ONE-PIECE INSULATING CONTAINER

Abstract

A one-piece insulating container is provided. The container is formed from a container template that includes a generally flat case blank and an insulation template secured to the case blank. The case blank and insulation template may be folded simultaneously to form the three-dimensional container. The insulation template is designed to cushion and insulate an interior volume defined by the formed case blank. When folding, the insulation template conforms to the shape of the folded case blank. The case blank and insulation template may thus be manipulated in tandem to provide a completely enclosed space that is insulated on all sides. The dimensions of the case blank and insulation template may be adjusted to establish containers of varying sizes and dimensions.

Description

CROSS REFERENCES

This application claims the benefit of U.S. Provisional Application No. 62/591,573, filed on Nov. 28, 2017, which application is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The subject matter of the present disclosure refers generally to a container for providing protection and temperature-control for contents of the container.

BACKGROUND

When shipping fragile or temperature-sensitive items, consumers generally have a limited number of container options that provide both insulation and cushioning sufficient to maintain and protect those items during transit. For spatially smaller shipments or mailings, paper envelopes lined with plastic bubble wrap are sometimes used. However, these envelops generally provide limited impact protection and virtually no insulation and thus are often unsuitable for fragile and/or temperature-sensitive items. In some instances, rolls of bubble wrap may be utilized to wrap individual items thereby equipping the same with an additional layer of padding during shipping. However, wrapping individual items in this manner may prove inconvenient, time-consuming, and costly—particularly for irregularly shaped items requiring shipment. Moreover, because mail carriers often do not permit the shipment of items encased in bubble wrap alone, items wrapped in bubble wrap generally must be placed within a container before the item can be shipped, which further increases the time, effort, and cost associated with shipping the item. For spatially larger items, containers, such as corrugated boxes, may be used. However, the corrugated walls of such boxes provide very little cushioning and, thus, generally cannot withstand significant impacts without the structural integrity of the container becoming compromised and the item stored therein from being damaged. Additionally, because the corrugated boxes currently used in the field are generally corrugated in a manner such that the interior of the box walls contains a substantial amount of air therein, corrugated boxes currently used in the field are generally poor insulators, and, as such, cannot be utilized in the shipment of temperature-sensitive items. Although boxes or other containers having expanded polystyrene therein may be used to help maintain temperature, expanded polystyrene provides limited cushioning and is generally non-biodegradable.

In some instances, foam peanuts or plastic pillows inflated with air may be used in conjunction with certain shipping containers to minimize the empty space present within the container. However, because these packaging devices generally do not occupy the entirety of the internal volume of the container not occupied by the item desired for shipment, both the foam peanuts or inflated plastic pillows as well as the item being shipped may shift within the container during transit, often resulting in breakage of the shipped item. Moreover, because foam peanuts and inflated plastic pillows are generally not designed to provide insulation, these packaging devices generally cannot be relied upon when shipping temperature-sensitive items, such as perishable food products.

Currently, thermal liners and a variety of refrigerants, such as ice packs or gel packs, are relied upon to regulate the temperature within a shipping container's interior volume. However, such liners and refrigerants are generally not components of the shipping container itself, but rather are separate elements designed to be placed or installed within a shipping container once the shipping container is fully constructed. Accordingly, to ship temperature-sensitive items using known containers, such as corrugated boxes, and liners and/or refrigerants, the container often must be manipulated from its template form, which is generally planar, into its constructed, three-dimensional box form and the liners and/or refrigerants subsequently installed within the interior volume of the box. Often, installation of the liners and/or refrigerants must be done by hand as such materials must be placed with precision to ensure the interior volume of the container exhibits proper thermal regulation. Accordingly, the step of installing or otherwise associating such liners and/or refrigerants with known shipping containers only after the container has been manipulated into a three-dimensional form often increases the time, effort, and costs associated with temperature-sensitive items.

Accordingly, a need exists in the art for a container having a one-piece design that provides improved cushioning and insulation for shipping fragile and/or temperature-sensitive items.

