Patent Publication Number: US-11046500-B2

Title: Insulated shipping system including one-piece insulative insert with strengthening inner layer

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present disclosure is a continuation-in-part of U.S. patent application Ser. No. 15/911,726, filed Mar. 5, 2018, which is a continuation of U.S. patent application Ser. No. 15/439,387 (now U.S. Pat. No. 9,908,684), filed Feb. 22, 2017, which is a continuation of U.S. patent application Ser. No. 14/266,156 (now U.S. Pat. No. 9,611,067), filed Apr. 30, 2014, which claims the benefit of U.S. Provisional Application No. 61/817,369, filed Apr. 30, 2013. The entire disclosures of the above applications referenced above are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to an insulative packaging system and, more particularly, to an insulative packaging system utilizing a chopped fiber insulative pad incorporating antimicrobial and absorbtive powders. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     The current technology provides paper mailers, lined with plastic bubble-wrap, or more expensive foam, or foam-lined boxes. These products are used primarily for shipping sensitive or fragile items, but suffer from the fact that they have extremely limited cushioning, no absorption properties, no antimicrobial properties, and practically no temperature-control value. 
     Foam, or foam-lined boxes are also used for shipping temperature-sensitive products such as medical samples, pharmaceuticals, chocolates, etc. These current products, in addition to being dramatically more expensive to purchase, warehouse, and ship (in-bound and outbound freight), are also more labor intensive, less user-and-environmentally friendly, and provide very limited protection during transit. Often these shipping containers utilize a significant amount of dry ice to maintain key low temperatures to prevent spoilage. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     According to the present teachings, an insulative packing system for bottles is disclosed. The system contains a plurality of corrugated members that interleave to form a plurality of bottle holding cavities. The system utilizes an insulative pad formed of a textile pad disposed within a polymer film sleeve. The insulative pad is disposed around the bottle holding cavities. The insulative pad has a textile pad having chopped fibers selected from the group polyester, nylon, acrylic, cotton, polypropylene, denim and combinations thereof. The textile pad has powder antimicrobials while the polymer film has biodegradable enhancers added therein. 
     According to the present teachings, an insulative packaging system has a shipping container, a plurality of corrugated members that interleave to form a plurality of bottle holding cavities, a three layered polymer film laminate container having an interior surface, and a textile padding disposed within the polymer film laminate container. The textile pad is disposed within the container and the polymer film and is formed of chopped fibers selected from the group polyester, nylon, acrylic, cotton, polypropylene, denim and combinations thereof. The textile pad further has microbial and super-absorbent powders disposed adjacent to an exterior surface of the textile pad or within. 
     An insulative packing system is presented having a box structure. Disposed within the box is a first U-shaped insulative member disposed against the box bottom and a first pair of box sides. Disposed above the insulative member is a plurality of interleaved members which form a plurality of bottle holding cavities. A second U-shaped insulative member is disposed over the interleaved members, so as to position portions of the second U-shaped member against a second pair of box interior sides. 
     According to further teachings, the insulative packaging system above further contains three fiber pads disposed within a polymer sleeve. The polymer sleeve is sealed at its ends and tacked together at locations between the fiber pads. 
     According to further teachings, a packaging system for bottles is disclosed. The system has a member defining a plurality of elongated bottle accepting cavities. Disposed about the member is a plurality of insulating planar pads. Each planar pad is disposed within a closed polymer envelope. Surrounding the polymer envelope and the member is a corrugated box. 
