United States
`9)
`a2) Patent Application Publication co) Pub. No.: US 2009/0001086 Al
`(43) Pub. Date: Jan. 1, 2009
`
`Roderick et al.
`
`US 20090001086A1
`
`(54)
`
`CONTAINER INSERT INCORPORATING
`THERMALLY INSULATIVE PANELS
`
`(75)
`
`Inventors:
`
`Kevin I. Roderick, Albuquerque,
`NM (US); Brian Glover,
`Albuquerque, NM (US); Douglas
`M.Smith, Albuquerque, NM (US)
`
`Correspondence Address:
`MARSH, FISCHMANN & BREYFOGLE LLP
`8055 East Tufts Avenue, Suite 450
`Denver, CO 80237 (US)
`
`(73)
`
`Assignee:
`
`Nanopore, Inc., Albuquerque, NM
`(US)
`
`(21)
`
`Appl. No.:
`
`12/102,703
`
`(22)
`
`Tiled:
`
`Apr. 14, 2008
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/911,386, filed on Apr.
`12, 2007.
`
`Publication Classification
`
`(51)
`
`Int. CL
`(2006.01)
`B65D 83/72
`(52) US. CL eee cece ccneene eens rece 220/592.2; 206/527
`(57)
`ABSTRACT
`
`A container insert for providing a thermally insulated enclo-
`sure. The containerinsert includes a bottompanel, side panels
`and end panels that are interconnected by a plastic backing
`sheet. The side panels and end panels can be pivoted upwardly
`to form side walls and end walls. The plastic backing sheet
`covers the seams betweenadjacent insulation panels to pro-
`vide a moisture barrier. ‘he plastic backing sheet can also
`urge adjacent pancls together to reduce the gap between adja-
`cent panels and improve thermal performance.
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`Patent Application Publication
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`Patent Application Publication
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`Patent Application Publication
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`Jan. 1,2009 Sheet 7 of 7
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`US 2009/0001086 Al
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`Jan. 1, 2009
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`CONTAINER INSERT INCORPORATING
`THERMALLYINSULATIVE PANELS
`
`CROSS-REFERENCE ‘TO RELATED
`APPLICATIONS
`
`[0001] This application claims priority to U.S. Provisional
`Patent Application Ser. No. 60/911,386 entitled “CON-
`
`TAINER INSERT INCORPORATING THERMALLY
`
`INSULATIVE PANELS”, filed Apr. 12, 2007, the disclosure
`of which is incorporated herein by reference inits entirety.
`
`BACKGROUND OFTHE INVENTION
`
`1. Field of the Invention
`[0002]
`[0003] The present invention relates to the field of ther-
`mallyinsulated containers that are adaptedfor the packaging,
`containment and/or transport oftemperature sensitive goods.
`[0004]
`2. Description of Related Art
`[0005]
`Insulated containers having thermally insulated
`walls are utilized for the containment and/or transport of
`goodsthat can be damagedor otherwise rendered unsuitable
`for use if exposed to temperatures outside of a particular
`temperature range. Thermal insulation can be used to main-
`tain a desired temperature within the container despite
`increases or decreases in the exterior (ambient) temperature.
`[0006]
`For cxample, the shipment of products that must
`have their temperature maintained within a specific range
`below ambientis one of the fastest growing market segments
`in the modern shipping industry. ‘This growthis driven by a
`number of factors including widespread concerns about
`safety in the cold food distribution chain, increasing numbers
`ofpharmaceutical andlife sciences products which must have
`their temperature maintained within certain limits, the rapid
`growth in high-value specialty chemicals such as those used
`in the semiconductor industry, the increasing number of
`sophisticated medical tests which require the shipment of
`patient specimens to an external laboratory,
`the increased
`numberof clinical trials associated with new pharmaceutical
`discovery and the increased delivery of products directly to
`the customeras a result of Internet ordering.
`[0007] This ficld is gencrally referred to as controlled tem-
`perature packaging (CTP). CTP can be segmented by the
`target temperature range, namely: frozen (below0° C.); 2° C.
