Reusable shipping container and method for using the same

Abstract

Embodiments disclose a reusable shipping container. The container may comprise six multi-layered walls of a plastic material. Further, the container may comprise a rail fastened to a top edge of the container with a plurality of first fasteners, wherein the fasteners penetrate on the rail, a first layer and a second layer of the container. Moreover, the container may comprise an insulation layer of vacuum insulation material and an inner layer corresponding to each wall of the container. Methods are also described for packing a parcel for shipment. The insulation layer and the inner layer are inserted into the container, wherein the inner layer encloses the parcel. Thereafter, an insulation layer corresponding to a top wall is inserted and the top wall is closed.

1 . A reusable shipping container comprising:
 (A) a bottom, two opposite side walls, and two opposite end walls, wherein the side walls and the end walls include upper edges defining a top edge of the container, and wherein each of the bottom wall, the side walls and the end walls includes
 (i) a first layer of a plastic material forming an external side of the container, the first layer having a thickness of about 5 mm to 7 mm; and 
 (ii) a second layer of the plastic material substantially coextensive with the first layer, the second layer being secured to the first layer, the second layer having a thickness of about 5 mm to 7 mm; 
   (B) a rail extending around the top edge of the container, the rail being secured to the container by a plurality of first fasteners, wherein the first fasteners penetrate only the rail and first layer of the side walls and the end walls; and   (C) a top wall forming a lid of the container and hingeably connected to a hinge end of the top edge, including
 (i) the first layer; 
 (ii) the second layer; 
 (iii) a third layer of the plastic material substantially coextensive with the second layer, the third layer being secured to the second layer, the third layer having a thickness of about 5 mm to 7 mm; and 
 (iv) a plurality of second fasteners adapted to secure the top wall to the hinge end, wherein the second fasteners penetrate only the first layer and the second layer of the top wall. 
   
   
   
       2 . The container according to  claim 1  further comprising:
 (A) an insulation layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the insulation layer includes a vacuum insulation material and is placed substantially coextensive with the second layer; and   (B) an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, the inner layer forming an internal side of the container, wherein the inner layer is placed substantially coextensive with the insulation layer.   
   
   
       3 . The container according to  claim 2 , wherein each insulation layer is pressure fitted in the container. 
   
   
       4 . The container according to  claim 2 , wherein each inner layer includes the plastic material. 
   
   
       5 . The container according to  claim 2 , wherein each inner layer includes a corrugated paper material. 
   
   
       6 . The container according to  claim 2 , wherein each inner layer includes a temperature holding material. 
   
   
       7 . The container according to  claim 2 , wherein the inner layer includes three first interlocking sides conjoined with three second interlocking sides to form six sides. 
   
   
       8 . The container according to  claim 1 , wherein the plastic material is corrugated polypropylene. 
   
   
       9 . The container according to  claim 1 , wherein the plastic material of the first layer of the side walls and the end walls comprises a plurality of flutes perpendicular to the bottom wall. 
   
   
       10 . The container according to  claim 1 , wherein the plastic material of the second layer of the side walls and the end walls comprises a plurality of flutes arranged at an angle of 0 degrees with respect to the bottom wall. 
   
   
       11 . The container according to  claim 1 , wherein the top wall includes a first thickness equivalent to a combined thickness of the first layer, the second layer and the third layer 
   
   
       12 . The container according to  claim 11 , wherein the first thickness of the top wall is equivalent to a depth of the rail. 
   
   
       13 . The container according to  claim 1  further comprising one or more hardware accessories adapted to handle the container, wherein the one or more hardware accessories are secured with a plurality of third fasteners. 
   
   
       14 . The container according to  claim 13 , wherein the third fasteners are fastened to one or more backers and penetrate only the first layer of the container. 
   
   
       15 . The container according to  claim 13 , wherein the third fasteners comprise rivets. 
   
   
       16 . The container according to  claim 1  further comprising one or more locking mechanisms adapted to secure a second end of the top wall to the container. 
   