     Other and further objects of the present invention will become apparent from the following detailed description of the invention when taken in conjunction with the appended drawings. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a diagrammatic perspective view of a bottle shipping container according to the present teachings; 
         FIG. 2  is a diagrammatic perspective view of a three-segment insert according to the invention which surrounds interleaved panels; 
         FIG. 3  is a top view of a four-segment insert; 
         FIG. 4  is a side view of a three-segment insert; 
         FIG. 5  is a top view of a sheet that can be folded into a box; 
         FIG. 6  is a perspective view of a cross-shaped six-panel insert with mitered joints; 
         FIG. 7  is a perspective view of a cross-shaped six-panel insert with scored joints; 
         FIGS. 8-10  are alternate insulative pads; 
         FIG. 11  is a top perspective view of a cross-shaped six-panel insert with a strengthening inner layer; 
         FIG. 12  a bottom perspective view of the insert of  FIG. 11 ; 
         FIG. 13  is a perspective view of the insert of  FIG. 11  folded and placed inside of a shipping container. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
       FIGS. 1 and 2  show an embodiment of a container  100  that ships to the user flat and includes a box  110 . The box  110  in the flat condition is like the box  110  shown in  FIG. 1 , but collapsed. Panels  125 - 130  are formed to complement the sides of the box  110 . The panels  125 - 130  have mitered joints. The panels  125 - 130  can be adhered to faces  111 - 115  of the box  110 . Glue is an example of a suitable adhesive to adhere the panels  125 - 130  to the box  110 . When the box  110  is folded, the panels  125 - 130  move with the box  110  into engagement with each other to form an insulated inner layer within the box  110 . The inner layer can be air-tight. 
     In  FIGS. 1 and 2 , an insulative packing system  20  for bottles is shown. The system  20  contains a plurality of corrugated members  22  that interleave to form a plurality of bottle holding cavities  24 . The system  20  utilizes an insulative panel  25  formed of an insulative pad  28  disposed within a polymer film sleeve  26 . The insulative panel  25  is disposed around the bottle holding cavities  24 . The insulative pad  28  has chopped fibers selected from the group polyester, nylon, acrylic, cotton, polypropylene, denim and combinations thereof. The insulative pad  28  is disposed within an interior surface of the polymer film sleeve  26  being attached to the pad  28 . The insulative pad  28  has powder antimicrobials while the polymer film sleeve  26  has biodegradable enhancers added therein. 
     The system  20  can be composed of materials that are 100% biodegradable. The outer surface of the polymer film sleeve  26  can consist of a non-petroleum based, biodegradable film or paper  48  that is also waterproof. Optionally, the polymer film sleeve  26  extends laterally so its lateral edges or margins can be heat sealed together. The bottom of the polymer film sleeve  26  is joined. 
     The inner surface of the polymer film sleeve  26  can be a non-petroleum based, biodegradable film or paper (substrate)  44  that is permeable. Sandwiched between the inner biodegradable film or paper (substrate)  44  and the outer film  48 , and sealed on all sides, is the biodegradable insulative pad  28 , which is made from re-cycled, purified, ground-up material to which super absorbent powders (for the absorption of spills), and antimicrobial powders (for the prevention of contamination in case of rupture for such products as blood or vaccines, etc.) have been added during manufacture. The antimicrobials are programmed to expire, after a pre-selected desired length of time, to allow for the eventual, natural, degradation/biodegradability of the mailer. 
     The outer surface of the polymer film sleeve  26  is encompassed within the water-proof, biodegradable film or paper  12 , sealed on two (or three) sides with polymer film sleeve  26 , which extends laterally coextensive with film  12 . Polymer film sleeve  26  may not surround the insulative pad  28  completely, and end portions of the polymer film sleeve  26  extend around the insulative pad  28  sufficiently to enable the end portions to be sealed with the film  12 . 
     The polymer film sleeve  26  can be stitched together with the insulative pad  28  in the following manner. A row of smaller stitches or heat produced couplings extend from top to bottom of the system  20  along each side thereof juxtaposed adjacent to the lateral edges of insulative panel  25 . Spaced slightly inwardly of stitches, is a second row of larger stitches that encompass the insulative pad  28  and the polymer film sleeve  26  on the inside of the insulative pad  28  and include portions on the outside of the insulative pad  28 . The second rows of stitches only extend longitudinally from the top of the mailer downwardly and terminate with the portions on the outside of the insulative pad  28 . Apart from the stitching and heat-staking of the polymer film sleeve  26  to film  12 , insulative pad  28  is not attached to film  12 . 