SUMMARY

In accordance with the present disclosure, a one-piece container, a container template for forming the container, and a method of forming the container are provided. The present container is designed to provide a completely enclosed space that is cushioned and insulated on all sides. The container generally comprises a container body formed from a case blank configured to transition from a generally flat configuration into a three-dimensional shape, such as a box, and an insulation template designed to cushion and insulate an interior volume defined by the container body. The insulation template is secured to the case blank and designed such that as the case blank transitions from a generally flat configuration into a three-dimensional shape of the container body, the insulation template transitions simultaneously with the case blank from a generally flat configuration into a three-dimensional shape. In this way, the present container does not require the container to be formed into a three-dimensional configuration before insulation material is associated therewith. The dimensions of the container body and insulation template may be adjusted to form containers of varying size and dimension. For instance, the dimensions of the container body and insulation template may be adjusted to correspond to standard sized cardboard boxes used by the United States Postal Service or other freight carriers, such as FedEx or UPS, for shipping items.

The case blank comprises a unitary piece of material, which is preferably corrugated cardboard, that is divided into a plurality of sections. To enable the container to be manipulated into a square or rectangular box shape, the case blank may be divided into four sections arranged in a row. The boundary of each section may be defined by a combination of cuts and fold lines present throughout the case blank. In addition to defining sectional boundaries, the cuts and fold lines facilitate folding of the case blank into a three-dimensional shape. In a preferred embodiment, each section of the case blank is subdivided into a side wall subsection and two opposing flaps attached to opposing sides of each side wall subsection. Depending on the load to be placed within the container, the number of subsections within each section may vary. For instance, for heavier loads, each section of the case blank may be subdivided into three subsections, including a side wall subsection and two opposing flaps. For lighter loads, the case blank may be designed such that the sections alternate between having one subsection and three subsections. For instance, the case blank may be divided into four sections where two of the four sections are subdivided into three subsections defining a side wall and a two flaps, while the remaining two sections only have a single subsection. To secure the container body in a three-dimensional configuration, the case blank may further comprise at least one tab attached to and extending from a section of the case blank. The at least one tab is preferably configured to secure to an exterior surface of a section positioned opposite from the section from which the at least one tab extends.

The insulation template comprises at least one insulating member. Each insulating member comprises a soft, flexible material that can be readily compressed and deformed to enable the insulation template to conform to the shape assumed by the container body and to provide cushioning and insulation for items placed within the container. Each insulating member preferably comprises cotton fibers to act as a cushioning agent. In one embodiment, each insulating member may comprise a bi-component fiber including cotton fibers and another type of fiber, such as polyester fibers or polyethylene fibers, which may be present in an amount sufficient to hold the cotton fiber together in order to form a distinct, defined insulating member that may be secured to the case blank as a unit of insulation so that the case blank and the insulation template secured thereto may be utilized to form a “one-piece” insulating container in a single folding step that includes simultaneous folding of the case blank and the insulation template. The fibers may also contain biodegradable additives. Each insulating member may further comprise a film or other material in which the insulation template materials may be encapsulated. The thickness of each insulating member may vary depending on the dimensions of the container body and the desired amount of cushioning or insulation to be provided thereby. To provide for additional insulation, the container may further comprise heating or cooling elements attached to the container body or embedded within or secured to the insulation template.

Accordingly, in a preferred embodiment, the present container is foldably formed from a container template comprising a generally flat case blank and a foldable insulation template secured to one side of the case blank. The case blank is adapted to foldably form a three-dimensional container having interior surfaces when folded. The case blank as four sections arranged in a row, and each section comprises a side wall subsection and opposing flaps attached to each side wall section. The insulation template is shaped to cover the side wall subsections of all four sections and to cover two opposing flaps of one of the four sections. The insulation template is adapted to simultaneously fold with the case blank so that the insulation template covers all interior surfaces of the three-dimensional container when folded. A method of forming the container is also provided. First, the foldable insulation template is secured to one side of the case blank. Once secured thereto, the case blank and insulation template are folded simultaneously so that the insulation template conforms to the shape of the case blank as they are folded. Once folded in tandem, the case blank and insulation template form a three-dimensional container in which all interior surfaces are covered by the insulation template.

The foregoing summary has outlined some features of the apparatus, system, and method of the present disclosure so that those skilled in the pertinent art may better understand the detailed description that follows. Additional features that form the subject of the claims will be described hereinafter. Those skilled in the pertinent art should appreciate that they can readily utilize these features for designing or modifying other structures for carrying out the same purposes of the apparatus and system disclosed herein. Those skilled in the pertinent art should also realize that such equivalent designs or modifications do not depart from the scope of the apparatus, system and methods of the present disclosure.

DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following description, appended claims, and accompanying drawings where:

FIG. 1 shows a top view of a disassembled container embodying features consistent with the principles of the present disclosure.

FIG. 2 shows a top view of a container embodying features consistent with the principles of the present disclosure.

FIG. 3 shows a perspective view of a container embodying features consistent with the principles of the present disclosure placed in a three-dimensional configuration.

FIG. 4 shows a perspective view of a container embodying features consistent with the principles of the present disclosure placed in a three-dimensional configuration.

FIG. 5 shows a top view of a container embodying features consistent with the principles of the present disclosure.

FIG. 6 shows a top view of a container embodying features consistent with the principles of the present disclosure.

DETAILED DESCRIPTION

In the Summary above and in this Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features, including method steps, of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with/or in the context of other particular aspects of the embodiments of the invention, and in the invention generally.

The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, steps, etc. are optionally present. For example, a system “comprising” components A, B, and C can contain only components A, B, and C, or can contain not only components A, B, and C, but also one or more other components.

Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility).

The term “removably secured” and grammatical equivalents thereof are used herein to mean the joining of two components in a manner such that the two components are secured together, but may be detached from one another and re-secured together without requiring the use of specialized tools.

In accordance with the present disclosure, a “one-piece” insulating container 10 is provided. FIGS. 1-6 illustrate preferred embodiments of the present insulating container 10. FIG. 1 illustrates a preferred embodiment of the container 10 disassembled to better illustrate certain features of the container 10. As shown in FIG. 1, the container 10 generally comprises a container body 100, which is in the form of a generally flat case blank 100 before assembly of the container, and a insulation template 200. Thus, the three-dimensional container may be formed from a container template 10 that comprises the generally flat case blank 100 and foldable insulation template 200. The case blank 100 preferably comprises a unitary piece of material adapted to foldably transition from a generally flat configuration, as shown in FIGS. 1, 2, 5, and 6, to a three-dimensional configuration as shown in FIGS. 3 and 4. In this way, the case blank 100 may be manipulated to form and retain a three-dimensional shape, such as a box, that defines an interior volume in which items and the insulation template 200 may be housed, as best shown in FIG. 4. As such, the container body 100 may define an exterior shell of the present container 10. To enable the case blank 100 to foldably transition from a flat configuration to a three-dimensional configuration, the case blank 100 has a series of fold lines 160 and cuts 170 therein. The fold lines 160 function as living hinges by which various sections of the case blank 100 may be folded to form a three-dimensional shape. The fold lines 160 may be formed by scoring, creasing, or perforating certain portions of the case blank. In some instances, the fold lines 160 may be formed by reducing the thickness of one or more defined portions of the case blank 100. As best shown in FIG. 1, the cuts 170 within the case blank 100 serve to disassociate one portion of the case blank 100 from an adjacent portion of the case blank 100.

The container body 100 may be made of a cardboard material that defines a single-face board, a single wall board, a double wall board, or a triple wall board. Alternatively, the container body 100 may at least partially comprise plastic, cotton, rubber, or any other suitable materials known for forming containers. The dimensions of the container body 100 may be adjusted to establish containers of varying size and dimension. In some instances, size and dimension of the container body 100 may be adjusted to correspond to standard sized boxes used by the United States Postal Service or other freight carriers, such as FedEx or UPS, for shipping items.

The case blank 100 is divided into four sections. To enable the container template 10 to be manipulated into a square or rectangular box shape, the case blank 100 may be divided into a first section 110, a second section 120, a third section 130, and a fourth section 140, as best shown in FIG. 1. However, one of skill in the art will readily appreciate that the container body may be divided into additional or fewer sections to facilitate the formation of different container shapes. For instance, the case blank 100 may be divide into only three sections such that the case blank may be formed into a triangular cuboidal shape. As shown in FIG. 1, the boundary of each section may be defined by one or more series of fold lines 160 and cuts 170. For instance, as shown in FIG. 1, the boundary between each section 110, 120, 130, and 140 may be defined by at least one boundary line comprising a fold line 160 disposed between and in line with two cuts 170. It is understood however, that the fold lines 160 and/or cuts 170 defining the boundary between adjacent sections may be oriented in different manners without departing from the inventive subject matter disclosed herein.

