Patent Description:
A conventional container for shipping temperature sensitive products includes a cardboard box, inside of which is a thermally insulating material. A conventional thermally insulating material is expanded polystyrene (EPS), e.g., Styrofoam. For example, panels of the expanded polystyrene can line the walls of the box, and another packing material, e.g., bubble wrap, can be placed surround and cushion the item being shipped inside the panels. Alternatively, expanded polystyrene can be machined or molded to form a "cooler" into which the item being shipped can be placed - this does not need an external box. In either case, a coolant, e.g., ice, dry ice or a gel pack, is placed in the cavity in the box with the item being shipped.

EPS is relatively inexpensive and easily formed into a variety of shapes, but is not compostable. Consequently, disposing of the material of the container can be a problem.

<CIT> describes a thermally insulated container ensures the preservation of temperature-sensitive goods during transportation. The walls of the container comprise relatively thin, vacuum-sealed panels , which contain a rigid open-cell structure The exterior of the panels consists of a thin layer of plastic having low gas and moisture permeability. The panels can be made in six separate pieces, each representing a wall of a box, or formed together in a number of multi-panel combinations with a flexible hinge separating each panel. Once arranged to accept temperature-sensitive goods in its cavity, the insulated container can be placed in a protective enclosure.

<CIT> describes a shock absorbing insulated shipping container including an external corrugated cardboard box, receiving a product box therein. Peripheral spaced, and upper and lower spaced between the external box and the product box receive insulating pellets, which are maintained under a compressive force in order to interlock these insulating pellets and prevent their migration during transit of the shipping container.

<CIT> describes a cold service thermal insulating box in which wo materials such as a first sheet-like foamed inner material and a second sheet-like foamed inner material which comprise the paper powder component or the vegetable powder component as the main component and respectively have three sheets of continuous inner sheet-like parts, are respectively bent and formed into approximately U-shapes.

A container is described that provides for thermal insulation of an item being shipped while the components are still recyclable or compostable.

In one unclaimed aspect, a shipping container to hold an item includes an exterior box, a cover to close off a top of the box, and a plurality of thermally insulating pads positioned in a cavity in the box. The box has a floor and a plurality of side walls to define the cavity therein and an opening to the cavity at the top of the box. The plurality of thermally insulating pads are positioned such that each of the floor, plurality of side walls and cover are adjacent to and covered by a pad from the plurality of thermally insulating pads. The plurality of thermally insulating pads are shaped to provide an interior space to receive the item. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

In another unclaimed aspect, a shipping container to hold an item includes an exterior box, a cover to close off a top of the box, and a thermally insulating pad positioned in a cavity in the box. The exterior box has a floor and a plurality of side walls to define the cavity therein and an opening to the cavity at the top of the box. The insulating pad is positioned such that each of the floor, plurality of side walls and cover are adjacent to and covered by a portion of the pad. The thermally insulating pad is shaped to provide an interior space to receive the item. The thermally insulating pad includes a solid compostable panel formed primarily of extruded milled sorghum, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket. The multi-section panel is scored across its width in at least five locations, each score extending partially but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at each score such that the panel provides six rectangular plates, each plate of the six rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plate is adjacent.

In another unclaimed aspect, a shipping container to hold an item includes an exterior box, a cover to close off a top of the box, and six thermally insulating pads positioned in a cavity in the box. The exterior box has a floor and a plurality of side walls to define the cavity therein and an opening to the cavity at the top of the box. The six thermally insulating pads are positioned such that each of the floor, plurality of side walls and cover are adjacent to and covered by a pad from the plurality of thermally insulating pads. The six thermally insulating pads are shaped to provide an interior space to receive the item. Each pad of the six thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket.

In another unclaimed aspect, a method of fabricating a shipping container to hold an item includes fabricating a plurality of thermally insulating pads, each pad fabricated by placing a solid compostable panel formed primarily of milled sorghum between two sheets of compostable water-proof film, and heat sealing the two sheets such that the panel is enclosed in a pocket of water-proof film that completely surrounds the panel with the panel loose in the pocket. At least one of the plurality of thermally insulating panels is scored across its width to provide a multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates. The plurality of thermally insulating pads are inserted into a cavity of an exterior box such that each of a floor, plurality of side walls and cover of the box is adjacent to and covered by a pad from the plurality of thermally insulating pads and the plurality of thermally insulating pads provide an interior space to receive the item. Each rectangular plate is dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent.

In a claimed aspect, a thermal insulation article is embodied according to claim <NUM>.

At least one of the plurality of thermally insulating pads is a multi-section pad including a plurality of rectangular panel sections enclosed by the film. The multi-section pad is configured to be foldable at a right angle along a boundary between the panel sections and each panel section is dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of rectangular panel sections is adjacent. The film provides both an interior surface of the multi-section pad and an exterior surface of the multi-section pad where the pad is folded.

