REUSABLE SHIPPING CONTAINER AND METHOD FOR USING THE SAME

Abstract

Embodiments disclose a reusable shipping container. The container may comprise six multi-layered walls of a plastic material. Further, the container may comprise a rail fastened to a top edge of the container with a plurality of first fasteners, wherein the fasteners penetrate on the rail, a first layer and a second layer of the container. Moreover, the container may comprise an insulation layer of vacuum insulation material and an inner layer corresponding to each wall of the container. Methods are also described for packing a parcel for shipment. The insulation layer and the inner layer are inserted into the container, wherein the inner layer encloses the parcel. Thereafter, an insulation layer corresponding to a top wall is inserted and the top wall is closed.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/041,459, filed Mar. 3, 2008, titled SHIPPING CONTAINER, SYSTEM AND PACKING METHOD, ALONG WITH REUSABLE PACKING ACCESSORY FOR USE THEREWITH, which is a continuation-in-part of U.S. patent application Ser. No. 11/665,762, filed Apr. 16, 2007, titled SHIPPING CONTAINER, which is a National Stage entry from PCT Application No. PCT/US2005/009400, filed Mar. 18, 2005, titled SHIPPING CONTAINER, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/554,559, filed Mar. 18, 2004, titled SHIPPING CONTAINER. This application is also a continuation-in-part of U.S. patent application Ser. No. 12/115,057, filed May 5, 2008, titled REUSABLE SHIPPING CONTAINER AND SYSTEMS THEREOF, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/047,234, filed Apr. 23, 2008, titled CONTAINER SYSTEM WITH SWELL LATCH. The entire contents and substance of the above applications are incorporated herein by reference.

FIELD

The present invention is broadly directed to containers. More specifically, the present invention is directed to reusable shipping containers suitable for shipping good(s) that are sensitive to temperature.

BACKGROUND

Various types of containers are available for holding and transporting products. Examples of such containers include corrugated cartons, tote containers, and other boxes. The containers may be designed according to the need of transportation and the properties of goods. For example, there are goods that must be held at a consistent temperature because of high risk of spoilage, such as blood, tissues, and so forth. Further, the duration of transportation may be crucial for the goods.

There are a wide variety of containers that use different temperature control techniques to keep the goods safe during the time of holding or transportation. One known technique uses wet pads or dry ice to control or maintain the temperature of the goods. For example, U.S. Pat. No. 4,294,079, assigned to Better Agricultural Goals Corporation, discloses an insulated shipping container for perishable goods, which uses dry ice as a refrigerant for controlling temperature. However, dry ice in amounts greater than 5.5 lbs are generally considered a hazard. Therefore, this technique can be limited for a small quantity of goods. Another known technique is the use of Vacuum Insulation Panels (VIP) in the containers. The VIP are high cost, high-value performance insulation manufactured by various companies such as American Aerogel, AcuTemp, and Nanopore. The VIP materials are sealed with a strong vacuum to effectively remove air from the VIP. As a result, a very effective material for maintaining temperature is generated. For example, the thermal resistance value (R-value) of VIP is about 50, as compared to an igloo cooler having a typical R-value of about 5 or 6. Moreover, temperature control material required in case of the VIP is drastically less as compared to other insulation techniques. Therefore, the weight and size of the shipment containing the goods may be reduced. Furthermore, there is an option, for example, to delay transport of the shipment from overnight to a second day or even ground transfer. As a result, these can be huge savings in the supply chain of transportation.

There are several limitations associated with the use of the VIP. First, the VIP are expensive. For example, depending on the size of other packaging material, the VIP may cost 15 to 30 times the cost of packaging material. Second, the VIP is very susceptible to puncture. As a result, in case of a puncture, the insulation value of the VIP is completely lost. Third, the VIP is intended to be reused; however it is occasionally the case that the VIP is generally destroyed during transportation. Generally, VIP are pressure fit into a cardboard box. However, sharp objects, such as sorting belts and equipment or other packages easily penetrate the box during transit. Cardboard is not rigid, therefore, any harsh handling of the box shifts the VIP insulation. As a result, air gaps are created in the seams. Therefore, the purpose of the VIP to eliminate air penetration is defeated. Moreover, the lack of rigidity of the cardboard box allows air to penetrate, resulting in a premature cooling. Furthermore, when the VIP is not reused, a lot of waste is generated, which is both a high cost and burden for recipients of temperature sensitive goods. For example, an existing technique as disclosed in U.S. Patent Application Publication No. 2007/0051734 assigned to VA-Q-TEC AG, uses vacuum insulation material in shipping containers. However, the technique does not identify means to prevent the vacuum insulation material from puncture. Moreover, the container and vacuum insulation of this technique are not designed for reuse.

