INSULATED CONTAINER

An insulated container and method of assembling the same utilize a side insulating member and top and bottom insulating members that define an insulated interior compartment within a container body. The side insulating member is folded into four portions that respectively contact four sides of the container body, while a bottom insulating member is sized to be inserted into the container body after the side insulating member with four edge portions of the bottom insulating member contacting the four portions of the side insulating member, and the top insulating member is sized to contact top edge surfaces of the four portions of the side insulating member. By doing so, enhanced sealing and structural support within the insulated container may be provided.

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Description
BACKGROUND OF THE INVENTION

Insulated containers are used in the storage and transport of goods for which it is desirable to maintain a controlled environment, e.g., to maintain goods at a temperature that is higher or lower than the ambient temperature of the surrounding environment. Worldwide sensitivity to sustainability has also increased interest in reducing the environmental impact of containers and other packaging. In addition, as with many types of containers and other packaging, it is often desirable to minimize material and manufacturing costs, minimize container weight (which can impact shipping costs), and simplify manufacturing, assembly and loading of insulated containers.

Therefore, a continuing need exists in the art for an insulated container that is capable of maintaining a controlled internal environment, and to do so in a cost effective and environmentally conscious manner.

SUMMARY OF THE INVENTION

The invention addresses these and other problems associated with the art by providing an insulated container and method of assembling the same that utilizes a side insulating member and top and bottom insulating members that define an insulated interior compartment within a container body. The side insulating member is folded into four portions that respectively contact four sides of the container body, while the bottom insulating member is sized to be inserted into the container body after the side insulating member with four edge portions of the bottom insulating member contacting the four portions of the side insulating member, and the top insulating member is sized to contact top edge surfaces of the four portions of the side insulating member. By doing so, enhanced sealing and structural support within the insulated container may be provided.

Therefore, consistent with one aspect of the invention, an insulated container may include a container body including a bottom and first, second, third, and fourth sides, a side insulating member received in the container body and folded into first, second, third, and fourth side portions that respectively contact the first, second, third, and fourth sides of the container body, each of the first, second, third, and fourth side portions including an inwardly-facing surface that faces away from the respective first, second, third, and fourth side of the container body and a top edge surface that faces away from the bottom of the container body, a bottom insulating member contacting the bottom of the container body, the bottom insulating member including an upwardly-facing surface that faces away from the bottom of the container body and an edge surface that circumscribes the upwardly-facing surface of the bottom insulating member and includes first, second, third, and fourth edge surface portions that respectively contact the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member, and a top insulating member including a downwardly-facing surface that faces the bottom of the container body and that contacts the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member.

In some implementations, the bottom insulating member has a length and a width and the top insulating member has a length and a width, the length of the top insulating member is larger than the length of the bottom insulating member, and the width of the top insulating member is larger than the width of the bottom insulating member. Also, in some implementations, each of the first, second, third, and fourth side portions of the side insulating member further includes an outwardly-facing surface that faces toward the respective first, second, third, and fourth side of the container body, where the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member defines a thickness separating the respective inwardly-facing and outwardly-facing surfaces of the respective first, second, third, and fourth side portion of the side insulating member. Further, in some implementations, a perimeter of the top insulating member is substantially coincident with a perimeter defined by the outwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member and a perimeter of the bottom insulating member is substantially coincident with a perimeter defined by the inwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member.

In some implementations, each of the first, second, third, and fourth side portions of the side insulating member further includes a bottom edge surface that contacts the bottom of the container body. In addition, in some implementations, the container body further includes a closable top, and the top insulating member further includes an upwardly-facing surface that contacts the closable top of the container body when the closable top is closed.

In some implementations, the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member against the respective first, second, third, and fourth sides of the container body. In addition, in some implementations, the bottom insulating member is sized and configured such that the edge surface forms a seal with the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member. Moreover, in some implementations, the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member to structurally support the side insulating member against the first, second, third, and fourth sides of the container body.

