US20220169435A1 - Thermal protection packaging - Google Patents

Abstract

A blank for forming an insulated carton including a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis an end tab hingedly attached to the central portion of the second side panel, wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier which has a higher thermal radiation reflectance than an under-lying layer for energy-insulating the interior space of the carton.

Description

• This application claims priority to U.S. Non-Provisional application Ser. No. 16/279,282 filed on Feb. 19, 2019, and U.S. Non-Provisional application Ser. No. 16/791,228 filed on Feb. 14, 2020, which are hereby incorporated by reference in their entirety.
BACKGROUNDTechnological Field
• The present disclosure relates to insulating blanks for marking cartons and inserts for insulating cartons, and more particularly to blanks and inserts having a reflective barrier.
Description of Related Art
• A variety of devices are known in the art for providing thermal protection to products being shipped.
• The conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for containers to minimize energy transfer with the outside. There also remains a need in the art for such containers to be economically viable, reusable, and recyclable. The present disclosure may provide a solution for at least one of these remaining challenges.
SUMMARY
• A blank for forming an insulated carton includes a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis, an end tab hingedly attached to the central portion of the second side panel, and wherein at least one surface of the blank includes a reflective barrier for energy-insulating the interior space of the carton and the blank defines an interior space of a carton when folded along each hinged attachment. Each of the panels can be different lengths, each of the panels can be of equal widths.
• The flap of each panel can be indirectly attached to at one flap of an adjacent panel. The flap of the front panel and the at least one flap of the rear panel can be rectangle shaped, and the at the flap of the first side panel and the flap of the second side panel can be trapezoid shaped.
• The end tab can include a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.
• The reflective barrier can face the interior space and an outwardly facing surface of the end tab which does not include a reflective barrier can be attached to the reflective barrier of the front panel when the carton is erected. It is also conceived that the end tab can be located on the outside of the carton when assembled.
• An insulating insert for a carton includes a frontal layer, including a reflective barrier for energy-insulating the interior space of a carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer, and a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert, wherein the top side and the bottom side each include at least one notch and at least one tab for mating with a second insert or third insert.
• The at least one tab of the top side can include two tabs aligned asymmetrically with respect to a length of the top side and the at least one tab of the bottom side can include two tabs aligned asymmetrically with respect to a length thereof. The at least one notch of the top side can also include two notches symmetrically disposed along a length of the top side and the at least one notch of the bottom side can include two notches symmetrically disposed along a length of the bottom side.
• A second insert can be detachably attached to a side of the first insert, wherein when the second insert can be detached and the rear layer of the first insert can abuts the rear layer of the second insert. The tabs of the two inserts can be of unequal height.
• The reflective barrier of the insert can face an interior space defined if the insert is joined with another five inserts, it is also considered that the reflective barrier faces away from the interior space. The at least one tab of the bottom side of the first insert can interlock with the at least one notch of the top side of the second insert.
• A system of inserts for insulating a carton includes a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier, for energy-insulating the interior space of the carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer. The top, bottom, a frontal, a rear, first side, and second side inserts define an interior space when the top, bottom, a frontal, a rear, first side, and second side inserts are mated together. Each of the top, bottom, a frontal, a rear, first side, and second side inserts include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert includes two tabs configured for mating with two notches of a frontal insert and the bottom side of the top insert includes two tabs configured for mating with notches of a rear insert, wherein the frontal insert and the rear insert are wider than the top insert and the bottom insert.
• The reflective barrier of the embodiments mentioned above can include an optical density greater than 2.0, can include metalized polyester, and can be laminated to the insert.