Each section 110-140 of the case blank 100 may be subdivided into a plurality of subsections to form a series of walls and flaps of the container body 100. For instance, section 110 may be divided into a side wall subsection 110b and two opposing flap subsections 110a and 110c that are each attached to the side wall subsection 110b. As best shown in FIG. 1, the boundary between adjacent subsections within each respective section may be defined by one or more fold lines 160. Depending on the load to be placed within or transported within the container 10, the number of subsections within each section 110-140 may vary. To support heavier loads, each section 110-140 of the case blank 100 may be subdivided into three subsections. In such embodiments, the first subsection within each section may define a first flap 110a, 120a, 130a, and 140a. The second subsection within each section may define a side wall 110b, 120b, 130b, and 140b. The third subsection within each section may define a second opposing flap 110c, 120c, 130c, and 140c. Accordingly, in some embodiments the container body 100 may comprise: four flaps 110a, 120a, 130a, and 140a on a first side of each side wall subsection; four side walls subsections 110b, 120b, 130b, and 140b; and four opposing flaps 110c, 120c, 130c, and 140c on a second side of each side wall subsection. In such embodiments, the shape and size of the first set of flaps may vary. For instance, two of the four flaps on the first side may be sized to cover half of an opening defined by the four side wall subsections when the container is placed in a three-dimensional configuration while the remaining two flaps may be sized to cover the entirety of such an opening, as best shown n FIGS. 1, 3, and 4. The opposing flaps may vary in size in the same manner. For lighter loads, the case blank 100 may be designed such that the certain sections comprise only a single subsection while other sections comprise two or more subsections. For instance, the first section 110 and third section 130 may each comprise a first, second, and third subsection defining a side wall and two opposing flaps, respectively, while the second section 120 and fourth section 140 may each comprise only a single subsection that defines a side wall. Thus, in some embodiments, the case blank 100 may comprise four side walls with opposing flaps attached to only two of the side walls. In such embodiments, the two flaps on one side may be equally sized with each other and the two flaps on the opposing side may be equally sized with each other.

To secure the container body in a three-dimensional configuration, the container body 100 further comprises at least one adhesive tab 150 attached to and extending outwardly from a section of the case blank 100. As shown in FIG. 1, the at least one tab 150 preferably extends outwardly from an end side wall subsection 110b or 140b of one of the outermost sections 110, 140 of the container body 100. The boundary between the at least one tab 150 and the side wall subsection 110b, 140b to which it extends from may be defined by a fold line 160. The at least one tab 150 is configured to secure the section to which the tab is attached to an opposing end section of the case blank 100 opposite the section from which the at least one tab 150 extends from. To this end, the at least one tab 150 may have adhesive on an interior surface of the tab, exterior surface, or both. For instance, the at least one tab 150 may extend from the side wall subsection 140b of the section 140 and have adhesive on its interior surface, such that the case blank 100 may be placed and then secured in a three-dimensional configuration by securing the interior surface of the at least one tab 150 to an exterior surface of side wall subsection 110b of section 110. In some instances, the at least one tab 150 may have an adhesive strip 151, as shown in FIG. 3, which may be used to secure the at least one tab 150 to another portion of the container body 100. Alternatively, the adhesive may be a fugitive glue or similar type of adhesive that has sufficient strength to keep sections of the case blank 100 secured together during normal use and shipping, but allows manual separation to deconstruct the container. Thus, the use of a fugitive glue may facilitate recycling of the case blank 100 by allowing easy removal of adhesive. In another alternative embodiment, one or more first securing members and one or more second securing members, where the first securing members are configured to interlock with the second interlocking members, may be used to hold the case blank 100 in a three-dimensional configuration. For instance, in one embodiment, a first securing member may be secured to the interior surface of the at least one tab 150 and the second securing member may be secured to the exterior surface of subsection 110b opposite from subsection 140b from which the at least one tab 150 extends. In some embodiments, the first and second securing members may comprise hook and loop fasteners, though any fastening or securing device suitable for removably securing one object to another including, but not limited to, snap buttons, magnets, and adhesive tapes, may be used as the first and second securing members.