     The insulative pad  28 , as duly noted, can be made from re-cycled, purified, ground-up material to which super absorbent powders (for the absorption of spills), and antimicrobial powders (for the prevention of contamination in case of rupture for such products as blood or vaccines, etc.) have been added during manufacture. The antimicrobials are programmed to expire, after a pre-selected desired length of time, to allow for the eventual, natural, degradation-biodegradability of the mailer. 
     As evident from the above description, the insulative pad  28  is covered by and disposed within a cavity defined by the polymer film sleeve  26  on the inside with polymer film sleeve  26  extending laterally beyond the insulative pad  28  to lie coextensive with the marginal edges of the film  12  so all marginal edges can be heat sealed together. Polymer film sleeve  26  extends around the longitudinal extremities of the insulative pad  28  so that the end portions of the polymer film sleeve  26  lie between the insulative pad  28  and the outer film  12  when the insulative pad  28  is located in the system  20 . These end portions enable the polymer film sleeve  26  to be heat sealed together with the film  12  around the mailer opening, thereby entrapping the insulative pad  28 . 
     The film is preferably a biodegradable polymer as defined by ASTM 1991, and is preferably biodegradable in 9 months to 5 years either anaerobically and aerobically. The film can be manufactured as a 3-layer construction. In this regard, each layer can be manufactured with a biodegradable additive from ECM Biofilms, Inc. of Painsville, Ohio 44077. Optionally, the inner and outer layer can be colored with colors such as white or silver. The inside layer can be laminated to the pad material using an adhesive or thermal bonding. The layered structure can be perforated and have an inner nylon core and low-density polyethylene skin. Optionally, this laminate structure can be formed using a molten material force fed through a die and subsequently cooled. 
     The insulative pad may be manufactured from any of a wide variety of textile compositions comprising, for example, polyester, nylon, acrylic, cotton, polypropylene, denim etc., or combinations thereof, including both natural and man-made fibers. Randomly distributed textile and binder fibers having lengths between 1/16 inch to 1.5 inches and a denier of between 5 and 12 may be used to form a textile fiber batt, which may be processed to form the insulative pad. 
     In one embodiment, two insulative pads are bonded to a biodegradable polymer layer to form an insulative construction. The insulative construction may be used as an insulative layer within a shipping container that can be formed of a polymer, paper, or cardboard material. There are several ways to make the insulative pad. In the first, the insulative pad can be formed of a textile fiber batt containing textile and binder fibers. The fiber batt is heated in an oven and compressed to form the insulative pad. Optionally, the insulative pad can be formed using needle setting technology. 
     Optionally, several layers of enveloped insulative pad can be used to form the construction. Each insulative pad within the system may be of equal thickness, or may be of unequal thickness. It is envisioned the insulative pad can have a thickness of about 1/16 of an inch or greater. The starting insulative pad may be split longitudinally to provide two, three or more partial thickness pads. Optionally, the fibers can include thermoplastic binder fibers and reinforcement fibers are laid randomly yet consistently in x-y-z axes. The reinforcement fibers are generally bound together by heating the binder fibers above their glass transition temperature. Typically, less than about 20% by weight binder fiber is used, and preferably about 15% binder fiber is used to form the insulative pad. 
     Thermoplastic binder fibers are provided having a weight of less than 0.2 pounds per square foot and, more particularly, preferably about 0.1875 pounds per square foot. The remaining reinforcement fiber is greater than 0.8 pounds per square foot, and preferably 1.0625 pounds per square foot. The binder fibers are preferably a mixture of thermoplastic polymers that consist of polyethylene/polyester or polypropylene/polyester or combinations thereof. 
     The insulative pad may be formed by heating the textile fiber batt in the oven to a temperature greater than about 350° F. and, more preferably, to a temperature of about 362° F. Such heating causes the binder fibers to melt and couple to the non-binder fibers, thus causing fibers to adhere to each other and solidify during cooling. Upon cooling, the binder fibers solidify and function to couple the non-binder reinforcement fibers together as well as function as reinforcement themselves. 
