阅读说明：本技术 热绝缘容器 (Thermally insulated container ) 是由 汤姆·约瑟夫·隆 于 2019-07-02 设计创作，主要内容包括：一种热绝缘运输容器,包括内衬以及外箱层,其中所述内衬由热绝缘片材制成；其中外箱层由防水热绝缘片材制成,其中外部热绝缘箱层的侧壁通过至少一个锁定接片连接至外部热绝缘箱层的相邻侧壁。(A thermally insulated shipping container comprising an inner liner and an outer box layer, wherein the inner liner is made of a thermally insulating sheet material; wherein the outer box layer is made of a waterproof heat insulating sheet material, wherein the side walls of the outer heat insulating box layer are connected to the adjacent side walls of the outer heat insulating box layer by at least one locking tab.)

1. A thermally insulated shipping container comprising:

an inner liner, wherein the inner liner is made of a thermally insulating sheet; and

an outer tank layer, wherein the outer tank layer is made of a waterproof heat-insulating sheet,

wherein the side wall of the outer box layer is connected to an adjacent side wall of the outer box layer by at least one locking tab.

2. The thermally insulated shipping container of claim 1, further comprising a lid, wherein the lid is made of a waterproof thermally insulating sheet.

3. A thermally insulated shipping container as set forth in claim 1 or claim 2 wherein said liner is made of a material comprising two or more layers.

4. A thermally insulated shipping container as set forth in claim 3 wherein one or more of said layers is a foam layer.

5. A thermally insulated shipping container as set forth in claim 3 or claim 4 wherein one or more of said layers is a closed cell foam layer.

6. A thermally insulated shipping container as set forth in any of claims 3 to 5 wherein said foam layer is encapsulated between two or more layers of reflective material.

7. The thermally insulated shipping container of any of claims 3-5, wherein the foam layer is encapsulated between two or more layers of antimicrobial material.

8. A thermally insulated shipping container as set forth in any of claims 3 to 5 wherein said foam layer is encapsulated between one or more layers of reflective material and one or more layers of antimicrobial material.

9. The thermally insulated shipping container of claim 7 or claim 8, wherein the antimicrobial material is a food grade antimicrobial material.

10. A thermally insulated shipping container as set forth in any of the preceding claims wherein said liner is made of a flexible thermally insulating sheet.

11. The thermally insulated shipping container of any of the preceding claims, wherein the liner is made of waterproof thermal insulation sheet material.

12. The thermally insulated shipping container of any of the preceding claims, wherein the outer box layer is made of a material comprising two or more layers.

13. A thermally insulated shipping container as set forth in any of the preceding claims wherein said outer box layer is made of corrugated double-walled plastic sheet.

14. A thermally insulated shipping container as set forth in any of the preceding claims wherein said thermal insulation sheet and said water resistant thermal insulation sheet have sealed edges.

15. The thermally insulated shipping container of any of the preceding claims, wherein at least one of the inner liner, the outer box layer, or the lid comprises one or more monitoring devices.

16. The thermally insulated shipping container of claim 15, wherein at least one monitoring device is used to track the position of the thermally insulated shipping container, the inner liner of the thermally insulated shipping container, the outer box layer of the thermally insulated shipping container, or the lid of the thermally insulated shipping container.

17. The thermally insulated shipping container of claim 15 or claim 16, wherein data obtained from the one or more monitoring devices is written to a blockchain.

Technical Field

The present invention relates to a thermally insulated shipping container. More particularly, the present invention relates to a thermally insulated shipping container for shipping temperature sensitive items (such as seafood and the like) out of a cold chain.

Background

Known packaging for storing and transporting temperature sensitive items such as seafood and the like, includes expanded polystyrene (styrofoam) boxes and polyethylene-coated or wax-impregnated corrugated fiberboard boxes filled with a cooling material such as ice or the like to keep the items refrigerated outside of cold chain storage and delivery within the recommended temperature range (which is typically 2 ℃ to 8 ℃ for seafood).

A disadvantage of using expanded polystyrene tanks is that they have a limited lifetime due to the decomposition of the tank during use. In addition, expanded polystyrene poses an environmental hazard in that polystyrene can be broken down into small pieces that cannot be significantly biodegraded. In addition, this type of packaging material tends to have poor barrier properties and may therefore be contaminated by its contents. In addition, they typically require a disposable environmentally unsustainable plastic liner bag.

Furthermore, the efficiency of use is limited because the bins are of fixed size and can be bulky to transport and store when not in use because they are not collapsible. Moreover, due to the fixed size, their availability is limited for non-standard sized items, especially when it is not possible to break the item to fit in a container (for food products such as fresh fish, restaurants preferably do not have product separation).

Polystyrene is banned in the food and grocery industry in many countries around the world-including the united states and the chinese hong kong, which are large sea product trading partners in australia. Airlines are reviewing the expanded polystyrene air freight approval status due to the amount of product spills that require cleaning and inspection of the aircraft.

It would therefore be an advantage if it were possible to provide an improved thermally insulated container or at least one that ameliorates the above problems.

It will be clearly understood that, if a prior art publication is referred to herein; this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in australia or in any other country.

Disclosure of Invention

The present invention relates to an improved thermally insulated container that may at least partially overcome at least one of the above disadvantages or provide a useful or commercial advantage to the consumer.

In view of the foregoing, the present invention relates to a thermally insulated container for containing and transporting temperature sensitive items, such as seafood and the like. The present invention provides the ability to deliver temperature sensitive items "out of the cold chain" through sustainable means while maintaining product quality. The thermally insulated container of the present invention provides a reusable alternative to polystyrene in a sustainable form.

In view of the foregoing, the present invention resides broadly in one form in a thermally insulated shipping container comprising:

an inner liner, wherein the inner liner is made of a thermally insulating sheet; and

an outer case layer, wherein the outer case layer is made of a waterproof heat insulating sheet,

wherein the side wall of the outer box tier is connected to an adjacent side wall of the outer box tier by at least one locking tab.

