Abstract:
A method of making a cold chain package, includes, providing corresponding rolls of dissimilar insulating packaging material; forming separate panels from sheets of dissimilar insulating packaging material provided by the corresponding rolls; enclosing the panels in a membrane, the membrane defining a hinge between the panels that are adjacent to each other; and folding the panels along each hinge to form a box-shaped chamber.

Description:
[0001]    This application is a divisional of U.S. patent application Ser. No. 12/508,803, filed Jul. 24, 2009, which claims priority under 35 USC 119(e) from Provisional Application 61/083,814 filed Jul. 25, 2008. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to thermally insulated packaging, and more specifically to packaging designed for maintaining packaged items in a refrigerated state. 
         [0003]    There is an increasing demand for so-called “cold chain” packaging that is suitable for maintaining items at temperatures in the range of 34-48° F. for at least as long as 8 days. Typical items shipped via cold chain packaging include pharmaceuticals, foodstuffs and similar perishable items. 
         [0004]    Conventional cold chain packaging typically consists of an outer container, such as a corrugated carton, provided with a lining of either Styrofoam or resilient foam in the form of formed, molded or precut pads, and at least one pre-chilled gel pack, which is a sealed bag-like container of heavy plastic filled with a gel which freezes upon chilling and maintains a relatively low temperature in the container. An exemplary cold chain package is sold by TCP Reliable (www.tcpreliable.com) under the “Timesaver” brand. When a package is desired that has a longer cooling period, a larger outer container is provided, and more layers of foam and gel packs create a thicker insulated compartment. 
         [0005]    Thus, current cold chain packaging is limited by size of the package and/or the length of time items can be kept cold. Also, conventional cold chain packages are largely single use, and as such are environmentally inefficient. 
       SUMMARY 
       [0006]    The present cold chain package includes an arrangement of layers having dissimilar materials that keeps shipped items that need to be kept cold at a designated temperature for a longer period of time than existing packaging. This allows such items to be shipped via ground transportation, i.e., truck, as well as air transportation. The package is also reusable and has a compact design that saves space and minimizes the size of the shipping containers needed to ship items. 
         [0007]    Specifically, the present cold chain package includes a plurality of panels surrounded by an overwrap, where each of the panels includes a plurality of layers of dissimilar materials. The package also includes a hinge formed between adjacent panels of the plurality of panels for facilitating folding of the panels to fit in a shipping container. 
         [0008]    Another embodiment provides a method of making a cold chain package that includes providing corresponding rolls of dissimilar insulating packaging material, forming separate panels from sheets of dissimilar insulating packaging material provided by the corresponding rolls, enclosing the panels in a membrane where the membrane defines a hinge between the panels that are adjacent to each other, and folding the panels along each hinge to form a box-shaped chamber. 
         [0009]    A further embodiment provides a method for distributing cold chain packaging that includes producing and assembling a cold chain package having a pre-printed address identifier that identifies a shipping location, inserting a cold chain package and an article to be delivered in a shipping container at the shipping location, the cold chain package maintaining the article at a desired temperature during shipping, delivering the shipping container to a designated location, returning the cold chain package to the shipping location identified by the pre-printed address identifier via a package courier and reusing the cold chain package in another shipping container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is an overhead plan view of a disassembled package incorporating the present invention; 
           [0011]      FIG. 2  is a schematic sectional view of the package of  FIG. 1  taken along the line  2 - 2  of  FIG. 1  in the direction generally indicated; 
           [0012]      FIG. 3  is an overhead plan view of the present package shown assembled; 
           [0013]      FIG. 4  is a schematic representation of a production line suitable for use in manufacturing the composite packaging material used in the present package; and 
           [0014]      FIG. 5  is a schematic representation of a distribution system suitable for use with the present package. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0015]    Referring now to  FIGS. 1-3 , the present composite cold chain package is generally designated  10  and is made of a web  12  formed, as by die cutting or similar technology into designated panels including front  14 , bottom  16 , left side  18 , right side  20 , rear  22  and top  24 . Overlying each panel  14 - 24  is a bag-like membrane  26 , preferably of a heavy gauge polyethylene overwrap that is heat sealed to form a hinge  26   a  between adjacent panels. It is contemplated that the overwrap material may change depending on the application. The hinge  26   a  facilitates the folding of the panels  14 - 24  into a box shape forming a cold-chain chamber  28 . An advantage of the overwrap  26  is that, after each use, the package web  12  can be cleaned with disinfectant to address microbial growth resulting from condensation during shipment. 
         [0016]    A feature of the present package  10  is that it occupies significantly less space than conventional cold chain packaging for obtaining a designated degree of insulation lasting a specified amount of time. This more efficient cooling power is achieved by creating a composite of dissimilar materials formed into each of the multi-layer panels  14 - 24 . Some of the layers in the present package  10  are novel combinations of otherwise conventional packaging materials. 