     The textile fiber batt is compressed to form the insulative pad so it has a density of greater than about 10 pounds per cubic foot. For systems, the insulative pad preferably has a density of greater than about 10 pounds per cubic foot and, more preferably, about 13.3 pounds per cubic foot with a thickness of about ⅛ inch. 
     The insulating properties of the material are tested under ASTME90-97, ASTME413-87. The insulative pad preferably has a compression resistance at 25% of the original thickness of greater than about 20 psi and preferably about 23.2 psi, at 30% of greater than about 35.0 psi and preferably about 37.0 psi, and at 50% of greater than about 180 psi and preferably about 219 psi. Additionally, the compression set at a compression of 25% of the original thickness is less than 20%, and preferably about 18.8%, and the tensile strength is between about 60 and 80 pounds and, most preferably, about 78.4 pounds. 
     Phase-change materials (refrigerants/gel packs) used in the mailer can also biodegradable, making the entire shipping system cost-effective, environmentally-friendly, and socially-responsible. The insulative properties of the mailer are roughly equivalent to one-half inch of foam, thus, allowing for the savings of second-day shipping as opposed to the cost of overnight priority freight/delivery charges as is required with current mailer technology. 
     The textile pad can serves six purposes: 1) insulation; 2) padding/cushioning; 3) absorption; 4) antimicrobial action; 5) biodegradability and; 6) cost efficiency (in terms of initial cost as opposed to a foam-lined box, set-up/fulfillment labor expenses, storage space, with attendant charges, and in-bound and out-bound freight charges). 
     A specific example of a mailer according to the present invention is one that is 14.5 inches long, 10 inches wide, and has a 4.5 inch flap. The top opening is about 8.5 inches across and can be opened to about 5 inches, thereby facilitating loading. 
     Examples of the materials used for the mailer are as follows. Tri-extruded degradable sheeting can be used as a film. The film is manufactured as 37″ lay flat at 0.004 inches. Grass green, opaque tri-extruded degradable sheeting can be used for polymer film sleeve  26 . The sheeting is manufactured with a degradable additive in all layers. The film is manufactured as 12″ lay flat at 0.0015 inches. For the film  12 , a white opaque outside/silver-color inside tri-extruded degradable sheeting can be used. The sheeting is manufactured with a degradable additive in all layers. The film is manufactured as 12″ lay flat at 0.004 inches. The films are obtainable commercially from a variety of suppliers. 
     An example of the sealing tape  18  is BP-1052 SIS block co-polymer rubber, obtainable from DarTape Technologies Corporation. Biodegradable materials are commercially available from ECM Biofilms, Inc., Painesville, Ohio. Incorporation of at least 1% of the ECM Masterbatch pellets will assure biodegradation. Antimicrobial materials useable are Lurol AM-7 obtainable from Goulston Technologies, Inc. of Monroe, N.C. The insulative pad  28  was made using new textile clippings mixed with commercially available antimicrobial and super-absorbent powders (such as carboxymethylcellulose), and then processed through a web forming operation to produce a pad or batten about 15 mm or 0.6 inches thick. Film  12  can be from about 2 mils thick to about 6 mils thick, and preferably about 4 mils thick. Polymer film sleeve  26  can be from about 0.5 mils thick to about 5 mils thick, and preferably about 3 mils thick. Insulative pad  28  can be from about 5 mm thick to about 25 mm thick, and preferably about 15 mm thick. 
     Optionally, the absorbent material can be incorporated into the batting material prior to the binding of the fibers. Optionally, the absorbent material can be sodium polyacrylate in the form of a white powder. The sodium polyacrylate can have a pH of 5.5-6.5, a melting point of &gt;390° F., and a specific gravity of 0.4-0.7 g/ml. 
     To support the bottles being shipped, the corrugated members  22  interleave to form the bottle holding cavities  24 . The flat members can have notches defined therein so as to allow the interleaving of the flat members  22 . Three interleaved members can form six cavities, four interleaves members  22  can for nine cavities and five interleaved members can be used to form six cavities. The insulative panel  25  is disposed about the side regions of the bottle holding cavities  24 . In addition to being positioned on the side regions of the bottle holding cavities, the insulative pads are positioned at the top and bottom of the plurality of corrugated members  22 . It is envisioned an additional square pad can be interference fit into the pad wrapped around the sides of the interleaved members. 
