Patent Publication Number: US-11377280-B1

Title: Biodegradable insulative shipping container

Description:
CROSS REFERENCES AND RELATED SUBJECT MATTER 
     This application is a continuation of U.S. patent application Ser. No. 16/044,593 filed Jul. 25, 2018, which is a divisional of U.S. patent application Ser. No. 15/006,814 filed on Jan. 26, 2016, which claims the benefit of priority to Provisional Application Ser. No. 62/115,237 filed Feb. 12, 2015. The foregoing applications are each incorporated by reference in their entirety herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to a shipping container. More particularly, the present disclosure relates to a shipping container that is capable of insulating its contents while being made of recyclable and biodegradable elements. 
     BACKGROUND 
     When certain items are shipped—especially perishable food items—it is highly desirable to maintain their temperature within a predetermined range. Considering the significant variations of temperature that may occur during the shipping process, however, this is often difficult to do. Along any shipping route, a package will experience variations in temperature due to time of day as well as geographic locale. In addition, certain conveyances—such as airplane cargo areas—may subject the package to rather significant temperature extremes. 
     Other than providing climate-controlled shipping environments, the most common way of reducing temperature variation is to employ insulated packaging materials. Among these, the most common is polystyrene based packaging—commonly known by the tradename STYROFOAM. Styrofoam is notoriously bad for the environment, as it cannot be easily recycled, and often ends up in landfills or polluting our oceans. Other insulative materials used in packaging suffer from a similar shortcoming—they are not safely biodegradable, recyclable, or sustainable. 
     Accordingly, in the state of the art of packaging, when selecting materials, package designers are forced to trade between desired insulating properties and using materials that do not harm the environment. 
     As an example, within the wine industry, often it is desirable to ship small quantities directly to consumers—such as for wine club shipments. In such applications, both pulp-based shipping containers and molded EPS (expanded polystyrene) containers are used. The issue with pulp shipping containers is that they have no significant insulative properties. EPS on the other hand are not recyclable by consumers. 
     While these units may be suitable for the particular purpose employed, or for general use, they would not be as suitable for the purposes of the present disclosure as disclosed hereafter. 
     In the present disclosure, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which the present disclosure is concerned. 
     While certain aspects of conventional technologies have been discussed to facilitate the present disclosure, no technical aspects are disclaimed and it is contemplated that the claims may encompass one or more of the conventional technical aspects discussed herein. 
     BRIEF SUMMARY 
     An aspect of an example embodiment in the present disclosure is to provide a shipping container that is biodegradable and recyclable. Accordingly, the container has both an outer tray and an inner tray made of pulp. 
     It is another aspect of an example embodiment in the present disclosure to provide a shipping container that is capable of providing thermal insulation to its contents. Accordingly, the shipping container includes a middle layer that includes insulative materials. 
     It is yet another aspect of an example embodiment in the present disclosure to provide a shipping container that employs biodegradable insulation so that it is fully biodegradable. Accordingly, by an example embodiment, starch pellets are employed to provide thermal insulation between the pulp-based outer and inner trays. 
     It is a still further aspect of an example embodiment to provide a shipping container suitable for shipping wine and related beverages. Accordingly, a packaging unit is created that has an inner tray sized and shaped to hold at least one bottle of wine, while providing a thermal insulative R value of 3-5. 
     It is yet a further aspect of an example embodiment to provide a shipping container that is easy and inexpensive to manufacture. Accordingly, the shipping container may be created using a simple process described in further detail hereinbelow. 
     Accordingly, the present disclosure describes a shipping container, particularly suited for shipping wine bottles within a shipping box, having a pair of container halves. Each container half includes an outer tray that is shaped to fit the shipping box, and an inner tray that is configured for securely holding one or more wine bottles. Both the outer tray and inner tray are made of readily recyclable pulp material, and have a void therebetween. A starch based biodegradable insulation material fills the void therebetween, such that the shipping container is made entirely of biodegradable material, yet is sturdy and has insulative properties. 