Another existing solution uses the VIP in a thermoformed container. However, the molding of an outer shell of the thermoformed container requires expensive tools. Therefore, the cost to change the design is high and as a result, size and shape of the container are limited. Further, the molded case design may include structural ridges, tapered edges, and rounded corners. As a result, the VIP having a square design profile may be difficult to fit in the container. Therefore, modifications and adjustments in the container are required to house the VIP, which leads to over-sizing of the container dimensions. Furthermore, the container may be designed with an onboard battery and sensor system to promote and maintain temperature control. For example, U.S. Pat. No. 6,771,183, assigned to Kodak Technologies Inc., discloses a thermal container with battery and other electronic circuitry to monitor temperature of goods. Yet another existing solution, disclosed in U.S. Pat. No. 5,943,876 assigned to Vacupanel Inc., uses a portable refrigerated container for housing vacuum insulation panel. However, there is an inherent risk if the battery system fails, which can result in failure of the cooling. As a result, the goods can be damaged.

Alternate designs use phase change material that can be frozen multiple times. However, the performance of these materials is decreased over time of usage. Moreover, phase change materials are expensive as compared to materials, such as gel pack, wet ice, and dry ice. In the case of the thermoformed container, the outer shell is sensitive to extreme shocks. Therefore, if the outer shell is damaged, generally the entire container is scrapped because of air penetration. Moreover, the repairing of the container may not be cost-effective. Further, the container is heavy due to the material, construction and design. For example, the material of the container is generally twice as heavy as compared to a cardboard box. Therefore, the weight of the empty container may exceed, for example, 50 lbs. The use of this solution may therefore, cause additional shipping and handling costs during transportation. Moreover, the wastage may be detrimental to the environment.

Yet another existing solution, as disclosed for example, in WO Publication No. 2009/067007 to Colratech B. V., explains the use of multiple layers of VIP as the material of contraction for the container. However, the VIP materials are vulnerable to puncture, which can result in damage to the goods. Further, a technique disclosed in WO Publication No. 2009/019251 to F. Hoffmann-La Roche A G uses multiple layers of foam material to form the walls of a container. The VIP are then arranged in the walls. However, the container may be susceptible to damage due to the material of the walls. Moreover, the shipping in this container may be limited only to a couple of days.

Generally, a secure and airtight locking is desirable for containers including VIP. An existing technique disclosed, for example in U.S. Pat. No. 6,244,458 assigned to Thermo Solutions Inc., explains the use of handles or latches that are secured by fasteners with one end in contact with VIP. However, the ends of the fasteners may damage the VIP during shipping or handling of the container. Another existing solution that houses the VIP uses hardware accessories that secured the lid of the container from the inside. For example, the hardware accessories include a flush mounted swell latch and one-fourth turn latch to close the lid from inside the container. One such container is disclosed in U.S. Patent Application Publication No. 2008/0203090 assigned to the assignee of the present invention and incorporated herein by reference. However, this design requires additional space inside the container. Moreover, additional foam is required to protect the VIP from the internal hardware accessories such as rivets, bolts or plates of handles, latches and the like. Furthermore, the foam tends to allow the VIP to shift during transportation, and hence create air gaps. Air gaps allow outside air to penetrate the container and the performance of the VIP is reduced. Moreover, the use of internal hardware accessories and foam adds to the size and weight of the container. This impacts overall shipping costs.

There has long been a need for a container that is rigid, lightweight, flexibly designed and extremely resistant to shock and vibration that are typically experienced when transporting high-value, prone-to-damage, and temperature sensitive goods. Accordingly, there is a need for a container to effectively house, protect, and repeatedly ship the high performance, yet fragile and tear-prone VIP. Further, there is a need for a reusable container that maximizes the interior space, while minimizing necessary coolant. Moreover, there is a need for a container that can be designed and manufactured for a wide variety of transportation requirements. The container should use hardware accessories and fasteners such that they do not puncture the VIP and can be reused. One or more of these needs is addressed by the present disclosure.

SUMMARY

One aspect of the exemplary embodiments disclosed herein is to a reusable shipping container.

Another aspect of the exemplary embodiments disclosed herein is to provide a container to effectively house vacuum insulation material.

According to one or more of the exemplary embodiments, a reusable shipping container is provided. The container generally includes a bottom, two opposite side walls (i.e., left and right), two opposite end walls (i.e., front and back), and a top wall. The side walls and the end walls include upper edges that define a top edge of the container.