`to 8° C.; and less than ambient (e.g., less than 30° C.). In
`addition, CTP may be segmented by container size, namely:
`greaterthan pallet; one cubic foot to pallet; and less than one
`cubic foot. The one cubic foot to pallet size segment is domi-
`nated by systemsusing, ice (e.g., frozen gel packs) and/or dry
`ice as a coolant where the containers are insulated using
`expanded polystyrene (EPS). The market segment for con-
`tainers less than about one cubic footin size is currently very
`limited due to the need for a small,
`lightweight cooling
`mechanismand due to the need to userelatively thin insulat-
`ing walls to maximize the available space for the product
`cavity.
`[0008] A relatively simple thermally-insulated container
`system includes a cardboard box into which EPS sheets have
`
`been cut and placed. The containeris thenfilled with dry ice
`in which, for example, frozenfish is shipped. A more sophis-
`ticated. approach is a validated. system consisting of custom
`molded EPS formsin a rigid box with both frozen and warm
`gel packs, the combination of which has been tested through
`arange of temperature cycles for specified thermal properties.
`Sucha validated system canbe used for shipping pharmaceu-
`
`
`
`
`
`ticals, or for long duration or high-value shipments. For
`example, many pharmaceulical products such as vaccines and
`antibodies must be maintained within a temperature range of
`2°C. to 8°C.
`[0009] The high cost ofshippingis at least partially related
`to the volumeoccupied by the EPSinsulation. Fora one cubic
`foot box with a 60 hour lifetime at 2° C. to 8° C., over 90
`percent of the container volumeis occupied by FPSandgel
`packs.
`Somereduction in volume and therefore shipping
`[0010]
`costs may be obtained by using vacuum insulation panels
`(VIPs) as the thermallyinsulating, material. VIPs have a high
`thermal resistance; however, they are much more costly than
`EPSsheets. Therefore, to be economically competitive, VIPs
`should be provided in a mannerthat the VIPs canbe readily
`used multiple times.
`[0011] When utilizing a container or similar article that is
`insulated with VIPs, the highest potential for thermal losses
`from the container occurs at the edges and corners where two
`VIPs are in contact. [laving an inadequate seal along these
`edges can severely degrade the performanceofthe thermally-
`insulated container. Sealing the edges of' adjacent VIPs can be
`difficult since the standard manufacturing method for VIPs
`involves evacuating the panel and sealing one or more of the
`panel edges, which results in a flap protruding from the edge.
`The presence of such a flap can inhibit gap-free mating
`betweenadjacent panels.
`[0012] U.S. Pat. No. 7,140,508 by Kuhn et al. discloses a
`shipping, box for shipping high-value objects such as framed
`paintings, where the walls of the shipping box can be lined
`with VIPs. To avoid thermal bridges and a decreasein perfor-
`mance, multiple layers of VIPs can be used where the joints
`between adjacent VIPs in onelayer are offset relative to the
`joints in an underlyinglayer. It is also disclosed that the edge
`flaps of the VIPs should not be located in the area in which
`adjacent VIPs touch, such as along the edgeofthe panel.
`[0013] US. Pat. No. 6,244,458 byI'rysingeret al. discloses
`VIPs where the barrier film is provided as a sheet material
`with edges that are sealed together. The edges are joined
`togetherover a sealed portion that extends for '4 inch or more
`from the underlying edge surface, such that the VIP does not
`have a smooth, uniform outer profile. Accordingly, adjacent
`vacuum panels cannot be positioned without space between
`them. Therefore, Frysingeret al. provide a compressible layer
`ofthermal msulation wrapped around eachofthe VIPs. It is
`disclosed by Frysinger et al. that the presence of the com-
`pressible insulation layer can reduce thermal edgelosses.
`[0014] ULS. Pat. No. 6,220,473 by Lehmanet al. discloses
`a soft-sided collapsible insulative container having a base,
`peripheral sidewalls extending from the base, and a lid. Each
`of the base, lid and sidewalls are formed of a scalable pocket
`having a compressible insulation lining. Each pocket
`is
`adapted to contain a piece of block insulation to thermally
`insulate the container. A flexible fabric casing extendstightly
`around the container in the fully closed position to exert
`uniform pressure on the container.