Consistent with another aspect of the invention, a method of assembling an insulated container may include inserting a side insulating member into a container body including a bottom and first, second, third, and fourth sides, the side insulating member folded into first, second, third, and fourth side portions that respectively contact the first, second, third, and fourth sides of the container body when the side insulating member is inserted into the container body, and each of the first, second, third, and fourth side portions including an inwardly-facing surface that faces away from the respective first, second, third, and fourth side of the container body and a top edge surface that faces away from the bottom of the container body, after inserting the side insulating member into the container body, inserting a bottom insulating member into the container body such that the bottom insulating member contacts the bottom of the container body, the bottom insulating member including a upwardly-facing surface that faces away from the bottom of the container body and an edge surface that circumscribes the upwardly-facing surface of the bottom insulating member and includes first, second, third, and fourth edge surface portions that respectively contact the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body, and after inserting the bottom insulating member into the container body, inserting a top insulating member into the container body, the top container body including a downwardly-facing surface that faces the bottom of the container body and that contacts the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member when the top insulating member is inserted into the container body.

In some implementations, the bottom insulating member has a length and a width and the top insulating member has a length and a width, the length of the top insulating member is larger than the length of the bottom insulating member, and the width of the top insulating member is larger than the width of the bottom insulating member. Moreover, in some implementations, each of the first, second, third, and fourth side portions of the side insulating member further includes an outwardly-facing surface that faces toward the respective first, second, third, and fourth side of the container body, where the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member defines a thickness separating the respective inwardly-facing and outwardly-facing surfaces of the respective first, second, third, and fourth side portion of the side insulating member. In some implementations, a perimeter of the top insulating member is substantially coincident with a perimeter defined by the outwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member and a perimeter of the bottom insulating member is substantially coincident with a perimeter defined by the inwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member.

In addition, in some implementations, each of the first, second, third, and fourth side portions of the side insulating member further includes a bottom edge surface that contacts the bottom of the container body. In some implementations, the container body further includes a closable top, and the top insulating member further includes an upwardly-facing surface that contacts the closable top of the container body when the closable top is closed.

Moreover, in some implementations, the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member against the respective first, second, third, and fourth sides of the container body when the bottom insulating member is inserted into the container body. Also, in some implementations, the bottom insulating member is sized and configured such that the edge surface forms a seal with the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body. In some implementations, the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body to structurally support the side insulating member against the first, second, third, and fourth sides of the container body.

In addition, in some implementations, the container body further includes a closable top, and the method further includes closing the closable top after inserting the top insulating member into the container body. Also, in some implementations, the top, bottom, and side insulating members define an insulated interior compartment in the container body, and the method further includes inserting an item and a heat or cold pack into the insulated interior compartment after inserting the bottom insulating member into the container body and before inserting the top insulating member into the container body.

These and other advantages and features, which characterize the invention, are set forth in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, and of the advantages and objectives attained through its use, reference should be made to the Drawings, and to the accompanying descriptive matter, in which there is described example implementations of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example implementation of an insulated container consistent with the invention, prior to assembly.

FIG. 2 is a perspective view of the insulated container of FIG. 1, and illustrating insertion of the side insulating member into the container body.

FIG. 3 is a perspective view of the insulated container of FIG. 1, and illustrating insertion of the bottom insulating member into the container body.

FIG. 4 is a perspective view of the insulated container of FIG. 1, and illustrating insertion of the top insulating member into the container body.

FIG. 5 is a front side elevational view of the insulated container of FIG. 1 after assembly and with the container body hidden.

FIG. 6 is a rear side elevational view of the insulated container of FIG. 1 after assembly and with the container body hidden.

FIG. 7 is a top plan view of the insulated container of FIG. 1 after assembly and with the container body hidden.

FIG. 8 is a bottom plan view of the insulated container of FIG. 1 after assembly and with the container body hidden.