The insulation template 200 is configured to provide cushioning and insulation for the container 10. The insulation template 200 comprises at least one insulating member. As shown in FIGS. 1, 2, and 5, the insulation template 200 may comprise a first insulating member 200a and a second insulating member 200b in one preferred embodiment. Alternatively, the insulation template 200 may comprise a single insulating member, as shown in FIG. 6. Each insulating member 200a, 200b, is constructed of soft, flexible material that can be readily compressed and deformed in order to provide cushioning and insulation for items placed within the container 10. Each insulating member 200a, 200b may comprise primarily natural cotton fibers to act as a cushioning agent. In one embodiment, each insulating member may comprise a bi-component fiber including cotton fibers and another type of fiber, such as polyester fiber or polyethylene fibers, which may be present in an amount sufficient to hold the cotton fiber together in order to form a distinct, defined insulating member that may be secured to the case blank 100 as a unit of insulation. The fibers may also contain biodegradable additives. In some instances, the insulating members may include recycled fabrics, polymers, and the like. Each insulating member 200a, 200b may optionally further comprise a film or other material that serves to encapsulate the insulating material and functions as an external layer of the insulating member. For instance, the insulating material of each insulating member may be encapsulated within polyethylene plastic or a polyester sheet. The external layer of the insulating members 200a, 200b may aid in securing the insulating and cushioning fibers together to form a unit of insulation template. The external layer of each insulating member and/or the insulating material contained therein may be biodegradable.

The thickness of each insulating member 200a, 200b may vary depending on the dimensions of the container body 100 and the desired amount of cushioning to be provided by the container 10. Each insulating member 200a, 200b preferably has a thickness that is at least twice as thick as the thickness of the case blank 100. In a preferred embodiment, each insulating member 200a, 200b is about one-quarter to two inches thick when in a decompressed state, as best shown in FIGS. 3-4.

The insulation template 200 is secured to one side of the case blank 100, which is the side that forms an interior surface of the container body 100, as shown in FIGS. 2-6. When the insulation template 200 is secured to the case blank 100, the container 10 is ready to be manipulated from the flat configuration into the three-dimensional configuration. The insulation template 200 is sized, shaped, and secured to the case blank 100 such that when the case blank 100 is manipulated to form a box, the insulation template 200 cushions and insulates the top, bottom, and each side of the formed box, as best shown in FIGS. 3-4. To this end, the template 200 may be shaped, sized, and secured to the case blank such that the insulation template 200 substantially covers the side wall subsections 110b, 120b, 130b, and 140b of all four sections 110, 120, 130, and 140, respectively, and substantially covers two opposing flaps of one of the four sections, which are preferably flaps 140a and 140c of end section 140. Thus, the insulation template 200 covers the entirety of one section of the case blank 100 and the side wall subsections of each of the remaining sections, as shown best in FIGS. 2 and 5. For instance, the insulation template 200 may substantially cover the entirety of section 140 of the container body 100 and cover the remaining side wall subsections 110b, 120b, and 130b, as shown in FIGS. 2 and 5. In instances where the insulation template 200 comprises a first insulating member 200a and a second insulating member 200b, the first insulating member 200a may be secured to section 140, and the second insulating member 200b may be secured to sections 110, 120, and/or 130 in. In such embodiments, the first insulating member 200a may be sized to define a perimeter that is smaller than the perimeter defined by the entirety of section 140, and the second insulating member 200b may be sized to define a perimeter that is smaller than the perimeter defined by the side wall subsections 110b, 120b, 130c of sections 110, 120, 130, as best shown in FIG. 2.

The insulation template 200 may be attached in alternative arrangements or configurations depending on the design of the case blank 100. For instance, in some embodiments, sections 110 and 130 of the case blank 100 may each have a side wall subsection and two opposing flaps, while sections 120 and 140 of the case blank 100 each have only a side wall subsection. In such embodiments, the insulation template 200 may be shaped and sized such that when secured to the case blank 100 the insulation template substantially covers the entire section 110 and covers the side wall subsections of sections 120, 130, and 140. As such, one of skill in the art will readily appreciate that the insulation template 200 may be secured to the case blank in any arrangement or configuration that causes the insulation template 200 to completely pad an interior volume defined by the container body 100 when the container body 100 is placed in a three-dimensional configuration, as shown in FIGS. 3-4. As shown in FIGS. 2, 5, and 6, in some embodiments, the template may form a “T” shape, though depending on the design of the container body 100, the shape, size, and orientation to which the insulation template 200 is secured thereto may vary.