Implementations may include one or more of the following features.

An interior of the pocket may be evacuated of air. The panel may be slidable within the pocket. The film may be affixed on at least one of an interior surface or exterior surface of the panel by an adhesive. The adhesive may be a portion of the panel exposed to water such that the starch in the portion of the panel becomes tacky.

The at least one of the plurality of thermally insulating pads may include a score across its width in at least one location on an interior surface of the panel, the score extending partially but not entirely through the thickness of the multi-section panel to divide the panel into the plurality of rectangular panel sections. The score may be a compressed portion or a cut out portion of the multi-section body.

The starch may be a grain starch, a root starch, a vegetable starch, or combinations thereof. The starch may include corn starch, wheat starch or milled sorghum. The panel of each pad may have a uniform homogenous composition. The plurality of rectangular panel sections may be part of a single unitary body.

In another unclaimed aspect, a thermal insulation article for placement in a shipping container to hold an item includes a multi-section thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover from two to five of out of a floor, four side walls and cover of the container while leaving an interior space to receive the item. The thermally insulating pad includes a plurality of solid compostable panel sections formed primarily of grain starch, and a compostable or polyethylene water-proof film forming a pocket enclosing the plurality of panel sections. Each panel section holds together as a single unit, and each panel section provides a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent.

The multi-section thermally insulating pad is configured to be foldable at a right angle along a boundary between the panel sections. The film covers both an interior surface of the multi-section thermally insulating pad and an exterior surface of the multi-section thermally insulating pad where the multi-section thermally insulating pad is folded.

An interior of the pocket may be evacuated of air. The plurality of solid compostable panel sections may be slidable within the pocket. The film may be affixed by an adhesive on at least one of an interior surface or exterior surface of one or more of the panel sections. The adhesive may be a portion of the panel exposed to water such that the starch in the portion of the panel becomes tacky.

The plurality of solid compostable panel sections may be part of a single unitary body. The unitary body may be a panel having a score across its width in at least one location on an interior surface of the panel, the score extending partially but not entirely through the thickness of the panel to divide the panel into the plurality of panel sections. The score may be a compressed portion or a cut out portion of the body. The multi-section thermally insulating pad may include a plurality of stacked panels.

The plurality of solid compostable panel sections may each have a thickness between of about <NUM>,<NUM> and <NUM>,<NUM> (¼ and <NUM> inch).

The plurality of solid compostable panel sections may each have a density of about <NUM> to <NUM>/cm<NUM>. Each of the plurality of solid compostable panel sections may be basically flat. One or more surfaces of one or more of the plurality of solid compostable panel sections may be corrugated. The starch may be a grain starch, a root starch, a vegetable starch, or combinations thereof. The starch may include corn starch, wheat starch or milled sorghum. The each solid compostable panel section may have a uniform homogenous composition.

Potential advantages may include (and are not limited to) one or more of the following.

The insulating material is compostable, and the exterior box is recyclable, so all of the components of the container are easily disposable. The film containing the insulating material is compostable or recyclable, and also easily disposed. The container can be easily assembled, and the insulating pads that fit inside the container can be manufactured at low cost. The insulating pads can provide equivalent thermal insulation to expanded polystyrene, and can be disposed in commercial and residential composting or recycling bins or garbage cans. The container components can be shipped in bulk in an unassembled state with minimal cost increase, and assembly of the container can be performed by the user.

Initially, some terminology may be beneficial. "Biodegradable" simply means that a product will eventually disintegrate into to innocuous material. "Recyclable" indicates that a product can be reused or treated in order to be made suitable for reuse. "Compostable" indicates both that a product will decompose quickly, e.g., within <NUM> days, and that the product will decompose into material that can be used as fertilizer (e.g., per ASTM D6400 or EN <NUM>). Products that are "biodegradable" need not be (and usually aren't) "compostable. " First, since there is no particular time limit for a "biodegradable" product to disintegrate, it need not decompose quickly. For example, even aluminum cans will biodegrade given several centuries. Moreover, even a biodegradable product that decomposes quickly might not provide a material that is suitable as fertilizer.

Most conventional thermally insulating materials for packaging, e.g., EPS, are not compostable. One technique for using a compostable insulating packaging material is to fill a volume between an inner wall and an outer wall of a box with loose-fill compostable cornstarch foam pellets (e.g., packing "peanuts") using layered stratification, and then compress each layer of foam pellets in within this volume to compact them. This technique requires either multiple boxes or a specialized box having both inner and outer walls, and also requires specialized machinery for layered stratification compaction of the pellets. The additional or specialized boxes increase the cost. In addition, the loose fill pellets are difficult to compost because they are messy when removed from the box. Moreover, a large amount of pressure, e.g., <NUM> lbs. or more, needs to be applied to close the top flaps of the box due to the resistance from the pellets.