FIG. 9 is a cross-sectional view of the insulated container of FIG. 1 after assembly and with the container body hidden, and taken through lines 9-9 of FIG. 7.

FIG. 10 is a cross-sectional view of one example implementation of an insulating member construction suitable for use in the insulating container of FIG. 1.

FIG. 11 is a cross-sectional view of another example implementation of an insulating member construction suitable for use in the insulating container of FIG. 1, and including an external wrap.

FIG. 12 is a cross-sectional view of another example implementation of an insulating member construction suitable for use in the insulating container of FIG. 1, and including a laminated layer.

 DETAILED DESCRIPTION

Some implementations consistent with the invention may provide an insulated container in which three insulating members are positioned within a container body, such as a corrugated cardboard box, to contact each of the six interior surfaces of the container body to form an insulated compartment bounded on all sides by insulation to assist in controlling the environment within the insulated interior compartment. As will become more apparent below, a side insulating member is folded into four portions that respectively contact four sides of the container body, while a bottom insulating member is sized to be inserted into the container body after the side insulating member with four edge portions of the bottom insulating member contacting the four portions of the side insulating member, and the top insulating member is sized to contact top edge surfaces of the four portions of the side insulating member. By doing so, enhanced sealing and structural support within the insulated container may be provided.

Turning to the Drawings, wherein like numbers denote like parts throughout the several views, FIG. 1 illustrates various components of an insulated container 10 consistent with some implementations of the invention. Insulated container 10, in particular, may include a container body 12 including four sides 14, 16, 18, 20, a bottom 22, and a closable top defined by a plurality of (e.g., four) flaps 24. Container body 12 may be formed of corrugated cardboard, cardboard, or practically any other suitable material, and generally forms a cuboid shape having a length LC, width WC and height HC. For the purposes of convenience, side 14 may also be referred to as a left side, side 16 may also be referred to as a right side, side 18 may also be referred to as a front side, and side 20 may also be referred to as a rear side, although it will be appreciated that each side may have a different orientation based on the perspective of the viewer. It will also be appreciated that the length, width, and height of the container body may vary in different implementations, and two or more of these dimensions may be the same in some implementations, although the invention is not so limited.

Insulated container 10 also includes a plurality of insulating members, which in the illustrated implementation include a top insulating member 26, a bottom insulating member 28, and a side insulating member 30. In some implementations, it is desirable to include only three insulating members; however, a greater or fewer number of insulating members capable of insulating the six surfaces of the container body may be used in other implementations.

Top insulating member 26 has a length LT, width WT, and thickness TT, while bottom insulating member 28 has a length LB, width WB, and thickness TB. Side insulating member 30 has a length LS, width WS, and thickness TS, and includes four portions 32, 34, 36, 38 that respectively have lengths of L1, L2, L3, and L4, and that are joined by a plurality of fold lines 40. In the illustrated implementation, side insulating member 30 is formed of a single contiguous piece of insulating material such that portions 32, 34, 36, 38 are formed by folding along fold lines 40, although in other implementations the portions may be separate members joined by flexible joints (e.g., using tape), or may be separate members and may not be joined to one another.

In some implementations, insulating members 26, 28, 30 are formed from the same insulating material, such that the thicknesses TT, TB, and TS of insulating members 26, 28, 30 are substantially the same, although in other implementations, different insulating materials and/or thicknesses may be used for insulating members 26, 28, 30. The length and width dimensions of each insulating member 26, 28, 30 in turn are generally selected based at least in part on the dimensions of container body 12.

In some implementations, for example, a friction fit may be desired in order to resist displacement of the insulating members during loading, unloading, or transport of the insulated container, as well as to minimize gaps between the insulating members that could allow for greater heat transfer between the insulated interior compartment and the exterior environment. As such, and depending upon the compressibility of the insulating members, the length and width may be somewhat less than, substantially greater than, or substantially equal to the matching dimensions of the container body. In other implementations, adhesive may be used to adhere some or all of the insulating members within the container body, such that the dimensions of the insulating members may differ more substantially from those of the container body.