The thermally insulated shipping container may be used for any suitable purpose. In an embodiment of the present invention, the thermally insulated transport container may be used for transporting perishable items. It will be understood that the term "perishable" as used throughout this specification refers to an item whose efficacy, freshness, value, safety to the consumer, etc., is temperature sensitive, time sensitive, or a combination of both.

For example, perishable items may include meat and meat by-products, fish and seafood, dairy products, fruits and vegetables, flowers, pharmaceutical products, chemicals, transplant organs, and the like. Preferably, the thermally insulated shipping container may be used to ship temperature sensitive goods. However, it is envisaged that in use, the thermally insulated shipping container may be used to ship any form of goods, where shipping and environmental conditions may have a detrimental effect on the quality, safety, appearance, shelf life, etc. of the goods over time.

Thermally insulated transport containers may be used to transport perishable items by land, air, train or ship. However, it will be appreciated that the type of transport may vary depending on a number of factors, such as the item to be transported, whether the transport requires a refrigerated container, and the destination of the item.

The thermally insulated shipping container may have any suitable size, shape or configuration. Preferably, the size and shape of the thermally insulated transport container is determined at least in part by the type of perishable object to be transported. For example, if a large whole fish (or more than one fish) is to be transported, a larger thermally insulated transport container may be required than when transporting fish filets. However, it will be understood that the size, shape and configuration of the thermally insulated shipping container may vary depending on a number of factors, such as commercial considerations, shipping type and destination, and whether the perishable item is live, fresh, chilled or frozen, etc.

The thermally insulated shipping container includes an inner liner. The liner may be made of any suitable type of material having thermal insulating properties. Preferably, the liner may be made of sheet material. Preferably, the inner liner may be made of a flexible sheet material. In an embodiment of the invention, the inner liner may be made of a thermally insulating sheet. Any suitable thermally insulating sheet may be used. However, it is envisaged that, in use, the thermal insulation sheet may reflect radiant heat, thereby reducing or minimising the temperature rise of an object at least partially surrounded by the thermal insulation sheet. Preferably, the thermal insulation sheet reflects a large portion of the radiant heat. In some embodiments of the invention, the thermal insulation sheet may reflect at least 50% of the radiant heat. More preferably, the thermal insulation sheet may reflect at least 75% of radiant heat. Most preferably, the thermal insulation sheet may reflect at least 95% of the radiant heat. In a preferred embodiment of the invention, the thermal insulation sheet reflects at least 87% of the radiant heat.

The thermal insulation sheet may comprise at least one layer. In embodiments of the present invention, the thermal insulation sheet may be a multilayer structure. In an embodiment of the invention, the thermal insulation sheet comprises an insulation layer between at least one upper layer and at least one lower layer. Preferably, the insulating layer may be encapsulated between the at least one upper layer and the at least one lower layer such that the insulating layer may be substantially surrounded by the at least one upper layer and the at least one lower layer. The insulating layer may be made of any suitable material. For example, the insulating layer may be made of an extruded polymer, a foamed polymer, or a combination thereof. Accordingly, the insulating layer may be made of a polymer (and particularly a foamed polymer) such as, but not limited to, polyethylene, ethylene vinyl acetate, ethylene propylene diene terpolymer, neoprene, nitrile, polyvinyl chloride, silicone, fluoroelastomer, urethane, and the like, or any suitable combination thereof. The insulation layer may be made of closed cell foam insulation or open cell foam insulation. In a preferred embodiment of the invention, the insulating layer may comprise a closed cell foam. The closed cell foam has an open cell content of 20% or less, 10% or less, 5% or less, and may have zero percent open cell content. In a preferred embodiment, the insulating layer may be a closed cell polyethylene foam core.

The upper and lower layers may be made of any suitable material. Preferably, the upper and lower layers may provide resistance to one or more environmental factors. Preferably, the upper and lower layers may be antimicrobial, reflective, thermally insulating, waterproof, water-impermeable, UV-resistant, chemical-resistant, impact-resistant, fire-resistant, or a combination thereof.

Preferably, the thermal insulation sheet comprises at least one reflective layer. The reflective layer may be made of any suitable material, including but not limited to metal foil (e.g., aluminum foil laminate, etc.), metalized plastic film, and the like. In an embodiment of the invention, the reflective layer may be metallized polyethylene. Although the layer may be positioned in any suitable orientation, it is contemplated that the reflective layer may be placed in contact with or in close proximity to the outer tank layer. Thus, in this embodiment of the invention, the reflective layer forms the outer surface of the liner. In an alternative embodiment of the invention, the reflective layer forms the inner surface of the inner liner. In an embodiment of the invention, the thermal insulation sheet comprises a foam layer encapsulated between two or more layers of reflective material.

Preferably, the thermally insulating sheet comprises at least one layer of antimicrobial material. The antimicrobial layer can be made of any suitable material, including but not limited to antimicrobial polymers, silver nanoparticle coated polymers, and the like. In embodiments of the present invention, the antimicrobial layer may be an antimicrobial polyethylene. While the layer may be positioned in any suitable orientation, it is contemplated that the antimicrobial layer may be placed in contact with or in close proximity to the perishable object. Thus, in embodiments of the present invention, the antimicrobial layer forms the inner surface of the liner. In an alternative embodiment of the invention, the antimicrobial layer forms the outer surface of the liner. In an embodiment of the invention, the thermal insulation sheet comprises a foam layer encapsulated between two or more layers of antimicrobial material. Preferably, the antimicrobial material may be a food grade antimicrobial material.

In an embodiment of the invention, the thermal insulation sheet comprises a foam layer encapsulated between one or more layers of reflective material and one or more layers of antimicrobial material.

Preferably, the inner liner may be made of a flexible thermal insulation sheet. The thermal insulation sheet may have any suitable thickness. It will be appreciated, however, that the thickness of the thermally insulating sheet may vary depending on a number of factors, such as the requirements of the perishable items to be transported, the ambient temperature, and the degree of flexibility required of the sheet material.