   
       17 . The container according to  claim 16 , wherein the one or more locking mechanisms comprises a latch and a receiver. 
   
   
       18 . The container according to  claim 17 , wherein the latch is secured to an end wall through a third plurality of fasteners, and wherein the third plurality fasteners penetrate only the first layer of the end wall. 
   
   
       19 . The container according to  claim 17 , wherein the receiver is secured to an end wall through the third fasteners, and wherein the third fasteners penetrate only the first layer and the second layer of the top wall. 
   
   
       20 . The container according to  claim 1 , wherein the rail engages the end walls and the side walls together. 
   
   
       21 . The container according to  claim 1 , wherein the first fasteners and the second fasteners comprise rivets. 
   
   
       22 . A reusable shipping container for housing one or more vacuum insulation panels, comprising:
 (A) a bottom, two opposite side walls, and two opposite end walls, wherein the side walls and the end walls include upper edges defining a top edge of the container, and wherein each of the bottom wall, the side walls and the end walls includes
 (i) a first layer of a plastic material forming an external side of the container, the first layer having a thickness of about 5 mm to 7 mm; and 
 (ii) a second layer of the plastic material substantially coextensive with the first layer, the second layer being secured to the first layer, the second layer having a thickness of about 5 mm to 7 mm; 
   (B) a rail extending around the top edge of the container, the rail being secured to the container by a first plurality of fasteners, wherein the first plurality of fasteners penetrate the rail and only the first layer of the side walls and the end walls;   (C) a top wall forming a lid of the container and hingeably connected to a hinge end of the top edge;   (D) an insulation layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the insulation layer includes the one or more vacuum insulation panels placed substantially coextensive with the second layer; and   (E) an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the inner layer is placed substantially coextensive with the insulation layer, and wherein the inner layer forms an internal side of the container.   
   
   
       23 . The container according to  claim 22 , wherein the top wall comprises:
 (i) the first layer;   (ii) the second layer;   (iii) a third layer of the plastic material substantially coextensive with the second layer, the third layer being secured to the second layer, the third layer having a thickness of about 5 mm to 7 mm; and   (iv) a plurality of second fasteners adapted to secure the top wall to the hinge end, wherein the second fasteners penetrate only the first layer and the second layer of the top wall.   
   
   
       24 . The container according to  claim 22 , wherein each inner layer includes a temperature holding material. 
   
   
       25 . The container according to  claim 22  further comprising one or more hardware accessories adapted to handle the container, wherein the one or more hardware accessories are secured with a plurality of third fasteners. 
   
   
       26 . The container according to  claim 25 , wherein the third fasteners are fastened to one or more backers and penetrate only the first layer of the container. 
   
   
       27 . The container according to  claim 22 , wherein each insulation layer includes vacuum insulation panels having an R-value of about 30 to 52. 
   
   
       28 . The container according to  claim 22 , wherein the thickness of each inner layer is about 3 mm to 4 mm. 
   
   
       29 . A method for packing a parcel for shipment to an intended recipient, comprising:
 providing a reusable shipping container, wherein the container includes a bottom wall, two opposite side walls, and two opposite end walls, and wherein each of the bottom wall, the side walls and the end walls include a first layer forming an external side of the container, and a second layer substantially coextensive with said first layer;   inserting an insulation layer corresponding to each of the bottom wall, the side walls, and the end walls into the container, wherein the insulation layer includes the one or more vacuum insulation panels placed substantially coextensive with the second layer;   inserting an inner layer corresponding to each of the bottom wall, the side walls, the end walls and the top wall, wherein the inner layer is placed substantially coextensive with the insulation layer, and wherein each inner layer provides a temperature controlled environment to the parcel located therein;   inserting the insulation layer corresponding to the top wall, wherein the insulation layer is placed substantially coextensive with the inner layer of the top wall; and closing the top wall of the container.   
   
   
       30 . The method according to  claim 29  including the step of closing the top wall of the container, wherein the top wall is closed by using one or more locking mechanisms.