However, instead of loose-fill foam pellets, a solid compostable panel formed primarily of extruded starch, e.g., milled extruded sorghum, can be enclosed by a biodegradable or compostable water-proof film to provide a thermally insulating pad, and this pad can be used as the insulating packaging in the container.

<FIG> is an exploded perspective view of an example of an insulated shipping container <NUM>. The shipping container <NUM> includes a box <NUM> and multiple thermally insulating pads <NUM> that fit inside an interior cavity <NUM> of the box <NUM>. The thermally insulating pads <NUM> are shaped such that when positioned in the box <NUM> they provide an interior space to receive the item and optionally a coolant, e.g., ice, dry ice or a gel pack.

The box <NUM> can be a rectangular prism, and can includes rectangular side walls <NUM> that define the interior cavity <NUM>. The bottom of the box may similarly be closed off by one or more flaps (not shown due to the perspective view). The top of the box <NUM> provides an opening to the interior cavity <NUM>. A cover for the box <NUM> can be provided by one or more flaps <NUM> that can be folded inwardly from the side walls <NUM> to close off the top of the cavity <NUM>. In some implementations, the side walls <NUM>, flaps <NUM> and bottom of the box are all part of a single integral sheet that is folded into an appropriate shape. Alternatively, the cover for the box <NUM> can be provided by a separate lid that fits over the side walls <NUM>.

The box <NUM> is a recyclable material. For example, the box <NUM> can be a cardboard box, e.g., paper board or corrugated cardboard.

As noted above, the container includes multiple thermally insulating pads <NUM> that fit inside the box <NUM>. Each pad <NUM> is formed by sealing a solid compostable panel (or multiple solid compostable panels) within a recyclable and biodegradable or compostable water-proof film. In some implementations, the pad includes a single panel. Each pad <NUM> is relatively thin, e.g., about <NUM>,<NUM>-<NUM>,<NUM> (<NUM>-<NUM> inch) thick, as compared to the length and width of the pad. The thickness of a pad <NUM> is considered to be along its narrowest dimension, whereas the length and width of the pad <NUM> are considered to be along the two directions along the primary face, perpendicular to the thickness.

Each panel can be formed primarily of starch, e.g., an extruded starch. The starch can be a grain starch, e.g., corn starch, wheat starch or sorghum (sorghum is also known as milo), a root starch, e.g., potato starch, a vegetable starch, or combinations thereof. Other materials that do not interfere with the compostable nature of the panel, e.g., a softener to improve adhesion of the starch, or a preservative or anti-fungal agent, can be present, but only in small quantities. For example, at least <NUM>%, e.g., at least <NUM>-<NUM>%, by weight of the panel is starch. Polyvinyl alcohol can be present, e.g., <NUM>-<NUM>% by weight.

Each panel is "solid", which in this context indicates that the panel holds together as a single unit, rather than being formed of loose-fill pellets. It may be noted that compressed starch pellets would not form a solid part; upon removal of pressure the pellets would disassemble, and increased pressure only fractures or pulverizes the pellets. A solid panel of extruded starch provides significant thermal insulation, while still being compostable.

It is possible for the panels to be a foam material, e.g., to include small pores or voids spread substantially uniformly through the panel. For example, <NUM>-<NUM>% of the volume of the panel can be pores or voids, e.g., <NUM>-<NUM>%, <NUM>-<NUM>%, <NUM>-<NUM>%, <NUM>-<NUM>%. The maximum size of the pores or voids can be about <NUM>. Although the panel could be a foam material, it is generally incompressible. The density of a panel can be about <NUM>-<NUM>/cm<NUM>, e.g., <NUM>-<NUM>/cm<NUM>, <NUM>-<NUM>/cm<NUM>, <NUM>-<NUM>/cm<NUM>.

Each panel can be of a uniform homogenous composition. Furthermore, each panel can be a unitary body - that is the body of the panel holds together by itself without adhesives or fasteners to join multiple sections together to form the panel.

The thickness of a panel can be about <NUM>,<NUM>-<NUM>,<NUM>, e.g. <NUM>,<NUM>-<NUM>,<NUM> ( <NUM>-<NUM> inches, e.g., <NUM>-<NUM> inches). Any given panel can have substantially uniform thickness across its primary surface. The surfaces of the panel can be generally flat, or one or more surfaces can be corrugated. Corrugation can increase the effective thickness of the pad, e.g., by a factor of up to <NUM>. In this case, the thickness of the panel can still be uniform, but the panel is shaped with corrugations.

Each panel can include one or more rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent. In some implementations, the whole of the panel, when in an unfolded configuration, is also rectangular.

The panels can be formed by an extrusion process. After extrusion, each panel can be cut to the appropriate size. In addition, the edges can optionally be beveled as to provide the beveling of the pads described above. In addition, the panel that provides the collar can be scored, as described below.