`[0015]
`Standard insulation materials, including the com-
`pressible insulation disclosed by Frysingeret al. and Lehman
`et al., do not provide the thermal resistance of VIPs, and will
`inherently contribute to thermal losses in a containerthat is
`otherwise lined with VIPs. There remains a need for a ther-
`mally-insulated shipping container system having improved
`thermal performance.
`SUMMARYOF THE INVENTION
`
`[0016] Accordingly,it is an object of the present invention
`to provide a thermally insulative container insert that is
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`FIG.4 illustrates a top viewof a containerinsert in
`[0022]
`a partially-assembled state according to an embodiment of
`the present invention.
`[0023]
`FIG. 5 illustrates a top viewofa container insert in
`an assembledstate according to an embodimentofthe present
`invention.
`[0024]
`FIG.6 illustrates a perspective view of a container
`insert in an assembled state according to an embodiment of
`the present invention.
`[0025]
`FIGS. 7(a) and 7(6)illustrate cross-sectional views
`of vacuum insulation panels according to an embodiment of
`the present invention.
`
`
`
`DESCRIPTION OF THE INVENTION
`
`
`
`
`
`adapted to be placed within a container, such as a shipping
`container. The insert can be placed within an outer container,
`such as a cardboard box, to provide thermal insulation for a
`product placed within the container.‘The insert can advanta-
`geously reduce the amount of manual
`labor previously
`required to thermally insulate a container, particularly when
`using vacuum insulation panels. The insert can also minimize
`or eliminate the gaps that can exist between adjacent insula-
`tion panels to increase thermal performance by reducing ther-
`malbridging and reducing the formation of condensation, or
`the formation of ice in frozen applications. For dry ice ship-
`ments in particular, ice can form within the container and
`increasethe heat load, serve as a thermal bridge and can push
`adjacent panels apart. The present invention can reduce or
`eliminate the formation of ice by providing a tightly sealed
`[0026] The present invention is directed to a container
`and thermally insulated productcavity.
`insert and a methodfor using the containerinsert to thermally
`[0017]
`Inone embodiment, a containerinsert for thermally
`insulate products contained therein. In this regard, the con-
`insulating a container is provided. The insert includes a base
`tainer insert includes thermallyinsulative panels that form the
`insulation panel having a top surface, a bottom surface and a
`walls of the container insert.
`peripheral edge surface. 'irst and secondside insulation pan-
`[0027]
`FIGS. 1(a) and 1(4)illustrate a thermally insulative
`els are provided each having a top surface, a bottom surface
`panel that can be utilized in the containerinsert. ‘lhe ther-
`and a peripheral edge surface. Theside panels are attached to
`mally insulative panel1 is preferablyrigid such that the panel
`the base panel in spaced-apart relation on opposite sidesofthe
`can form a rigid wall of the container insert. The panel 1
`base panel by a plastic backing sheet. First and second end
`includes a top surface 2 and a mutually opposed bottom
`insulation panels are also provided each having a top surface,
`surface 6. The thermal insulation panel also includes a periph-
`a bottom surface and a peripheral edge surface. Each of the
`eral edge surface 4 extending along the perimeter of the
`end panels is attached to the base panel in spaced-apart rela-
`insulation panel 1. In one embodiment, the peripheral edge
`tion on opposite ends ofthe base panel bya plastic backing
`surface 4 can have a thickness of from about 4 inch to about
`2 inches.
`sheet. Each of the side panels and the end panels can be
`pivoted upwardly toward the base panel to contact the base
`In one particularly preferred embodiment, the insu-
`[0028]
`panel along a seam and form side walls and end walls. The
`lative panel 1
`is a vacuuminsulation panel (VIP). In this
`plastic backing sheet coversat least a portion of each of the
`regard, the insulative panel 1 includes a thermally insulative
`seams between the base panel and the side panels and
`core material 8 surroundedbyabarrierfilm 9. Thebarrier film
`between the base panel and the end panels to form an enclo-
`9 is preferably a polymerbarrierfilmto facilitate heat welding
`sure having a base, side walls and end walls and a top opening.