       FIG. 5  shows a sheet that can be folded into the box  110 . The sheet includes a row of four rectangular segments: front  112 , right  114 , back  113 , and left  115 . Flaps  111 , which will form the top when folded, extend from a top edge of the row of segments  112 ,  114 ,  113 , and  115 . Flaps  111 , which will form the bottom when folded, extend from a bottom edge of the row of segments  112 ,  114 ,  113 , and  115 . A tab  116  is included on one edge and is used during assembly of the box  110  from the sheet. Fold lines  118  are disposed between the flaps  111 , the segments  112 - 115 , and the tab  116 . 
     According to the present teachings, an insulative packaging system has a shipping container, a plurality of corrugated members that interleave to form a plurality of bottle holding cavities, a three layered polymer film laminate container having an interior surface, and a textile padding disposed within the polymer film laminate container. The textile pad is disposed within the container and the polymer film and is formed of chopped fibers selected from the group polyester, nylon, acrylic, cotton, polypropylene, denim and combinations thereof. The textile pad further has microbial and super-absorbent powders disposed adjacent to an exterior surface of the textile pad or within. 
     Disposed within the box  110  is a first U-shaped insulative member or three-segment insert  120  disposed against the box bottom and a first pair of box sides. Disposed above the insulative member  120  is a plurality of interleaved members which form a plurality of bottle holding cavities. A second U-shaped insulative member or three-segment insert  120  is disposed over the interleaved members, so as to position portions of the second U-shaped member against a second pair of box interior sides. 
     The three-segment insert  120  contains three fiber pads disposed within a polymer sleeve. The polymer sleeve is sealed at its ends and tacked together at locations between the fiber pads. As described below, disposed about the interleaved members which form a plurality of bottle holding cavities is a plurality of insulating planar pads. Each planar pad is disposed within a closed polymer envelope. Surrounding the polymer envelope and the member is a corrugated box. 
       FIGS. 1-4  show an embodiment of a panel of stiffened flocked material in to form the three-segment insert  120 . The three-segment insert  120  is made from the stiffened flocked material described previously. The three-segment insert  120  includes three panels  121 ,  122 , and  121  configured in a row. Each segment  121  or  122  is configured to overlay a respective inner surface of the box  110 . A miter joint  123  is formed between each segment  121 ,  122 , and  121 . 
     As shown in  FIGS. 1-4 , three-segment inserts  120  can be used with the box  110  to form a container  100 . First, the box  110  is assembled. Tape  117  can be added around the box  110  to secure the box  110  in its folded shape. Next, a three-segment insert  120  is folded from its unfolded flat form shown in  FIGS. 3 and 4  into a folded U-shaped form shown in  FIG. 1 . As shown in  FIG. 2 , a first folded three-segment insert  120  is inserted into the box  110 . The first leg  121  overlies the right of the box  110 . The base  122  overlies the bottom of the box  110 . The second leg  121  overlies the left of the box  110 . The U-shape member is placed with the base  122  on the bottom of the box  110  to allow a second U-shaped member to be inserted. Next, as shown in  FIG. 1 , a second three-segment insert  120  is folded into a U-shape and inserted into the box  110 . A first leg  121  of the second insert  120  overlies a back  113  of the box  110 . A top  122  of the second insert  120  overlies a top (i.e., folded flaps  111 ) of the box  110 . When the two U-shaped members  120  are inserted within the box  110 , an insulated container is formed. The walls of the U-shaped members  120  are sized to contact each other to prevent air from being able to penetrate the insulated layer. 
       FIGS. 6 and 7  show two cross-shaped embodiments, which are referred to as six-panel inserts  124 , of panels of stiffened flocked material. The panels take the form of four panels  125 ,  130 ,  126 ,  129  aligned in a column and a row of three panels  126 ,  127 , and  128  (i.e., two laterally opposed panels  127  and  128  extending from the top and bottom edges of the second panel  126  in the column). In the embodiment shown in  FIG. 6 , the panels  125 - 130  have miter joints  123  between them. In the embodiment shown in  FIG. 7 , the panels  125 - 130  have scores  130  between them to assist in folding. 
