(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2008/0006628A1
`Goncharko et al.
`(43) Pub. Date:
`Jan. 10, 2008
`
`US 2008OOO6628A1
`
`(54) INSULATING CONTAINER MADE FROM
`RECTANGULARPANELS OF
`COMPRESSIBLE MATERAL STRAPPED
`
`TOGETHER
`(76) Inventors:
`
`Michael Goncharko, Englishtown,
`NJ (US); Anthony Alleva,
`Piscataway, NJ (US)
`
`Correspondence Address:
`Eric P. Mirabe
`Suite 100, 35 Technology Drive
`Warren, NJ 07059
`
`(21) Appl. No.:
`
`11/483,338
`
`(22) Filed:
`
`Jul. 7, 2006
`Publication Classificati
`O
`SSCO
`
`(51) Int. Cl.
`B65D 6/00
`
`(2006.01)
`
`(52) U.S. Cl. ...................................................... 220/4.33
`
`
`
`ABSTRACT
`(57)
`Disclosed is a sealed container formed from six rectangular
`f
`insulati
`ls. The ed
`f it
`f th
`9.
`1
`
`RMingyidaried of the Nied
`of the panels forming the two other opposing sides. The
`upper s of the E. panel of the R i. positioned
`to face the lower edges of all the sides. The sides are then
`strapped together under tension (one or more straps around
`the outer side of the sides; and, one strap around the edges
`of each of the two of the opposing sides and the lower
`surface of the bottom panel, to hold the bottom panel in
`place). The compressibility of the foam allows the panel
`edges to compress into the area of the panel sides contacted,
`thereby bonding the structure firmly together. The cargo is
`placed inside the container, atop the panel forming the
`bottom. Alternatively, the bottom panel is not strapped, but
`the container is placed inside a box, and sealing the box
`holds the bottom (and top) panels in place. A top panel for
`the container is positioned in the appropriate place relative
`tO the edges of the side panels, and then fixed into place,
`optionally with strapping, or otherwise. Generally, the con
`tainer is placed inside a corrugated box for shipment of
`CargO.
`
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`Patent Application Publication
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`Jan. 10, 2008 Sheet 1 of 3
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`US 2008/0006628A1
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`Patent Application Publication
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`Jan. 10, 2008 Sheet 2 of 3
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`US 2008/0006628A1
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`FIG.2
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`atent Application Publication
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`Jan. 10, 2008 Sheet 3 of 3
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`US 2008/0006628A1
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`FIG. 3
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`US 2008/0006628A1
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`Jan. 10, 2008
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`INSULATING CONTAINER MADE FROM
`RECTANGULARPANELS OF
`COMPRESSIBLE MATERAL STRAPPED
`TOGETHER
`
`FIELD OF THE INVENTION
`0001. The disclosure relates to insulated shipping con
`tainers.
`
`BACKGROUND
`0002. In the pharmaceutical, transplant and food indus
`tries, insulated containers are widely used to maintain the
`temperature of shipped materials near refrigeration levels,
`thereby promoting preservation of the material. Such con
`tainers can be made from a number of materials including
`expanded polystyrene (EPS), extruded polystyrene (XPS),
`Urethane foam, vacuum insulated panels (VIP) or other
`insulating materials. Often, for shipment, such containers
`are placed inside a corrugated box, which is then sealed with
`tape or banding.
`0003 Generally, insulated containers are sold fully
`assembled. A disadvantage of an assembled foam container
`is that the foam is fragile and easily fractures, unless
`precautions are followed during shipping to the customer.
`Rather than incurring additional expenses involved with
`pre-assembled containers, it is possible for a customer to
`purchase panels and self-assemble them. Shipping of panels
`avoids shipping a fully-assembled, fragile foam container
`and provides the additional advantage of saving space
`during shipping. However, it is not clear how to readily form
`a functional foam container from a series of panels, as Such
`containers are generally molded by the manufacturer, or
`formed from bonded panels, to provide proper insulation by
`avoiding lack of hermetic Sealing at the edges. Panels could
`be shipped and bonded, but bonding is difficult and time
`consuming for the customer. An easy-to-assemble container
`made from panels of foam would be useful.
`
`SUMMARY
`0004 Disclosed is a sealed container formed from six
`rectangular (or square) foam insulating panels. The edges of
`two of the panels forming opposing sides are positioned to
`face the inner sides of the panels forming the two other
`opposing sides. Generally, the four sides are strapped, under
`tension, first, for example, with one strap, or preferably with
`two or more spaced-apart straps that Surround the sides. The
`bottom panel can then Strapped to the sides, using one strap
`(or possibly more) around the edges of each of the two of the
`opposing sides and the lower Surface of the bottom panel, to
`hold the bottom panel in place. After the cargo is added, the
`top panel can be held in place using one or more straps
`around the outer sides of the top and bottom panels, or
`attached by other means. Strapping can be done if the
`customer/shipper adding the cargo has strapping equipment
`on-site.