`ofthe panel 1 to a plastic backing sheet, as is described below.
`[0018]
`Inanother embodiment, a containerinsert includes a
`[0029] A container insert according to an embodiment of
`base insulation panel having an interior surface, an exterior
`the present invention is illustrated in FIGS. 2-5, which each
`surface and a peripheral edge surface. First and second side
`illustrate a top-view of the container inserl 10 in various
`insulation panels are transversely disposed at opposite sides
`stages of assembly.‘The insert 10 is illustrated in FIG. 2 in the
`ofthe base panelto form side walls, where each side panel has
`fully flat and unassembled configuration, before assembly by
`an interior surface, an exterior surface and a peripheral edge
`a user(e.g., a shipper) and placementinto an outer container,
`surface. First and second end insulation panels are trans-
`such as a cardboard box. It is a significant advantage that the
`versely disposed at opposite ends of the base panel to form
`container insert 10 can be shipped to a user inthis flat con-
`end walls, each end panel having interior surface, an exterior
`figuration and assembled by the user when needed to store or
`surface and a peripheral edge surface. A plastic backing sheet
`transport temperature sensitive goods.
`is disposed aroundatleast a portion ofthe exterior surfaces of
`[0030] The insert 10 is adapted to be assembled and form a
`the base panel, side panels and end panels. The plastic back-
`thermally insulated bottom wall, side walls and end walls to
`ing sheet covers at least a portion of each of the seams
`define a thermally insulated product cavity. The product can
`between the base panel and the side panels and between the
`be inserted through a top opening, and then a thermally insu-
`base panel and the end panels, and coversatleast a portion of
`lated lid panel can be placed over the top opening to provide
`each of the seams between adjacent side panels and end
`a thermally insulated product cavity.
`panels, such that the plastic backing sheet urges adjacent
`[0031] Referring to FIG. 2, the insert 10 includes a base
`panels together along the seams.
`insulation panel 12,a first side insulation panel 14, a second
`side insulation panel 16, a first end insulation panel 18 and a
`second endinsulation panel 20. Although the various panels
`and walls ofthe insert 10 are described as being disposed on
`the bottom,side and endofthe containerinsert, the insert can
`be utilized in various orientations and such terms are not
`intended to belimiting in this regard. For example, each ofthe
`insulation panels could be a square panel of equivalent
`dimensions.
`[0032] Each ofthe panels is thermally insulative panel, for
`example a polyurethane panel, an expanded polystyrene
`panelor the like.According to one embodiment, the thermally
`
`
`
`DESCRIPTION OF THE DRAWINGS
`
`FIG. 1(@) and 1(d)illustrate a thermal insulation
`[0019]
`panel that is useful in the container insert of the present
`invention.
`
`FIG.2 illustrates a top view of a container insert
`[0020]
`according to an embodimentofthe present invention.
`[0021]
`FIG. 3 illustrates a top view of a containerinsert in
`a partially-assembled stale according to an embodiment of
`the present invention.
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`insulative pancls comprise vacuum insulation panels (VIPs).
`VIPsutilize the insulative effects ofa near-vacuum to provide
`a high thermalresistance, and can provide such high thermal
`resistance at reduced thicknesses as compared to conven-
`tional insulation, such as EPS, therebyincreasing the useful
`internal volume(e.g., the product cavity) of a container lined
`with the insulative panels. VIPs are disclosed in more detail
`below with respect to FIGS. 7(a) and 7(8).
`[0033] According to the present invention, the insulation
`panels are interconnected bya plastic backing sheet 26 thatis
`attached to the bottom surface of each insulation panel. For
`example, the backing sheet can be heat welded to the bottom
`surface of each of the insulation panels. The end panels and
`side panels are attached to the plastic backing, sheet 26 in
`spaced apart relation to the base panel 12 ina mannerthat they
`can be pivoted upwardly toward the base panel to form side
`walls and end walls of the container insert. Although
`described herein as one contiguousplastic backing sheet, the
`backing sheet can comprise two or more individual and sepa-
`rate portions, so long as the backing sheet connects the base
`panel
`to the side panels and end panels in the manner
`described herein.
