in  FIG. 2   b  walls  30   a  and  30   b  of lower body portion  80  can be connected by connecting portions  29  and interior wall  30   a ′ and exterior wall  30   b ′ of lid  85  can be connected by connecting portions  29 ′. The connecting portions  29  and  29 ′ can be constructed of the same piece of material as that of the interior and exterior walls that they connect. In some embodiments the connecting portions  29  and  29 ′ can be constructed of a different material and/or piece of material as that of the interior and exterior walls that they connect. 
         [0028]    In some embodiments the vacuum space(s)  30   c  and/or  30   c ′ has perlite or some other insulating material disposed therein. 
         [0029]    In some embodiments, the box  10  can have a height, width, and/or depth of greater than 2 feet. In some embodiments the box  10  can have a height, width, and/or depth of greater than 20 feet. In some embodiments the box  10  is integral to a truck (e.g. the storage portion of a tractor trailer). In some embodiments, the box  10  is the entire box of a railroad boxcar, or the entire cargo portion of a van, truck, or trailer of a tractor trailer. In some embodiments the box  10  is only a portion of a box of a railroad boxcar or only a portion of the cargo portion of a van, truck, or trailer of a tractor trailer. In some embodiments, the box  10  is an entire room, storage facility, and/or warehouse. There are multiple other structures and storage facilities that can be constructed with walls having a vacuum as this invention can be used in place of other temperature insulating walls, panels, and/or barriers. 
         [0030]    In some embodiments, as shown in  FIG. 3 , the box  10  has handles  50  for lifting. The handles  50  are shown disposed in a recessed portion  57  in a wall of the lower body  80  of the box  10 . In some embodiments one or more handles can be disposed within the lid  85 . In some embodiments, one or more handles 50/50′ are disposed on multiple walls of the box  10 . As shown in  FIGS. 3 and 3   a  multiple types of handles 55/55′ can be disposed on a single wall  30  of the box  10 . A wall can have a recessed portion  57  having a handle  55 . A hand can enter the recessed portion  57  and grasp the handle  55 . The handle  55  can be tubular. The handle  55  can be a separate piece that is disposed within the recessed portion  57 . 
         [0031]    In some embodiments the recessed portion  57 ′ is configured such that it has a finger space  58 ′ and forms a handle  55 ′. As noted previously one or more handles and/or types of handles can be on a given wall  30 . In some embodiments one handle can be on one wall  30  and another handle on the wall  30  directly opposite. Handles can be disposed on any of the boxes disclosed in this application. 
         [0032]    In  FIG. 4  an embodied box  10  is shown in cross-section. The lower body portion  80  has a composite wall  30  comprising exterior walls  30   b  and interior walls  30   a  and a vacuum  30   c  there between the interior and exterior walls. The lid  85  has a composite wall comprised of interior wall  30   a ′ and exterior wall  30   b ′ and vacuum  30   c ′ there between interior wall  30   a ′ and exterior wall  30   b ′. As shown, interior wall  30   a  is constructed from a separate work piece than that of exterior wall  30   b . Here, interior wall  30   a  includes an interior lip  32  that contacts or rests on an exterior lip  33  of exterior wall  30   b . The lower body seal  34  can assist in maintaining the vacuum  30   c  between the interior wall  30   a  and exterior wall  30   b . The bottom portion of inner walls  30   a  and/or exterior walls  30   b ′ can include struts or support bosses  65  as shown. These struts/bosses  65  can provide added support between interior walls  30   a  and exterior walls  30   b . In some embodiments the struts/bosses  65  are not included and separation between the bottom portion of interior walls  30   a  and exterior walls  30   b  is maintained in large part by support at the interface of interior lip  32  and exterior lip  33 . In some embodiments, the lower body seal  34  is not used and inner wall  30   a  and/or exterior wall  30   b  are not readily separable (e.g. the walls are designed to fixedly remain connected). In some embodiments, interior walls  30   a  and exterior walls  30   b  are formed of the same integral piece. In some embodiments, interior walls  30   a  and exterior walls  30   b  are affixed together by welding. 
