Container insert incorporating thermally insulative panels

Abstract

A container insert for providing a thermally insulated enclosure. The container insert includes a bottom panel, 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 between adjacent insulation panels to provide a moisture barrier. The plastic backing sheet can also urge adjacent panels together to reduce the gap between adjacent panels and improve thermal performance.

1 . A container insert, comprising:
 a base insulation panel having a top surface, a bottom surface and a peripheral edge surface;   first and second side insulation panels each having a top surface, a bottom surface and a peripheral edge surface, where the side panels are attached to the base panel in spaced-apart relation on opposite sides of the base panel by a plastic backing sheet;   first and second end insulation panels each having a top surface, a bottom surface and a peripheral edge surface, where the end panels are attached to the base panel in spaced-apart relation on opposite ends of the base panel by a plastic backing sheet;   wherein each of the side panels and the end panels can be pivoted upwardly toward the base panel to contact the base panel along a seam and form side walls and end walls, wherein the plastic backing sheet covers at least a portion of each seam between the base panel and the side panels and between the base panel and the end panels, to form an enclosure having a base, side walls, end walls and a top opening.   
   
   
       2 . A container insert as recited in  claim 1 , wherein said plastic backing sheet is heat welded to said insulation panels. 
   
   
       3 . A container insert as recited in  claim 2 , wherein said plastic backing sheet comprises a thermoplastic film layer. 
   
   
       4 . A container insert as recited in  claim 1 , wherein said end panels and side panels are spaced apart from said base panel of a distance approximately equal to the thickness of the base panel. 
   
   
       5 . A container insert as recited in  claim 1 , further comprising a thermally insulated lid that is adapted to fit over the top opening. 
   
   
       6 . A container insert as recited in  claim 1 , wherein said plastic backing sheet comprises a plastic film that is substantially impermeable to water vapor. 
   
   
       7 . A container insert as recited in  claim 1 , wherein said plastic backing sheet comprises a laminate polymer structure. 
   
   
       8 . A container insert as recited in  claim 7 , wherein said plastic backing sheet comprises a thermoplastic film. 
   
   
       9 . A container insert as recited in  claim 1 , wherein said insulation panels comprise vacuum insulation panels. 
   
   
       10 . A container insert as recited in  claim 9 , wherein said vacuum insulation panels comprise a core material and a barrier film surrounding the core material, and wherein the barrier film comprises a plastic film. 
   
   
       11 . A container insert as recited in  claim 10 , wherein said barrier film consists essentially of polymeric materials. 
   
   
       12 . A container insert as recited in  claim 11 , wherein said barrier film is a laminate film that comprises at least a first polymer film layer and a second polymer film layer. 
   
   
       13 . A container insert as recited in  claim 12 , wherein said first polymer film layer comprises polyethylene and said second polymer film layer comprises a material selected from the group consisting of ethylene vinyl alcohol (EvOH), polyamide, polyethylene terephthalate (PET) and polyvinylidene chloride (PVDC). 
   
   
       14 . A container insert as recited in  claim 1 , further comprising means for removably attaching said plastic backing sheet to an exterior surface of said end panels. 
   
   
       15 . A container insert as recited in  claim 14 , wherein the attachment means comprises hook and loop fasteners. 
   
   
       16 . A method for shipping a product, comprising the step of providing a container insert as recited in  claim 1 , placing the container insert within a shipping container, placing a product within the container insert, placing a lid on the container insert and transporting the shipping container to a desired location. 
   
   
       17 . A method as recited in  claim 16 , further comprising cooling the product cavity defined by the shipping container insert. 
   
   
       18 . A container insert, comprising:
 a base insulation panel having an interior surface, an exterior surface and a peripheral edge surface;   first and second side insulation panels transversely disposed at opposite sides of the base panel to form side walls, each side panel having an interior surface, an exterior surface and a peripheral edge surface;   first and second end insulation panels transversely disposed at opposite ends of the base panel to form end walls, each end panel having an interior surface, an exterior surface and a peripheral edge surface; and   a plastic backing sheet disposed around at least a portion of the exterior surfaces of the base panel, side panels and end panels;   wherein the plastic backing sheet covers at least a portion of the seams between the base panel and the side panels and between the base panel and the end panels, and covers at least a portion of the seams between adjacent side panels and end panels such that the plastic backing sheet urges adjacent panels together along the seams.   
   
   
       19 . A container insert as recited in  claim 18 , wherein each of said base panel, side panels and end panels is a vacuum insulation panel. 
   
   
       20 . A container insert as recited in  claim 18 , wherein said plastic backing sheet is a laminate polymer film comprising at least first and second polymer layers. 
   
   
       21 . A container insert as recited in  claim 18 , wherein said plastic backing sheet is heat welded to said insulation panels.