• The system can further include a thermal regulating device to be placed on the inside of the carton. The thermal regulating device can include an insulated envelope configured to contain a thermal element therein to reduce thermal transfer between the thermal element and the contents of the carto. The insulated envelope can include an outer liner and an insulating material disposed within the outer liner. An amount of the insulating material can be selected to control temperature of the outer liner and/or rate of heat transfer to the thermal element.
• In certain embodiments, the liner can include natural and/or synthetic materials, e.g., at least one of paper, a board, a plastic, or nylon. For example, the liner can be a flexible paper liner (e.g., kraft liner). Any other suitable material is contemplated herein.
• In certain embodiments, the insulating material can be natural and/or synthetic materials, e.g. cellulose insulation, recycled cellulose insulation, plastic, PET, Styrofoam, etc. For example, the insulating material can be fluff pulp. Any other suitable insulating material is contemplated herein.
• In certain embodiments, the thermal regulating device can include the thermal element. For example, the thermal element can be dry ice (e.g., a brick of dry ice disposed within the envelope). Any other suitable thermal element is contemplated herein. In certain embodiments, the envelope can be configured to control a location of where sublimated gas escapes.
• The envelope can be configured such that a time to about 31 degrees C. internal temperature of the carton containing the envelope having two pounds of dry ice disposed in the envelope when the carton is consistently exposed to about 40.6 degrees C. is greater than 18 hours.
• In accordance with at least one aspect of this disclosure, a package can include a first volume for storing an item to be shipped, and a second volume divided from the first volume by at least one wall, the second volume configured to retain a thermal element to reduce an amount of dead space surrounding the thermal element. The package can include the thermal element (e.g., as disclosed above). In certain embodiments, the second volume is configured to reduce sublimation of the dry ice brick.
• A method can include insulating a thermal element within an insulated package, placing the insulated package within the carton to regulate a temperature within the carton for at least a predetermined amount of time. The thermal element can be dry ice, for example. Placing the insulated package can include placing the insulated package at a bottom of the carton. The method can include any other suitable method(s) and/or portions thereof.
• In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured such that a time to about 31 degrees C. internal temperature of a carton containing the envelope having two pounds of dry ice disposed in the envelope when the shipping package is consistently exposed to about 40.6 degrees C. is greater than 18 hours.
• In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured to contain a thermal element, the thermal regulating device comprising an R factor of greater than about 0.001 ft²·° F.·h/BTU and less than about 10 ft²·° F.·h/BTU. For example, the thermal element can be at least one of dry ice, a gel pack, or a heat source.
• In accordance with at least one aspect of this disclosure, a thermal regulating device can be configured to contain a thermal element, the device having a substantially linear gravimetric slope of greater than about −0.19 lbs-dry-ice/hour at an atmospheric temperature of 73 degrees F. In certain embodiments, the gravimetric slope can be about −0.085 lbs-dry-ice/hour at an atmospheric temperature of 73 degrees F. The gravimetric slope in a cooler exposed to 73 degrees F is about −0.067 lbs-dry-ice/hour.
• These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
• So that those skilled in the art to which the subject invention appertains will readily understand how to make and use the devices and methods of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
• FIG. 1 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;
• FIG. 1ais a perspective view of portion la ofFIG. 1, showing the reflective layer of the blank.
• FIG. 1bis a perspective view of a carton formed from the blank ofFIG. 1, showing a carton with open flaps;
• FIG. 2 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;
• FIG. 2ais a perspective view of portion2aofFIG. 2, showing the reflective layer of the blank;
• FIG. 2bis a perspective view of a carton formed from the blank ofFIG. 2, showing a carton with open flaps;
• FIG. 3 is an exploded view of insulating inserts for a carton;
• FIG. 4 is a partially exploded view of the insulating inserts ofFIG. 5, showing being placed in the carton;
• FIG. 5 is a perspective view of an insulating insert ofFIG. 3, showing the insert in a pre-folded stage;
• FIG. 5ais a perspective view of a detail5A ofFIG. 5, showing connection of the two portions of the insert;