`0005. The compressibility of the foam material allows the
`panel edges to compress into the area of the panel sides
`contacted, thereby bonding the structure firmly together, as
`the straps are tensioned with a conventional strapping appa
`ratus. Generally, the container is placed inside a corrugated
`box for shipment of cargo.
`0006 Instead of strapping the top and bottom panels to
`the sides, the side panels can be first strapped as described
`
`above, and then placed in position inside in a corrugated box
`(or other Suitable container) which is sized to accommodate
`the insulated container and which includes a suitable bottom
`panel inside the box. The top panel is also placed in position
`atop the edges of the side panels inside the open corrugated
`box (after adding the cargo). Sealing the box with banded,
`strapping or tape acts to hold the top and bottom panels in
`place, and strapping/banding need not be directly applied to
`those panels. However, it would also be possible to pass one
`or more bands or straps around the outward facing sides of
`the panels forming the bottom and the top to provide
`additional Support holding the top and bottom panels in
`place.
`0007. The container formed as described above provides
`equivalent insulating capacity to conventional foam-based
`coolers, formed by bonding sides or molding the entire
`structure. The tension in the Strapping/banding (and/or that
`on the inward sides of the top and bottom panels resulting
`from sealing the corrugated box), and resulting compression
`of the foam provides a suitable insulating seal.
`0008. The advantages of this structure and assembly
`method is that it can be assembled (starting from panels)
`quickly and easily, and requires only a banding machine to
`do so. Different sized panels can be used to provide con
`tainers to house different sized cargo. No custom fixtures, or
`other modifications to a basic flat foam panel are required to
`hold the panels in place, and unlike a bonding procedure,
`there is no waiting for the bonding material to cure. Addi
`tionally, the structure can be sold to customers/shippers as a
`four-sided strapped panel structure, and the customer fin
`ishes assembly by adding the bottom and top at the time of
`shipping material inside the structure.
`0009. The container can be made from any of a number
`of foam materials with Suitable insulating properties and
`compressibility, including EPS, extruded polystyrene
`(XPS), urethane foam and VIPs. The container can be used
`for any purpose a conventional foam container is used
`including, but not limited to, providing protection and
`insulation during shipping.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0010 FIG. 1 is a plan view of an assembled container
`strapped around the sides only (with the top facing down),
`and without a top panel in place, and having a cut-away on
`one side to view the inside.
`0011
`FIG. 2 is an exploded view of a container as
`described herein.
`0012 FIG. 3 is a plan view of an assembled container
`strapped around the sides and the top and bottom, having the
`top and bottom panels in place.
`
`DETAILED DESCRIPTION
`(0013 Referring to FIG. 1, an inverted container 10
`having a cargo access opening 12, straps 14 around the sides
`and various panels 16, 18, 20 and 22, is shown. Straps 15 and
`17 pass around the edges of panels 18 and 22, respectively,
`and around bottom panel 26 (no top panel is in place on
`container 10). The tension in straps 14 pulls the inward
`surfaces of sides 16 and 20 against the edges of sides 18 and
`22, and due to the compressibility of the foam material the
`panels are formed from, a groove is thereby formed on these
`inward surfaces and the structure is held together and the
`edges of the container are sealed. Similarly, the tension
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`provided by straps 15 and 17 pulls the inner surface of the
`bottom panel 26 against the edges of the panels 16, 18, 20
`and 22. The upper portion of the cargo 13 can be viewed
`through the cut-away in the side 16.
`0014 FIG. 2 shows an exploded view of container 10,
`with the bottom panel 26, and upper panel 24, shown, along
`with the manner in which they fit above and below the sides
`16, 18, 20 and 22, to provide a stable container. As noted
`above, the top and bottom need not be strapped to the sides,
`but rather, after strapping the four sides together, the
`assembled sides can be placed in a container (such as a
`corrugated box), and the bottom and top panels placed
`therein. Sealing the box acts to hold the top and bottom
`panels in place.
`0015 FIG. 3 shows a fully assembled container 10 (not
`inverted), with top panel 24 in place, and straps 28 and 30
`(which were added after a cargo was placed into the con
`tainer through opening 12, and top panel 24 was put in
`place). Straps 28 and 30 pass around the outer surfaces of
`upper panel 26 and bottom panel 24 and hold panel 24 in
`place. It would be possible to use only one strap or additional
`straps to hold panel 24 in place. Such straps, together with
`the pressure on the edges of panels 24 and 26 provided by
`strap pair 14, and the pressure on bottom panel 24 provided
`by straps 15 and 17, hold all panels in place.