The water-proof film can be a plastic film. In some implementations, the film is air-tight.

In some implementations, the water-proof film is compostable, e.g., a bioplastic that meets ASTM D6400 standards. Suitable materials for a compostable film include polymers based on one or more of polylactic acid (PLA), poly(beta-amino) esters (PBAE), polyhydroxyalkanoate (PHA), polycapralactones (PCL), polybutyrate adipate terephthalate (PBAT) polyvinylalcohol (PVA), or ethylene vinyl alcohol (EVOH). For example, a combination of PBAT and PE may be suitable. As another example, a combination of PE and PLA may be suitable. In some implementations, the polymer can be mixed with an organic product, e.g., a starch, such as corn starch.

In some implementations, the water-proof film is recyclable and biodegradable. A suitable material for the recyclable film is polyethylene. For example, the film can be a low-density polyethylene (LDPE), a medium-density polyethylene (MDPE) or a high-density polyethylene (HDPE). An advantage of polyethylene is ease of fabrication and good water resistance.

A problem with starch-based insulation is that it dissolves easily in water. If the item being shipped is cold or a coolant is placed in the interior of the container <NUM>, condensation can form on the interior surfaces of the pad <NUM>. However, the film prevents liquid, e.g., the condensation, from reaching the starch panel, thus enabling the starch panel to be usable as a thermal insulator in the container.

To fabricate a pad <NUM>, the starch panel can be placed between two sheets of the water-proof film. The edges of the water-proof film can be heat-sealed to each other, e.g., along the entire perimeter of the panel, thus enclosing and sealing the panel in a pocket of the compostable water-proof film that has only slightly larger dimension than the panel itself. A suitable sealing temperature is above <NUM>° C. Excess film outside the heat seal can be cut away.

In the directions parallel to the primary surface of the panels, the pocket can be up to about <NUM>,<NUM> (<NUM> inches) larger on each side than the panel.

Alternatively, the film can be provided in a tubular form. To fabricate a pad <NUM>, the panel is slid inside the tube of water-proof film, and the two open ends of the tube are heat sealed. This forms a pocket in which the panel sits.

According to the invention the panel sits loose inside the pocket formed by the film. That is, the panel is not bonded or otherwise fixed to the film. Thus, the panel can slide inside the pocket relative to the film. For example, the film can be in sliding contact with the panel. The interior of the pocket can include a small amount of air. In some implementations, the air is vacuumed out before the pocket is sealed.

In some implementations not according to the invention, the panel is affixed to the film. For example, the film can be secured to the panel by heat bonding the film to the panel. As another example, the film can be secured to the panel by an adhesive. The adhesive can be a separate additive, or the adhesive can be provided by applying water to the panel to cause the starch in a portion of the panel at the surface to become tacky such that the film sticks to the panel.

The film can be affixed on both the interior and exterior surface of the panel, or on just one surface of the panel, e.g., just the interior surface or just the exterior surface of the panel. In addition, for each of the interior and exterior surface of the panel, the film can be affixed across the entire surface, or on just a portion of the surface, e.g., a perimeter portion along the edge or a central portion that is spaced away from the edge fo the panel.

Other than one or panels, there need not be any other thermally insulating material within the water-proof film. For example, unless one of the panels fractures due to applied stress, there are no loose pellets or pieces of other insulating material in the volume enclosed by the film. In some implementations, the pad <NUM> consists of, i.e., includes only, one or more panels, the water-proof film, and optionally some air inside the volume enclosed by the film.

Where both the panel and water-proof film are compostable, the entire pad can be disposed of as a unit in a composting bin. Where the panel is compostable and water-proof film are is recyclable, the film can be ripped off the panel manually by the recipient of the package, and then the panel can be disposed of in a composting bin and the film can be disposed of a recycling bin.

In the implementation shown in <FIG>, the thermally insulating pads <NUM> include a bottom pad <NUM>, a collar <NUM>, and a top pad <NUM>.

The bottom pad <NUM> has a length and width that match the bottom of the box <NUM>, or are slightly smaller, e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance, so that bottom pad <NUM> fits snugly at the bottom of the cavity <NUM> on the bottom of the box <NUM>.

The collar <NUM> includes a single panel that is folded into four wall members <NUM>. Each wall member <NUM> has a height (in the vertical direction) about equal to the height of the box <NUM>, less the combined thickness of the top pad <NUM> and bottom pad <NUM>. Each wall member <NUM> has a width (in the lateral direction) that matches the adjacent side wall <NUM> of the box <NUM>, or is slightly smaller, e.g., e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance. Thus, the collar <NUM> fits snugly into cavity <NUM> on top of the bottom pad <NUM>, with each wall member <NUM> adjacent, e.g., in contact with, one of the side walls <NUM>.