         [0033]    Lid  85  as illustrated in  FIG. 4  is also shown to have interior wall  30   a ′ constructed from a separate work piece than that of exterior wall  30   b ′. Here, interior wall  30   a ′ engages exterior wall  30   b ′. The lid seal  36  can assist in maintaining the vacuum  30   c ′ between the interior wall  30   a ′ and exterior wall  30   b ′. Interior wall  30   a ′ and/or exterior wall  30   b ′ can include struts or support bosses  65  as shown. These struts/bosses  65  can provide added support between interior walls  30   a ′ and exterior walls  30   b ′. As with the lower body  80 , in some embodiments the struts/bosses  65  are not used in the construction of the lid  85 . In some embodiments, the lid seal  36  is not used and inner wall  30   a ′ and/or exterior wall  30   b ′ are not readily separable (e.g. the walls are designed to fixedly remain connected). In some embodiments, interior walls  30   a ′ and exterior walls  30   b ′ are formed of the same integral piece. In some embodiments, interior walls  30   a ′ and exterior walls  30   b ′ are affixed together by welding. 
         [0034]    As shown in  FIG. 4 , the lid  85  contacts the lip  32  of interior wall  30   a . Storage seal  31  can be used to assist in maintaining the temperature within the storage space  20 . The portion of the lid  85  contacting the lip  32  of interior wall  30   a  can be constructed of a material with a high R-value such that heat is exchanged more slowly through this point of contact. In some embodiments a rubber and/or plastic is used at the point of contact between the lip  32  of inner wall  30   a  and lid  85 . The rubber and/or plastic used at the point of contact can be part of the lip  32  and/or part of the lid  85 . It should be noted that seals  31 ,  34 , and  36  can extend around the entire circumference of lips  33 ,  32 , and outer wall  30   b ′. In some embodiments the seals  31 ,  34 , and  36  are not recessed within lips  33 ,  32 , and outer wall  30   b ′. In some embodiments rubber and/or plastic in the form of a flat gasket is used in place of seals  31 ,  34 , and  36 . The gaskets can extend about a portion or the entire circumference of lips  33 ,  32 , and/or outer wall  30   b ′. The rubber and/or plastic can be in the form of a sheet in some embodiments. In some embodiments the sheet of rubber and/or plastic inhibits heat transfer between the contacting surfaces. In some embodiments multiple seals and/or gaskets can be used on lips  32  and/or  33 . In some embodiments one or more seal and/or gasket can be applied to the horizontal portion and the vertical portion of the lip  32  to form a seal between the lid  85  and the interior wall  30   a . In some embodiments one or more seal and/or gasket can be applied to the horizontal portion and the vertical portion of the lip  33  to form a seal between the exterior wall  30   b  and the interior wall  30   a . In some embodiments of any of the boxes disclosed the sealing of the vacuum portion  30   c / 30   c ′ is facilitated by the pulling of the vacuum as the surfaces being sealed are brought closer to one another through the vacuum creation process. 
         [0035]    In some embodiments as illustrated in  FIG. 4  the lid  85  is secured to the lower body  80  by clasps  90 . In some embodiments the clasp  90  snaps over ridge  92  to secure the lid  85  to the lower portion  80 . In some embodiments a single clasp  90  is used as the lid  85  is hinged to the lower body  80  on one side. Many forms of securing the lid  85  to the lower body  80  are contemplated within this invention; screwing or bolting, adhesives, soldering or welding, clamping, magnetism, and any combination thereof. 
         [0036]    The use of the terms “lower body portion” and “bottom portion” are merely used in describing the details based on the orientation of  FIGS. 1-4  and any other applicable figures herein which are identified as having a “lower body portion” and/or “bottom portion”. In use the box  10  may rest on the exterior wall adjacent the lid or may even rest on its lid. 
         [0037]    In  FIG. 5  a portion of an embodied lower body portion  80  having a top and side opening is shown. The exterior walls  30   b  with support struts  60  are shown. The lower body portion  80  includes a seal within seal groove  81 . The seal can be an o-ring vacuum seal that in some embodiments is compressed when a vacuum is applied. The exterior walls  30   b  can have interior walls  30   a  disposed within the space formed by exterior walls  30   b  as shown in  FIG. 6 . The wall support struts  60  can provide support for the exterior walls  30   b  when a vacuum is pulled in the vacuum space disposed between exterior wall  30   b  and interior wall  30   a . In some embodiments as shown in  FIG. 5 , bottom support struts  65  can be used. They can have a grid pattern as shown in  FIG. 5  or struts extending in a single direction. The struts  60  are shown to taper from the bottom to top. In some embodiments, there is no taper, the taper is less pronounced, or the taper extends from top to bottom. In some embodiments the wall struts  60  and/or the bottom struts  65  taper differently from other wall struts  60  and/or bottom struts  65 . 