Each of the bottom wall, the side walls and the end walls include a first layer of a plastic material forming an external side of the container, and a second layer of the plastic material substantially coextensive with the first layer, the second layer being secured to said first layer. The first layer and the second layer may have a thickness of about 5 mm to 7 mm.

The container further includes a rail extending around the top edge of the container. The rail may be secured to the container by a plurality of first fasteners. The first fasteners may penetrate only the rail and first layer of the side walls and the end walls. Moreover, the container may include a locking mechanism or hardware accessories. The locking mechanism or hardware accessories may be secured to the container by fasteners that penetrate only the first layer of the container.

The top wall of the container may form a lid of the container and may be hingeably connected to a hinge end of the top edge. The top wall may include the first layer, the second layer, and a third layer substantially coextensive with the second layer. The third layer may be formed of the plastic material and may have a thickness of about 5 mm to 7 mm. Further, the top wall may comprise a plurality of second fasteners adapted to secure the top wall to the hinge end of the rail. The second fasteners may penetrate only the first layer and the second layer of the top wall.

The container may further include an insulation layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall. The insulation layer may include vacuum insulation material and may be placed substantially coextensive with the second layer. Furthermore, the container may include an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall. The inner layer may form an internal side of the container and may be placed substantially coextensive with the insulation layer.

A method for packing a parcel for shipment to an intended recipient is also contemplated. According to this method, insulation layers and the inner layers corresponding to a bottom wall, two opposite side walls, and two opposite end walls may be inserted into the container. The inner layer may enclose the parcel. Thereafter, an insulation layer corresponding to a top wall is inserted and the top wall is closed. Further, the method may include a step of closing the top wall by using one or more locking mechanisms.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a perspective view of a shipping container according to an exemplary embodiment;

FIG. 2a is a perspective view of the shipping container shown in FIG. 1 (with the lid open), in an unpacked, or pre-shipment state;

FIG. 2b is a perspective view of the shipping container shown in FIG. 1 (with the lid removed) displaying insulation layers and inner layers inside the container;

FIG. 3a is a representative cross sectional view depicting the layered construction for the side walls, end walls, or a bottom wall of the container shown in FIG. 1;

FIG. 3b is a cross sectional view as shown in FIG. 3a, along with insulation layers and inner layers of the container shown in FIG. 1;

FIG. 3c is a cross sectional view as shown in FIG. 3b, illustrating the penetration of multiple fasteners;

FIG. 3d is a cross sectional view, illustrating the penetration of a rail by the fasteners at a top edge of the container shown in FIG. 1;

FIG. 3e is a cross sectional view of a top wall of the container shown in FIG. 1, along with the insulation layer and the inner layer; and

FIG. 4 illustrates a cross sectional view of a lower corner region of the container shown in FIG. 1 with a parcel located therein.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Illustrative embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

With initial reference to FIG. 1, a reusable shipping container 10 is shown closed, locked and ready for shipment to an intended recipient. Container 10 is a rigid, lightweight container, flexibly designed and extremely resistant to shock and vibration typically experienced when transporting high-value, prone-to-damage goods. Moreover, container 10 is adapted to hold, store and transport goods that are sensitive to temperature. Container 10 is generally rectangular or box-like in shape to maximize the internal size. Various components of container 10 are described with reference to FIGS. 1, 2a, and 2b. As shown with reference to FIGS. 2a and 2b, container 10 is adapted to receive a parcel 32. The various components of container 10 may generally include, as shown with reference to FIGS. 1, 2a-b, 3a-e and 4, a bottom wall 12, two opposite side walls 14(1)-14(2), two opposite end walls 16(1)-16(2), a top wall 18, insulation layers 28(1)-28(6), and inner layers 30(1)-30(6).

Other container constructions which can be adapted to benefit from the insulative characteristics and other features described herein include those described in the various applications referred to in the “Cross Reference to Related Applications” section above, each of which is specifically incorporated herein by reference in its entirety.