As one illustrative example, where a friction fit is used, for top insulating member 26, the length LT and width WT may be selected based on the length LC and width WC of container body 12. Bottom insulating member 28, however, is sized to be inserted into container body 12 after side insulating member 30, so the length LB and width WB may be selected to be smaller than the LT and width WT of top insulating member 26 by about 2 x the thickness TS of side insulating member 30.

For side insulating member 30, the width WS is generally selected based on the height HC of container body 12, and in some implementations, may be smaller than height HC by a distance of about the thickness TT of top insulating member 26, such that when side insulating member 30 and top insulating member 26 are placed in container body 12, substantially all of the interior space of container body 12 is occupied by the insulating members. In other implementations, however, it may be desirable to select a width WS that is substantially less than the height HC to provide space for an uninsulated compartment within insulated container 10, e.g., if it is desirable to provide a compartment for items that do not need to be (or are desirably not) maintained at the same temperature as items within the insulated interior compartment.

In the illustrated implementation, the overall length LS of side insulating member 30 is selected to be similar to, but slightly less, than the perimeter of top insulating member 26, which may be considered to be substantially equal to 2 x (LT + WT). In particular, it may be desirable in some implementations to subtract the thickness TS of side insulating member 30 from the perimeter such that one side portion, e.g., side portion 38, is sized to account for an end of the opposite end side portion 32 to be in contact with the same side of container body 12. The lengths of the individual side portions 32, 34, 36, 38 are accordingly selected based on the length LC and width WC of container body 12, e.g., with the lengths L1 and L3 of side portions 32 and 36 selected based on the length LC of container body 12 and the lengths L2 and L4 of side portions 34 and 38 selected based on the width WC of container body 12, but with the length L4 of side portion 38 reduced relative to length L2 of side portion 34 by the thickness TS for the reasons discussed above.

Assembly of insulated container 10 is illustrated in FIGS. 2-4. First, as illustrated in FIG. 2, side insulating member 30 is folded along fold lines 40 and inserted into container body 12. Side insulating member 30 includes a bottom edge surface 42 and a top edge surface 44, and side portion 32 thereof includes a side edge surface 46 and side portion 38 includes a side edge surface 48. In addition, when folded into the configuration illustrated in FIG. 2, side insulating member 30 may be considered to include an outwardly-facing surface 50 that defines for each side portion 32, 34, 36, 38 an outwardly-facing surface that faces the respective sides 14, 16, 18, 20 of container body 12, as well as an inwardly-facing surface 52 that defines for each side portion 32, 34, 36, 38 an inwardly-facing surface that faces away from the respective sides 14, 16, 18, 20 of container body 12 and towards an insulated interior compartment 54 for insulated container 10.

It should be noted that when side insulating member 30 is folded and inserted into container body 12, side portion 32 contacts side 16 of container body 12, side portion 34 contacts side 20 of container body 12, side portion 36 contacts side 14 of container body 12, and side portion 38 contacts side 18 of container body 12. Moreover, by virtue of the aforementioned dimensions of side portions 32 and 38, side edge surface 46 of side portion 32 also contacts side 18 of container body 12, while side edge surface 48 of side portion 38 contacts a portion of inwardly-facing surface 52 defined on side portion 32. Moreover, bottom edge surface 42 contacts bottom 22 of container body 12, while top edge surface 44 faces away from the bottom of the container body.