The top pad <NUM> has a length and width that match the top of the box <NUM>, or are slightly smaller, e.g., e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance, so that the perimeter of the top pad <NUM> can sits on the wall members <NUM> of the collar <NUM> and the top pad <NUM> itself fits snugly at the cavity <NUM>. When the top of the box <NUM> is closed, e.g., by closing the flaps <NUM> or placing a lid, the top pad <NUM> sits adjacent, e.g., in contact with, the top of the box <NUM>.

In some implementations, the surfaces of the pads <NUM> are basically flat up to and including their edges. "Basically flat" is used to indicate flat at the scale of the thickness of the pad, but still encompasses the possibility of small scale surface texturing. Thus, the lower rim of the collar <NUM> simply sits basically flat on the perimeter of the top surface of the bottom pad <NUM>, and the perimeter of the top pad <NUM> simply sits basically flat on the upper rim of the collar <NUM>. Alternatively, the interior surfaces of each pad, i.e., the surface of the pad facing the cavity and further from the box <NUM>, can be beveled at the edge that is adjacent another pad. Thus, the beveled lower rim of the collar <NUM> sits on the beveled perimeter of the bottom pad <NUM>, and the beveled perimeter of the top pad <NUM> sits of the beveled upper rim of the collar <NUM>. In this latter case, the outer surface of each wall member <NUM> can have a height about equal to the height of the box <NUM>.

<FIG> illustrate an example of construction of the pads <NUM> of the insulating shipping container <NUM> shown in <FIG>.

Referring to <FIG>, an exploded perspective view, the collar <NUM> can be fabricated by forming a solid compostable panel <NUM> that has a length L approximately equal to or slightly less than the length of the lateral perimeter of the box <NUM>, and a width W approximately equal or slightly less than the height of the box <NUM>. The panel <NUM> is then placed between two sheets <NUM> of the compostable water-proof film. Referring to <FIG>, a cross-sectional side view, the two sheets <NUM> are heat sealed along a path than extends around the entire perimeter of the panel <NUM>. The seal can be positioned no more than about <NUM>,<NUM> (<NUM> inch), e.g., no more than about <NUM>,<NUM> (<NUM>/<NUM> inch), from the edge of the panel <NUM>. Excess film outside the heat seal can be cut away.

<FIG> is a cross-sectional side view, and <FIG> is a perspective view. Referring to <FIG>, before or after sealing the panel <NUM> between the sheets <NUM>, one surface of the panel <NUM> (which will be the inward facing surface of the panel) can be scored in three locations to divide the panel <NUM> into four rectangular plates <NUM>, which correspond to the four side walls of the collar <NUM>. The length of each plate <NUM> corresponds to the width of the corresponding side wall <NUM> of the collar <NUM>. Scoring can be performed by compression with an angled rigid body.

Each score can create a recess <NUM> that extends across the width W of the panel. The recess <NUM> extends partially, but not entirely through the thickness of the panel <NUM>. For example, the recess <NUM> can extend through about <NUM>-<NUM>% of the thickness of the panel <NUM>. The scoring can be angled, so the recess has a triangular cross-section.

The reduced thickness of the panel <NUM> in the scored areas increases the flexibility of the panel so that the panel <NUM> can be bent at a right angle without breaking. In particular, the panel <NUM> can be folded inwardly (with the inside surface being the side with the recess <NUM>). This permits the panel <NUM> to remain as a single unitary part when the collar <NUM> is folded and placed in the box <NUM>, which can improve thermal insulation by reducing creation of gaps in the insulating material.

<FIG> is a schematic exploded perspective view. <FIG> is a schematic cross-sectional side view. <FIG> is a schematic perspective view. Referring to <FIG>, construction of the top pad <NUM> and bottom pad <NUM> is even simpler. A panel <NUM> is formed having lateral dimensions approximately equal to or slightly less than the corresponding dimensions of the top or bottom the box <NUM>. This panel <NUM> is then placed between two sheets <NUM> of the compostable water-proof film (see <FIG>), and the two sheets <NUM> are heat sealed along a path than extends around the entire perimeter of the panel <NUM> (see <FIG>) to provide the top pad <NUM> or bottom pad <NUM>. Excess film outside the heat seal can be cut away.

<FIG> illustrate another example of construction of the pads <NUM> for the insulating shipping container <NUM>. In the example of <FIG>, rather than three pads, the thermally insulating pads <NUM> include a first three-sectioned pad <NUM> and a second three-sectioned pad <NUM>.

<FIG> are schematic exploded perspective views of the two three-sectioned pads. <FIG> are schematic cross-sectional side view of the two three-sectioned pads. <FIG> are schematic perspective views of the two three-sectioned pads. <FIG> is a schematic exploded perspective view showing how the two three-sectioned pads are positioned relative to each other.