`
`[0034] The plastic backing sheet 26 can perform several
`functions in the assembled container insert 10, including
`covering and sealing of the seams where adjacent insulation
`panels are in contact and facilitatmg the compression of the
`adjacent panels along the scamsto reduce or climinate gaps
`between adjacentpanels. In this regard, it should be noted that
`adjacent insulation panelsare in direct contact whenthe insert
`is assembled, as opposed to having a material layer disposed
`therebetween. The plastic backing sheet 26 is preferably
`vapor impermeable, particularly with respect to water vapor
`to provide a condensation barrier between the product cavity
`and the outside environment. The plastic backing, sheet 26 can
`also provide abrasion resistance to the exterior surfaces of the
`containerinsert 10.
`
`[0035] The plastic backing sheet 26 can comprise a single
`layer ofa plastic material, preferably a thermoplastic material
`
`such as polyethylene (PE). Morepreferably, the plastic back-
`ing sheet 26 is a multilaminate material comprising two or
`morelayers ofplastic materials to provide multiple function-
`alities. For example, the plastic backing sheet can comprise
`twolayers of PE, with a layer of a material disposed therebe-
`tween, such as a polyamide layer (e.g., Nylon) or a polypro-
`pylene (PP) layer.
`[0036] The end panels 18 and 20 are attached to theplastic
`backing sheet 26 al opposite ends of the base panel 12. The
`end panels 18 and 20 are spaced-apart from the base panel 12
`by a distance that is approximately equal to the thickness of
`the base panel 12, witha portionofthe backing sheet 26 being
`disposed between the end panels and the base panel 12, pref-
`erablyalong the entire edge of each end panel that is adjacent
`to the base panel. In one embodiment, the base panel 12 is a
`VIP having a thickness of at least about “4 inch and up to
`about 2 inches, and therefore the distance between the end
`panels and the base panel can also be from about % inch to
`about 2 inches. In this manner, when the end panels are
`pivoted upwardly and towardthe base panel to form end walls
`(FIG. 3),
`the portions of the backing sheet 26 disposed
`between the base panel 12 and the end panels 18 and 20 forms
`a tight seal along the bottom horizontal seams where the end
`panels contact the base panel 12.
`[0037] The plastic backing sheet 26 can also include linear
`perforations 28a, 28, 28c and 28d extending outwardly from
`
`the opposed edges ofthe end pancls 18 and 20 toward the base
`panel. The backing sheet perforations facilitate the pivoting
`ofthe end panels toward the base panel 12 to form end walls
`without moving the side walls. ‘the backing sheet perfora-
`tions can be, for example, scores in the sheet to enable the
`sheet to be easily separated, or can be a cut directly through
`the sheet 26.
`
`Side panels 14 and 16 are disposed on oppositesides
`[0038]
`of the base panel 12 in spaced-apart relation to the base panel.
`Aswiththe end panels, a portion ofthe plastic backing sheet
`26 is disposed between the side panels and the base panel,
`preferably along the entire edge ofthe panels that is adjacent
`to the base panel. The spacing betweenthe base panel 12 and
`the side panels 14 and 16 is preferably about equal to the
`thickness of the base panel 12 to facilitate the formation of a
`tight scal along the lower seamsofthe side panels when they
`are pivoted upwardly toward the base panel to form side
`walls.
`Asillustrated in FIG.2, the insert 10 also includes
`[0039]
`means to secure the backing sheet 26 around the exterior
`walls of the containerinsert, that is, around the exterior sur-
`faces (outside the product cavity) of the end panels and side
`panels. In this regard, the plastic backing sheet 26 extends
`beyond the opposed side edges of the side panels 14 and 16.
`In this manner, whenthe end panels are pivoted upwardlyand
`the side panels are then pivoted upwardly, that portion of the
`backing sheet extending beyond the edges of the end panels
`can be wrapped aroundthe exterior surface of the panels and
`canbe attached to the end panels.
`[0040]
`In the embodimentillustrated in FIG. 2, the attach-
`ment means includes hook and loop fasteners having hook
`portions 226 and 246 attachedto theplastic backing sheet 26,
`and loop portions 22a and 24a attached to the bottom surface
`of the end panels.