Next, as illustrated in FIG. 3, bottom insulating member 28 is inserted into container body 12. Bottom insulating member 28 includes an edge surface 56 including edge surface portions 58, 60, 62, 64, an upwardly-facing surface 66 that is configured to face away from bottom 22 of container body 12, and a downwardly-facing surface 68 that is configured to face towards and contact bottom 22 of container body 12. Moreover, edge surface 56 circumscribes each of surfaces 66, 68, and due to the sizing of bottom insulating member 28, edge surface portions 56, 58, 60, 62 are respectively configured to contact the portions of inwardly-facing surface 52 defined on side portions 32, 34, 36, 38 of side insulating member 30. Moreover, by virtue of the sizing of bottom insulating member 28, the perimeter of the bottom insulating member is substantially coincident with a perimeter defined by the inwardly-facing surface 52 of side insulating member 30 when insulating members 28, 30 are inserted into container body 12. In some implementations, it may be desirable to size the bottom insulating member to be slightly larger than the perimeter defined by the inwardly-facing surface 52 of side insulating member 30 when side insulating member 30 is disposed within container body 12 such that edge surface 56 of bottom insulating member presses side portions 32, 34, 36, 38 of insulating member 30 against sides 14, 16, 18, 20 of container body 12, thereby forming a seal with the inwardly-facing surface 52 and providing additional structural rigidity to retain side insulating member 30 in position within container body 12.

Next, prior to shipment, items may be placed into insulated interior compartment 54, and further, an ice pack, heat pack, or other system for controlling the temperature within interior compartment 54 may be placed within the interior compartment. Thereafter, as illustrated in FIG. 4, top insulating member 26 may be inserted into container body 12 to seal off insulated interior compartment 54. Top insulating member 26 includes an upwardly-facing surface 70 that faces away from bottom 22 of container body 12 and faces towards and contacts a closable top defined when flaps 24 are moved to a closed position, as well as a downwardly-facing surface 72 that faces towards the bottom 22 of container body 12 and into insulated interior compartment 54. In the illustrated implementation, by virtue of the sizing of top insulating member 26, the perimeter of the top insulating member is substantially coincident with a perimeter defined by the outwardly-facing surface 50 of side insulating member 30, such that top insulating member 26 is supported on top edge surface 44 of side insulating member 30. It may also be desirable in some implementations for a side edge surface 74 of top insulating member 26 to further contact each of sides 14, 16, 18, 20 of container body 12. Thereafter, flaps 24 may be moved to closed positions and sealed, e.g., using tape, adhesives, staples, etc., whereby insulated container 10 is then closed and ready for shipment and/or storage.

FIGS. 5-9 further illustrate the arrangement of insulating members 26, 28, 30 after assembly of insulated container 10. Container body 12 is hidden in these figures for clarity purposes. As illustrated in these figures, top insulating member 26 is sized and configured to be supported on top of side insulating member 30, while bottom insulating member 28 is sized and configured to be inserted inwardly from side insulating member 30, such that edge surface portions 56, 58, 60, 62 contact the portions of inwardly-facing surface 52 defined on side portions 32, 34, 36, 38 of side insulating member 30, e.g., as illustrated by edge surface portions 58 and 60 that respectively contact side portions 32 and 36 of side insulating member 30.

In addition, it will be appreciated that downwardly-facing surface 68 of bottom insulating member 28 and bottom edge surface 42 of side insulating member 30 cooperatively define a bottom of insulated interior compartment 54 and are both in contact with the bottom 22 of container body 12. Furthermore, it will be appreciated that bottom insulating member 28 may be friction fit within the interior space defined by side insulating member 30 in a manner in which edge surface portions 56, 58, 60, 62 are in contact with, and in some instances, pressing outwardly against, inwardly-facing surface 52 of side insulating member. Such an arrangement may be beneficial in some implementations as it may provide superior leak resistance to an alternate configuration where a bottom insulating member is sized similarly to a top insulating member such that it overlaps the entire bottom of the container body and the bottom edge surface of the side insulating member sits on top of the bottom insulating member. Moreover, as compared to the aforementioned alternate configuration, such an arrangement may provide additional structural support to the insulated container by pressing side portions 32, 34, 36, 38 of side insulating member 30 against sides 14, 16, 18, 20 of container body 12, and restricting movement of the individual side portions 32, 34, 36, 38 within container body 12.