`0016. Accordingly, there is provided a sealed, insulating
`shipping container which can be quickly and readily
`assembled from rectangular foam panels with a strapping/
`banding apparatus, and can be fitted to accommodate Vari
`ous sized cargos depending on the size of the panels used.
`0017. In one embodiment, the panels are made of
`expanded polystyrene. The straps are tensioned with a
`banding machine to the point the foam is observed to begin
`to compress. Additional tension may break the panels or
`damage them. In general, more than one band should be used
`on the sides, but one may be sufficient for some applications.
`As noted above, the container is generally placed inside a
`corrugated box following assembly, for additional Support
`and protection during shipment.
`0018. It should be understood that the terms, expressions
`and features in the drawings shown herein are exemplary
`only and not limiting, and that the invention scope is defined
`only in the claims which follow, and includes all equivalents
`of the subject matter of the claims.
`
`What is claimed is:
`1. A container formed from six rectangular foam panels
`which are strapped together comprising:
`two opposing edges of two of the panels forming oppos
`ing sides positioned to contact the inward facing sides
`of the panels forming the two other opposing sides;
`inward facing sides of the panels forming the bottom of
`the container and the panel forming the top of the
`container positioned to respectively contact the lower
`and upper edges of the panels forming the sides;
`at least one strap under tension and positioned around the
`outer side of the panels forming the sides; and
`two straps under tension, each Surrounding the edges of a
`respective opposing side and passing around the out
`ward facing side of the panel forming the bottom.
`2. The container of claim 1 further including one or more
`additional straps under tension positioned around the outer
`side of the panels forming the sides.
`
`3. The container of claim 1 wherein the panels are
`expanded polystyrene (EPS), extruded polystyrene (XPS),
`Urethane foam, or vacuum insulated panels.
`4. The container of claim 1 further including a cargo
`inside.
`5. The container of claim 1 wherein said container is
`placed inside a corrugated box which is then sealed,
`strapped, banded or taped closed.
`6. The container of claim 1 wherein the panels are square.
`7. The container of claim 1 wherein at least one strap
`passes around the outward facing sides of the panels forming
`the bottom and the top.
`8. A container formed from six rectangular foam panels
`placed inside a box comprising:
`two opposing edges of two of the panels forming oppos
`ing sides positioned to contact the inward facing sides
`of the panels forming the two other opposing sides;
`inward facing sides of the panels forming the bottom of
`the container and the panel forming the top of the
`container positioned to respectively contact the lower
`and upper edges of the panels forming the sides; and
`at least one strap under tension and positioned around the
`outer side of the panels forming the sides.
`9. The container of claim 8 wherein the box is sealed,
`banded, strapped or taped closed to hold panels forming the
`bottom and top of the container in place.
`10. The container of claim 8 wherein at least one strap
`passes around the outward facing sides of the panels forming
`the bottom and the top.
`11. The container of claim 8 further including one or more
`additional straps under tension positioned around the outer
`side of the panels forming the sides.
`12. The container of claim 8 wherein the panels are
`expanded polystyrene (EPS), extruded polystyrene (XPS),
`Urethane foam, or vacuum insulated panels.
`13. The container of claim 8 further including a cargo
`inside.
`14. The container of claim 8 wherein the panels are
`Square.
`15. The container of claim 8 wherein the box is corrugated
`cardboard.
`16. A method of assembling a container formed from six
`rectangular foam panels comprising:
`providing two panels forming opposing sides wherein two
`opposing edges are positioned to contact the inward
`facing sides of panels forming the two other opposing
`sides;
`positioning the inward facing sides of the panels provided
`to form the bottom of the container and the top of the
`container to respectively contact the lower and upper
`edges of the panels provided to form the sides;
`passing at least one strap around the outer side of the
`panels forming the sides and tensioning said strap; and
`passing a strap around each of the edges of a respective
`opposing side and around the outward facing side of the
`panel forming the bottom and tensioning said straps.
`17. The method of claim 16 further including passing one
`or more additional straps around the outer side of the panels
`forming the sides and tensioning said straps.
`18. The method of claim 16 further including passing one
`or more additional straps around the outer side of the panels
`forming the top and bottom of the container and tensioning
`said straps.
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`3
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`19. The method of claim 16 further including placing a
`cargo inside before placing the top panel in position.
`20. The method of claim 16 wherein said container
`formed after the last step is placed inside a corrugated box
`which is then sealed, strapped, banded or taped closed.
`
`21. The method of claim 16 further including passing at
`least one strap around the outward facing sides of the panels
`forming the bottom and the top and tensioning said strap.
`
`k
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