• FIG. 5bis a perspective view of an insulating insert ofFIG. 5, showing the insert in a folded stage;
• FIG. 5cis a perspective view of a detail5C ofFIG. 5b, showing connection of the two portions of the insert;
• FIG. 6 is a perspective view of an insulating insert ofFIG. 3, showing an insert in a pre-folded stage;
• FIG. 6ais a perspective view of an insulating insert ofFIG. 6, showing the insert in a folded stage;
• FIG. 7 is a perspective view of an insulating insert ofFIG. 3, showing an untabbed insert in a pre-folded stage;
• FIG. 7ais a perspective view of an insulating insert ofFIG. 7, showing the insert in a folded stage;
• FIG. 8 is a perspective view of an embodiment of the carton ofFIG. 1bin accordance with this disclosure, showing an embodiment of an envelope in accordance with this disclosure disposed within a shipping package having a thermally reflective layer;
• FIG. 9 is a perspective view of the embodiment of an envelope ofFIG. 1b, shown open at an end thereof and having a thermal element and an insulating material disposed therein;
• FIG. 9ais a cross-sectional view of the embodiment ofFIG. 9;
• FIG. 9bis a cross-sectional view of the embodiment ofFIG. 9, shown having a larger thermal element and little to no dead space;
• FIG. 10 is a perspective view of an embodiment of a package for containing a thermal element in accordance with this disclosure;
• FIG. 11ais a perspective view of an embodiment of a package for containing a thermal element in accordance with this disclosure; and
• FIG. 11bis a cross-sectional side view of an embodiment of a shipping packaged in accordance with this disclosure, shown having the package ofFIG. 11adisposed therein.
DETAILED DESCRIPTION
• Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject invention. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a blank for forming an insulated carton in accordance with the invention is shown inFIG. 1 and is designated generally byreference character100. Other embodiments of blanks for forming an insulated carton in accordance with the invention, or aspects thereof, are provided inFIGS. 2-11b,as will be described. The systems of the invention can be used to increase the insulation of cartons, reduce production costs, and provide better temperature control of shipments.
• Referring toFIGS. 1-1b,a blank100 for forming an insulated carton includes afront panel102 hingedly attached to afirst side panel104, thefirst side panel104 hingedly attached to arear panel106, therear panel106 hingedly attached to asecond side panel108 along alongitudinal axis110 of the blank100, wherein each panel102-108 includes acentral portion1020,1040,1060,1080 disposed between and hingedly attached to at least oneflap1021,1041,1061,1081, arranged transverse to thelongitudinal axis110, anend tab112 hingedly attached to thecentral portion1080 of thesecond side panel108, and wherein at least one surface of the blank includes areflective barrier114, for energy-insulating the interior space the carton, and the blank100 defines aninterior space116 of a carton when folded along each hinged attachment. Thereflective barrier114 has a higher thermal radiation reflectance than an underlying layer. Thereflective barrier114 attached to the underlying layer by an adhesive. Thereflective barrier114 or film is applied such that it can be removed as a whole or partially. The ability to remove ensures that end-of-the-line users are able to remove thereflective barrier114 and discard or recycle the carton properly. Thereflective barrier114 uses an adhesive such that it can be peeled off by hand at room temperature and does not require any machinery to so. The following adhesives are considered: formulated water based copolymer emulsions, formulated water based acrylic polymer emulsions, formulated water based vinyl acrylic copolymer emulsions, formulated water based styrene acrylic copolymer emulsions, formulated water based acrylate polymer emulsions, formulated water based pressure sensitive polymer emulsions, formulated water based polyvinyl acetate copolymer emulsions, formulated water based poly(vinyl acetate: vinyl alcohol) emulsions, formulated water based poly(vinyl acetate: ethylene) emulsions, formulated water based rubber polymer and rubber copolymer emulsions, formulated water based styrene butadiene rubber emulsions, formulated water based neoprene dispersions, formulated water based urethane dispersions, solvent based formulations including the polymers previously named, liquid polyurethane adhesives, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt adhesives, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.
• Thereflective barrier114 of the embodiments mentioned above include an optical density greater than 2.0, can include metalized polyester, and can also be laminated to the insert. Thereflective barrier114 can include a starting point that enables a user to peel away thereflective barrier114. Thereflective barrier114 can include a corner that does not include the adhesive and is not attached to the underlying layer. This corner is grabbed and can be used as the start point for peeling away the reflective barrier.
