Insulated package insert apparatus and method

Abstract

An insulated packaging insert, and apparatus and a method of producing the insert are disclosed, wherein a sealing and a cutting process for producing the insert from a blank of material optimizes a fit of the insert to a shipping container; minimizes a contamination of the insert; and minimizes a cost of the insert.

1 . A container insert comprising a bottom having an outer edge, a plurality of sidewalls extending upwardly from the outer edge of the bottom forming an open upper end, the bottom and the sidewalls formed from a rectangular sheet of thermally insulated material 
   
   
       2 . The insert according to  claim 1 , wherein the material is a foil laminated insulated material. 
   
   
       3 . The insert according to  claim 2 , wherein the foil laminated insulated material includes a laminate of air bubble cushioning material. 
   
   
       4 . The insert according to  claim 1 , including at least one fluid tight seam joining one of the sidewalls to the edge of the bottom of the insert. 
   
   
       5 . The insert according to  claim 1 , including at least one flap formed at the open upper end of the insert and extending upwardly from one sidewall and adapted to fold to a closed position over the open upper end. 
   
   
       6 . The insert according to  claim 5 , including an adhesive disposed on the at least one flap and adapted to secure the flap in the closed position. 
   
   
       7 . The insert according to  claim 6 , wherein the adhesive is a pressure sensitive adhesive. 
   
   
       8 . The insert according to  claim 1 , wherein an adhesive is disposed on at least one of the sidewalls and adapted to secure the insert within a container. 
   
   
       9 . An apparatus for manufacturing a container insert comprising:
 a framework defining a shape of a container insert to be formed from the perform; and   a sealing member disposed adjacent the framework for selectively cooperating with the framework to form linear seals in the preform.   
   
   
       10 . The apparatus according to  claim 9 , including at least one cutting arm attached to the framework and moveable between an open position and a closed position. 
   
   
       11 . The apparatus according to  claim 10 , including an actuator to selectively move the at least one cutting arm to the open position and the closed position. 
   
   
       12 . The apparatus according to  claim 11 , wherein the at least one cutting arm includes a pair of spaced apart cutting blades, the cutting blades adapted to penetrate the material forming the preform when the at least one cutting arm is in the closed position. 
   
   
       13 . The apparatus according to  claim 9 , wherein the sealing member includes a support frame having a rotatable cross member journaled thereto, a pair of elongate spaced apart bars extending outwardly from the cross member and moveable between an open position and a closed position. 
   
   
       14 . The apparatus according to  claim 13 , wherein each bar includes at least one electrical heating element. 
   
   
       15 . The apparatus according to  claim 14 , wherein the at least one electrical heating element contacts the preform received on the frame when the bars are in the closed position. 
   
   
       16 . A method of producing a container insert comprising the steps of:
 providing a preform formed from a substantially rectangular sheet of material, the perform having opposing spaced apart sealed side edges, an open end and a spaced apart closed end between the edges;   providing a framework to receive the open end of the perform;   disposing the preform on the framework causing the preform to substantially conform to the shape of the framework;   folding the material adjacent the closed end of the preform forming a pair of spaced apart pouches extending from opposing edges of the closed end of the preform;   forming a seal in each pouch along the respective edges of the closed end;   separating the pouches from the preform; and   removing the preform from the frame.   
   
   
       17 . The method according to  claim 16 , including the step of forming a pair of spaced apart longitudinal slits in at least one side of the preform as the preform is removed from the frame, the slits extending to the open end of the preform forming at least one flap adapted to fold to a closed position. 
   
   
       18 . The method according to  claim 18 , including the step of applying an adhesive to the at least one flap, wherein the adhesive strip is adapted to secure the at least one flap in the closed position. 
   
   
       19 . The method according to  claim 16 , including the step of applying an adhesive to at least one side of the preform to secure the insert within a container.