Collapsible insulating container liner

• US 10,322,843 B2
• Filed: 11/15/2017
• Issued: 06/18/2019
• Est. Priority Date: 12/01/2016
• Status: Active Grant

• Current Assignee: Drew Foam Companies Inc.
• Original Assignee: Drew Foam Companies Inc.
• Inventors: Givens, Jr., William C.
• Primary Examiner(s): Skurdal, Corey N
• Application Number:
  US15/813,656
• Publication Number:
  US 20180155076A1
• Time in Patent Office: 580 Days
• CPC Class Codes: B29C 53/063 combined with folding
• CPC Class Codes: B32B 15/043 of metal B32B15/01 takes precedence
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 15/12 of paper or cardboard
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 23/042 of metal
• CPC Class Codes: B32B 23/08 of synthetic resin
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2439/00 Containers; Receptacles closures therefor B32B2435/00
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B65D 5/48048 : Single partition formed by folding one or more blanks and provided with flaps fixed to or maintained by parts of the container body B65D5/4804 takes precedence
• CPC Class Codes: B65D 81/3816 : formed of foam material
• CPC Class Codes: B65D 81/3823 : formed of different materials, e.g. laminated or foam filling between walls
• CPC Class Codes: B65D 81/3897 : formed of different materials, e.g. laminated or foam filling between walls

Abstract

Collapsible insulating container liners and methods of manufacturing the same are disclosed herein. The container liner is formed as one unitary, foldable body that includes, in one example, beveled edges that form top panel(s), bottom panel(s), and side panel(s) that facilitate folding of the body to form the resulting liner.

Claims

1. A collapsible, insulating container liner, comprising:

a unitary body having at least one top panel, at least one bottom panel, a plurality of side panels, and two opposing surfaces,

wherein a portion of the panels are adjacent to each other, and

wherein an inner lamination layer formed of a polymer film is applied to one of said opposing surfaces of the unitary body, and an outer lamination layer formed of a metallic film is applied to the other of said opposing surfaces of the unitary body; and

a gap extending between adjacent panels, such that they may be folded relative to each other,

wherein each of the at least one top panel, at least one bottom panel, and plurality of side panels has beveled edges around its outer perimeter, such that the beveled edge of one panel contacts the beveled edge of an adjacent panel when folded to form an enclosed structure, and

wherein the beveled edge of one panel and the beveled edge of an adjacent panel from a groove at the gap open at the inner lamination layer,

wherein the inner lamination layer does not extend onto the beveled edges, and

wherein the groove is cut through the inner lamination layer and does not extend through the outer lamination layer.

2. The collapsible, insulating container liner of claim 1, wherein the unitary body is formed of a thermally insulating material.

3. The collapsible, insulating container liner of claim 2, wherein the unitary body is formed of expanded polystyrene.

4. The collapsible, insulating container liner of claim 1, wherein the polymer film is polyethylene.

5. The collapsible, insulating container liner of claim 1, wherein the metallic film is aluminum foil.

6. The collapsible, insulating container liner of claim 1, wherein the groove is a V-shaped groove.

7. The collapsible, insulating container liner of claim 1, wherein, when folded, the inner lamination layer faces an interior of the enclosed structure and the outer lamination layer faces an exterior of the enclosed structure.

8. The collapsible, insulating container liner of claim 1, wherein the enclosed structure is a box-shaped structure.

9. The collapsible, insulating container liner of claim 1, wherein the unitary body has a generally cruciform shape.

10. The collapsible, insulating container liner of claim 1, wherein the gap has a width of about one sixteenth of an inch to about one eighth of an inch.

11. The collapsible, insulating container liner of claim 1, wherein each of the plurality of side panels is adjacent to the at least one bottom panel at no more than one side.

12. An insulating shipping container, comprising:

a collapsible, insulating container liner, including,

a unitary body having at least one top panel, at least one bottom panel, a plurality of side panels, wherein a portion of the panels are adjacent to each other, and two opposing surfaces, wherein an inner lamination layer formed of a polymer film is applied to one of said opposing surfaces of the unitary body, and an outer lamination layer formed of a metallic film is applied to the other of said opposing surfaces of the unitary body; and

a gap extending between adjacent panels, such that they may be folded relative to each other,

wherein each of the at least one top panel, at least one bottom panel, and plurality of side panels have beveled edges around their outer perimeter, such that the beveled edge of one panel contacts the beveled edge of an adjacent panel when folded to form an enclosed structure,

wherein the beveled edge of one panel and the beveled edge of an adjacent panel form a groove at the gap open at the inner lamination layer, wherein the inner lamination layer does not extend onto the beveled edges, and

wherein the groove is cut through the inner lamination layer and does not extend through the outer lamination layer; and

a shipping container,

wherein the collapsible, insulating container liner is placed inside of the shipping container.

13. A method of forming a collapsible, insulating container liner, comprising the steps of:

cutting bulk material to form a unitary body;

heat laminating two opposing surfaces of the unitary body to form an inner lamination layer and an outer lamination layer, before cutting the unitary body to a predetermined shape;

cutting the unitary body to a predetermined shape; and

making a plurality of beveled cuts through the inner lamination layer and through a thickness of the unitary body to form at least one top panel, at least one bottom panel, and a plurality of side panels,

wherein the inner lamination layer is formed of a polymer film, and the outer lamination layer is formed of a metallic film, and

wherein the plurality of beveled cuts are made through the inner lamination layer, such that the inner lamination layer does not extend onto the beveled edges, and the thickness of the unitary body and do not extend through the outer lamination layer.

14. The method of claim 13, wherein the step of cutting the bulk material to form a unitary body includes the steps of cutting the bulk material to a predetermined length, width and thickness.

15. The method of claim 13, wherein the predetermined shape is a generally cruciform shape.

16. The method of claim 13, wherein each of the cutting steps are performed by hot wire cutting.

17. The method of claim 13, wherein the step of making the plurality of beveled cuts includes weighing down the unitary body on a table before cutting.

18. The method of claim 13, wherein each of the plurality of beveled cuts are made simultaneously.