     The present disclosure addresses at least one of the foregoing disadvantages. However, it is contemplated that the present disclosure may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claims should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed hereinabove. To the accomplishment of the above, this disclosure may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact, however, that the drawings are illustrative only. Variations are contemplated as being part of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings, like elements are depicted by like reference numerals. The drawings are briefly described as follows. 
         FIG. 1A  is a diagrammatic perspective view, providing an outside view of a shipping container, wherein the shipping container halves are mated together to close the container. 
         FIG. 1B  is a diagrammatic perspective view, illustrating one of the halves of the shipping container. In the example illustrated, the container is configured for securely holding and shipping bottles of wine. 
         FIG. 2A  is a cross sectional view of one of the shipping container halves, illustrating a multi-layer construction made in accordance with the principles of the present disclosure, wherein an insulation tray is placed between the outer tray and inner tray. 
         FIG. 2B  is a cross sectional view, similar to  FIG. 2A , illustrating fabrication of one of the container halves using expandable insulation pellets that are introduced into the void between the outer tray and inner tray. 
         FIG. 3  is an exploded view, illustrating a further embodiment of the shipping container, wherein the inner tray and outer tray are being assembled. 
         FIG. 4  is a diagrammatic perspective view, showing the embodiment of  FIG. 3  wherein the inner tray and outer tray are assembled into the container half. 
         FIG. 5A  is a cross sectional view, illustrating the embodiment of  FIG. 3 . 
         FIG. 5B  is a cross sectional view, illustrating the embodiment of  FIG. 3 , in the position shown in  FIG. 4 , with the insulation not shown for clarity of illustration. 
     
    
    
     The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, which show various example embodiments. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that the present disclosure is thorough, complete and fully conveys the scope of the present disclosure to those skilled in the art. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1A  illustrates a shipping container  10 . The shipping container includes two shipping container halves  12 , each having a mating edge  14 . The shipping container  10  is substantially rectangular prism shaped, and are thereby sized and shaped to fit within a shipping box, such as a standard corrugated box. The shipping container halves  12  are substantially the same size and shape, and are substantially symmetrical with respect to the mating edge  14 . When the shipping container is in a closed position, as illustrating, the mating edges  14  of the shipping container halves  12  are aligned and contact each other. 
     Referring now to  FIG. 1B , one of the shipping container halves  12  has been removed, revealing the interior of the shipping container  10 . In particular each shipping container half  12  includes an outer tray  21  and an inner tray  22 . The outer tray  21  is generally black and the inner tray  22  is generally white. Note that the outer tray  21  is generally shaped to conform to the rectangular shipping box in which it is placed during ordinary usage. The inner tray  22 , however, is configured to accept, securely hold, and cushion the desired contents, namely shipping goods intended to be transported. Such shipping goods may include (but are not limited to) items such as wine bottles, as well as various food and medical items. In the example illustrated, wine bottles  40  are the shipping goods that the shipping container  10  is adapted to hold securely for shipment. Each wine bottle  40  has a body  42  and a neck  44 . 
     The inner tray  22  is configured with several large cavities  24 , each large cavity for holding the body  42  of one of the wine bottles  40 . In addition a plurality of ribs  26  extend into each cavity to contact the body  42  of its associated wine bottle  40 . By contacting only a portion of the bottle, the ribs  26  aid the insulative performance of the container  10 . In addition, the inner tray  22  provides a neck hollow  28  for each wine bottle, for accommodating the neck thereof. The inner tray also has several protruding mating portions  29 A and receding mating portions  29 B, which protrude and recede from the plane of the mating edge  14 , such that the protruding mating portions  29 A are received within the receding mating portions  29 B of the other container half  12 , and vice versa. 
     Note that in the example illustrated the inner tray  22  is configured for holding three wine bottles. It should be understood, however, that the inner tray  22  may be easily reconfigured or resized to hold a different number of wine bottles. In addition, the precise layout of the inner tray, and its topological features, may be varied while adhering to the principles described herein. 