Preferably, the inner liner may be assembled from food grade approved thermal insulation sheets. For the purposes of this specification, the term "food grade" means that the liner is allowed to come into contact with food for human or animal consumption.

In a preferred embodiment, the liner may be provided with resistance to one or more environmental factors. For example, the inner liner may be waterproof, water impermeable, UV resistant, chemical resistant, impact resistant, fire resistant, or combinations thereof. In a preferred embodiment of the invention, the inner liner may be at least waterproof. Preferably, the liner may be substantially impermeable to water so that if the cooling material melts or the frozen product thaws, the water produced does not leak out of the liner.

Any suitable means of providing water resistance to the liner may be used. For example, the liner may be formed from a substantially water resistant, thermally insulating sheet material, may be provided with a water repellant coating, may be provided with a liner having a high moisture barrier, or may be assembled in such a manner that the liner may be at least partially water tight or water resistant, or a combination thereof. Preferably, the thermal insulation sheet may have sealed edges. In this way, the thermal insulating ability of the material is improved and the sheet has improved water resistance. The edges of the sheet may be sealed using any suitable technique. However, it should be understood that the sealing technique may vary depending on a number of factors, such as the type of sheet to be sealed, the thickness of the sheet, and the degree of sealing desired. For example, the edges of the sheet may be sealed by using an adhesive or adhesive tape, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof.

In embodiments of the invention, at least a portion of the perimeter of the sheet may be sealed. In an alternative embodiment of the invention, substantially all of the periphery of the sheet may be sealed. In embodiments of the invention, at least a portion of the perimeter of the sheet may be sealed prior to assembly of the sheet into the liner. In embodiments of the invention, at least a portion of the perimeter of the liner may be sealed after assembly from the sheets.

The liner may have any suitable size, shape, or configuration. Preferably, however, the inner liner is of sufficient size and shape to fit within the interior dimensions of the outer tank layer. In embodiments of the invention, the inner liner may be adapted to be at least partially received and retained within the outer carton layer. Preferably, substantially all of the inner liner may be received and retained within the outer carton layer.

In an embodiment of the invention, the dimensions of the inner liner are smaller than the internal dimensions of the outer tank layer, such that only a portion of the inner liner may be held in abutment with or in close proximity to the inner surface of the outer tank layer. In an alternative embodiment of the invention, the dimensions of the inner liner are substantially the same as the internal dimensions of the outer box layer such that substantially all of the inner liner may be maintained in abutting or close proximity to the inner surface of the outer box layer.

In embodiments of the invention, the inner liner may be held adjacent to the inner surface of the outer tank layer but not attached thereto. It is envisaged that, in use, the air gap formed between the inner liner and the outer box layer may create a thermal barrier between the inner liner and the outer box layer. The inner liner may be held adjacent the inner surface of the outer tank layer by any suitable means. In embodiments of the invention, an insulating material may be disposed between the inner liner and the outer case layer. In an alternative embodiment of the invention, the inner liner may be at least partially supported by at least one support member attached to the inner surface of the outer tank layer such that the at least one support member provides a spacing between the inner liner and the inner surface of the outer tank layer. In another embodiment of the invention, a cooling material (such as ice or gel packs, etc.) may be disposed between the inner liner and the outer box layer.

In an alternative embodiment of the invention, the inner liner may be attached to at least one inner surface of the outer tank layer. It is envisaged that in use, attaching the inner liner to at least one inner surface of the outer box layer may reduce migration of and potential damage to the contents of the thermally insulated shipping container. The inner liner may be attached to the inner surface of the outer tank layer by any suitable means. In embodiments of the present invention, the inner surface of the outer box layer may be attached to the inner surface of the outer box layer using an adhesive, tape, aluminum foil tape, or mechanical fasteners (such as stitches, staples), or any suitable combination thereof.

The liner may be formed in any manner known in the art, for example, by bending a sheet of material into a sleeve and longitudinally closing the sleeve by joining overlapping or abutting side edges of the sheet to form a side wall. Alternatively, at least one side wall of the liner may be formed by folding a blank or stamped sheet along a preformed line to create the sleeve.

One or more sheets may be used to form the liner. In embodiments of the invention, two or more sheets of material may be used to form the liner. The liner may have any suitable shape when viewed from above. For example, one or more sidewalls of the container may define a generally circular, square, rectangular, hexagonal, or octagonal void in which perishable items may be placed. In an embodiment of the invention, the side walls of the liner may be formed by bending a sheet of flexible material along a preformed line and closing the ends longitudinally with an aluminium strip. Preferably, the side walls of the liner may be formed by bending a sheet of flexible material along a preformed line and fastening the adjacent side edges together.

Any suitable technique may be used to secure the overlapping portions or abutting side edges of the sheets together. However, it should be understood that the fastening technique may vary depending on a number of factors, such as the type of sheet to be sealed, the thickness of the sheet, and the degree of sealing desired. For example, overlapping portions or abutting side edges of the sheets may be secured using adhesives, tapes, aluminum foil tape, mechanical fasteners (such as stitching, staples, etc.), heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or any suitable combination thereof. In embodiments of the invention, adjacent side edges may be secured together by heat sealing. Alternatively, the edges of the sheets may be secured together by inserting one or more locking tabs located on the edges of the sheets at least partially into one or more tab retaining slots located on the opposite edges of the sheets. It is envisaged that, in use, more than one technique for securing the edges of the sheet material may be used. In embodiments of the invention, overlapping portions or abutting side edges of the sheets may be sealed with adhesive water-impermeable tape. In this case, it is envisaged that sealing the abutting side edges of the liner with a water impermeable tape may improve the water resistance of the liner.

The thermally insulated shipping container may be provided with a cooling material. Any suitable cooling material may be provided. Preferably, however, the type of cooling material that may be used is at least partially determined by the type of thermally insulated shipping container and associated shipping and food regulations. Suitable cooling materials include dry ice, wet ice, gel coolant, ice gel packs, or combinations thereof. The cooling material may be positioned in any suitable portion of the thermally insulated shipping container. For example, the cooling material may be positioned adjacent to the perishable item to be transported, between the inner liner and the outer box layer, or combinations thereof. It is contemplated that the location of the cooling material may depend on the type of perishable item to be transported.