         [0017]    Referring now to  FIG. 2 , the preferred layers, which are schematically shown, include material A, including a combination of a sheet of aluminum foil  30  laminated to a corresponding sheet of Bubble Wrap® brand cushioning material  32 , with a transition material  34  therebetween. Suitable cushioning material of this type is manufactured by Sealed Air Corp., www.sealedair.com under the trademark TEMPSHIELD™. As is known in the plastic thermoforming arts, transition materials facilitate thermal bonding between otherwise dissimilar materials. A representative transition material  34  is a heat sealable polyethylene or polyvinylchloride (PVC). A second optional insulating layer is material B, including a combination of preferably polyethylene closed cell foam  36  to which is laminated a sheet of aluminum foil  38  with a transition layer  40  therebetween. Suitable material is also manufactured by Sealed Air Corp under the designation CA-250. It is preferred that the foil  38  face the interior of the package  10 . 
         [0018]    Still another optional layer is material C, which is approximately 1 inch thick foam, preferably closed cell polyurethane foam; however other foams are considered suitable and the thickness may vary. Yet another optional layer is material D, including a layer of Mylar® polyester film  42  laminated to a sheet of fiberfill synthetic filling material  44  with a transition layer  46  therebetween. In some cases, an additional layer of transition material (not shown) may be placed upon the Mylar® film  42  on the opposite side from the transition layer  46 . 
         [0019]    As seen in  FIG. 2 , the web  12  is preferably made of a composite of materials in layers as follows: DABABAB. It will be appreciated that the number, orientation and arrangement of layers may vary to suit the situation. It is also contemplated that at least some of the layers DABABAB may be secured to each other as by heat sealing, or the layers may be loosely contained within the overwrap  26 . 
         [0020]    Referring now to  FIG. 3 , upon assembly, the web  12  is folded into an outer container  50 , typically a corrugated carton so that each of the panels  14 - 24  is associated with a panel of the container. The folded web  12  forms the cold chain chamber  28  into which an article to be shipped  52  is placed, preferably surrounded by pre-chilled gel packs  54 . It has been found that the assembled panels,  14 - 24 , each much thinner than conventional cold chain packaging, have a thickness in the range of 1.5-2.5 inches. It will be understood that the thickness may vary with the number of layers and the combination of composite materials selected. In any event, the package  10  is significantly thinner than conventional cold chain packages with similar temperature maintenance/insulation capabilities. Despite this relatively thin profile, the package  10  has been shown to retain a temperature of 48° F. for at least eight days. 
         [0021]    Referring now to  FIG. 4 , a schematic of the production of the composite layers of materials A, B and D is shown. A supply of each of the insulating materials, such as foam, Bubble Wrap® cushioning material, aluminum foil, foam, Mylar® film, etc. is each provided in a respective roll  58 ,  60 . The transition material  34 ,  40 ,  44 ,  46  is also provided in a roll  62 . A rack  64  is created to arrange the rolls  58 ,  60 ,  62  so that the components of the composite material are arranged in a web format that is placed on a conveyor table  66  which conveys the layers to a heat source  68 , where they are laminated together. After lamination, the composite material is placed upon a take up roll  70 . 
         [0022]    Referring now to  FIG. 5 , besides having reduced weight and bulk compared to conventional cold chain packaging having similar temperature insulation qualities, another feature of the present package  10  is that it is reusable. A network of collection and refurbishing facilities is envisioned for facilitating the reuse of such packages, further reducing the cost to the shipper. The smaller size of the present package facilitates such shipment. 
         [0023]    More specifically, the present network, generally designated  80 , includes a Distribution Center  82  where the packages  10  are produced by assembling the webs  12  into packages and inserting the packaged articles  52 . The packages  10  are shipped by courier, such as UPS, FedEx, USPS and the like to an end user  84 . Due to the longer temperature retention properties of the present cold chain packaging, the shipping process can be extended to at least as long as 7 days. Thus, goods which previously had to be shipped by air can now travel by ground. 
         [0024]    Since the packages  10  have preprinted return labels, bar code identification, RFID tags or similar identifiers, the end user  84  can return them to the Distribution Center  82 , or to a Refurbishing facility  86 , where the package is disassembled, checked for damage and reassembled as needed prior to reshipment in bulk to the Distribution Center  82 . In this manner, the packaging is reused numerous times, reducing packaging and shipping cost compared to conventional cold chain packaging technology. Due to the identifiers, the Distribution Center  82  can grant credits, discounts, rewards or other incentives to the end user  84  to encourage return of the packages  10 . Conversely, the same identifiers can be used so that the end user  84  is charged if the package  10  is not returned. 
         [0025]    While a particular embodiment of the present cold chain package has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.