One-piece insulating container and template for making the same

Abstract

A one-piece cushioning and insulating container and insulation template for forming the container are provided. The insulation template includes a case blank and an insulating member secured thereto. The template may be formed into a three-dimensional container that provides cushioning and insulating items contained inside the container by simultaneously folding the case blank and insulating member. The template is designed to provide a completely enclosed space that is cushioned and insulated on all sides. The dimensions of the template may be adjusted to create containers of varying dimensions. The container may be constructed of various materials with a layer of soft, flexible material secured therein. The template may have heating or cooling elements, including phase change materials, incorporated into insulating member.

What is claimed is: 
     
         1 .) An insulation template for foldably forming a container having an insulated and cushioned interior, said template comprising:
 a generally flat case blank adapted to fold along fold lines arranged to form a three-dimensional container having interior surfaces when folded, wherein the case blank has a plurality of adhesive tabs configured to secure adjacent side walls of the three-dimensional container to each other; and   an insulating member secured to one side of the case blank and arranged so that the insulating member covers all interior surfaces of the three-dimensional container when folded.   
     
     
         2 .) The insulation template of  claim 1 , wherein the insulating member is secured to the case blank by an adhesive. 
     
     
         3 .) The insulation template of  claim 1 , wherein the insulating member has a plurality of angled miters shaped to form miter joints when the case blank is folded into a three-dimensional container. 
     
     
         4 .) The insulation template of  claim 1 , wherein the insulating member comprises fibers contained within an encapsulating material. 
     
     
         5 .) The insulation template of  claim 4 , wherein the insulating member further comprises temperature-control elements contained within the encapsulating material. 
     
     
         6 .) The insulation template of  claim 1 , wherein the case blank has a cross shape and is symmetrical. 
     
     
         7 .) An insulated container comprising:
 a container body, wherein adjacent side walls of the body are secured to each other by adhesive tabs each attached to a side wall; and   an insulating member secured to an interior surface of the container body and arranged so that the insulating member covers all interior surfaces of the container body.   
     
     
         8 .) The insulated container of  claim 7 , wherein the insulating member is secured to the interior surface of the container body by an adhesive. 
     
     
         9 .) The insulated container of  claim 7 , wherein the insulating member has a plurality of angled miters shaped to form miter joints at angled corners of the interior surface of the container body so that all interior surfaces of the container body are covered. 
     
     
         10 .) The insulated container of  claim 7 , wherein the insulating member comprises fibers contained within an encapsulating material. 
     
     
         11 .) The insulated container of  claim 10 , wherein the insulating member further comprises temperature-control elements contained within the encapsulating material. 
     
     
         12 .) A method of forming an insulated container, said method comprising the steps of:
 providing a generally flat case blank adapted to fold along fold lines arranged to form a three-dimensional container having interior surfaces when folded, wherein the case blank has a plurality of adhesive tabs configured to secure adjacent side walls of the three-dimensional container to each other;   providing an insulating member;   securing the insulating member to one side of the case blank; and   folding the case blank and the insulating member simultaneously, after the step of securing the insulating member to one side of the case blank, to form a three-dimensional container, wherein the insulating member is arranged so that the insulating member covers all interior surfaces of the three-dimensional container.   
     
     
         13 .) The method of  claim 12 , wherein the step of securing the insulating member to one side of the case blank comprises applying an adhesive to the case blank or to the insulating member. 
     
     
         14 .) The method of  claim 12 , wherein the insulating member has a plurality of angled miters shaped to form miter joints in the step of folding the case blank to form a three-dimensional container. 
     
     
         15 .) The method of  claim 12 , wherein the insulating member comprises fibers contained within an encapsulating material. 
     
     
         16 .) The method of  claim 15 , wherein the insulating member further comprises temperature-control elements contained within the encapsulating material, and the step of providing an insulating member comprises installing the temperature-control elements within the encapsulating material. 
     
     
         17 .) The method of  claim 12 , wherein the case blank has a cross shape and is symmetrical.