The thermally insulated shipping container includes an outer box layer. The outer carton layer may have any suitable size, shape or configuration. In embodiments of the invention, the outer box layer may be substantially the same size as the thermally insulated shipping container. Preferably, the outer box layer is the outer layer of the thermally insulated transport container. The outer carton layer may have any suitable shape when viewed from above. For example, one or more side walls of the container may define a substantially circular, square, rectangular, hexagonal, or octagonal void in which the liner may be placed.

In an embodiment of the invention, the thermally insulated shipping container comprises a lid. The cover may be of any suitable size, dimension or configuration. Preferably, however, the lid is of sufficient size, shape and configuration to enclose the outer tank layer.

The outer tank layer and/or the cover may be made of any suitable type of material having relatively high impact resistance and thermal insulation properties. For example, the outer box layer and/or the lid may be made of any suitable material, including but not limited to corrugated fiberboard, cardboard, biopolymers, polymers, semi-rigid plastics, and combinations thereof. In embodiments of the invention, the outer tank layer and/or the lid may be made of a polypropylene material. In embodiments of the invention, the outer carton layer and the lid may be made of the same type of material. In alternative embodiments of the invention, the outer tank layer and the lid may be made of different types of materials.

In a preferred embodiment, the outer box layer and/or the cover may have resistance to one or more environmental factors. For example, the outer tank layer and/or the lid may be waterproof, water-tight, UV-resistant, chemical-resistant, impact-resistant, fire-resistant, or a combination thereof. In a preferred embodiment of the invention, the outer tank layer and/or the cover may be at least waterproof. Preferably, the outer box layer may be substantially impermeable to water so that if the cooling material melts or the frozen product thaws, the water produced does not leak out of the outer box layer. Preferably, the cover may be substantially impermeable to water, such that rain or water leaking from the container located above the thermally insulated transport container does not penetrate into the thermally insulated transport container.

Any suitable means of providing water resistance to the outer tank layer and/or lid may be used. For example, the outer tank layer and/or the cover may be formed from a substantially water-proof, thermally insulating sheet, may be provided with a water-proof coating, may be provided with an inner liner having a high moisture barrier, or assembled in such a way that the outer tank layer and/or the cover may be at least partially water-tight or water-proof, or a combination thereof. Preferably, the waterproof thermal insulation sheet may have a sealing edge. In this way, the thermal insulating ability of the material is improved and the sheet has improved water resistance. The edges of the sheet may be sealed using any suitable technique. However, it should be understood that the sealing technique may vary depending on a number of factors, such as the type of sheet to be sealed, the thickness of the sheet, and the degree of sealing desired. For example, the edges of the sheet may be sealed by using an adhesive or adhesive tape, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, etc.), or a combination thereof.

In an embodiment of the invention, at least a portion of the perimeter of the sheet may be sealed. In an alternative embodiment of the invention, substantially all of the periphery of the sheet may be sealed. In embodiments of the invention, at least a portion of the perimeter of the sheet may be sealed prior to assembly of the sheet into the outer box layer and/or lid. In embodiments of the invention, at least a portion of the perimeter of the outer box layer and/or lid may be sealed after assembly from the sheet material.

In an embodiment of the invention, the outer tank layer and/or the cover may be made of a waterproof thermal insulation sheet. In another embodiment of the invention, the outer box layer and/or cover may be made of a waterproof thermal insulating sheet, wherein the overlapping or abutting side edges of the sheets may be sealed with an adhesive, a water impermeable tape. In this case, it is envisaged that sealing the abutting side edges of the outer box layer and/or cover with a water-impermeable adhesive tape may improve the water resistance of the outer box layer and/or cover. Preferably, the waterproof thermal insulation sheet may have a sealing edge. In this way, the thermal insulating ability of the material is improved and the sheet has improved water resistance.

The water resistant thermal insulation sheet may include at least one layer. In an embodiment of the present invention, the waterproof thermal insulation sheet may be a multilayer structure. In a preferred embodiment, the waterproof thermal insulating sheet may be a double-walled plastic structure. Preferably, the waterproof thermal insulation sheet may be a corrugated plastic. In an embodiment of the invention, the waterproof thermal insulation sheet comprises a plastic corrugated double wall sheet consisting of two flat sheets connected by parallel ribs. In some embodiments of the invention, the waterproof thermal insulation sheet may be made of: polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polycarbonate, acrylonitrile butadiene styrene, and the like, or any suitable combination thereof.

Suitable commercially available water repellent thermal insulation sheets include those manufactured by Corex Plastics (Australia) Pty. Co., LtdA sheet.

In embodiments of the invention, the outer tank layer and/or the lid may be at least UV resistant. Any suitable means of providing UV resistance to the outer box layer and/or lid may be used. For example, the outer box layer and/or the cover may be formed from a substantially UV resistant thermally insulating sheet, may be provided with a UV resistant coating, or a combination thereof. In an embodiment of the invention, the outer tank layer and/or the lid may be provided with a coating in the form of a UV-resistant film, such as a metallized plastic film or the like. In a preferred embodiment of the invention, the outer tank layer and/or the lid may be provided with a metallised polypropylene film. Preferably, the outer tank layer and/or the lid may be provided with a metallized oriented polypropylene film. It is envisaged that in use, the metallised plastic film may improve the thermal performance of the outer box layer and/or lid when exposed to sunlight.

The outer box layer and/or lid may be formed in any manner known in the art, for example, by folding a blank or stamped sheet along a preformed line to raise the side and end panels from the bottom panel. One or more sheets of material may be used. In embodiments of the invention, the top wall integrally formed as part of the outer carton layer blank may be folded to form the lid. In this case, it is envisaged that the top wall may be an extension to one or more side walls of the outer carton layer blank. Alternatively, the lid in the form of an open box-like structure may be formed from a blank. In this case, it is envisaged that the lid may be fitted over the outer box layer such that the side panels of the lid extend at least partially over the side panels of the outer box layer. In another embodiment of the invention, a sheet of material may be attached to the upper edge of the outer box layer to form a lid or closure.

