Sustainable insulated shipper pack assembly

Abstract

A sustainable insulated shipper pack assembly to transport temperature sensitive and perishable items such as food, pharmaceuticals, and medical specimens within a consistent temperature range for an extended period of time. The assembly is made of entirely recyclable materials to enable curbside recycling, such materials included for example cellulose, cardboard, corrugated cardboard, and paper-based insulation, and materials preferably made from postconsumer paper, and other environmentally friendly materials The insulated shipper pack assembly comprises an outer container, an intermediate sleeve, an inner tray, bottom insulation pad, side insulation pads, and a lid with a top insulation pad. The components of the shipper pack assembly are configured to form a close fit with one another to eliminate or significantly reduce the possibility of exposed gaps between components and between the insulation materials to minimize or eliminate temperature loss from gaps or edge loss from the contents being transported or stored.

What is claimed is: 
     
         1 . A sustainable insulated shipper pack assembly, the assembly comprising:
 an outer container having a top, a bottom, and sides, the outer container having a plurality of bottom panels foldable to form the bottom of the outer container, a plurality of side panels forming the sides and surrounding an interior of the outer container, the interior being accessible from the top of the outer container, and a plurality of top panels foldable to close the top of the outer container;   a bottom insulation pad, the size and shape of the bottom insulation pad corresponding to the size and shape of the bottom of interior of the outer container;   an intermediate sleeve sized and configured to be inserted within the interior of the outer container, the intermediate sleeve having an interior space defined by internal facing sides of the intermediate sleeve;   a side insulation pad sized and configured to be inserted into the interior space and along the internal facing sides of the intermediate sleeve;   an inner tray having a bottom and sides surrounding a content receiving cavity, the inner tray being sized and configured to be inserted into the interior space of the inner space, the side insulation pad being positioned between the intermediate sleeve and the inner tray;   a lid having an interior area; and   a top insulation pad contained within the interior area of the lid.   
     
     
         2 . The insulated shipper pack assembly of  claim 1 , wherein the side insulation pad has a generally rectangular shape with free ends. 
     
     
         3 . The insulated shipper pack assembly of  claim 1 , wherein the side insulation pad has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 37 in. to 74¾ in., and a width of approximately 16⅜ in. 
     
     
         4 . The insulated shipper pack assembly of  claim 1 , wherein the bottom insulation pad fits against the interior facing surfaces of the sides and into the corners of the interior of the outer container to minimize air gaps between the bottom insulation pad and the sides and ensures a tight seal against gaps or edge loss to minimize or eliminate temperature loss from within the insulated shipper pack assembly. 
     
     
         5 . The insulated shipper pack assembly of  claim 1 , wherein the close tolerance of the side insulation pad between the sides of the outer container and the intermediate sleeve functions to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly. 
     
     
         6 . The insulated shipper pack assembly of  claim 1 , wherein the bottom insulation pad is a rectangle and corresponds to the shape of the interior of the intermediate sleeve. 
     
     
         7 . The insulated shipper pack assembly of  claim 1 , wherein the bottom insulation pad, the side insulation pad, and the top insulation pad are made of a recyclable material. 
     
     
         8 . The insulated shipper pack assembly of  claim 7 , wherein the insulation material is a two-piece pre-consumer paper insulation adhered between two paper layers best suited for applications where temperature control is critical during transportation and can be discarded in curbside recycle bins. 
     
     
         9 . The insulated shipper pack assembly of  claim 7 , wherein the insulation material includes at least one of cellulose, cotton/denim jute, starch, hemp, and PET recycled plastic. 
     
     
         10 . The insulated shipper pack assembly of  claim 1 , wherein the inner tray is made of a recyclable corrugated cardboard or other recyclable materials. 
     
     
         11 . The insulated shipper pack assembly of  claim 1 , wherein the inner tray is formed of a plurality of bottom panels forming the bottom of the inner tray, a plurality of top panels including a plurality of scored sections that allow the top panels to be bent or folded along the score line to be positioned over and to cover a portion of the side insulation pad. 
     
     
         12 . The insulated shipper pack assembly of  claim 10 , wherein the inner tray is inserted into the intermediate sleeve with the side insulation pad installed therebetween, the intermediate sleeve fits tightly against interior facing surfaces of the sides of the outer container and into the interior of the outer container to minimize air gaps between the intermediate sleeve and the sides of the outer container. 
     
     
         13 . The insulated shipper pack assembly of  claim 12 , wherein the inner tray fits tightly against the interior facing surfaces of the side insulation pad to snugly hold the side insulation pad between the intermediate sleeve and the inner tray. 
     
     
         14 . The insulated shipper pack assembly of  claim 12 , wherein a close tolerance between the inner tray, insulation pad, and the intermediate sleeve, and a close tolerance between the intermediate sleeve and the outer container function to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly. 
     
     
         15 . The insulated shipper pack assembly of  claim 12 , wherein the insertion of the inner tray into the intermediate sleeve creates a double-walled structure with the side insulation pad therebetween to further enhance the insulating capability to maintain a desired temperature range within the interior of the outer container. 
     
     
         16 . The insulated shipper pack assembly of  claim 1 , wherein the lid is a rectangular box having a top, bottom, sides, and ends surrounding the interior area, the lid have a flap to cover the ends of the lid. 
     
     
         17 . The insulated shipper pack assembly of  claim 1 , wherein the top insulation pad has a thickness of approximately 0.5 in. to 1.5 in., a length of approximately 20¼ in., and a width of approximately 19⅜ in. 
     
     
         18 . The insulated shipper pack assembly of  claim 1 , wherein the top insulation pad is placed inside the lid, the lid is securely placed on top of the inner container and inserted inside the outer container, the lid closes a top content-receiving cavity of the inner tray and functions as an insulated cover for the top of the outer container. 
     
     
         19 . The insulated shipper pack assembly of  claim 1 , wherein the lid containing the top insulation pad is fitted against the interior facing surfaces of the sides and into the corners of the interior of the outer container to minimize air gaps between the lid and sides of the outer container and to minimize any unwanted temperature gain or loss for the contents of the insulated shipper pack assembly. 
     
     
         20 . The insulated shipper pack assembly of  claim 1 , wherein the top panels of the outer container are folded to close the top of the outer container.