Insulating members 26, 28, 30 may be constructed in a number of different manners consistent with the invention. As illustrated in FIG. 10, for example, an insulating member 100 consistent with some implementations may be constructed of a single insulating material 102, e.g., a pre-consumer post-industrial cotton or synthetic waste, or practically any other material having suitable insulating properties as well as other desirable characteristics in terms of weight, cost, and/or sustainability. Such a material 102 may be used in a roll or sheet form that may be cut by a knife or press to form each insulating member 26, 28, 30.

In some implementations, multi-material and/or multi-layer constructions may be used. FIG. 11, for example, illustrates an alternate insulating member 110 including an insulating material 112 that is encased in an external wrap 114, e.g., a biodegradable or recyclable poly-wrap, or any other suitable wrap material, which in some implementations may also have printed text and/or images thereon. FIG. 12, as another example, illustrates an alternate insulating member 120 including an insulating material 122 that is covered on an inwardly-facing surface 124 by a laminated layer 126. Laminated layer 126 may be formed from kraft paper, fluted-corrugate paper, coffee filter paper, or any other suitable laminate material, and may also have printed text and/or images thereon. Other materials and/or constructions may be used for each insulating member in other implementations.

It will be appreciated that, while certain features may be discussed herein in connection with certain implementations and/or in connection with certain figures, unless expressly stated to the contrary, such features generally may be incorporated into any of the implementations discussed and illustrated herein.

Moreover, features that are disclosed as being combined in some implementations may generally be implemented separately in other implementations, and features that are disclosed as being implemented separately in some implementations may be combined in other implementations, so the fact that a particular feature is discussed in the context of one implementation but not another should not be construed as an admission that those two implementations are mutually exclusive of one another. Various additional modifications may be made to the illustrated implementations consistent with the invention. Therefore, the invention lies in the claims hereinafter appended.

Claims

1. An insulated container, comprising:

a container body including a bottom and first, second, third, and fourth sides;
a side insulating member received in the container body and folded into first, second, third, and fourth side portions that respectively contact the first, second, third, and fourth sides of the container body, each of the first, second, third, and fourth side portions including an inwardly-facing surface that faces away from the respective first, second, third, and fourth side of the container body and a top edge surface that faces away from the bottom of the container body;
a bottom insulating member contacting the bottom of the container body, the bottom insulating member including an upwardly-facing surface that faces away from the bottom of the container body and an edge surface that circumscribes the upwardly-facing surface of the bottom insulating member and includes first, second, third, and fourth edge surface portions that respectively contact the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member; and
a top insulating member including a downwardly-facing surface that faces the bottom of the container body and that contacts the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member.

2. The insulated container of claim 1, wherein the bottom insulating member has a length and a width and the top insulating member has a length and a width, the length of the top insulating member is larger than the length of the bottom insulating member, and the width of the top insulating member is larger than the width of the bottom insulating member.

3. The insulated container of claim 2, wherein each of the first, second, third, and fourth side portions of the side insulating member further includes an outwardly-facing surface that faces toward the respective first, second, third, and fourth side of the container body, wherein the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member defines a thickness separating the respective inwardly-facing and outwardly-facing surfaces of the respective first, second, third, and fourth side portion of the side insulating member.

4. The insulated container of claim 3, wherein a perimeter of the top insulating member is substantially coincident with a perimeter defined by the outwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member and a perimeter of the bottom insulating member is substantially coincident with a perimeter defined by the inwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member.

5. The insulated container of claim 4, wherein each of the first, second, third, and fourth side portions of the side insulating member further includes a bottom edge surface that contacts the bottom of the container body.

6. The insulated container of claim 1, wherein the container body further includes a closable top, and the top insulating member further includes an upwardly-facing surface that contacts the closable top of the container body when the closable top is closed.