One or more of the side walls and/or the lid of the outer box layer may be attached to the adjacent side wall by any suitable technique. For example, adhesive, tape, aluminum foil tape, or mechanical fasteners (such as stitching, staples, etc.), or any suitable combination thereof, may be used to secure the overlapping portions or abutting side edges of the sheets. Alternatively, the edges of the sheets may be secured together by inserting one or more locking tabs located on the edges of the sheets at least partially into one or more tab retaining slots located on the opposite edges of the sheets. Alternatively, the edges of the sheets may be secured together by folding one or more locking tabs located on the edges of the first portion of the sheets such that the one or more folded locking tabs may extend at least partially across the edges of adjacent portions of the sheets. It is envisaged that, in use, more than one technique for securing the edges of the sheet material may be used. In embodiments of the invention, overlapping portions or abutting side edges of the sheets may be sealed with adhesive water-impermeable tape. In this case, it is envisaged that sealing the abutting side edges of the liner with a water impermeable tape may improve the water resistance of the liner.

The outer box layer and/or the lid may be provided with one or more straps. The belt may be of any suitable size, shape and configuration. Preferably, however, the belt has sufficient size and mechanical properties (strength, rigidity, shape, etc.) to move and lift the thermally insulated shipping container. In use, it is envisaged that one or more straps may also secure the lid to the outer carton layer.

In an embodiment of the invention, the thermally insulated shipping container further comprises a cardboard outer container. In an alternative embodiment of the invention, the thermally insulated shipping container further comprises a paperboard sleeve. Any suitable paperboard outer container or paperboard sleeve may be used. It is envisaged that in use, company brands, sender details, recipient details, information relating to perishable items, etc. may be printed on the cardboard outer container or cardboard sleeve. In this way, the thermally insulated shipping container can be reused by different companies.

The thermally insulated transport container may be provided with one or more monitoring devices. The monitoring device may be of any suitable type and may monitor any suitable parameter associated with the thermally insulated shipping container. Preferably, however, the one or more monitoring devices provide information about the condition of the inner liner and/or outer tank layer and/or lid. For example, a suitable monitoring device may be an electronic monitoring device. The electronic monitoring device may include an electronic chip, an internet of things (loT) module, a data recorder, a Radio Frequency Identification (RFID) chip, a Near Field Communication (NFC) tag, a smart tag, and the like. It is contemplated that in use, the monitoring device may be used to track and/or find the thermally insulated shipping container or individual components thereof, identify worn or damaged components, monitor temperature or humidity at one or more locations within the thermally insulated shipping container, or a combination thereof. In embodiments of the invention, one or more of the inner liner, outer carton layer and lid may be provided with one or more monitoring devices.

For example, tracking and verification of reusability and recyclability of thermally insulated shipping containers may be accomplished by embedding an electronic chip (loT) at the point of manufacture of each of the individual components of the container. Each layer may be scanned at the point of manufacture (and one or more other points of the product lifecycle such as by a sender, a conveyor, a receiver, a recycler, etc.) via an electronic chip reading device, and data from each embedded electronic chip may be transmitted to a receiver, such as an API and cloud of a blockchain platform, etc. Thus, data may be written to the chain of blocks. Advantageously, this allows the position of the thermally insulated shipping container to be tracked throughout its life (e.g., from first use to recycling). It is envisaged that this may be sufficient verification of re-use and recyclability delivery. In addition, this information can be used to help replenish the inventory.

The one or more monitoring devices may be located in any suitable portion of the inner liner, outer carton layer and lid. However, it will be appreciated that the location of the monitoring device may vary depending on a number of factors, such as the function and transmission frequency of the monitoring device (in terms of the temporal frequency of the monitoring device transmission and/or the radio frequency of the monitoring device transmission), and so forth. In embodiments of the invention, the monitoring device may be positioned on a surface of the inner liner and/or outer tank layer and/or the lid. In this case, it is contemplated that the monitoring device may be at least partially covered by a polymeric film to provide a protective barrier for the monitoring device and to secure the monitoring device to the inner liner and/or outer tank layer and/or the lid. In embodiments of the invention, the monitoring device may be located within the structure of the inner liner and/or outer tank layer and/or lid.

The inventors have found that the combination of an inner liner, a waterproof outer box layer and a lid as described above provides an alternative to polystyrene as an "outside cold chain" shipping container.

The present invention provides a number of advantages over the prior art. For example, the present invention provides improved thermal insulation, which makes it an efficient transport container suitable for "out of cold chain" product transport. Furthermore, the present invention improves flexibility of use through customizable configurations and improves the ability to fold (flat pack) for convenient "cost effective transport" and convenient storage when not in use. The present invention also improves cost efficiency and sustainability through the ability to reuse and recycle without decomposing the material. Furthermore, the present invention does not require an additional moisture/leakage barrier in the form of a disposable plastic lined bag, which improves the ability of the shipping container to be fully recyclable.

In another aspect, the invention resides broadly in a thermally insulated shipping container comprising:

an inner thermally insulating sheet layer; and

a waterproof outer heat-insulating box layer,

wherein the side wall of the outer box tier is connected to an adjacent side wall of the outer box tier by at least one locking tab.

In another aspect, the invention resides broadly in the following method:

manufacturing a thermally insulated container comprising the steps of:

a. obtaining an inner thermally insulating sheet layer;

b. creasing the inner thermally insulating sheet layer and folding along the formed crease to form at least one edge of a desired dimension in the inner thermally insulating sheet layer;

c. creasing the outer thermally insulating sheet layer and folding along the formed creases to form at least one sidewall of a desired dimension in the outer thermally insulating sheet layer;

d. placing the folded inner thermal insulator sheet layer from step b within the folded outer thermal insulator sheet layer from step c; and is

e. At least one locking tab positioned on a side wall of an outer thermally insulated box tier is connected with an adjacent side wall of an adjoining outer thermally insulated box tier.