To secure the insulation template 200 to the case blank 100, the interior surface of one or more subsections of the case blank 100 may have adhesives or film applied thereto. In embodiments where the insulation template 200 comprises a first insulating member 200a and a second insulating member 200b, preferably at least two subsections of the case blank 100 have film or adhesive applied thereto such that a first subsection with adhesive or film secures the first insulating member 200a in place and a second subsection with adhesive or film secures the second insulating member 200b in place. In alternative embodiments, each subsection of the case blank 100 may have adhesive or film applied thereto. In a preferred embodiment, the adhesive is a fugitive glue or similar type of adhesive that has sufficient strength to keep the insulation template secured to the case blank 100 during normal use and shipping, but allows manual separation of the insulation template 200 from the case blank 100. Thus, the use of a fugitive glue may facilitate recycling of both the case blank 100 and the insulation template 200 by allowing easy removal of adhesive from these components. Alternatively, to enable the insulation template 200 to be associated and disassociated with the case blank 100 as desired, the insulation template 200 may be removably secured to the case blank 100 in some embodiments. In such embodiments, the insulation template 200 may be secured to the case blank 100 by interlocking one or more first securing members secured to an interior surface of the case blank 100 with one or more second securing members secured to a surface of the insulation template 200.

Once the insulation template 200 is secured to the interior surface of the case blank 100, the container template 10 is ready to foldably transition from a flat configuration, as shown in FIGS. 1, 2, 5, and 6, into a three-dimensional configuration forming a box shape, as shown in FIG. 4. To form the three-dimensional container 10, the case blank 100 and the insulation template 200 secured thereto are folded simultaneously so that the shape of the insulation template 200 conforms to the shape of the case blank 100. The transitioning may begin by folding the first section 110 about the fold line 160 separating the first side wall subsection 110b from the second side wall subsection 120b such that the first and second side wall subsections 110b and 120b form an approximately 90-degree angle. The case blank 100 is then folded about the fold line 160 separating the second side wall subsection 120b from the third side wall subsection 130b such that the second side wall subsection 120b and the third side wall subsection 130b form an approximately 90-degree angle, as shown in FIG. 3. The case blank 100 may then be folded about the fold line 160 separating the third side wall subsection 130b from the fourth side wall subsection 140b such that third side wall subsection 130b and the fourth side wall subsection 140b form an approximately 90-degree angle and the first side wall subsection 110b and the fourth side wall subsection 140b form an approximately 90-degree angle, as shown in FIG. 3.

As further shown in FIG. 3, when the container body 100 is manipulated in the above-described manner, the first section 110 is opposite the third section 130, and the second section 120 is opposite to the fourth section 140, causing the container 10 to assume a cube shape having a top opening 190 and a bottom opening 180. Because the insulation template 200 comprises a soft, flexible material that can be readily compressed and deformed, the insulation template 200 conforms to the shape assumed by the container body 100 and pads each side of the cube, as further shown in FIG. 3. To secure the container 10 in such an open cube configuration the at least one tab 150 is then secured to the first section 110 via adhesives or through the interlocking of a first and second securing members. Preferably, the interior surface of the at least one tab 150 is configured to secure to the exterior surface of the first section 110, as best shown in FIG. 3. Alternatively, the exterior surface of the at least one tab 150 may be configured to secure to the interior surface of the first section 110.

The bottom opening 180 of the cube may be closed by folding each bottom flap subsection inwardly. Depending on the design of the container body, this may involve folding two or four bottom flaps inwardly. In embodiments having four bottom flaps, the first bottom flap subsection 110c and the third bottom flap subsection 130c are opposite each other, and the second bottom flap subsection 120c and the fourth bottom flap subsection 140c are opposite each other when the container is placed in an open-cube configuration, as shown in FIG. 3. As shown best in FIG. 1, the second and fourth flap subsections 120c and 140c may be larger than the first and third flap subsections 110c and 140c. Preferably, at least one bottom flap subsection of the container body 100 is shaped and sized to define an area approximately equal to the size of the bottom opening 180. In some embodiments, the second and fourth bottom flap subsections 120c and 140c may be sized and shaped to define an area approximately equal to the size of the bottom opening 180 of the container 10, and the first and third bottom flap subsections 110c and 130c may be sized and shaped to define an area approximately equal to one-half the size of the bottom opening 180 of the container 10, as shown best in FIGS. 1, 3, and 4. However, one of skill in the art will appreciate the shape and size of each respective bottom flap subsection may vary without departing from the inventive subject matter disclosed herein. For instance, to support heavier loads, each bottom flap subsection may be shaped and sized to define an area approximately equal to the size of the bottom opening 180.