These pads <NUM> are constructed similarly to the pads discussed above for <FIG>, with each pad <NUM>, <NUM> formed by sealing a solid compostable panel within a compostable water-proof film. In particular, each three-sectioned pad <NUM>, <NUM> is constructed in a manner similar to the collar <NUM> discussed above, but with scoring in two locations rather than three locations.

In particular, referring to <FIG>, the first three-sectioned pad <NUM> can be fabricated by forming a solid compostable panel <NUM> that has a length L approximately equal to or slightly less than the length of three side walls of the box <NUM>, and a width W approximately equal or slightly less than the height of the box <NUM>. Referring to <FIG>, the second three-sectioned pad <NUM> can be fabricated by forming a solid compostable panel <NUM> that has a length L approximately equal to or slightly less than the length of top and bottom of the box <NUM> plus the height of one of the side walls of the box, and a width W approximately equal or slightly less than the lateral length of one of the side walls of the box <NUM>.

Referring to <FIG>, each panel <NUM> is then placed between two sheets <NUM> of the compostable water-proof film, and the two sheets <NUM> are heat sealed, as discussed above.

Referring to <FIG>, before or after sealing each panel <NUM> between the sheets <NUM>, one surface of the panel <NUM> (which will be the inward facing surface of the panel) can be scored in two locations to divide the panel <NUM> into three rectangular plate <NUM>, which correspond to the four side walls of the collar <NUM>. The length of the plates <NUM> of the first three-section pad <NUM> correspond to the width of the three corresponding side walls of the box <NUM>. The length of the plates <NUM> of the second three-section pad <NUM> correspond to the width of the top side, the length of the remaining side wall, and the width of the bottom side, respectively, of the box <NUM>.

Together, the resulting two three-sectioned pads <NUM>, <NUM> cover each of the six sides of the box <NUM> when inserted in the interior <NUM> of the box <NUM>.

It should be realized that other configurations are possible for the two three-sectioned pads <NUM>, <NUM>. For example, the first three-sectioned pad could cover the bottom and two opposing sides of the box, and the second three-sectioned pad could cover the top and the other two opposing sides of the box.

<FIG> illustrate yet another example of construction of the pads <NUM> for the insulating shipping container <NUM>. In the example of <FIG>, rather than three pads, the thermally insulating pads <NUM> include six pads <NUM>, one for each of the six sides of the box <NUM>.

<FIG> is a schematic exploded view of one of the pads. <FIG> is a schematic cross-sectional side view of one of the pads. <FIG> is a schematic perspective view of one of the pads. <FIG> is a schematic exploded perspective view showing how the two three-sectioned pads are positioned relative to each other.

These pads <NUM> are constructed similarly to the pads discussed above for <FIG>, with each pad formed by sealing a solid compostable panel within a compostable water-proof film. Each pad (and each panel of the pad) has a length and width appropriate for the dimensions of the associated side of the box <NUM>, along the lines discussed above.

The example of <FIG> does not require scoring, and consequently can be easier to manufacture. However, the increased number of gaps could decrease the effectiveness of the thermal insulation.

<FIG> illustrate still another example of construction of the pads <NUM> for the insulating shipping container <NUM>. In the example of <FIG>, rather than three pads, the thermally insulating pads <NUM> include a three-sectioned pads <NUM>, and three individual pads <NUM>.

<FIG> is a schematic exploded perspective view of the three-sectioned pad. <FIG> are schematic cross-sectional side views of the three-sectioned pad. <FIG> is a schematic perspective view of the two three-sectioned pad. <FIG> is a schematic exploded view of one of the individual pads. <FIG> is a schematic cross-sectional side view of one of the individual pads. <FIG> is a schematic perspective view of one of the individual pads. <FIG> is a schematic exploded perspective view showing how the two three-sectioned pads are positioned relative to each other.

Referring to <FIG>, the three-sectioned pad <NUM> is constructed similarly to the three-sectioned pads discussed above for <FIG>, with the pad <NUM> formed by sealing a solid compostable panel within a compostable water-proof film. Referring to <FIG>, the three-sectioned pad <NUM> can be fabricated by forming a solid compostable panel <NUM> that has a length L approximately equal to or slightly less than the height of two side walls of the box <NUM> plus the length of the bottom of the box <NUM>, and a width W approximately equal or slightly less than the width of one of the sides of the box <NUM>.

Referring to <FIG>, the three individual pads <NUM> are constructed similarly to the top and bottom pads <NUM>, <NUM> discussed above for <FIG>, with the pads <NUM> formed by sealing a solid compostable panel within a compostable water-proof film. Each pad <NUM> (and each panel of the pad) has a length and width appropriate for the dimensions of the side of the box <NUM> which it will line, as generally discussed above.

Although <FIG> show the three-sectioned pad having a center section that corresponds to the bottom of the box, this is not necessary. The center section could correspond to one of the side walls or the top of the box.