• It is further conceived that thereflective barrier114 can be removed as a whole or in pieces. The reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely in order to make the carton available for recycling and other processing. However, as recycling technology changes and adapts, less of the reflective barrier needs to be removed. Thereflective barrier114 can be attached such that it is substantially, a majority, is removable from the underlying layer. Thereflective barrier114 can include perforations or other divisions that split the layer into multiple parts ensuring that each of the parts can be removed smoothly. Thereflective barrier114 is meant to be removed such that the underlying layer is not damaged or disturbed. When thereflective barrier114 is removed no more than 10% of the underlying layer need to be disturbed, or removed along with the reflective barrier.
• Each of the panels can be different lengths L1-L4, each of the panels can be of equal widths W1. The lengths L1-L4 of the flaps vary in order to accommodate the thickness of thereflective barrier114. The flap of each panel can be indirectly attached to a flap of an adjacent panel, each of the panels being rectangular.
• Thereflective barrier114 can face theinterior space116 and an outwardly facingsurface115 of theend tab112 which does not include a reflective barrier can be attached to thereflective barrier114 of thefront panel102 when the carton is erected. Thereflective barrier114, can be used for both keeping energy within the carton and for keeping excess energy from entering from the outside. Also, the panels102-108 of the blank100 are folded in such a way so as to minimize the airflow into and out of the carton. The carton can be airtight when folded properly.
• Referring toFIGS. 2-2b,the flaps of thefront panel2021,2022 and the at flaps of therear panel2061,2062 can be rectangle shaped, and the flaps of thefirst side panel2041,2042 and the flaps of thesecond side panel2081,2082 can be trapezoidal shaped. Theend tab212 can include acentral portion2120 disposed between and hingedly attached to two opposingflaps2121,2122 arranged transverse to thelongitudinal axis210.Panels202 and206 can be approximately the equal lengths, and panels204 and208 can be approximately equal lengths. All panels202-208 can include differing lengths. The flap of each panel can be at least partially directly attached to a flap of an adjacent panel. It is also conceived that theend tab212 can be located on the outside of the carton when assembled.
• Referring toFIGS. 3 and 4, system of inserts for insulating a carton includes atop insert302, abottom insert304, afrontal insert306, arear insert308, a first side insert, and asecond side insert312. The top302, the bottom304, the frontal306, the rear308, thefirst side310, and thesecond side312 inserts define an interior space when the inserts302-312 are mated together. Each of the top302, bottom304, a frontal306, a rear308,first side310, and second side inserts312 include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of thetop insert3021 includes twotabs320 configured for mating with twonotches322 of afrontal insert306 and the bottom side3023 of thetop insert302 includes twotabs324 configured for mating with twonotches326 of arear insert306, wherein thefrontal insert306 and therear insert308 are wider than thetop insert302 and thebottom insert304. The two side inserts310,312 can be without locking features. The two side inserts310,312 can be shorter than the front306 and rear308 inserts, and be less wide than then top302 and bottom304 inserts. Thetabs320,324 andnotches322 of the two inserts are of unequal height, allowing the insert to be locked mated together without atab320,324 protruding past anotch322.
• Referring toFIGS. 5-7a,each inset includes a frontal layer including areflective barrier314 attached to amiddle layer315 including at least one layer of corrugated cardboard and attached to arear layer316. The top side of the insert shown inFIG. 5-5cincludes twotabs320 aligned asymmetrically with respect to a length L9 of the top side. The insert shown inFIG. 5-5ccorresponds to the top302 and bottom304 inserts ofFIG. 3. The insert shown inFIG. 6-6aincludes twonotches322 symmetrically disposed along a length L12. The insert shown inFIG. 6-6acorresponds to the front306 and rear308 inserts ofFIG. 3 The insert shown inFIG. 7-7adoes not include notches, tabs, or other locking features. The insert shown inFIG. 7-7bcorresponds to thefirst side310 and thesecond side312 inserts ofFIG. 3. It is also conceived that the inserts can be arranged to form an interior space without being interlocked by the tabs and notches. The inserts can fit together and be further held in place by the carton.