As shown in FIG. 3, at least one of the flap subsections that form the bottom of the container has a portion of the insulation template 200 associated therewith. To provide padding for the bottom portion of the box shown in FIG. 4, the bottom flap subsection having a portion of the insulation template 200 associated therewith is first folded inwardly to establish a padded bottom wall for the container 10. The bottom flap subsection that is opposite to the bottom flap subsection having a portion of the insulation template 200 associated therewith is then folded inwardly. If additional bottom flap subsections are present within the container body 100, those bottom flap subsections are subsequently folded inwardly. To hold the bottom flaps in an inwardly folded, closed configuration, tape, adhesives, staples, banding, or other known elements may be used. Once the bottom flap subsections are folded and held in the closed configuration, the bottom opening 180 shown in FIG. 3 is closed by a padded bottom wall. As such, items may be placed within a partially enclosed interior volume defined by the container body's 100 side wall subsections and bottom flap subsections and the insulation template 200.

The top opening 190 of the cube shown in FIGS. 3-4 may be closed by folding each flap subsection forming the top of the container inwardly. Depending on the design of the container body, this may involve folding two or four top flaps inwardly. In embodiments having four top flaps, the first top flap subsection 110a and the third top flap subsection 130a are opposite each other, and the second top flap subsection 120a and the fourth top flap subsection 140a are opposite each other when the container is placed in an open-cube configuration, as shown in FIG. 3-4. As shown best in FIG. 1, the second and fourth top flap subsections 120a and 140a may be larger than the first and third top flap subsections 110a and 130a. Preferably, at least one top flap subsection of the container body 100 is shaped and sized to define an area approximately equal to the size of the top opening 190. In some embodiments, the second and fourth top flap subsections 120a and 140a may be sized and shaped to define an area approximately equal to the size of the top opening 190, and the first and third top flap subsections 110a and 130a may be sized and shaped to define an area approximately equal to one-half the size of the top opening 190, as shown best in FIGS. 1, 3, and 4. However, one of skill in the art will appreciate the shape and size of each respective top flap subsection may vary without departing from the inventive subject matter disclosed herein. For instance, to support heavier loads, each top flap subsection may be shaped and sized to define an area approximately equal to the size of the top opening 190.

As shown in FIG. 4, at least one of the top flap subsections has a portion of the insulation template 200 associated therewith. To provide padding for the top portion of the box shown in FIG. 4, the top flap subsection having a portion of the insulation template 200 associated therewith is first folded inwardly to establish a padded top wall. The top flap subsection that is opposite the top flap subsection having a portion of the insulation template 200 associated therewith is then folded inwardly. If additional top flap subsections are present within the container body 100, those top flap subsections are subsequently folded inwardly. To hold the top flap subsections in an inwardly folded, closed configuration, tape, adhesives, staples, banding, or other known elements may be used. Once the top flap subsections are folded and held in the closed configuration, the top opening 190 shown in FIG. 4 is closed by a padded top wall. At this point, the container 10 defines a completely enclosed, padded interior volume in which items desired for shipment may be housed during transit.

As show in FIG. 5, in some embodiments, the container 10 may further comprise heating or cooling elements 210. The heating or cooling elements may be incorporated directly into or onto the insulation template 200, as shown in FIG. 5, and/or may alternatively be incorporated directly into or onto the case blank 100. In some instances, water-based ice and gel packs configured to keep materials cold around 0° Celsius may be used. In a preferred embodiment, the container 10 may include phase change materials. As used herein, phase change materials (PCMs) may include, but are not limited to, water-based, salt hydrates, paraffins, and vegetable-based materials. Salt hydrates consist of inorganic salts and water. The use of salt hydrates may be preferred as they possess a high latent heat storage capacity, precise melting point, have high thermal conductivity, and are generally inflammable. The melting point of such hydrates may range between 15° Celsius and 80° Celsius. Paraffins, typically, are derived from petroleum and have a waxy consistency at room temperature. The use of such paraffins may be desirable as they generally possess good thermal storage capacity, are proven to freeze without super cooling, have improved chemical stability over many heating and freezing cycles, are non-corrosive, and are compatible with most encapsulation materials. Such paraffins may have a melting point ranging between −8° Celsius and 40° Celsius. Bio-based PCMs are organic compounds derived from animal fat and plant oils. Such bio-based PCMs may have a melting point between 40° Celsius and 151° Celsius. The use of bio-based PCMs may be preferred as they are often derived from fatty acids and have higher efficiency than salt hydrates and petroleum-based phase change material. One of skill in the art will appreciate that other PCMs may be used with the container 10 of the present disclosure and fall within the scope of the inventive subject matter.