With reference again to container 10, taking each of the components in turn, bottom wall 12 forms the base, and top wall 18 forms the lid of container 10. Side walls 14(1)-14(2) and end walls 16(1)-16(2) form the sides of container 10. As shown with reference to FIG. 1 and FIG. 2, side walls 14(1)-14(2) and end walls 16(1)-16(2) define a top edge 36 of container 10. Preferably, top wall 18 is hingeably connected to a hinge end 38 of the top edge 36 of container 10 by using multiple second fasteners 42, as available from Fastenel of Minnesota as part No. CM-AAA612. Therefore, top wall 18 can move about an open and a closed position on container 10. Each of bottom wall 12, side walls 14(1)-14(2), end walls 16(1)-16(2), and top wall 18 may have multiple layers and may be formed of a plastic material. The plastic material can be, for example, polypropylene. The arrangement of the various layers of side walls 14(1)-14(2), end walls 16(1)-16(2), or bottom wall 12 is shown with reference to FIGS. 3a-3d, and the arrangement of the layers of top wall 18 is shown with reference to FIG. 3e. Container 10 includes a rail 34 which extends along the top edge 36. Rail 34 may generally be of a plastic material, for example, but not limited to, Polyvinyl Chloride (PVC). Further, rail 34 may have an ‘h’ shape as generally known in the art. As shown with reference to FIG. 3d, rail 34 is secured to side walls 14(1)-14(2) and end walls 16(1)-16(2) through first fasteners 20, as available from Fastenel of Minnesota as part No. AB6-4A. Rail 34 engages side walls 14(1)-14(2) and end walls 16(1)-16(2) together. Further, rail 34 provides additional rigidity to container 10. Moreover, rail 34 may be easily placed or removed from container 10. Therefore, container 10 can be easily repaired in case of any damage.

With reference to FIG. 3a, a partial cross sectional view is shown which may correspond to an exterior portion of either bottom wall 12, one of side walls 14(1)-14(2), or one of end walls 16(1)-16(2). FIG. 3a, thus, illustrates an exemplary arrangement of the various layers for these walls. As shown, the layers include a first (or outermost) layer 44 and a second layer 46 generally formed of the plastic material. The plastic material may be, for example, corrugated polypropylene. Second layer 46 is placed parallel and substantially coextensive with first layer 44. Second layer 46 may be secured to first layer 44 by using adhesives or glues. In an embodiment of the invention, end walls 16(1)-16(2) may have flaps that fold in to create a double-layer of corrugated plastic. Therefore, the flaps may form second layer 46 of end walls 16(1)-16(2).

First layer 44 forms the exterior of container 10 and may generally include flutes of corrugated plastic, which are arranged perpendicular to bottom wall 12. Further, second layer 46 may also include flutes of corrugated plastic, which are arranged parallel to bottom wall 12. The thickness of each of first layer 44 and second layer 46 may be about 5 mm to 7 mm. This arrangement of flutes provides extra strength and rigidity to container 10 and further increases resistance to puncture. Moreover, this arrangement of flutes helps in absorbing and distributing shocks on container 10 during transportation.

FIG. 3b is a cross sectional view as shown in FIG. 3a, along with insulation layers 28(1)-28(6) and inner layers 30(1)-30(6) of the container 10. As shown, only one layer of insulation layers 28(1)-28(6) and inner layers 30(1)-30(6) is visible in FIG. 3b. A person skilled in the art will appreciate that the cross section as shown in FIG. 3b is similar for each of bottom wall 12, side walls 14(1)-14(2), or end walls 16(1)-16(2). Therefore, a specific mention of a particular insulation layer is not required. Insulation layers 28(1)-28(6) may be formed of vacuum insulation material. The vacuum insulation material may be, for example, Vacuum Insulation Panels (VIP) manufactured by various companies such as American Aerogel, AcuTemp, and Nanopore. The VIP are high cost, high-value performance thermal insulation material with a thermal resistance value (R-value) of about 30 to 52. Generally, the VIP is placed in container 10 as six insulation layers 28(1)-28(6), as supplied by the manufacturers. A typical VIP is disclosed in U.S. Pat. No. 7,005,181 assigned to American Aerogel Corporation. However, the VIP are also very susceptible to puncture. For example, sharp objects, such as sorting belts and equipment or other packages can easily penetrate container 10 during transit. Moreover, any mechanical fasteners with edges can penetrate the VIP. Any puncture in the VIP can lead to loss of insulation and deterioration of temperature sensitive goods in container 10. However, the design and construction of container 10 prevents damage to insulation layers 28(1)-28(6). Moreover, the fasteners used in container 10 are designed and used so as not to touch insulation layers 28(1)-28(6) and hence prevent any damage.

