Barrier materials and containers made therefrom

• US 20050118366A1
• Filed: 10/28/2004
• Published: 06/02/2005
• Est. Priority Date: 06/25/2003
• Status: Abandoned Application

• Current Assignee: James S. Holicker, Richard C. Cox, Robert B. Piemonte
• Original Assignee: James S. Holicker, Richard C. Cox, Robert B. Piemonte
• Inventors: Cox, Richard C., Piemonte, Robert B., Holicker, James S.
• Application Number:
  US10/976,355
• Publication Number:
  US 20050118366A1
• Time in Patent Office: Days
• US Class Current: 428/34.100
• CPC Class Codes: H05K 9/009 comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]

Abstract

A barrier structure comprises: a first membrane substantially reflective of electromagnetic radiation; a second membrane spaced apart from the first membrane and bound to the first membrane about an edge thereof to form a bladder, the second membrane resistant to vapor transmission; and a fibrous insert disposed between the first membrane and the second membrane so as to maintain the spaced apart relationship, the fibrous insert defining a space holding an insulating medium resistant to the transmission of thermal energy and interspersed therethough. The first membrane may further comprise a multilayer composite and may include a polymer resistant to vapor transmission, for example including at least one of H₂O, CO₂ and O₂. The polymer may be a polyester. The multilayer composite may further comprise a structure substantially reflective of thermal energy. The composite may further comprise one or both of an outer metallization layer and an inner metallization layer. The composite may further comprise a sealing member. The sealing member may be a polyethylene layer. The fibrous insert may comprise randomly oriented fibers of plural deniers bonded together in a crush-resistant structure. The plural deniers may be within a range of 3 to 100 denier. The fibrous insert may further comprise an acrylic binder, an EVCL binder, a polyvinyl acetate (PVA) binder or other polymer binder and combinations thereof. The EVCL binder may be included in the fibrous insert as a percentage of material comprising the fibrous insert of about 35-75% w/w. The first membrane, the second membrane and the fibrous insert may all possess substantially similar melt flow indices. Also shown, a shipping container may comprise plural wall structures according to the thermal barrier structure described, disposed on at least two sides of a payload region, such as a box or envelope. The plural wall structures may be bonded together along at least one edge, for example to form a shipping envelope having an interior payload region surrounded by the bladders of the plural wall structures. The plural structures may further comprise a third membrane resistant to vapor transmission; and another fibrous insert disposed between the second membrane and the third membrane.

Claims

1. A barrier structure, comprising:

a first membrane substantially reflective of electromagnetic radiation;

a second membrane spaced apart from the first membrane and bound to the first membrane about an edge thereof to form a bladder, the second membrane resistant to vapor transmission; and

a fibrous insert disposed between the first membrane and the second membrane so as to maintain the spaced apart relationship, the fibrous insert defining a still air space resistant to the transmission of electromagnetic radiation and interspersed therethough.

2. The structure of claim 1, wherein the first membrane further comprises:

a multilayer composite.

3. The structure of claim 2, wherein the composite includes a polymer resistant to vapor transmission.

4. The structure of claim 3, wherein the vapor whose transmission the polymer resists includes at least one of H₂O, CO₂ and O₂.

5. The structure of claim 4, wherein the polymer is a polyester.

6. The structure of claim 2, wherein the multilayer composite further comprises:

a structure substantially reflective of thermal energy.

7. The structure of claim 6, wherein the composite further comprises:

one of an outer metallization layer and an inner metallization layer.

8. The structure of claim 7, wherein the composite further comprises:

another one of an outer metallization layer and an inner metallization layer.

9. The structure of claim 8, wherein the composite further comprises:

a sealing member.

10. The structure of claim 9, wherein the sealing member further comprises:

a polyethylene layer.

11. The structure of claim 10, wherein the fibrous insert comprises:

randomly oriented fibers of plural deniers bonded together in a crush-resistant structure.

12. The structure of claim 11, wherein the plural deniers are within a range of 3 to 100 denier.

13. The structure of claim 12, wherein the fibrous insert further comprises:

at least one of an EVCL binder, an acrylic binder and a PVA binder.

14. The structure of claim 13, wherein the fibrous insert further comprises:

an EVCL binder.

15. The structure of claim 14, wherein the EVCL binder is included in the fibrous insert as a percentage of material comprising the fibrous insert of about 35-75% w/w.

16. The structure of claim 1, wherein the first membrane, the second membrane and the fibrous insert all possess substantially similar melt flow indices.

17. The structure of claim 1, wherein the second membrane comprises:

a corrosive inhibiting film.

18. The structure of claim 17, wherein the corrosive inhibiting film comprises:

a reactive intercept barrier film.

19. A shipping container comprising:

plural wall structures according to the thermal barrier structure of claim 1, disposed on at least two sides of a payload region.

20. The shipping container according to claim 19, wherein the plural wall structures are bonded together along at least one edge.

21. The shipping container according to claim 20, wherein the plural structures are bonded together to form a shipping envelope having an interior payload region surrounded by the bladders of the plural wall structures.

22. The shipping container according to claim 21, wherein each of the plural structures further comprises:

a third membrane resistant to vapor transmission; and

another fibrous insert disposed between the second membrane and the third membrane.

23. The shipping container according to claim 19, wherein the plural structures are incorporated in walls of a box structure.

24. The structure of claim 19, wherein the one of the outer metallization layer and the inner metallization layer is capable of receiving a static electric discharge to the structure without damage to items carried therein.

25. The structure of claim 19, wherein the second membranes of the plural barrier structures are adjacent a payload region, and the second membranes comprise:

a corrosive inhibiting film.

26. The structure of claim 25, wherein the corrosive inhibiting film comprises:

a reactive intercept barrier film.

27. An insert for a shipping container, the shipping container defined by an outer wall, the inset comprising:

an inner wall membrane resistant to vapor transmission and defining a payload space;

a fibrous insert disposed between the inner wall and the outer wall, so as to maintain the outer wall and the inner wall in a spaced-apart relationship, the fibrous insert defining a still air space resistant to the transmission of electromagnetic radiation and interspersed therethrough;

wherein closing the shipping container forms a bladder defined by the fibrous insert and the still air space which together surround the payload space.

28. The insert of claim 27, wherein the fibrous insert further comprises:

randomly oriented fibers having plural denier within a range of 3 to 100 denier and the insert has a surface resistivity less than about 10¹¹ Ω

/□

.

29. The insert of claim 28, wherein the fibers are at least one of polyethylene, polypropylene and polyester.

30. The insert of claim 29, wherein the fibers are hollow.

31. The insert of claim 27, wherein the fibrous insert further comprises:

a binder having at least one of anti-bacterial, anti-fungal and anti-static properties.

32. The insert of claim 31, wherein the binder comprises EVCL.

33. The insert of claim 27, wherein the inner wall membrane further comprises:

a corrosion inhibiting film.

34. The insert of claim 33, wherein the corrosion inhibiting film comprises:

a reactive intercept barrier film.

35. The insert of claim 34, wherein the reactive intercept barrier film comprises:

a reactive layer, reactive with inorganic ions; and

an absorber layer, absorptive of organic ions.

36. The insert of claim 35, wherein the reactive intercept barrier film further comprises:

a composite including

a substrate resistant to transmission of H₂O or O₂,

an outer layer of conductive carbon, forming the absorber layer, and

an inner layer of a material to which free ions are attracted, forming the reactive layer.

37. The insert of claim 36, wherein the reactive intercept barrier film further comprises:

a metallized film on the outer layer of conductive carbon.

38. The insert of claim 36, wherein the substrate further comprises:

polyethylene teraphthalate.