         [0038]    The support struts  60  and  65  shown in  FIG. 5  can also be applied to the interior walls  30   a . The struts  60  and  65  can be applied to the inside and/or outside of the interior walls  30   a  and exterior walls  30   c . In some embodiments, the support struts applied to the interior walls do not contact the support struts applied to the exterior walls. In some embodiments contact between the support struts applied to the interior walls and to the exterior walls does occur. In some embodiments, the support struts supporting the exterior walls also support the interior walls. 
         [0039]    In some embodiments, skid openings  68  are included with the box  10  as shown in  FIG. 5 . The skid openings  68  can be used by a lift truck or pallet jack when moving the box  10 . 
         [0040]    As shown in  FIG. 5 , a material port  96  can be disposed within port recess  94  on lower portion  80 . A material port  96  can be disposed on all of the boxes disclosed within this application and can provide fluid communication between the vacuum portion and the outside of the box  10 . The port  96  can be used in the lid  85  or lower portion  80  and can be used to introduce insulating material within the vacuum portion (identified as  30   c  or  30   c ′ throughout the application). As shown, the port  96  is disposed on the opposite side of the lower portion  80  from the vacuum valve  45  (e.g. shown in  FIG. 7 ). In some embodiments disposing the vacuum valve  45  and that material port  96  on opposite sides of the box facilitates a more complete and/or even distribution of the insulating material within the vacuum portions. 
         [0041]    In some embodiments a material port  96  is not disposed on the box  10 . In some embodiments, the material port  96  and the vacuum valve  45  can be disposed in a wide range of configurations and/or distances from one another on the box  10  (e.g. there can be one or more vacuum valves and/or material ports also and/or they can be disposed immediately beside one another and/or at the furthest points from one another on the box). 
         [0042]    The insulating material can be included in the vacuum portion for purposes of maintaining a better thermal barrier in case the vacuum is weak, punctured, damaged, and/or fails. In some embodiments a filter is included in the vacuum valve port  45  to prevent insulating material passing through the vacuum valve port. In some embodiments an access door is attached to the recessed pocket and/or the port recess  94 . Though a recessed pocket is desirable in many embodiments, the valves, gauges, indicator lights, and ports need not be within the recessed pocket  90 . In some embodiments some are within the recessed pocket while others are not. 
         [0043]    In some embodiments as shown in  FIG. 6 , the box  10  has an interior opening  70  that comprises the top  72  and a side  74  of the box  10 . The opening  70  of  FIG. 6  can allow items to be placed in and taken out of the box more easily than with a box having an opening in only the top as the box of  FIGS. 1-4 . As shown, the lid  85  folds up. In some embodiments the lid  85  is rigid and does not fold. In some embodiments, the lid only comprises a portion of a top and/or side rather than an entire side or top as illustrated in  FIGS. 1-6 . In some embodiments, the lid  85  can be secured or latched to the body portion of the box  10  (e.g. as used by securement device  90  as shown in  FIG. 4 ). In some embodiments two or more securement devices (e.g. latches, clasps, snaps, etc.) can be used on each side of the box  10 . In some embodiments one or more securement devices  90  are used on the top of the lid  85  and/or one or more securement devices  90  are used on the side of the lid  85 . 
         [0044]    In some embodiments the lid  85  and/or lower body portion  80  each include a single vacuum valve  45 . In some embodiments multiple vacuum valves can be included. In some embodiments a recessed pocket  90  is included in the lid  85  and/or lower body portion  80 .  FIG. 7  illustrates a recessed pocket  90 , here disposed in the lower body portion  80 . A vacuum valve port  45  is included as well as a “vacuum indicator gauge”/“warning indicator light”  92 . Other equipment that can be placed within the pocket  90  is a material port (as shown in  FIG. 5 ) for inserting insulating material within the vacuum portion (identified as  30   c  or  30   c ′ throughout the application). The insulating material can be included in the vacuum portion for purposes of maintaining a better thermal barrier in case the vacuum is punctured, damaged, and/or fails. In some embodiments a filter is included in the vacuum valve port  45  to prevent insulating material passing through the vacuum valve port. In some embodiments an access door is attached to the recessed pocket. Though a recessed pocket is desirable in many embodiments, the valves, gauges, indicator lights, and ports need not be within the recessed pocket  90 . In some embodiments some are within the recessed pocket while others are not. 
         [0045]    Throughout this application it should be understood that the shapes used for the box  10  are illustrative. In some embodiments the box is cylindrical. 
         [0046]    The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. The various elements shown in the individual figures and described above may be combined or modified for combination as desired. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. 
         [0047]    Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim  1  should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below. 
         [0048]    This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.