With reference to FIG. 3c, multiple third fasteners 48 are illustrated that secure hardware accessories, such as handle 22 or latch 24, to the layers of side walls 14(1)-14(2) and end walls 16(1)-16(2). Handle 22 may be as available from Penn Elcom Inc. of California as part No. H1078. Here, third fasteners 48 include rivets that are designed to penetrate only first layer 44. Of course, a person skilled in the art will appreciate that third fasteners 48 can include other means of mechanical securing, such as bolts, nuts, and screws of various sizes or configurations. Further, third fasteners 48 are affixed to a tail or a backer (not shown) to provide holding strength to the hardware accessories. The ends of third fasteners 48 are covered by second layer 46, and therefore, are prevented from contacting insulation layers 28(1)-28(6). Third fasteners 48 may be as available from Fastenel of Minnesota as part No. 48 AB6-6A.

Referring again to FIG. 1, an exemplary locking mechanism containing latch 24 and a receiver 26, as available from Penn Elcom Inc., California as part Nos. L0737/46 and L0926-90Z, is used from outside to close top wall 18 of container 10. Therefore, there is no contact of the locking mechanism with insulation layers 31(1)-31(6). This design is a preferred replacement to flush mounted swell latch and ¼ turn latch described in U.S. Patent Application Publication No. 2008/203090, assigned to the assignee of the present invention. The earlier design required crucial space and used additional foam on the inside of the container to prevent insulation layers 28(1)-28(6) from touching the locking mechanism. Further, these modifications added to the size and weight of the container, while also risking the stability of insulation layers 28(1)-28(6).

With reference to FIG. 3d, a cross sectional view of side walls 14(1)-14(2) or end walls 16(1)-16(2) near the top edge 36 of container 10 is illustrated. Further, FIG. 3d illustrates a portion of rail 34 and first fasteners 20. First fasteners 20 secure rail 34 to the top edge 36 of container 10. As shown, first fasteners 20 penetrate only rail 34 and first layer 44. Therefore, as also discussed in conjunction with FIG. 3c, insulation layers 28(1)-28(6) are prevented from touching first fasteners 20. Therefore, the chances of puncture to insulation layers 28(1)-28(6) are reduced.

With reference to FIG. 3e, a cross sectional view of top wall 18 near hinge end 38 is illustrated. During transport, container 10 may come under weight or pressure of other parcels, boxes or containers. The weight or pressure of other containers may damage insulation layers 28(1)-28(6) and parcel 32. Therefore, top wall 18 of container 10 needs to be strong to prevent the damage. Moreover, top wall 18 may not have any component that may be caught between sorting belts and equipment during the transport of container 10. As shown with reference to FIG. 3e, top wall 18 includes first layer 42 and second layer 46, as discussed with reference to previous figures. Further, top wall 18 includes a third layer 50 of a plastic material. Third layer 50 may have a thickness of about 5 mm to 7 mm and is substantially coextensive with second layer 46. The plastic material of third layer 50 may be corrugated polypropylene. As shown, top wall 18 is connected to container 10 at hinge end 38 with second fasteners 42. Further, second fasteners 42 penetrate first layer 44 and second layer 46 of top wall 18 to provide strength to hinge 52. Hinge 52 may be as available from ONO Inc. of Pennsylvania as part no. FFH2/4050 Flex-Fold 2 Bk. Moreover, second fasteners 42 may be affixed to a tail or a backer (not shown) to provide holding strength to the hinge. Thereafter, third layer 50 is secured over second layer 46. Third layer 50 may be secured by gluing it to second layer 46 to provide a smooth, penetration-free surface to top wall 18. A person skilled in the art will appreciate that other means of securing third layer 50 to second layer 46 can be used. The total thickness of top wall 18 may include the thickness of first layer 44, second layer 46, and third layer 50. This total thickness of top wall 18 may be equivalent to a depth of rail 34 to provide a smooth surface on top of container 10 when closed. Therefore, the chances of damage to container 10 from sorting belts, other packages or hardware during transportation are reduced.

With reference to FIGS. 1, 2a-b, 3b, 3c, 3d, 3e, and 4, inner layers 30(1)-30(6) are placed substantially coextensive with insulation layers 28(1)-28(6). A person skilled in the art will appreciate that the cross section as shown in FIGS. 3b, 3c, 3d, or 3e is similar for each of bottom wall 12, side walls 14(1)-14(2), or end walls 16(1)-16(2). Therefore, a specific mention of a particular inner layer is not required. Inner layers 30(1)-30(6) may be made of corrugated plastic, generally 3 mm to 4 mm in thickness. Further, inner layers 30(1)-30(6) may be made of single wall corrugated paper, or a standard commercial grade Polyethylene (PE) or Polyurethane (PU) foam supplied as Foam-Tech™ of Vermont. Additionally, inner layers 30(1)-30(6) may be a temperature holding material as supplied by RNC Industries of Atlanta, Ga.