• Referring further toFIGS. 5-7basecond insert303 is detachably attached to a side of thefirst insert302. Thesecond insert303 can be attached at a first side. Thesecond insert307 can be attached at a bottom side. Thesecond insert303 can be identical to thefirst insert302. Thesecond insert303 is folded such that therear layer316 of thefirst insert302 abuts therear layer316 of thesecond insert303. Thereflective barrier314 of each first insert faces theinterior space401, and thereflective barrier314 of eachsecond insert303 faces away from theinterior space401. This arrangement ensures that energyloss and gain are limited to theinterior space401. When assembled, the inserts minimize airflow into and out of the interior space. It is also conceived that thereflective barrier314 faces the exterior, to provide further energy efficiency. The interior space can be airtight when folded the inserts are assemble properly.
• It is also considered that the insert system can include a pair of inserts each covering three sides of the insert system. In this embodiment each of the inserts is “C-shaped.” Each insert would include three panels hingedly attached to each other. After a first insert was placed within the carton, the second insert would also be inserted and coupled. These inserts can also couple with each other using the tabbed system described above. This system simplifies assembly by mistake proofing the process by eliminating four assembly steps.
• Referring toFIGS. 8 and 9, apackage1100,1200 can include athermal regulating device1101, for example. Athermal regulating device1101 can include aninsulated envelope1101aconfigured to contain athermal element1303 therein to reduce thermal transfer between thethermal element1303 and the atmosphere (e.g., air in a shipping package). Theinsulated envelope1101acan include anouter liner1105 and an insulatingmaterial1107 disposed within theouter liner1105. An amount of the insulatingmaterial1107 can be selected to control temperature of theouter liner1105 and/or a rate of heat transfer to the thermal element1303 (e.g., from the atmosphere). For example, an amount of insulation in an envelope for ambient applications may be more than for frozen applications, for example (e.g., to ensure sufficient cooling action). As used herein, the term “envelope” can be any suitable enclosure, e.g., a flexible pouch, a rigid box, and/or any other suitable structure.
• Theliner1105 can include any suitable natural and/or synthetic materials. For example, in certain embodiments, theliner1105 can include at least one of paper (e.g., kraft), a board (e.g., paperboard, corrugate), a plastic (a flexible plastic, corrugate), or nylon. For example, theliner1105 can be a flexible paper liner (e.g., kraft liner) or any other thin sheet material. Any other suitable material is contemplated herein. A thickness of theliner1105 can be selected to control heat transfer to produce a certain loss of thermal power of the thermal element, for example.
• In certain embodiments, the insulatingmaterial1107 can be natural and/or synthetic materials, e.g. cellulose insulation, recycled cellulose insulation, plastic, PET, Styrofoam, etc.
• For example, the insulatingmaterial1107 can be fluff pulp (e.g., nonwoven cellulose fibers), e.g., as shown inFIG. 9. For example, embodiments can include a fibrous material as the insulating layer, cellulose fiber insulation, and the liner can be one or more of kraft liner, plastic (e.g., bubble wrap), nylon, and/or corrugated outer casing/liner. Any other suitable insulating material is contemplated herein.
• In certain embodiments, theenvelope1101acan have a pouch shape, e.g., as shown. In certain embodiments, theenvelope1101acan have individually sized components (e.g., tearable pouches to select a number of thermal packages to use in a given shipping package to control a temperature of the shipping package).
• In certain embodiments, thethermal regulating device1101 can include thethermal element1303. For example, thethermal element1303 can be dry ice (e.g., a brick of dry ice disposed within theenvelope1101a). Any other suitablethermal element1303 is contemplated herein (e.g., a cold pack, a chemical heater). It is contemplated that eachenvelope1101aand/or each portion thereof can be sold including a fixed amount of dry ice (e.g., in a freezer) and/or can include a metric printed thereon for a user to determine howmany envelopes1101aor portions thereof to use to achieve a desired cooling effect (temperature and/or length of cooling time below a certain temperature) for a standardized volume of packaging.
• In certain embodiments, theenvelope1101acan be configured to control a location of where sublimated gas escapes (e.g., one or more holes on the bottom of theenvelope1101a). As shown, theenvelope1101acan form at least one opening at an end thereof. The at least one opening can be enclosed using any suitable tape, adhesive, or any other suitable enclosure.