The above-described PCMs may be attached or incorporated directly into the case blank 100 and/or the insulation template 200. In this way, the PCMs may be activated, either chemically or physically, and immediately packed for shipping. For example, containers 10 utilizing gel packs may be stored in a refrigerated area along with the goods being stored. In this way, the gel packs will cool to the shipping temperature in the same facility in which it is loaded and will not require additional energy for cooling the packs. In another embodiment, a user may chemically set a PCM for a specific temperature range. Upon setting the temperature range of the material, the container 10 may be immediately folded into a three-dimensional box configuration, loaded, and shipped.

The dimensions of each component of the container 10 described herein may be adjusted to form containers of varying dimensions. For instance, the container body 100 and/or template discussed above may be shaped and sized to correspond to standard sized boxes or containers used by the United States Postal Service or other freight carriers, such as FedEx or UPS, for shipping fragile or temperature-sensitive items.

The devices and methods shown and described herein are exemplary. Though certain characteristics of the present disclosure are described above, the description is illustrative only. It is understood that versions of the container disclosed above may come in different forms and embodiments. Additionally, it is understood that one of skill in the art would appreciate these various forms and embodiments as falling within the scope of the invention as disclosed herein.

Claims

1) A container template for foldably forming a container having an insulated and cushioned interior, said container template comprising:

a generally flat case blank adapted to foldably form a three-dimensional container having interior surfaces when folded, wherein the case blank has four sections arranged in a row, wherein each section comprises a side wall subsection and opposing flaps attached to each side wall subsection; and

an insulation template secured to one side of the case blank and shaped to cover the side wall subsections of all four sections and to cover two opposing flaps of one of the four sections, wherein the insulation template is adapted to fold simultaneously with the case blank so that the insulation template covers all interior surfaces of the three-dimensional container when folded.

2) The container template of claim 1, wherein the insulation template is secured to the case blank by an adhesive.

3) The container template of claim 1, wherein the insulation template comprises fibers contained within an encapsulating material.

4) The container template of claim 3, wherein the insulation template further comprises temperature-control elements contained within the encapsulating material.

5) The container template of claim 1, wherein an end side wall subsection of the case blank has an adhesive tab attached thereto and configured to secure the end side wall subsection to which the adhesive tab is attached to an opposing end side wall subsection.

6) A method of forming an insulated container, said method comprising the steps of:

providing a generally flat case blank adapted to foldably form a three-dimensional container having interior surfaces when folded, wherein the case blank has four sections arranged in a row, wherein each section comprises a side wall subsection and opposing flaps attached to each side wall subsection;

providing a foldable insulation template shaped to cover the side wall subsections of all four sections and to cover two opposing flaps of one of the four sections;

securing the insulation template to one side of the case blank in a position in which the insulation template covers the side wall subsections of all four sections of the case blank and covers two opposing flaps of one of the four sections; and

folding the case blank and the insulation template simultaneously, after the step of securing the insulation template to one side of the case blank, to form a three-dimensional container in which all interior surfaces of the three-dimensional container are covered by the insulation template.

7) The method of claim 6, wherein the step of securing the insulation template to one side of the case blank comprises applying an adhesive to the case blank or to the insulation template.

8) The method of claim 6, wherein the insulation template comprises fibers contained within an encapsulating material.

9) The method of claim 8, wherein the insulation template further comprises temperature-control elements contained within the encapsulating material, and the step of providing an insulation template comprises installing the temperature-control elements within the encapsulating material.

10) The method of claim 6, wherein an end side wall subsection of the case blank has an adhesive tab attached thereto and configured to secure the end side wall subsection to which the adhesive tab is attached to an opposing end side wall subsection, further comprising the step of securing the end side wall subsection to which the adhesive tab is attached to the opposing end side wall subsection with the adhesive tab.