Fully recyclable insulated shipping container

Abstract

The present invention generally relates to an insulated shipping container made entirely of standard recyclable materials for use in transporting heated or cooled payloads. The entire container and its insulation may be placed in a standard recycling bin after use, without any disassembly or separation of materials. The container comprises multiple layers that are easily folded together by the transporter prior to the additional of a payload for delivery to an end user. The container contains multiple formed paper panels that provide a tight seal for insulation purposes.

What is claimed is: 
     
         1 . An insulated shipping container comprising:
 an outer shell defined by a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position;   an inner shell defined by a series of insulation-containing panels carried by selected said wall sections, wherein at least one of said insulation-containing panels is carried on a selected said wall section and defines an enclosed insulation cavity between said wall section of said outer shell and an interior side of said insulation-containing panels; wherein said insulation-containing panels carried on at least said bottom wall and side walls abut each other to defining a cargo receiving area when said wall sections are folded into said operable position;   an insulation material defining an insulated liner disposed in said insulation cavity that extends directly between said outer shell and an interior side of said inner shell;   wherein said outer shell, said inner shell and said insulated liner are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.   
     
     
         2 . The insulated shipping container of  claim 1  wherein said foldable interconnected wall sections include a top wall defining a lid section that encloses said cargo receiving area when folded into said operable position. 
     
     
         3 . The insulated shipping container of  claim 1  including a detached lid section mounted to said side walls; wherein said lid section encloses said cargo receiving area when said foldable interconnected wall sections are folded into said operable position. 
     
     
         4 . The insulated shipping container of  claim 1  including a lid section having at least one said insulation-containing panel that abuts said insulation-containing panels carried by said side walls for enclosing said cargo receiving area. 
     
     
         5 . The insulated shipping container of  claim 4  wherein said plurality of insulation-containing panels define a uniform insulation cavity so that a uniform insulation thickness of said insulated liner is formed among said wall sections and said lid section. 
     
     
         6 . The insulated shipping container of  claim 1  wherein each of said insulation-containing panels includes a chamfered surface that abuts a complementary chamfered surface of an adjacent said insulation-containing panel when said wall sections are folded into said operable position. 
     
     
         7 . The insulated shipping container of  claim 6  wherein said chamfered surfaces are formed at approximately a 45° angle along a perimeter edge portion of each said insulation-containing panels. 
     
     
         8 . The insulated shipping container of  claim 7  wherein said chamfered surfaces on adjacent insulation-containing panels abut when a given said wall section is folded to approximately 90° relative to adjacent wall sections. 
     
     
         9 . The insulated shipping container of  claim 6  including an adhesive disposed along said chamfered surface of said insulation-containing panels, wherein said adhesive interlocks and seals together abutting said insulation-containing panels when said wall sections are folded into said operable position so that said cargo receiving area is sealed to resist air movement between abutting insulation-containing panels. 
     
     
         10 . The insulated shipping container of  claim 1  wherein said outer shell is comprised of a corrugated paperboard. 
     
     
         11 . The insulated shipping container of  claim 1  wherein said inner shell is comprised of a rigid or semi-rigid paper based material. 
     
     
         12 . The insulated shipping container of  claim 11  wherein said inner shell is comprised of food grade based paper material. 
     
     
         13 . The insulated shipping container of  claim 1  wherein said insulated liner comprises a loose fill cellulose based insulation material. 
     
     
         14 . The insulated shipping container of  claim 13  wherein said loose fill cellulose based insulation material comprises shredded paper. 
     
     
         15 . The insulated shipping container of  claim 1  wherein an air chamber extends around a perimeter of each of said insulation-containing panels and is defined by side surfaces of abutting said insulation-containing panels and said outer shell when said wall sections are folded into said operable position. 
     
     
         16 . The insulated shipping container of  claim 1  including an insert panel carrying a secondary insulation container disposed in said cargo receiving area for providing layered insulation within said cargo receiving area. 
     
     
         17 . The insulated shipping container of  claim 16  wherein said secondary insulation container comprises one of said insulation-containing panels with loose fill cellulose based insulation material contained within an insulation cavity defined between said insert panel and an inner surface of said insulation-containing panel. 
     
     
         18 . The insulated shipping container of  claim 16  wherein said secondary insulation container comprises a bag containing loose fill cellulose based insulation material. 
     
     
         19 . A method of forming an insulated shipping container, said method comprising the steps of:
 providing an outer shell having a series of foldable interconnected wall sections, wherein said wall sections include at least a bottom wall and a plurality of side walls when folded into an operable position;   mounting a series of insulation-containing panels to selected said wall sections to form an inner shell;   inserting an insulation material into an insulation cavity disposed between said outer shell and an interior side of said inner shell;   wherein said outer shell, said inner shell and said insulation material are comprised of a cellulose based material to provide single channel recycling of the entire shipping container.   
     
     
         20 . The method of  claim 19  including the step folding said outer shell so that said insulation-containing panels carried on said wall sections abut each other to define a cargo receiving area when said wall sections are folded into said operable position.