Inner layers 30(1)-30(6) may have a pad-set design, where three interlocking sides are conjoined with another three interlocking sides to form six sides for fitting into container 10. Of course, the top side would be free to pivot about its hinge and otherwise not interconnected to the other sides. In an embodiment of the invention, inner layers 30(1)-30(6) may have a one-piece design to form six sides of container 10. Inner layers 30(1)-30(6) may be designed to fit snugly inside the six insulation layers 28(1)-28(6) and, together, form the interior of container 10.

Inner layers 30(1)-30(6) enclose parcel 32 and may have cushioning, air-restriction, and temperature holding properties. Parcel 32 being shipped in container 10 may be required to be free from disease-causing contaminants, or in other words require a sterile enclosure. For example, parcel 32 can include blood sample, or organic tissues. Therefore, inner layers 30(1)-30(6) may be changed after transportation of such parcel 32. As a result, insulation layers 28(1)-28(6) may not be required to be changed and may be reused. The reuse of insulation layers 28(1)-28(6) reduces the wastage after every shipment and reduces adverse environmental impact. Furthermore, various colors may be used for inner layers 30(1)-30(6) to either hide or show its soiling. Therefore, an intended usage or sterility requirements of inner layers 30(1)-30(6) may be displayed. Moreover, inner layers 30(1)-30(6) may provide protection to insulation layers 28(1)-28(6) from coolants during shipment. Further, inner layers 30(1)-30(6) may enhance temperature holding performance beyond just insulation layers 28(1)-28(6).

With reference to FIG. 4, a cross sectional view reveals the arrangement of various layers near bottom wall 12, side walls 14(1)-14(2) or end walls 16(1)-16(2) of container 10. As shown in FIG. 4, parcel 32 is enclosed by inner layers 30(1), 30(4) and 30(5), which are in turn enclosed by insulation layers 28(1), 28(4), and 28(5). Of course a person skilled in the art will appreciate that parcel 32 will also be enclosed by inner layers 30(2), 30(3) and 30(6) and insulation layers 28(2), 28(3), and 28(6), which are not shown in FIG. 4 for the sake of simplicity of the drawing and description.

As a result of the encapsulation, the insulation and temperature of parcel 32 is maintained. Further, first layer 44, second layer 46 and third layer 50 provide strength and rigidity to container 10, and smooth and penetration-free surfaces for insulation layers 28(1)-28(6).

The design, material and construction of container 10 as described above allow the dimensions of container 10 to be easily and rapidly adapted based on the dimensions of parcel 32 or requirement of transportation. Further, container 10 can be easily repaired in case of damage. Furthermore, the plastic material of container 10 can be reused various times, which increases the usage life of container 10. Moreover, the weight and wastage of material is reduced.

Now that the components of container 10 have been described, the assembly thereof can be more readily understood. As may be appreciated, any suitable hardware accessories such as latch 24 of the locking mechanism or handle 22 may be secured to first layer 44 of container 10. Moreover, rail 34 is secured to the top edge 36 of container 10 by using first fasteners 20. Rail 34 engages side walls 14(1)-14(2) and end walls 16(1)-16(2) together to form four sides of container 10. The hardware accessories and rail 34 may be secured with fasteners such as rivets. The rivets may be designed according to the thickness of first layer 44. Further, first fasteners 20 may be designed to penetrate only rail 34 and first layer 44. The rivets may be reusable. Therefore, the rivets can be replaced or reused with container 10. The ends of the fasteners are affixed to first layer 44 by using backers or tails. Thereafter, second layer 46 is secured substantially coextensive with first layer 44 to cover the ends of the fasteners and provide a smooth penetration free surface to the interior of container 10. Second layer 46 is designed to match the thickness of rail 34. As a result, foam or shim may not be required to fill any gap between rail 34 and second layer 46.

Top wall 18 may be connected to the top edge 36 of container 10 at the hinge end 38 by using second fasteners 42. Second fasteners 42 penetrate first layer 44 and second layer 46 of top wall 18. Further, the ends of second fasteners 42 are affixed to second layer 46 by using backers or tails to provide more strength to container 10. Thereafter, third layer 50 is secured substantially coextensive with second layer 46 of top wall 18 to cover the ends of second fasteners and provide a smooth penetration-free surface to the interior of top wall 18.

