Insulated packaging and method of making same

Abstract

Insulated packaging is provided including an inner substrate and an outer substrate attached to the inner substrate to form an air gap therebetween. An expandable material including expandable microspheres is provided with the expandable material disposed between the inner substrate and the outer substrate. An adhesive material different than the expandable material is disposed between the inner substrate and the outer substrate to attach the inner substrate to the outer substrate. A method for forming the insulated packaging is also provided.

What is claimed is: 
     
         1 . Insulated packaging comprising:
 an inner substrate;   an outer substrate attached to the inner substrate to form an air gap therebetween;   an expandable material comprising expandable microspheres disposed between the inner substrate and the outer substrate; and   an adhesive material different than the expandable material, the adhesive material disposed between the inner substrate and the outer substrate to attach the inner substrate to the outer substrate.   
     
     
         2 . The insulated packaging of  claim 1  wherein the expandable microspheres have an activation temperature not exceeding 190° F. 
     
     
         3 . The insulated packaging of  claim 1  wherein the adhesive material is a hot melt adhesive. 
     
     
         4 . The insulated packaging of  claim 1  wherein the inner and outer substrates are of a paper stock material. 
     
     
         5 . The insulated packaging of  claim 4  wherein the paper stock material is provided in roll or web form. 
     
     
         6 . The insulated packaging of  claim 5  wherein the paper stock material is flexible to be provided in roll or web form. 
     
     
         7 . The insulated packaging of  claim 4  wherein the paper stock material of the inner substrate is different from the paper stock material of the outer substrate. 
     
     
         8 . The insulated packaging of  claim 1  wherein the expandable material comprises expanded, non-ruptured microspheres with the inner substrate permanently attached to the outer substrate by the adhesive therebetween. 
     
     
         9 . The expandable packaging of  claim 1  wherein the attached inner and outer substrates having the expandable material and the different adhesive material therebetween are configured for forming an insulated bag. 
     
     
         10 . The expandable packaging of  claim 1  wherein the expandable material is disposed between the inner substrate and the outer substrate such that the expandable material engages both the inner substrate and the outer substrate.