`[0041]
`FIG. 3 illustrates a top-view of the partially-as-
`sembled container insert 10, namely wherethe end panels 18
`and 20 have been pivoted upwardly and toward the base panel
`12 to form end walls for the container insert 10. ‘The portion
`of the backing sheet 26 disposed between the base panel 12
`and the end panels 18 and 20 thereby forms a tight seal along
`the entire seam wherethe peripheral edge surface of the end
`panels and the top surface of the base panel are in direct
`contact. This advantageously reduces the permeation ofwater
`vaporinto the product cavity and hence reduces condensation
`of water vapor when the interior product cavity of the con-
`tainerinsert 10 is al a reduced temperature.
`[0042]
`FIG. 4 illustrates a top view of the partially
`assembled container insert 10. Compared to FIG.3, the side
`wall panels 14 and 16 have beenpivoted upwardly and toward
`the base panel 10 to form side walls for the containerinsert 10.
`As with the end panels, the portion of the backing sheet 26
`disposed between the side panels and the base panel 12 forms
`a tight seal along the seam where the base panel and side
`panels are in contact to reduce the permeation ofwater vapor
`into the productcavity.
`[0043] Whenthe side panels are pivoted and placed on the
`base panel 12 to form side walls, it can be seenthat a portion
`of the backing sheet 26 extends away from opposite ends of
`eachside panel and each suchportionofthe backing sheet 26
`includes a hook portion 226/244 of a hook and loop fastener.
`In this regard, these portions of the backing shect can be
`pulled tightly and attached to the back side of the end panels
`18 and 20 whichhave loop portions 22a/24a adaptedto allach
`to the hook portions 22/246, Whenthe backing sheet 26 is
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`VIP includes a core material 44a and a barricr film 42a
`pulled tightly in this manner, the backing shect 26 urges the
`disposed around the core material 44a. During the manufac-
`seams between the end panels and side panels together to
`turing process, the core material 44a can be pressed into the
`reduceor eliminate any gaps between the panels and thereby
`general shape ofthe panel(e.g., a rectangular shape) which is
`improve the thermal performanceofthe containerinsert.
`placed into an envelope of the barrier material 42a. The
`[0044] Other means and methodsofattaching the backing
`barrier material envelope is then evacuated and sealed to form
`sheet 26 so that it securely and tightly wraps around the
`a rigid VIP.
`periphery ofthe insert 10 and secures the panels can be used.
`[0049] The core material provides structural strength to
`For example, the backing sheet 26 can be attached by heat
`prevent the panel walls from collapsing and to provide heat
`welding the backing sheet to the external surface of the end
`transfer resistance, and a gas impermeable barrier film sur-
`panels, which can also includea plastic material. However,
`rounding the core material that is sealed after a near vacuum
`temporary fasteners such as hook-and-loop fasteners provide
`is achieved inside the panel. The vacuum insulation panelis
`the advantage that the insert can be easily disassembled and
`re-used.
`evacuated to a lowpressure, such not greater than about 100
`mbar (about 75 torr), or less.
`[0045] A top view of an assembled container insert 10 is
`[0050] The core material can comprise a variety of materi-
`illustrated in FIG. 5. It can be seen that the plastic backing
`als, such as opencell polyurethane or polystyrene foam(e.g.,
`sheet 26 is wrapped tightly around the exterior of the side
`INSTILL, available from the Dow Chemical Company).
`walls and. end walls and is attached to the end panels by hook
`According to a preferred embodiment, the core material is a
`and loop fasteners 22 and 24. This provides at least two
`particulate material, such assilica, titania and/or carbon. The
`advantages—the plastic sheet compresses the panel edges
`particulates can form a branched network ofprimary particles
`against each other to form a lightseal alongthe vertical edges
`which aggregate into larger particles. Preferably, the core
`between panels, and the plastic material of the backing sheet
`material has pore sizes ranging from about 10 nm to about 100
`26 providesa barrier to prevent penetration ofwater vapor or
`mm. The VIPs can also include getter or desiccants within the
`othergases into the productcavity defined bythe insert. It will
`panelthat are adapted to adsorb residual gases and moisture,
`be appreciated that while the backing sheet perforations 28
`whichincreases the useful lifetime of the panels.