Thereafter, insulation layers 28(1)-28(5) corresponding to bottom wall 12, side walls 14(1)-14(2), and end walls 16(1)-16(2) are disposed inside container 10. Insulation layers 28(1)-28(5) are substantially coextensive with second layer 46 of bottom wall 12, side walls 14(1)-14(2), and end walls 16(1)-16(2). Insulation layers 28(1)-28(5) may be pressure fitted into container 10 to remove any air between the layers. Inner layers 30(1)-30(5) are then provided to cover inside surfaces of insulation layers 28(1)-28(5). Thereafter, parcel 32 for shipment is disposed in container 10 and is covered on top by inner layer 30(6). As a result, parcel 32 is enclosed completely by inner layers 30(1)-30(6). Insulation layer 28(6) corresponding to top wall 18 is then placed on top of inner layer 30(6).

Top wall 18 may then be closed by moving it about hinge end 38. Further, top wall 18 may provide pressure on insulation layer 28(6) to remove any air or air gap for better insulation. Top wall 18 may be secured from outside container 10 by using the locking mechanism. If desired, a locking structure could be provided to retain latch 24 and receiver 26 at their closed position. Other appropriate locking structures are also contemplated that would retain locking mechanisms in the closed position so as to safely retain parcel 32 in container 10.

With the above components and assembly thereof in mind, it should be appreciated that alternative components, constructions and materials can be used to accomplish the benefits derived from container 10. For example, container 10 may include multiple locking mechanisms of different types. Further, the locking mechanisms can be placed on different walls of container 10. Also, the arrangement of the flutes of the various layers can be modified so that the same strength or rigidity is provided to container 10.

Having discussed the exemplary embodiments and contemplated modifications to the container, it should be appreciated that a method of packing a parcel to be shipped in the container is also contemplated. According to this method, a reusable shipping container is provided. The container includes a bottom wall, two opposite side walls, two opposite end walls, and a top wall, each having at least a first layer and a second layer. The first layer forms an external side of the container, and the second layer is substantially coextensive with said first layer. An insulation layer of vacuum insulation material is inserted in the container corresponding to each of the bottom wall, the side walls, the end walls into the container. Thereafter, an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall is inserted substantially coextensive with the insulation layer. The parcel is then disposed in the container, and each inner layer provides a temperature-controlled environment to the enclosed parcel. Thereafter, an insulation layer corresponding to the top wall is inserted substantially coextensive with the inner layer of the top wall, and the top wall is closed to retain the parcel. The method further comprises the step of securing the top wall with a locking mechanism to retain the parcel securely in the container.

While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.

This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of embodiments of the invention is defined in the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A reusable shipping container comprising:

(A) a bottom, two opposite side walls, and two opposite end walls, wherein the side walls and the end walls include upper edges defining a top edge of the container, and wherein each of the bottom wall, the side walls and the end walls includes (i) a first layer of a plastic material forming an external side of the container, the first layer having a thickness of about 5 mm to 7 mm; and (ii) a second layer of the plastic material substantially coextensive with the first layer, the second layer being secured to the first layer, the second layer having a thickness of about 5 mm to 7 mm;

(B) a rail extending around the top edge of the container, the rail being secured to the container by a plurality of first fasteners, wherein the first fasteners penetrate only the rail and first layer of the side walls and the end walls; and

(C) a top wall forming a lid of the container and hingeably connected to a hinge end of the top edge, including (i) the first layer; (ii) the second layer; (iii) a third layer of the plastic material substantially coextensive with the second layer, the third layer being secured to the second layer, the third layer having a thickness of about 5 mm to 7 mm; and (iv) a plurality of second fasteners adapted to secure the top wall to the hinge end, wherein the second fasteners penetrate only the first layer and the second layer of the top wall.

2. The container according to claim 1 further comprising:

(A) an insulation layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the insulation layer includes a vacuum insulation material and is placed substantially coextensive with the second layer; and

(B) an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, the inner layer forming an internal side of the container, wherein the inner layer is placed substantially coextensive with the insulation layer.

3. The container according to claim 2, wherein each insulation layer is pressure fitted in the container.

4. The container according to claim 2, wherein each inner layer includes the plastic material.

5. The container according to claim 2, wherein each inner layer includes a corrugated paper material.

6. The container according to claim 2, wherein each inner layer includes a temperature holding material.

7. The container according to claim 2, wherein the inner layer includes three first interlocking sides conjoined with three second interlocking sides to form six sides.

8. The container according to claim 1, wherein the plastic material is corrugated polypropylene.

9. The container according to claim 1, wherein the plastic material of the first layer of the side walls and the end walls comprises a plurality of flutes perpendicular to the bottom wall.