     The embodiment shown in  FIGS. 9-10  can be shipped flat (as shown in  FIGS. 9-10 ) to the user. Then, the user can fold the six-panel inserts  124  into a box shape. The folded six-panel insert  124  is placed within the box  110 . The size of the panels  125 - 130  are configured to overlap corresponding panels  111 - 115  of the box  110 , as shown in  FIG. 10 . 
       FIG. 8  shows a six-panel insert  140 . The six-panel insert is made from six separate panels  125 - 130 . The panels  125 - 130  correspond to the faces  111 - 115  of the box  110 . The panels  125 - 130  are inserted within the box and overly the interior of the faces  111 - 115 . The panels  125 - 130  contact each other to form an insulated layer and compartment within the box  110 . 
       FIGS. 11 and 12  show a one-piece insulative insert  150  including a first pad  152  of the stiffened flocked material, a second pad  154  of the stiffened flocked material, a third pad  156  of the stiffened flocked material, and a strengthening inner layer  158 . The first, second, and third pads  152 ,  154 , and  156  are joined to the inner layer  158  using, for example, an adhesive. The inner layer  158  is formed from a material that is stronger than the stiffened flocked material. In one example, the inner layer  158  is formed from corrugated paper. Thus, when the first, second, and third pads  152 ,  154 , and  156  are joined to the inner layer  158 , the inner layer  158  improves the strength of the insert  150  relative to the strength of the insert  150  without the inner layer  158 . As a result, the strength of a box used with the insert  150 , such as a box  200  shown in  FIG. 13 , may be reduced relative to the strength of a box used with an insert that is similar to the insert  150  but does not include the inner layer  158 . For example, due to the inner layer  158 , a single-wall box may be used with the insert  150  as opposed to a double-wall box (i.e., the box  200  may be a single-wall box as opposed to a double-wall box). 
     The insert  150  is a six-panel insert including six interlinked panels that form a cross configuration similar to that shown in  FIGS. 6 and 7 . The interlinked panels include a first panel  160 , a second panel  162 , a third panel  164 , a fourth panel  166 , a fifth panel  168 , and a sixth panel  170 . Each of the panels  160 - 170  may have a rectangular shape and/or all of the panels  160 - 170  may have the same width and/or the same length. The first, second, third, and fifth panels  160 ,  162 ,  164 , and  168  are aligned with one another and are arranged in a straight row, with at least one of end of each of the aligned panels being attached to an end of another one of the aligned panels. The fourth and sixth panels  166  and  170  are offset relative to the straight row and are attached to opposite sides of the fifth panel  168 . 
     The first pad  152  may have a first length L 1 , the second pad  154  may have a second length L 2 , and the third pad  156  may have a third length L 3 . The first pad  152  may form the insulative portion of the first panel  160 , the second pad  154  may form the insulative portions of the second and third panels  162  and  164 , and the third pad  156  may form the insulative portions of the fourth, fifth, and sixth panels  166 ,  168 , and  170 . Thus, the second length L 2  may be two times greater than the first length L 1 , and the third length L 3  may be three times greater than the first length L 1 . 
     The insert  150  includes a long section  172  and a short section  174  that intersects the long section  172  to form a cross shape. The long section has a first end  176  and a second end  178 , and the short section  174  has a first end  180  and a second end  182 . The long second  172  includes the first and second pads  152  and  154  and the fifth panel  168  of the third pad  156 . The short section  174  includes the entire third pad  156 , and therefore includes the fourth, fifth, and sixth panels  166 ,  168 , and  170 . 