`facilitate pivoting of the end panels 18 and 20 to form end
`walls (TIG. 2), such perforations should not also be included
`[0051] The barrier film 42ais a substantially gas-imperme-
`with respect to the side pancls, as this would preclude the
`able material that can be sealed at the edges to form an
`ability to tightly wrap the backing sheet 26 aroundtheperiph-
`envelape for the core material. The barrier film can be a
`ery of the container insert 10. However, seams could extend
`laminate film that includes a metallic layer and at least one
`fromthe edgesofthe side panels, in lieu ofthose illustrated in
`plastic layer, such as a laminate that includes a metallic layer
`the figures extending from the end panels.
`sandwiched between two plastic layers. However, barrier
`filmsthat include a metallic layer can be disadvantageous in
`[0046]
`FIG. 6illustrates a perspective view ofan assembled
`container insert 10. The insert 10 includes a base insulation
`the container insert since the metallic layer can serve as a
`thermal bridge at the edgesofthe insert, reducing the thermal
`panel 12 as well as side walls and end walls. The end walls are
`performanceofthe insulation. Further, metallized layers are
`formed bythefirst end insulation panel 18 and the second end
`subject to stress cracking, which also can reduce thermal
`insulation panel 20. The end panels are transversely disposed
`performance.
`on the base panel at opposite ends ofthe base panel to form the
`end walls. Similarly, the side walls are formed bya first side
`[0052]
`Itis therefore preferred that the barrier film does not
`insulation panel 14 and a second side insulation panel 16
`include a metallized barrier. In this regard,the barrier film can
`whichare also transversely disposed on the base panel at
`include a first plastic film layer, preferably a thermoplastic
`opposite sides ofthe base panel 12. Byvirtue ofthis assembly,
`layer, on the internal surface so that the inner layer of
`the
`horizontal seams exist where the side panels and end panels
`barrier film can be heat sealed after evacuation ofthe panel. It
`contact the base panel and vertical seams exist where the
`is also preferred that the barrier film include an outer layer
`adjacent side panels and end panels are in contact. For
`that is also fabricated from a plastic material, such as PE, to
`example, horizontal seams 13a and 13d are formed between
`enable heat welding of the panels to the plastic backing sheet
`the base panel 12 and each ofthe side wal! 16 and the end wall
`of the container insert. According to one embodiment, the
`20. Similarly, vertical scams 20@ and 206 form between the
`barrier film comprises a multi-layer coextrudate which is not
`end panel 20 and the two adjacentside panels 14 and 16. The
`susceptible to stress cracking. For example, the coextrudate
`backing sheet 26 advantageously covers these seams and
`can includealayer ofPF anda layerof ethylene vinyl alcohol
`
`urges (compresses) the panels together to reduce any gap
`(EvOB), with a layer of a material such as polyamide(e.g.,
`between the panels.
`Nylon) or polyethylene terephthalate (PET) disposed ther-
`
`[0047] A lid 30 can be placed ontheinsert to seal the top
`ebetween. The EVOH layer can provide an oxygenbarrier
`
`opening. The lid can include, for example, an insulation panel
`and the polyamide or PET can provide toughness, e.g., abra-
`32 of a size and type similar to the base panel 12. A piece of
`sion resistance, Other layers could include polyvinylidene
`foam 34 such as polyethylene foam or a similar material can
`chloride (PVDC)or a similar material for a moisturebarrier.
`be placed on top ofthe insulation panel 32 so that the botlom
`[0053]
`Theseplastic barrier film materials can be made, for
`surface of the insulation panel 32 is compressed against the
`example, by coextrusion or lamination. Pigments can also be
`top edge surfaces of the side panels and end panels when the
`added to one or more of the various layers for aesthetic
`top lid of a container is closed and pressed against the foam
`purposes, i.e., so that the core material is not visible to the
`34.
`user. In this regard, the plastic barrier film can also be com-
`prised of