Any feature described herein may be combined with any one or more of the other features described herein, in any combination, within the scope of the invention.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of prior art forming part of the common general knowledge.

Drawings

Preferred features, embodiments and variations of the present invention will be apparent from the following detailed description, which provides those skilled in the art with sufficient information to practice the invention. The detailed description should not be construed to limit the scope of the foregoing summary in any way. The detailed description will refer to the following several figures:

FIG.1 shows a perspective view of a thermally insulated container without a lid according to an embodiment of the invention;

FIG.2 shows a perspective view of a liner according to an embodiment of the present invention;

FIG.3 shows a liner in a storage condition according to an embodiment of the present invention;

FIG.4 shows a perspective view of a thermally insulated container according to an embodiment of the present invention, wherein the inner liner is not sealed;

FIG.5 shows a front view of a thermally insulated container according to an embodiment of the invention, wherein the liner is not sealed;

FIG.6 illustrates a blank for forming an outer box layer according to an embodiment of the present invention;

FIG.7 shows a blank for forming a lid for a layer of an outer carton according to an embodiment of the invention;

FIG.8 illustrates a blank for forming an inner liner according to an embodiment of the present invention;

FIG.9 illustrates a blank for forming an inner liner according to an embodiment of the present invention;

FIG.10 shows a perspective view of an outer box layer according to an embodiment of the invention;

FIG.11 illustrates a top view of a lid for an outer box tier, shown in an inverted state, according to an embodiment of the present invention;

FIG.12 shows a close-up view of the side edges of the liner according to an embodiment of the invention;

FIG.13 shows a front view of a cover according to an embodiment of the invention;

FIG.14 shows a graph of temperature change for an airline-approved expanded polystyrene container and a thermally insulated shipping container according to an embodiment of the present invention;

FIG.15 shows a graph of temperature change for an airline-approved expanded polystyrene container and a thermally insulated shipping container according to an embodiment of the present invention;

FIG.16 illustrates a top perspective view of a thermally insulated shipping container without a lid, according to an embodiment of the present invention;

FIG.17 shows a top perspective view of a liner according to an embodiment of the present invention;

FIG.18 shows a perspective view of a thermally insulated shipping container according to an embodiment of the present invention;

FIG.19 illustrates a thermally insulated shipping container in use, according to an embodiment of the present invention;

FIG.20 illustrates a thermally insulated shipping container according to an embodiment of the present invention;

FIG.21 illustrates a thermally insulated shipping container according to an embodiment of the present invention in use;

FIG.22 illustrates a thermally insulated shipping container according to an embodiment of the present invention in use;

FIG.23 shows a graph of temperature and humidity over a 1.2 day period during a shipping test of an airline approved corrugated paperboard container;

FIG.24 shows a graph of temperature and humidity over a period of 1.2 days during a shipping test of a shipping container made from a plastic corrugated double wall sheet; and

fig.25 shows a graph of temperature and humidity over a 1.2 day period during a shipping test of a thermally insulated shipping container according to an embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION

In fig.1, a thermally insulated shipping container (100) according to an embodiment of the present invention is shown. The heat-insulated transport container (100) comprises an inner liner (1) and an outer box layer (2). A cover (not shown) for the outer tank layer (3) may be provided. The outer tank layer (2) may include one or more apertures (10a, 11a, 13a) substantially aligned with monitoring devices (10, 11, 13) positioned on the inner liner (1). The aperture (16) may be at least partially covered by a polymer film to provide a protective barrier for the device and to maintain the water resistance of the outer tank layer (2). The outer box layer (2) may comprise one or more monitoring devices (9), such as NFC tags or the like, which may track the position of the outer box layer or passively monitor and record the temperature. The side walls of the outer box layer (2) may be connected to the adjacent end walls by at least one male locking tab (4) which fits into a corresponding female locking recess (not shown).

In fig.2, an inner liner (1) of a thermally insulated shipping container (100) according to an embodiment of the present invention is shown. In fig.3 is shown an inner liner (1) of a thermally insulated transport container according to an embodiment of the invention in storage condition. In fig.4, a thermally insulated transport container (100) according to an embodiment of the invention is shown in use, wherein the inner liner (1) in a partially assembled state is substantially received in the outer box layer (2).

In fig.2 to 4, the inner liner (1) comprises an outer surface made of a metallized reflective layer and an inner surface made of a food grade antimicrobial layer. An NFC tag (13) is positioned on the outer surface of the liner (1). In the fully assembled state, it is envisaged that the ends of the liner (1) may be folded over heat-induced fold lines (17) in the liner (1) and sealed by compression (18) to close the liner (1). (the band (12) holding the liner closed is for display purposes only. the weight (25) holding the liner flat is for display purposes only.)

In fig.5, a thermally insulated transport container (100) according to an embodiment of the invention is shown in use, with the inner liner (1) partially received in the outer box layer (2) in a partially assembled state. In the assembled state, the plurality of side locking tabs (7) on the side walls of the outer box layer (2) are folded such that they extend at least partially across the plurality of side locking tabs (6) and into the cavity of the outer box layer (2). In this way, it is envisaged that the side locking flaps (7) substantially maintain the end walls and side walls of the outer box tier (2) in an upright condition. In the assembled condition, the male locking tabs (4) fitted into corresponding female locking recesses (5) of the outer box layer (2) substantially retain the end and side walls of the outer box layer (2) in an upright condition.

In fig.6, a blank for forming an outer box layer (2) according to an embodiment of the invention is shown. The outer box layer (2) comprises male locking tabs (4) which fit into corresponding female locking recesses (5) and side locking tabs (7) which fit into corresponding locking recesses (6) in the end walls of the outer box layer.

In fig.7, a blank for forming a lid (3) of an outer box layer (2) according to an embodiment of the invention is shown. The lid (3) includes end locking tabs (19) positioned on the edges of the end walls and side walls of the lid (3) and end locking flaps (20) hingedly attached to each end wall of the lid (3). The cover (3) further comprises a plurality of male locking tabs (21), the male locking tabs (21) fitting into corresponding female locking recesses (22). An indication (200) may be provided on the outer surface of the cover (3).