Even further configurations are possible for the pads <NUM>, provided each wall of the box is provided with an individual pad or a section of a pad. For example, there could be three two-sectioned pads, or a three-sectioned pad, two-sectioned pad and an individual pad.

Moreover, there could be just a single pad <NUM> that fits inside the box <NUM> and covers all six sides of the box <NUM>. For example, <FIG>, which is a schematic top view of a pad <NUM> in an unfolded configuration, illustrates a single six-sectioned pad. To fabricate this six-sectioned pad <NUM>, the panel can be formed in a "cross-shape", or another shape that when folded will correspond to the sides of the rectangular prism of the box <NUM>. The panel is sandwiched between two sheets, as discussed above, and the edges are sealed along a path that runs close to the perimeter of the panel. Excess material of the sheets can be cut off. The panel can be scored with cuts <NUM> in five locations to divide the panel into six sections. The scoring corresponds to the positions necessary for the panel to be folded such that each section corresponds to one of the sides of the box <NUM>. Although the implementation shown in <FIG> is for a cubical box, this is not required.

The example of <FIG> may provide improved good thermal insulation due to fewer gaps, and there can be a convenience for the customer to have just a single pad for each box. On the other hand, this configuration may have a cumbersome form factor.

The box <NUM> and pad or pads <NUM> that form the insulated shipping container <NUM> can be provided as an unassembled kit, and be assembled by a customer. For example, the box <NUM> and pads <NUM> could be shrink-wrapped or otherwise sealed together in packaging.

In any of the various examples discussed above, one or more apertures, e.g., about <NUM>,<NUM> to <NUM>,<NUM> (<NUM>/<NUM> to <NUM> inches) across, can be formed through the film <NUM> on the side of the pad <NUM> closer to the box <NUM>, that is the side opposite the opposite the cavity in which the item to be shipped is to be positioned. These apertures are not present on the side facing the cavity in which the item to be shipped is to be positioned; the film <NUM> on that side of the pad <NUM> is unbroken. The apertures can prevent pocket from acting like a balloon when the pad is inserted into the box - the film <NUM> can collapse against primary surfaces of the panels.

In some implementations, a pad includes only one panel in the pocket formed by the film. However, referring to <FIG>, cross-sectional side views, in some implementations, the pad <NUM> includes multiple panels <NUM>. The panels <NUM> are stacked along their thickness direction, and not arranged side-by-side. This permits fabrication of a thicker pad <NUM>, thus increasing the thermal insulating capability. For example, this permits the total thickness of the pad to be about <NUM>,<NUM>-<NUM>,<NUM> (<NUM>-<NUM> inches). In addition, avoiding gaps between that would occur with side-by-side panels can improve thermal insulation. In the example shown in <FIG>, there are three panels 50a, 50b and 50c, but there could be just two panels or four or more panels.

For a multi-section panel, when the panels <NUM> are scored, the scoring <NUM> can be performed by compressing the stack of panels along a line (rather than cutting the panels). As a result, in the scored region some of the panels can be driven partially into the underlying panel.

Where the panels <NUM> are multi-section panels, sections at each end of the pad can be shorter than the section immediately underneath to compensate for the stacking arrangement such that the ends of panels are substantially aligned. For example, as shown in <FIG>, section 52b1 is shorter than the underlying section 52a1. In addition, the ends of the sections at the end of each pad can be cut at an angle. For example, as shown in <FIG>, the ends of sections 52a1 and 52b1 can be cut at an angle, e.g., a <NUM>° angle. Thus, as shown in <FIG>, when the multi-section panels are folded inwardly, e.g., to form the U-shaped pad, the ends of the panels <NUM> align.

In the various implementations discussed above, the individual pads <NUM> will rest on one another when inserted in the cavity of the box <NUM>. However, the pads <NUM> are not fixed to each other, e.g., the pads are not secured by adhesive or interlocking components to each other.

In some implementations, the solid compostable panels could be used, but without enclosing or coating the panels with a water-proof film. <FIG> is an exploded perspective view of an example of another implementation of an insulated shipping container <NUM>. The shipping container <NUM> includes a recyclable box <NUM> and multiple thermally insulating compostable panels <NUM> that fit inside the interior cavity <NUM> of the box <NUM>. The panels <NUM> are shaped such that when positioned in the box <NUM> they provide an interior space to receive the item and optionally a coolant, e.g., ice, dry ice or a gel pack.

Optionally, a recyclable interior box <NUM>, e.g., a cardboard box, can fit into a space defined by the interior of the panels <NUM>. In this case, the interior cavity of the interior box <NUM> provides the space to receive the item and optionally a coolant. The interior box <NUM> can provide additional thermal insulation, and can protect the panels from water, e.g., condensation caused by coolant. However, as noted above, the item and coolant could be placed into the interior space, without using the interior box.

