Thermally insulating shipping system

• US 6,325,281 B1
• Filed: 03/30/2000
• Issued: 12/04/2001
• Est. Priority Date: 03/30/2000
• Status: Expired due to Term

• Current Assignee: Sonoco Development Inc (Sonoco Products Company)
• Original Assignee: Polyfoam Packers Corp (Sonoco Products Company)
• Inventors: Grogan, Kevin
• Primary Examiner(s): Elkins, Gary E.
• Application Number:
  US09/539,663
• Time in Patent Office: 614 Days
• Field of Search: 229/103.11, 229/122.32, 229/122.33, 229/122.34, 220/561.1, 220/560.12, 220/560.15, 220/592.25, 220/592.26, 220/592.27, 62/60, 623/71, 623/72
• US Class Current: 229/103.11
• CPC Class Codes: B65D 81/3862 with a foam formed container located inside a folded box

Abstract

An insulating shipping container includes an outer cardboard carton with a foldable top; an open-top, rigid, first thermally insulating housing formed of expanded polystyrene and removably disposed in the outer carton; a second open-top, thermally insulating housing formed of vacuum insulating panels and removably disposed in the first housing; an inner cardboard carton with a foldable top removably disposed in the second housing; and a closure structure including a vacuum insulating panel and expanded polystyrene panels for closing the open tops of the second and first housings.

Claims

1. A thermally insulating container comprising:

an outer closable carton,

a first substantially rigid insulating housing removably disposed within said outer carton and formed of a first thermally insulating material different from the material of the outer carton,

a second substantially rigid insulating housing removably disposed within said first housing and formed of a second thermally insulating material different from the first thermally insulating material and from the material of the outer carton, and

an inner closable carton removably disposed within said second housing.

2. The container of claim 1, wherein each of said inner and outer cartons is formed of corrugated cardboard.

3. The container of claim 1, wherein said first thermally insulating material is expanded polystyrene.

4. The container of claim 1, wherein said second housing is formed of vacuum insulation panels.

5. The container of claim 1, wherein each of said vacuum insulation panels includes a core and a barrier film surrounding the core for preserving a vacuum therein.

6. The container of claim 5, wherein said core includes a granular insulating material.

7. The container of claim 1, wherein each of said inner and outer cartons includes a foldable top.

8. The container of claim 1, and further comprising closure structure for closing the tops of said first and second housings.

9. The container of claim 8, wherein said closure structure is of integral construction.

10. A thermally insulating container comprising:

an outer closable carton,

a first open-top insulating housing removably disposed within said carton and formed of a first thermally insulating material,

a second open-top insulating housing removably disposed within said first housing and formed of a second insulating material,

an inner closable carton removably disposed within said second housing, and

closure structure for closing the tops of said first and second housings,

said closure structure including a support panel dimensioned to overlie said first housing at the open top thereof for support thereon, a first closure panel secured to said support panel and dimensioned to be received in the open top of said first housing for housing for closing same, and a second closure panel secured to said first closure panel and dimensioned to be received in the open top of said second housing for closing same.

11. The container of claim 10, wherein said support panel and said first closure panel are formed of expanded polystyrene and said second closure panel is a vacuum insulation panel.

12. The container of claim 11, wherein said vacuum insulation panels are rigid.

13. The container of claim 11, wherein each of said vacuum insulation panels includes a granular insulating material.

14. The container of claim 10, wherein each of said inner and outer cartons is formed of corrugated cardboard.

15. The container of claim 14, wherein each of said inner and outer cartons includes a foldable top.

16. A thermally insulating container comprising:

an outer closable carton

a first substantially rigid insulating housing removably disposed within the outer carton and formed of expanded polystyrene,

a second insulating housing removably disposed within the first housing and formed of vacuum insulation panels, and

an inner closable carton removably disposed within the second housing.

17. The container of claim 16, wherein each of the inner and outer cartons is formed of corrugated cardboard.

18. The container of claim 16, wherein the vacuum insulation panels are rigid.

19. The container of claim 16, wherein each of the inner and outer cartons includes a foldable top.

20. The container of claim 16, and further comprising closure structure for closing the tops of the first and second housings.