     In various implementations, the first, second, and third pads  152 ,  154 , and  156  of the stiffened flocked material may be replaced with fourth, fifth, and sixth pads of the stiffened flocked material. The fourth pad may form the entire insulative portion of the long section  172  of the insert  150 , and therefore may include the first, second, third, and fifth panels  160 ,  162 ,  164 , and  168 . The fifth pad may form the insulative portion of the fourth panel  166 , and the sixth pad may form the insulative portion of the sixth panel  170 . Thus, each of the fifth and sixth pads may have a length (and/or width) that is equal to the first length L 1 , and the fourth pad may have a width that is four times greater than the first length L 1 . 
     The inner layer  158  includes various features that facilitate folding the insert  150  to fit within a box and removing the insert from a box. For example, the inner layer  158  includes a first fold line  184 , a second fold line  186 , a third fold line  188 , a fourth fold line  190 , a fifth fold line  192 , a first pair of slits  194 , a second pair of slits  196 , and a semi-circular slot  198 . The fourth and fifth fold lines  190  and  192  may be perpendicular to the first, second, and third fold lines  184 ,  186 , and  188 . The fold lines  184 - 192  may be formed by crimping the inner layer  158 . Since crimping compacts material, the density of the inner layer  158  at the fold lines  184 - 192  may be greater than the density of the remainder of the inner layer  158 . The slits  196 ,  198  and the semi-circular slot  198  may be formed by cutting or stamping the inner layer  158 . 
       FIG. 13  shows the insert  150  placed within the cubical box  200  having six sides including a top, a bottom, and four sidewalls. The box  200  may be made from corrugated paper. The box  200  includes four flaps  202  that collectively form the top of the box  200 . To rearrange the insert  150  from the shapes shown in  FIGS. 11 and 12  to the shape shown in  FIG. 13 , the insert  150  is folded along the first, second, fourth, and fifth fold lines  184 ,  186 ,  190 , and  192 . The slits  194 ,  196  facilitate folding the insert  150  along the fourth and fifth fold lines  190  and  192 . 
     Once the insert  150  is arranged as shown in  FIG. 13  and placed within the box  200 , an item to be shipped may be placed within the interior of the insert  150 . Then, the insert  150  may be folded along the third fold line  188  to fully enclose the item, and the flaps  202  of the box may be folded over the third panel  164  of the insert  150  to form the top of the box  200  and thereby close the box  200 . To remove the item from the box  200 , the flaps  202  of the box  200  may be unfolded to their positions shown in  FIG. 13 , and the third panel  164  of the insert  150  may be unfolded to its position shown in  FIG. 13  using the semi-circular slot  198 . More specifically, the semi-circular slot  198  enables one to insert a finger past the inner layer  158  (through the semi-circular slot  198 ) and to pull upward on the inner layer  158  to unfold the third panel  164  of the insert  150  and thereby provide access to the item in the box  200 . 
     As indicated above, the inner layer  158  of the insert  150  enables the strength of the box  200  to be reduced while achieving the same overall strength as the box  200  with the insert  150  when the strength of the box  200  is not reduced and the insert  150  does not include the inner layer  158 . For example, when the insert  150  includes the inner layer  158 , the box  200  made be made from single-wall corrugated paper instead of double-wall corrugated paper. In addition, the cross configuration shown in  FIGS. 11 and 12  enables the insert  150  to lie flat for packaging and shipment thereof, and to fold into the cube-shape configuration shown in  FIG. 13  for placement inside of the box  200 . Further, the insert  150  may be preassembled so that packaging personnel need only fold the insert  150  for placement inside of the box  200  as opposed to, for example, attempting to join the inner layer  158  to the pads  152 - 156  inside of the box  200 . 
     Samples of the inert  150  and the box  200  were tested using a box compression test procedure (TAPPI T804/ASTM D642) and a box puncture test procedure (TAPPI T803). The samples of the insert  150  included a die-cut, single-wall, C-flute corrugated paper laminated to a post-industrial, pre-consumer recycled textile pad. The samples of the insert  150  had inner dimensions of 7 inches (in.) by 7.5 in. by 7.75 in. The samples of the box  200  were made of Regular Slotted Carton (RSC), single-wall, C-flute corrugated paper and had outer dimensions of 10 in. by 10 in. by 10 in. The samples were conditioned at 73 degrees Celsius and 50% relative humidity prior to testing. 