• Theenvelope1101acan be configured such that a time to about 31 degrees C/87.8° F. internal temperature of ashipping container1109,1209 (e.g., a corrugate box, an insulated box) containing theenvelope1101ahaving two pounds of dry ice disposed in the envelope when the shipping package (e.g., when enclosing theenvelope1101a) is consistently exposed to about 40.6 degrees C/105° F. is greater than 18 hours. This is an unexpectedly longer time to failure than traditional packages. As shown inFIG. 1, theshipping container1109 can include thermal insulation and/or an inner thermalreflective layer1211. In such a case, the time to about 31 degrees C/87.8° F. can be greater than 24 hours (e.g., 28 hours or more).
• In certain embodiments, thethermal regulating device1101 can include an R value greater than about 0.001 ft²·° F.·h/BTU and less than about 10 ft²·° F.·h/BTU. Any suitable R value to allow a controlled thermal transfer from thethermal regulating device1101 to a package (e.g., to hold the package at a desired temperature), for example, is contemplated herein. For example, an R value above that of basic plastic sheet packaging (of negligible R value of about 0) for dry ice, and below the R value of a vacuum flask.
• As described above, as shown inFIG. 8, in certain embodiments of the outer liner can be composed of an outer kraft liner with an inner fiber-based fiberized layer. Embodiments of apackage1100,1200 and/or theenvelope1101acan be a drop-in cooling agent inside a shipping package. In certain embodiments, thepackage1100,1200 can include theshipping container1109,1209 having theenvelope1101adisposed therein. In certain embodiments, thepackage1100,1200 can be theenvelope1101aalone.FIG. 9 shows an opening of theenvelope1101acomposed of an outer kraft liner with an inner fiber-based fiberized layer encompassing dry ice. As disclosed above, theenvelope1101acan be sealed from the top by an adhesive, for example. Certain embodiments can be completely sealed, e.g., where not using subliming coolant, but can have some gas path or permeability to allow gas to escape (e.g., to avoid expansion of the envelope). Any suitable arrangement is contemplated herein.
• Referring toFIG. 10, and alternative design for an encasement material is shown that can be used as both the encasement layer as well as full or partial insulation within a shipping package. A first C-pad1401 (e.g., having 3 panels) and a second C-pad (e.g., having a fourth flap configured to fold over a middle panel) can be folded and inserted into a shipping package to provide insulation and retain the thermal element. For example, the extra flap on the second C-pad403 can fold over and cover a dry ice brick to sandwich the dry ice brick. This extra flap can be adhered, taped, or otherwise attached or sealed to the other panels of the second C-pad to retain and/or seal in the thermal element and reducing or eliminating dead space. This assembly can then be inserted into the shipping container, for example.
• Referring toFIGS. 11aand11b,a four panel design of encasement material can be used as both the encasement layer as well as full or partial insulation within a shipper, for example. The embodiment ofFIG. 11acan be similar to the embodiment ofFIG. 4, but instead of a T-shaped structure, the C-pad can have a fourth flap in a line (e.g., withpanels1,2,3, and4, which can be folded over and attached to cover and retain the thermal element. Any other suitable assembly is contemplated herein. Embodiments of a package can include any suitable materials, coatings, and/or components as appreciated by those having ordinary skill in the art for any suitable application (e.g., food transport, medicine transport, etc.).
• A method can include insulating a thermal element within an insulated package, placing the insulated package within a shipping container to regulate a temperature within the shipping container for at least a predetermined amount of time. The thermal element can be dry ice, for example. Placing the insulated package can include placing the insulated package at a bottom of the shipping container. The method can include any other suitable method(s) and/or portions thereof.
• As described above, embodiments can provide a target temperature based on amount of insulation and/or other thermal properties of material surrounding the thermal element. Embodiments control the flow of heat to/from the coolant/heater to the surrounding package volume. The thermal packaging for a thermal element can be selected (e.g., more or less insulation, thickness of liner, holes in liner and/or insulation) to provide a predetermined heat transfer between the thermal element and the package volume to produce a predetermined temperature range or value in the package volume. Embodiments can reduce heat transfer to the thermal element and greatly extend the life of the thermal element to cool or heat a shipping package volume to the desired temperature range or value.
• The methods and systems of the present disclosure, as described above and shown in the drawings, provide for an insulating system with superior properties including increased energy conservation. While the apparatus a of the subject disclosure have been showing and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and score of the subject disclosure.

