Abstract: A method of making a thermally insulated shipper for a temperature sensitive payload is provided. The shipper comprises vacuum insulated panels located between inner and outer molded shells.

Abstract: A thermally insulated VIP sandwich shipper for a temperature sensitive payload is provided. The shipper comprises an outer shell, an inner shell and vacuum insulated panels sandwiched therebetween. The outer shell and the inner shell may be unitary rigid structures made of an expanded foam material and comprising a bottom having a perimeter and sides extending from the bottom perimeter and terminating in a rim. The inner shell rim may be spaced from the outer shell rim to define a gap, the gap being sealed to create an enclosed space within which the vacuum insulated panels are located. Each vacuum insulated panel may be oriented substantially orthogonally to at least one adjacent vacuum insulated panel and have an edge that abuts the adjacent vacuum insulated panels.

Abstract: A thermally insulated pallet shipper is provided for use in any industry where temperature sensitive products are shipped, including the pharmaceutical, hospital and food industries, particularly for shipping payloads by air. The pallet shipper is made from just four individual foam molded structures: a base, a first corner structure, a second corner structure and a lid.

Abstract: A double bag vacuum insulation panel for use in a temperature assured shipper made in a steam chest molding machine is provided. The double bag VIP comprises a porous core, a heat sealable inner envelope and an outer bag. The inner envelope is made from a substantially gas impermeable first material having a first thickness and defines an interior having a pressure of less than or equal to about 30 millibar. The outer bag is made from a substantially gas impermeable second material having a second thickness. The outer bag encapsulates the inner envelope. The double bag vacuum insulation panel has an R value of at least about 28 hr-ft2—° F./BTU-in and the R value drops less than about 10% after being exposed to a temperature of up to 95C for up to 7 seconds.

Abstract: A method is provided of molding recycled EPS and other suitable expanded bead materials using a powder adhesive and steam. The method allows for molding EPS parts with over 5% and up to 100% recycled content. The method involves using an adhesive to fuse the regrind EPS particles under pressure from steam. The adhesive may be in powder form and preferably comprises small particles having a high surface area per unit weight and high static so the adhesive powder sticks to the surface of the regrind EPS particles during a dry blending step.

Abstract: A support for supporting a shower pan is provided. The support comprises an expanded polypropylene tray defining a cavity, an intermediate layer made of oriented strand board and disposed with the cavity, and a top layer made of expanded polystyrene foam disposed with the cavity and having a contoured top surface substantially matching the contoured underside of the shower pan.

Abstract: A packaging system for a temperature sensitive payload is provided. The system comprises insulative panels, including side panels and end panels, forming a product compartment. Cooling layers within the product compartment are located below and above the products. Channel members affixed to the side panels and/or the end panels create spaces and channels for convective air movement.

Abstract: A method of making a thermally insulated sandwich polyurethane (PUR) shipper for a temperature sensitive payload is provided. The method comprises the steps of mounting an inner box upside down on a tool, adhering an insulating panel to the outer facing surfaces of the inner box, positioning an outer box around the inner box assembly, pouring liquid polyurethane into the gap between the outer box and inner box assembly, and foaming the liquid polyurethane. The PUR foam fills the space between the VIP panels and the outer box, and preferably covers the VIP panels.

Abstract: A thermally insulated sandwich polyurethane (PUR) shipper for a temperature sensitive payload is provided. The sandwich PUR shipper comprises an outer corrugated box, an inner corrugated box, vacuum insulated panels (such as VIP panels) and PUR foam. The inner box is nested within the outer box and has a bottom, sides and a top. The inner box defines a payload compartment. The VIP panels are adhered to the outer facing surfaces of the inner box. Preferably the VIP panels are wedged against each other so that a side edge of one VIP panel abuts an adjacent VIP panel. The PUR foam fills the space between the VIP panels and the outer box. The PUR foam may cover the top edges of the VIP panels.

Abstract: A thermally insulated sandwich polyurethane (PUR) shipper for a temperature sensitive payload is provided. The sandwich PUR shipper comprises an outer corrugated box, an inner corrugated box, vacuum insulated panels (such as VIP panels) and PUR foam. The inner box is nested within the outer box and has a bottom, sides and a top. The inner box defines a payload compartment. The VIP panels are adhered to the outer facing surfaces of the inner box. Preferably the VIP panels are wedged against each other so that a side edge of one VIP panel abuts an adjacent VIP panel. The PUR foam fills the space between the VIP panels and the outer box. The PUR foam may cover the top edges of the VIP panels.

Abstract: A thermally insulated VIP sandwich shipper for a temperature sensitive payload is provided. The shipper comprises an outer shell, an inner shell and vacuum insulated panels sandwiched therebetween. The outer shell and the inner shell may be unitary rigid structures made of an expanded foam material and comprising a bottom having a perimeter and sides extending from the bottom perimeter and terminating in a rim. The inner shell rim may be spaced from the outer shell rim to define a gap, the gap being sealed to create an enclosed space within which the vacuum insulated panels are located. Each vacuum insulated panel may be oriented substantially orthogonally to at least one adjacent vacuum insulated panel and have an edge that abuts the adjacent vacuum insulated panels.

Abstract: A support for supporting a shower pan is provided. The support comprises an expanded polypropylene tray defining a cavity, an intermediate layer made of oriented strand board and disposed with the cavity, and a top layer made of expanded polystyrene foam disposed with the cavity and having a contoured top surface substantially matching the contoured underside of the shower pan.

Abstract: In one embodiment, a multilayer article comprises: a core layer comprising a core layer polycarbonate resin, a core flame retardant additive, and an opacity additive, and a cap layer comprising a cap layer polycarbonate resin and a cap flame retardant additive. The core layer comprises a sufficient amount of core flame retardant additive and the cap layer comprises a sufficient amount of cap flame retardant additive such that the multilayer article can pass a smoke density test as set forth in FAR 25.5, Appendix F, Part V. In one embodiment, a method of making a multilayer article comprises: forming a core layer comprising a core layer thermoplastic resin, and a core non-brominated flame retardant additive, and forming a cap layer comprising a cap layer thermoplastic resin, a cap non-brominated flame retardant additive, and thermoforming the multi-layer film.