     For the box compression test, the samples of the box  200  were tested both with and without the samples of the insert  150  placed therein. When the samples of the box  200  were tested without the insert  150  placed therein, the samples of the box  200  withstood an average peak load of 506.6 pounds-force (lbf) and an average deflection at peak load of 0.313 in. When the samples of the box  200  were tested with the insert  150  placed therein, the samples of the box  200  withstood an average peak load of 635.3 pounds-force (lbf) and an average deflection at peak load of 0.618 in. Thus, the insert  150  increased the average peak load of the box  200  by 128.7 lbf or 25 percent (%), and the insert  150  increased the average deflection at peak load by 0.305 or 97%. 
     For the box puncture test, samples of the insert  150  were tested without the box  200  and with impact to the corrugated paper, samples of the insert  150  were tested without the box  200  and with impact to the textile pad, and the samples of the box  200  were tested with the insert  150  placed therein and with impact to the box  200 . The insert  150  had a puncture energy of 3.00 Joules (J) with impact to the corrugated paper, the insert  150  had a puncture energy of 8.88 J with impact to the textile pad, and the box  200  had a puncture energy of 8.40 J with the insert  150  placed therein and with impact to the box  200 . 
     Samples of the insert  150  were also tested to evaluate the compression resistance and compression force deflection (CFD) of the insert  150  when the textile pad is facing upward and when the textile pad is facing downward. Compression resistance is the pressure required to compress a sample by a certain percentage (e.g., 25% or 50%), and compression resistance is measured immediately after the compression force is applied. CFD is the pressure required to compress a sample by the certain percentage, and CFD is measured some period (e.g., 60 seconds) after the compression force is applied. 
     When the textile pad is facing upward and the insert  150  is compressed by 25% relative to its original state, the insert  150  has a compression resistance of 0.780 pounds per square inch (psi) and a CFD of 0.586 psi. When the textile pad is facing upward and the insert  150  is compressed by 50% relative to its original state, the insert  150  has a compression resistance of 2.14 psi and a CFD of 1.55 psi. When the textile pad is facing downward and the insert  150  is compressed by 25% relative to its original state, the insert  150  has a compression resistance of 0.730 psi and a CFD of 0.561 psi. When the textile pad is facing downward and the insert  150  is compressed by 50% relative to its original state, the insert  150  has a compression resistance of 2.12 psi and a CFD of 1.55 psi. 
     Samples of the inert  150  were also tested using ASTM C518-17 to evaluate the steady state thermal transmission properties thereof. The samples tested included a first sample having a thickness of 33.2 millimeters (mm) (1.309 in.), a second sample having a thickness of 31.7 mm (1.248 in.), and a third sample having a thickness of 22.3 millimeters (0.879 in.). Each of the first, second, and third samples included a piece of cardboard adhered to one face thereof and having a thickness of 3.2 mm (0.125 in.). 
     The first sample exhibited an average thermal resistance of 0.813 Kelvins meter squared per Watts (K·m2/W) and an R-value of 4.6. The second sample exhibited an average thermal resistance of 0.662 K·m2/W and an R-value of 3.8. The third sample exhibited an average thermal resistance of 0.559 K·m2/W and an R-value of 3.2. 
     The test results set forth above are only example values of the corresponding properties of the insert  150  and the box  200 , and may define a range of acceptable values for the insert  150  and the box  200 . For example, the insert  150  and the box  200  may have properties that are greater than or equal to the values set forth above and/or less than or equal to the values set forth above. In another example, the insert  150  and the box  200  may have properties that are within a predetermined range (e.g., 5%, 10%, 20%, 30%, 40%, 50%) of the values set forth above. In addition, relationships may be drawn between the properties of the samples and the corresponding test results, and those relationships may be used to determine other example values of the properties of the insert  150  and the box  200 . 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the Figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Although the invention has been described in terms of preferred embodiments, changes can be made which do not depart from the inventive concept. Such changes are deemed to fall within the purview of the appended claims. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.