Claims (34)

What is claimed is:

1. A blank for forming an insulated carton comprising:

a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis;

an end tab hingedly attached to the central portion of the second side panel; and

wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton.

2. The blank ofclaim 1, wherein the reflective barrier is attached to the underlying layer by an adhesive.

3. The blank ofclaim 2, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

4. The blank ofclaim 2, wherein the reflective barrier is substantially removable from the underlying layer.

5. The blank ofclaim 2, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

6. The blank ofclaim 1, wherein each of the panels are different lengths.

7. The blank ofclaim 1, wherein each of the panels are equal widths.

8. The blank ofclaim 1, wherein the at least one flap of each panel is indirectly attached to the at least one flap of an adjacent panel.

9. The blank ofclaim 1, wherein the at least one flap of the front panel and the at least one flap of the rear panel are rectangular, and the at least one flap of the first side panel and the at least one flap of the second side panel are trapezoidal.

10. The blank ofclaim 1, wherein the end tab includes a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.

11. The blank ofclaim 1, wherein the reflective barrier is configured to face the interior space when the carton is erected.

12. The blank ofclaim 11, wherein an outwardly facing surface of the end tab does not include a reflective barrier and is attached to the reflective barrier of the front panel.

13. An insulating insert for a carton comprising:

a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer; and

a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert.

14. The insert ofclaim 13, wherein the reflective barrier is at least partially removably attached to the underlying layer by an adhesive.

15. The insert ofclaim 14, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

16. The insert ofclaim 14, wherein the reflective barrier is substantially removable from the underlying layer.

17. The insert ofclaim 14, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

18. The insert ofclaim 14, wherein the adhesive includes a formulated water emulsion, a formulated water dispersion, a solvent based formulation, liquid polyurethane, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.

19. The insert ofclaim 13, wherein the top side and the bottom side each include at least one notch and at least one tab configured for mating with a second insert.

20. The insert ofclaim 13, wherein the at least one tab of the top side includes two tabs aligned asymmetrically with respect to a length thereof and the at least one tab of the bottom side includes two tabs aligned asymmetrically with respect to a length thereof.

21. The insert ofclaim 13, wherein the at least one notch of the top side includes two notches symmetrically disposed along a length thereof and the at least one notch of the bottom side includes two notches symmetrically disposed along a length thereof.

22. The insert ofclaim 13, further comprising a second insert detachably attached to a side thereof, wherein when the second insert is detached and the rear layer of the first insert abuts the rear layer of the second insert.

23. The insert ofclaim 22, wherein the tabs of the two inserts are of unequal height.

24. The insert ofclaim 13, wherein the reflective barrier of the insert faces an interior space defined by the insert being joined with another five inserts.

25. The insert ofclaim 13, wherein the reflective barrier of the insert faces away from an interior space by the insert being joined with another five inserts.

26. The insert ofclaim 25, wherein the at least one tab of the bottom side interlocks with the at least one notch of the top side.

27. A system of inserts for insulating a carton comprising:

a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer;

the top, bottom, a frontal, a rear, first side, and second side inserts defining an interior space when mated together;

wherein each of the top, bottom, a frontal, a rear, first side, and second side inserts includes a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof.

28. The system ofclaim 27, wherein the reflective barrier is at least partially removably attached to the underlying layer by an adhesive.

29. The system ofclaim 28, wherein the reflective barrier is removably attached to the underlying layer by an adhesive such that the reflective barrier is removable entirely.

30. The system ofclaim 28, wherein the reflective barrier is substantially removable from the underlying layer.

31. The system ofclaim 28, wherein the reflective barrier when removed removes less than 5% of the underlying layer.

32. The blank ofclaim 1, wherein the reflective barrier includes an optical density greater than 2.0.

33. The insert ofclaim 13, wherein the reflective barrier includes a polyester film.

34. The blank ofclaim 1, wherein the adhesive includes a formulated water emulsion, a formulated water dispersion, a solvent based formulation, liquid polyurethane, pressure sensitive hot melt adhesives, copolymer ethylene vinyl acetate hot melt, rubber based hot melt adhesives (SBS, SIS, SEBS, SEPS, deblock, triblock or mixtures thereof), or olefin based hot melt adhesives.

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