10. The container according to claim 1, wherein the plastic material of the second layer of the side walls and the end walls comprises a plurality of flutes arranged at an angle of 0 degrees with respect to the bottom wall.

11. The container according to claim 1, wherein the top wall includes a first thickness equivalent to a combined thickness of the first layer, the second layer and the third layer

12. The container according to claim 11, wherein the first thickness of the top wall is equivalent to a depth of the rail.

13. The container according to claim 1 further comprising one or more hardware accessories adapted to handle the container, wherein the one or more hardware accessories are secured with a plurality of third fasteners.

14. The container according to claim 13, wherein the third fasteners are fastened to one or more backers and penetrate only the first layer of the container.

15. The container according to claim 13, wherein the third fasteners comprise rivets.

16. The container according to claim 1 further comprising one or more locking mechanisms adapted to secure a second end of the top wall to the container.

17. The container according to claim 16, wherein the one or more locking mechanisms comprises a latch and a receiver.

18. The container according to claim 17, wherein the latch is secured to an end wall through a third plurality of fasteners, and wherein the third plurality fasteners penetrate only the first layer of the end wall.

19. The container according to claim 17, wherein the receiver is secured to an end wall through the third fasteners, and wherein the third fasteners penetrate only the first layer and the second layer of the top wall.

20. The container according to claim 1, wherein the rail engages the end walls and the side walls together.

21. The container according to claim 1, wherein the first fasteners and the second fasteners comprise rivets.

22. A reusable shipping container for housing one or more vacuum insulation panels, comprising:

(A) a bottom, two opposite side walls, and two opposite end walls, wherein the side walls and the end walls include upper edges defining a top edge of the container, and wherein each of the bottom wall, the side walls and the end walls includes (i) a first layer of a plastic material forming an external side of the container, the first layer having a thickness of about 5 mm to 7 mm; and (ii) a second layer of the plastic material substantially coextensive with the first layer, the second layer being secured to the first layer, the second layer having a thickness of about 5 mm to 7 mm;

(B) a rail extending around the top edge of the container, the rail being secured to the container by a first plurality of fasteners, wherein the first plurality of fasteners penetrate the rail and only the first layer of the side walls and the end walls;

(C) a top wall forming a lid of the container and hingeably connected to a hinge end of the top edge;

(D) an insulation layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the insulation layer includes the one or more vacuum insulation panels placed substantially coextensive with the second layer; and

(E) an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the inner layer is placed substantially coextensive with the insulation layer, and wherein the inner layer forms an internal side of the container.

23. The container according to claim 22, wherein the top wall comprises:

(i) the first layer;

(ii) the second layer;

(iii) a third layer of the plastic material substantially coextensive with the second layer, the third layer being secured to the second layer, the third layer having a thickness of about 5 mm to 7 mm; and

(iv) a plurality of second fasteners adapted to secure the top wall to the hinge end, wherein the second fasteners penetrate only the first layer and the second layer of the top wall.

24. The container according to claim 22, wherein each inner layer includes a temperature holding material.

25. The container according to claim 22 further comprising one or more hardware accessories adapted to handle the container, wherein the one or more hardware accessories are secured with a plurality of third fasteners.

26. The container according to claim 25, wherein the third fasteners are fastened to one or more backers and penetrate only the first layer of the container.

27. The container according to claim 22, wherein each insulation layer includes vacuum insulation panels having an R-value of about 30 to 52.

28. The container according to claim 22, wherein the thickness of each inner layer is about 3 mm to 4 mm.

29. A method for packing a parcel for shipment to an intended recipient, comprising:

providing a reusable shipping container, wherein the container includes a bottom wall, two opposite side walls, and two opposite end walls, and wherein each of the bottom wall, the side walls and the end walls include a first layer forming an external side of the container, and a second layer substantially coextensive with said first layer;

inserting an insulation layer corresponding to each of the bottom wall, the side walls, and the end walls into the container, wherein the insulation layer includes the one or more vacuum insulation panels placed substantially coextensive with the second layer;

inserting an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the inner layer is placed substantially coextensive with the insulation layer, and wherein each inner layer provides a temperature controlled environment to the parcel located therein;

inserting the insulation layer corresponding to the top wall, wherein the insulation layer is placed substantially coextensive with the inner layer of the top wall; and closing the top wall of the container.

30. The method according to claim 29 including the step of closing the top wall of the container, wherein the top wall is closed by using one or more locking mechanisms.