In fig.8 and 9, a blank for forming an inner liner (1) according to an embodiment of the present invention is shown. The liner (1) includes heat-induced fold lines (17) and one or more monitoring devices (10, 11), such as NFC tags or the like, which can track the position of the outer box layer or passively monitor and record the temperature. At least a portion of the liner (1) includes a sealing edge (23). The inner liner (1) comprises an outer surface made of a metallized reflective layer, the perimeter of the inner liner (1) extending beyond the perimeter of the inner surface at (the overlap material 24). It is envisaged that the overlapping material (24) on one portion of the liner (1) may abut the overlapping material (24) on a second portion of the liner (1) when the liner is assembled. The abutting overlapping material (24) may be sealed to provide a water barrier.

In fig.10, the lid (3) in the form of an open box-like structure may be fitted over the outer box layer (2) such that the side panels of the lid extend substantially over the side panels of the outer box layer (2). The cover (3) comprises a male locking tab (21), the male locking tab (21) fitting into a corresponding female locking recess (22). The lid (3) may be provided with one or more monitoring devices (8), the monitoring devices (8) may track the position of the outer tank layer or passively monitor and record the temperature. The lid (3) may also be provided with an aperture (16) which is substantially aligned with the monitoring means (10, 11 and 13) located on the liner (1). The aperture (16) may be at least partially covered by a polymer film to provide a protective barrier for the device and to maintain the water resistance of the outer tank layer (2). The cover (3) may include one or more monitoring devices (8), such as NFC tags or the like, which may track the position of the outer box layer or passively monitor and record temperature.

In fig.11, a top view of the lid of the outer box layer in an inverted state is shown. The locking tabs (20) on the end walls of the lid (3) are folded such that the folded locking tabs extend at least partially across the locking tabs (19) and into the cavity of the lid (3), the locking tabs (19) being located on adjacent end walls and side walls of the lid (3). In this way, it is envisaged that the end locking flaps (20) substantially maintain the end walls and side walls of the lid (3) in an upright condition. In the assembled state, the cover (3) comprises a plurality of male locking tabs (21) which fit into corresponding female locking recesses (22) substantially keeping the end walls and side walls of the cover (3) in an upright state.

In fig.12, a close-up view of the side edges of the liner (1) according to an embodiment of the present invention is shown. The liner (1) comprises a fold line (17) and a sealing edge (23) formed by heat induction.

In fig.13, a front view of the cover (3) according to an embodiment of the present invention is shown. The lid (3) is provided with a metallized oriented polypropylene film (29) for improved thermal performance. The metallized oriented polypropylene film (29) may be provided with a plurality of holes (16) substantially aligned with monitoring devices (10, 11 and 13) positioned on the outer tank layer and/or the inner liner (not shown). The aperture (16) may be at least partially covered by a polymer membrane to provide a protective barrier for the device and to maintain the cover (3) waterproof. The cover (3) may include one or more monitoring devices (8), such as NFC tags or the like, which may track the position of the cover or passively monitor and record temperature.

In fig.14, the test results for evaluating the change in the internal temperature of the airline-approved expanded polystyrene box and the heat-insulated transport container of the present invention are shown (see example 2). Surprisingly, the thermally insulated shipping container of the present invention has a higher thermal resistance than expanded polystyrene boxes, exhibiting a slower temperature rise than current airline approved expanded polystyrene boxes.

In fig.15, a graph of the temperature change of an embodiment of an airline-approved expanded polystyrene box and a thermally insulated shipping container of the present invention is shown (see example 3). Surprisingly, the thermally insulated shipping container of the present invention has a higher thermal resistance than expanded polystyrene boxes, exhibiting a slower temperature rise than current airline approved expanded polystyrene boxes. Experiments have also shown that providing the thermally insulated shipping container with an additional reflective layer on the outer surface of the lid (case 1 and case 2, Silver KoolPak, compare case 3, White KoolPak) improves the thermal performance of the thermally insulated shipping container.

In fig.16, a thermally insulated shipping container (300) according to an embodiment of the present invention is shown. A thermally insulated shipping container (300) includes an inner liner (301) and an outer box layer (302). The outer box layer (302) and inner liner (301) are shown in a substantially rectangular prismatic configuration that may be used for the transport of whole fish.

In fig.17, the inner liner (301) of the thermally insulated shipping container (300) is shown in a partially assembled state. The inner liner (301) is made of a layer of thermally insulating sheet material comprising a foam layer encapsulated between an upper reflective layer and a lower reflective layer. The edges (305) of the liner have been sealed to improve the thermal insulating ability of the material and to aid in the approval of the food grade state. In use, it is envisaged that the side walls (303) of the liner may be formed by bending a flexible sheet along a pre-formed line (306) and closing the ends (304) longitudinally using an aluminium strip (307).

In fig.18, the outer box layer (302) of the thermally insulated shipping container (300) is shown. The outer tank layer (302) is made of a waterproof heat insulating sheet layer in the form of a pair of sheets separated by a plurality of ribs. The outer box layer may have sealed edges (not shown) to improve the thermal insulating ability of the material and to aid in the approval of the food grade state. In use, it is envisaged that the outer box layer (302) may be formed by folding a box blank along a pre-formed line to form a base (not shown), side walls (313) and end walls (314). The side walls (313) may be connected to the adjacent end wall (314) by at least one male locking tab (318) which fits into a corresponding female locking recess (not shown). The cover (319) may be formed by bending the side wall (313) along a preformed line and securing the abutting edges of the cover (319) and side wall (313) with adhesive tape.

In fig.19 and 20, a thermally insulated shipping container (300) in a carton (320) is shown. Optionally, a strap (321) may be provided to secure the cover (319) to the outer box layer (302). In use, it is envisaged that the strap (321) may assist in moving and lifting the thermally insulated shipping container (300).