     Referring now to  FIG. 2A , interior construction of the shipping container  10  is illustrated. In particular, generally between the inner tray  22  and outer tray  21  is a void  23 . Note that the mating edge  14  may actually be layered—formed of portions of both the inner tray  22  and outer tray  21 , such that the mating edge  14  actually becomes a sealing surface between the inner tray  22  and outer tray  21 . In accordance with the principles of the present disclosure, it is desirable to fill the void  23  with a biodegradable, recyclable and sustainable, insulative material. Illustrated in  FIG. 2A , the void is filled with an insulation tray  51 , that is substantially solid and in a single, pre-shaped piece as fabricated, and shaped to fit the void  23 . A suitable material for the insulation tray  51  is a starch and fiber based material sold under the tradename PAPERFOAM. To manufacture the shipping container according to this embodiment, the insulation tray  51  is placed between the inner tray  22  and outer tray  21 . In the example illustrated, the three trays  21 ,  51 ,  22 , are then heat-pressed together. Other techniques may be employed for joining the inner tray  22  and outer tray  21 , as will be described further, hereinbelow. 
     In the embodiment of  FIG. 3  and  FIG. 5A , the mating edge  14  includes four flaps  14 A that extend from the inner tray  22  and are configured to fold and extend into the outer tray  21  and secure thereto. In particular, the inner tray has a top  22 T and a substantially rectangular peripheral edge  22 P located along the top  22 T. The flaps  14 A extend outwardly from the peripheral edge  22 P and are foldable to extend downwardly therefrom (as shown). In addition, the outer tray  21  has four side walls  21 S that are substantially perpendicular to each other and have a side wall top  21 T. The outer tray  21  also has a bottom panel  21 B, the side walls  21 S extending upwardly from the bottom panel  21 B by a sidewall height. The inner tray  22  includes an irregular concave valley  24 A, the valley is a continuous surface that extends downwardly from the peripheral edge  22 P and top  22 T to define an interior volume that is adapted to accept shipping goods, and may include the large cavities  24  for holding wine bottles or other shipping goods, as described above with reference to  FIG. 1B . The concave valley  24 A only extends below but does not protrude above the top  22 T. The concave valley  24 A includes a recessed channel  25  spanning the longitudinal length of concave valley  24 A to the neck hollow  28 . The recessed channel  25  helps with air flow through the inner tray  22  when the shipping container is closed. 
     Referring now to  FIG. 5B , the flaps  14 A are configured to fit within the outer tray  21 , such that they extend within the side walls  21 S toward the bottom panel  21 B. The flaps may be coated with an adhesive such that as they extend against the side walls  21 S they will bond securely thereto, to affect a tight seal between the inner tray  22  and outer tray  21 . Once insulative material is placed in the void  23  between the inner tray  22  and outer tray  21 , as described herein, they thereby form the completed shipping container half  12 , shown in  FIGS. 4 and 5B . 
       FIG. 2B  shows a further embodiment of the container, wherein the void  23  between the inner tray  22  and outer tray  21  is filled with expandable starch insulation pellets  52 . The assembly of the outer tray  21  and inner tray  22  with the starch insulation pellets  52  is then heated within a pressurized oven. As the pellets are heated, they expand to fill up the void  23  between the outer tray  21  and inner tray  22 . Once removed from the oven, the assembly is then heat pressed to seal the outer tray  21  and inner tray  22  together—trapping the now expanded insulation pellets  52  therebetween. 
     It is understood that when an element is referred hereinabove as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. 
     Moreover, any components or materials can be formed from a same, structurally continuous piece or separately fabricated and connected. 
     It is further understood that, although ordinal terms, such as, “first,” “second,” “third,” are 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 are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. 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 herein. 
     Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, are 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. It is understood that the spatially relative terms are 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 can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Example embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein, but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims. 
     In conclusion, herein is presented a biodegradable insulative shipping container. The disclosure is illustrated by example in the drawing figures, and throughout the written description. It should be understood that numerous variations are possible, while adhering to the inventive concept. Such variations are contemplated as being a part of the present disclosure.