Each panel <NUM> can be fabricated as discussed above, e.g., formed primarily of extruded milled sorghum, so as to be compostable. However, the panels are not coated with, enclosed in, or otherwise protected by a water-proof film. Rather, the panels <NUM> are simply inserted into the cavity <NUM> in the box. One or more of the panels <NUM> can be a multi-section panel, which is scored as discussed in the various implementations discussed above, and then folded at right angle to provide multiple rectangular plates.

In the implementation shown in <FIG>, the thermally insulating panels <NUM> include a bottom panel <NUM>, a collar <NUM>, and a top pad <NUM>.

The bottom panel <NUM> has a length and width that match the bottom of the box <NUM>, or are slightly smaller, e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance, so that bottom panel <NUM> fits snugly at the bottom of the cavity <NUM> on the bottom of the box <NUM>.

The collar <NUM> includes a single panel that is folded into four rectangular plates. The four rectangular plates provide four wall members <NUM>, which are equivalent to the wall members discussed with respect to <FIG>, but without the water-proof film. Each wall member <NUM> has a height (in the vertical direction) about equal to the height of the box <NUM>, less the combined thickness of the top panel <NUM> and bottom panel <NUM>. Each wall member <NUM> has a width (in the lateral direction) that matches the adjacent side wall <NUM> of the box <NUM>, or is slightly smaller, e.g., e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance. Thus, the collar <NUM> fits snugly into cavity <NUM> on top of the bottom panel <NUM>, with each wall member <NUM> adjacent, e.g., in contact with, one of the side walls <NUM>.

The top panel <NUM> has a length and width that match the top of the box <NUM>, or are slightly smaller, e.g., e.g., by about an <NUM>,<NUM> (<NUM>/<NUM> inch) tolerance, so that the perimeter of the top panel <NUM> can sit on the wall members <NUM> of the collar <NUM> and the top panel <NUM> itself fits snugly at the top of the cavity <NUM>.

Although <FIG> illustrates a configuration for the panels <NUM> that is similar to the configuration of pads <NUM> in <FIG> and <FIG>, other configurations for the panels, e.g., equivalent to those shown in <FIG>, <FIG>, <FIG>, or <FIG>, are possible. Similarly, multiple panels <NUM> can be stacked, e.g., as illustrated in <FIG>, but again without the water-proof film.

Although milled sorghum is discussed above, as noted it may be possible to form the panel out of a grain starch, such as corn starch or wheat starch. However, sorghum is generally superior in that it can provide superior thermal insulation than corn starch. In addition, the particulates of milled sorghum may be more amenable to extrusion.

Referring to <FIG>, although in some implementations multiple panels can be stacked without being joined, it is also possible for multiple panels <NUM> to be stacked and laminated together. This can increase the total thickness of the resulting panel, e.g., to <NUM>,<NUM> to <NUM>,<NUM> (<NUM> to <NUM> inches) thick. The stacked panels can be joined by a thin layer of compostable adhesive <NUM>.

It should be understood that although various terms such as "top", "bottom", "vertical" and "lateral" are used, these terms indicate relative positioning of components under the assumption that an opening to the box <NUM> is at the top, and don't necessarily indicate an orientation relative to gravity; in use, or even during assembly, the container <NUM> could be on its side or upside down relative to gravity. The term "slightly" indicates no more than about <NUM>%, e.g., no more than <NUM>%.

Claim 1:
A thermal insulation article (<NUM>) for placement in a shipping container to hold an item, comprising:
a multi-section thermally insulating pad (<NUM>) shaped to be positioned in a cavity (<NUM>) of a rectangular prism shipping container to be adjacent to and cover from two to five of out of a floor, four side walls and cover of the container while leaving an interior space to receive the item, wherein the thermally insulating pad (<NUM>) includes
a plurality of solid compostable sections into which a panel is divided, wherein the sections are formed primarily of starch, each section of the panel (<NUM>) holding together as a single unit, each section of the panel (<NUM>) providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls (<NUM>) or cover that the rectangular plate (<NUM>) is adjacent, and
a compostable water-proof film forming a water-proof pocket enclosing the plurality of sections of the panel or a recyclable polyethylene film forming a water-proof pocket enclosing the plurality of sections of the panel (<NUM>), wherein the film forms the pocket enclosing the panel (<NUM>) without being bonded to the panel (<NUM>);
wherein the panel (<NUM>) of the multi-section thermally insulating pad (<NUM>) is configured to be foldable at a right angle along a boundary between the sections of the panel (<NUM>), and
wherein the film provides both an interior surface of the multi-section thermally insulating pad (<NUM>) and an exterior surface of the multi-section thermally insulating pad (<NUM>) where the panel (<NUM>) of the multi-section thermally insulating pad (<NUM>) is folded.