In fig.21, a thermally insulated shipping container according to an embodiment of the present invention is shown in use. The inner liner (2) comprising an inner surface made of a food grade antimicrobial layer (26) has been filled with fresh fish filets (28) and a frozen gel pack (27). Fig.21 is an empty state of the container used in the transport test (example 3, box 2 silveropak (Silver KoolPak)).

In fig.22, a thermally insulated shipping container according to an embodiment of the present invention is shown used in shipping tests (see example 1). An inner liner (301) comprising an inner surface made of a reflective layer and sealed with an aluminium strip (307) has been filled with fish filets (28), the fish filets (28) being in a plastic bag.

Fig. 23-25 show the change in temperature and humidity over a period of 1.2 days during shipping tests of an airline approved corrugated cardboard container (fig. 23), a shipping container made of plastic corrugated double wall sheet (fig. 24), and a thermally insulated shipping container according to an embodiment of the present invention as illustrated in example 1 (fig. 25). Surprisingly, the thermally insulated shipping container of the present invention is more effective in maintaining stable humidity and temperature than current airline approved packaging options.

Example 1: temperature and humidity monitoring using different transport containers

The data logger was placed in a 100 micron polyethylene bag with the entire fish inside and tied down with a gooseneck cable. The packaging was contained in a second 100 micron polyethylene bag containing a cooling gel pack, which was also tied down with a gooseneck cable (keeping the fish and gel packs separated). Both fish and gel packs were present inside a heat lining that was fitted inside the test shipping container (see fig. 22). The test shipping containers included airline approved corrugated cardboard containers, shipping containers made from plastic corrugated double wall sheet ("fluted PP shipping containers"), and the thermally insulated shipping containers of the present invention. The fluted PP shipping container and the thermally insulated container of the present invention are placed within corrugated paperboard containers approved by the airline for shipping to comply with the appropriate regulations.

The humidity and temperature of the interior of each tank was monitored every 15 minutes over a period of 1.2 days.

The results for an airline approved corrugated paperboard container can be found in fig. 23.

Humidity and temperature in paperboard containers vary greatly. The temperature varied between 18.6 ℃ and 2.5 ℃, averaged 6.9 ℃, and represented 3 "out of cold chain" shipments for different durations. Temperature and humidity are only around 20: time point 53 stabilizes after reentering the cold chain.

This clearly shows that airline approved, corrugated cardboard containers are not effective in maintaining the required temperature and humidity to ensure the quality of the product, and are therefore not suitable as stand-alone "off-cold-chain" shipping containers.

The results for the slotted PP shipping container can be found in figure 24.

While the insulating qualities of the grooved PP shipping containers are somewhat reduced, both humidity and temperature change. The temperature varied between 15.9 ℃ and 3.20 ℃ with an average of 3.60 ℃. Humidity varied between 85.2% and 68.9%, with an average of 82.1%. Temperature and humidity are only around 20: time point 53 stabilizes after reentering the cold chain.

This clearly shows that transport containers made of plastic corrugated double wall sheet are not effective in maintaining the required temperature and humidity to ensure the quality of the product and are therefore not suitable as stand-alone "out of cold chain" transport containers.

The results of the thermally insulated shipping container of the present invention can be found in fig. 25.

Both humidity and temperature are relatively constant and only vary during activation and placement in the shipping item. The temperature varied between 15.1 ℃ and-0.6 ℃ with an average of 0.2 ℃. But stabilized at about 06: 08, the change is negligible. Humidity varied between 93.1% and 68.2%, with an average of 90.6%. But stabilized at about 06: 08, the change is negligible.

This shows that the thermally insulated shipping container of the present invention is effective in maintaining the required temperature and humidity to ensure product quality.

Example 2: measurement of thermal resistance of expanded polystyrene Box and thermally insulated transport Container of the present invention

The airline-approved expanded polystyrene box and the heat-insulated transport container of the present invention are provided with a data logger and sealed. The tank was placed in an environment with a temperature of 4 ℃ and when equilibrated was transferred to a second environment with a temperature of 30 ℃. The temperature of the interior of the empty tank was monitored at one minute intervals over a period of approximately 90 minutes. The results are shown in fig. 14.

The internal temperature of the polystyrene tank reached 25 ℃ after 30 minutes and 30 ℃ after about 65 minutes. In contrast, the container of the present invention required about 43 minutes and 83 minutes, respectively, to reach the same temperature.

The results clearly show that the container of the present invention has a higher thermal resistance than the expanded polystyrene tank.

Example 3: measuring thermal resistance of different transport containers

The airline-approved expanded polystyrene box and the heat-insulated transport container of the present invention are provided with a data logger and sealed. Two thermally insulated shipping containers were provided with a metallized oriented polypropylene film on the outer surface of the lid.

The box was placed in an environment with a temperature of 4 ℃ and when equilibrated was transferred outdoors with an ambient temperature of 33 ℃ and exposed to sunlight. The temperature of the interior of the empty tank was monitored at one minute intervals over a period of approximately 90 minutes. The results are shown in FIG. 15.

The internal temperature of the polystyrene tank reached 25 ℃ after 20 minutes and exceeded ambient temperature (33 ℃) after about 25 minutes. The shipping container of the present invention (oriented polypropylene film without metallization) required about 30 and 40 minutes, respectively, to reach the same temperature. The shipping container of the present invention (with metallized oriented polypropylene film) required about 30 and 50 minutes, respectively, to reach the same temperature.

The results clearly show that the containers of the invention have a higher thermal resistance than polystyrene. The results also show that providing the shipping container of the present invention with an additional reflective layer on the outside of the lid improves the thermal performance of the shipping container when exposed to sunlight.

In this specification and in the claims, if any, the word "comprising" and its derivatives, including "and" comprising ", include each of the stated integers but do not preclude the inclusion of one or more other integers.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

In compliance with the statute, the invention has been described in language more or less specific as to structural or methodical features. It is to be understood that the invention is not limited to the specific features shown or described, since the means herein described comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any), appropriately interpreted by those skilled in the art.