7. The insulated container of claim 1, wherein the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member against the respective first, second, third, and fourth sides of the container body.

8. The insulated container of claim 1, wherein the bottom insulating member is sized and configured such that the edge surface forms a seal with the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member.

9. The insulated container of claim 1, wherein the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member to structurally support the side insulating member against the first, second, third, and fourth sides of the container body.

10. A method of assembling an insulated container, comprising:

inserting a side insulating member into a container body including a bottom and first, second, third, and fourth sides, the side insulating member folded into first, second, third, and fourth side portions that respectively contact the first, second, third, and fourth sides of the container body when the side insulating member is inserted into the container body, and each of the first, second, third, and fourth side portions including an inwardly-facing surface that faces away from the respective first, second, third, and fourth side of the container body and a top edge surface that faces away from the bottom of the container body;
after inserting the side insulating member into the container body, inserting a bottom insulating member into the container body such that the bottom insulating member contacts the bottom of the container body, the bottom insulating member including a upwardly-facing surface that faces away from the bottom of the container body and an edge surface that circumscribes the upwardly-facing surface of the bottom insulating member and includes first, second, third, and fourth edge surface portions that respectively contact the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body; and
after inserting the bottom insulating member into the container body, inserting a top insulating member into the container body, the top container body including a downwardly-facing surface that faces the bottom of the container body and that contacts the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member when the top insulating member is inserted into the container body.

11. The method of claim 10, wherein the bottom insulating member has a length and a width and the top insulating member has a length and a width, the length of the top insulating member is larger than the length of the bottom insulating member, and the width of the top insulating member is larger than the width of the bottom insulating member.

12. The method of claim 11, wherein each of the first, second, third, and fourth side portions of the side insulating member further includes an outwardly-facing surface that faces toward the respective first, second, third, and fourth side of the container body, wherein the top edge surface of each of the first, second, third, and fourth side portions of the side insulating member defines a thickness separating the respective inwardly-facing and outwardly-facing surfaces of the respective first, second, third, and fourth side portion of the side insulating member.

13. The method of claim 12, wherein a perimeter of the top insulating member is substantially coincident with a perimeter defined by the outwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member and a perimeter of the bottom insulating member is substantially coincident with a perimeter defined by the inwardly-facing surfaces of the first, second, third, and fourth side portions of the side insulating member.

14. The method of claim 13, wherein each of the first, second, third, and fourth side portions of the side insulating member further includes a bottom edge surface that contacts the bottom of the container body.

15. The method of claim 10, wherein the container body further includes a closable top, and the top insulating member further includes an upwardly-facing surface that contacts the closable top of the container body when the closable top is closed.

16. The method of claim 10, wherein the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member against the respective first, second, third, and fourth sides of the container body when the bottom insulating member is inserted into the container body.

17. The method of claim 10, wherein the bottom insulating member is sized and configured such that the edge surface forms a seal with the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body.

18. The method of claim 10, wherein the bottom insulating member is sized and configured such that the edge surface presses the inwardly-facing surfaces of the first, second, third, and fourth portions of the side insulating member when the bottom insulating member is inserted into the container body to structurally support the side insulating member against the first, second, third, and fourth sides of the container body.

19. The method of claim 10, wherein the container body further includes a closable top, the method further comprising closing the closable top after inserting the top insulating member into the container body.

20. The method of claim 10, wherein the top, bottom, and side insulating members define an insulated interior compartment in the container body, the method further comprising inserting an item and a heat or cold pack into the insulated interior compartment after inserting the bottom insulating member into the container body and before inserting the top insulating member into the container body.

Patent History
Publication number: 20260336909
Type: Application
Filed: Apr 2, 2026
Publication Date: Oct 29, 2026
Inventors: Frank Butch (West Chester, PA), Chen Zhang (Aberdeen, NJ)
Application Number: 19/637,175
Classifications
International Classification: B65D 81/38 (20060101); B65D 5/02 (20060101);