Shipping system for storing and/or transporting temperature-sensitive materials

Abstract

Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls and bottom and top closure flaps. An insulation unit is positioned within the outer box. The insulation unit includes a base and a lid assembly hingedly connected to the base. The base includes vacuum insulated panels arranged to define a cavity and an inner shield mounted within the cavity. The lid assembly includes a support hingedly connected to the base. A vacuum insulated panel and a protective cover are mounted on a bottom surface of the support. A compressible pad is mounted on a top surface of the support, and a cover sheet is mounted over the compressible pad. The cover sheet includes an integral handle. A plurality of temperature-control members and a product box may be removably positioned in a cavity defined by the inner shield.

What is claimed is: 
     
         1 . A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising:
 (a) an insulation unit, the insulation unit comprising
 (i) a base, the base comprising one or more base vacuum insulated panels configured to define a base cavity bounded by a bottom wall, one or more side walls, and an open top; and 
 (ii) a lid assembly, the lid assembly comprising a lid vacuum insulated panel and a lid support, the lid support comprising a sheet folded to comprise a first portion and a second portion, the first portion being secured to one of the one or more side walls of the base, the second portion being secured to the lid vacuum insulated panel and being movable relative to the first portion between a first position in which the base cavity is open and a second position in which the base cavity is closed by the lid assembly; 
   (b) a product box, the product box removably disposed within the base cavity; and   (c) one or more temperature-control members removably disposed within the base cavity.   
     
     
         2 . The shipping system as claimed in  claim 1  further comprising an outer box, the outer box comprising a box cavity bounded by at least one side wall, at least one bottom closure flap, and at least one top closure flap, and wherein the base and the lid assembly of the insulation unit are removably disposed within the box cavity of the outer box. 
     
     
         3 . The shipping system as claimed in  claim 2  wherein the lid vacuum insulated panel is secured to a bottom surface of the second portion of the lid support and wherein the lid assembly further comprises a compressible pad, the compressible pad being secured to a top surface of the second portion of the lid support. 
     
     
         4 . The shipping system as claimed in  claim 3  wherein the lid assembly further comprises a pad cover, the pad cover being secured to a top surface of the compressible pad. 
     
     
         5 . The shipping system as claimed in  claim 4  wherein the pad cover is shaped to include an integral handle. 
     
     
         6 . The shipping system as claimed in  claim 5  wherein the integral handle comprises a hinged tab having a cutout. 
     
     
         7 . The shipping system as claimed in  claim 6  wherein the compressible pad comprises a recess and wherein the recess is aligned with the cutout of the pad cover. 
     
     
         8 . The shipping system as claimed in  claim 4  wherein the lid assembly further comprises a lid cover, the lid cover covering a bottom surface of the lid vacuum insulated panel. 
     
     
         9 . The shipping system as claimed in  claim 8  wherein the lid assembly is dimensioned so that the pad cover engages the at least one top closure flap of the outer box when the at least one top closure flap is closed, thereby ensuring that the lid cover fully closes the base cavity. 
     
     
         10 . The shipping system as claimed in  claim 2  wherein the insulation unit further comprises a shock absorbance pad and wherein the shock absorbance pad is positioned in the outer box below the base. 
     
     
         11 . The shipping system as claimed in  claim 1  wherein the first portion of the lid support is removably secured to the base. 
     
     
         12 . The shipping system as claimed in  claim 1  wherein the one or more base vacuum insulated panels comprise a bottom vacuum insulated panel and four side vacuum insulated panels, the four side vacuum insulated panels being disposed on top of the bottom vacuum insulated panel. 
     
     
         13 . The shipping system as claimed in  claim 12  wherein the base further comprises one or more binding members encircling the four side vacuum insulated panels. 
     
     
         14 . The shipping system as claimed in  claim 13  wherein the one or more binding members comprise one or more elastic bands. 
     
     
         15 . The shipping system as claimed in  claim 13  wherein the one or more binding members comprise a strip of stretch tape. 
     
     
         16 . The shipping system as claimed in  claim 13  wherein the base further comprises a base support, wherein the base support is shaped to comprise a central portion and four side portions, wherein the central portion is disposed under the bottom vacuum insulated panel, and wherein the four side portions are disposed between the four side vacuum insulated panels and the one or more binding members. 
     
     
         17 . The shipping system as claimed in  claim 16  wherein the base further comprises a plurality of corner boards, wherein the base support has a plurality of corners, and wherein one of the corner boards is positioned at each corner of the base support between the base support and the one or more binding members. 
     
     
         18 . The shipping system as claimed in  claim 16  wherein the base further comprises a shock absorbance pad and wherein the shock absorbance pad is positioned between the bottom vacuum insulated panel and the base support. 
     
     
         19 . The shipping system as claimed in  claim 13  wherein the base further comprises an inner shield, wherein the inner shield is removably disposed in the base cavity, and wherein the product box and the one or more temperature-control members are removably disposed within a space defined by the inner shield. 
     
     
         20 . The shipping system as claimed in  claim 1  wherein the first portion of the sheet and the second portion of the sheet are separated only by a single crease. 
     
     
         21 . The shipping system as claimed in  claim 1  wherein the first portion of the sheet and the second portion of the sheet are separated by a pair of creases forming a hinge. 
     
     
         22 . A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising:
 (a) an insulation unit, the insulation unit comprising
 (i) a base, the base comprising one or more base vacuum insulated panels configured to define a base cavity bounded by a bottom wall, one or more side walls, and an open top; and 
 (ii) a lid assembly, the lid assembly being pivotally mounted on the base to selectively cover and uncover the base cavity, the lid assembly comprising
 (A) a lid vacuum insulated panel, the lid vacuum insulated panel having a top surface and a bottom surface; 
 (B) a first cover, the first cover positioned over and coupled to the top surface of the lid vacuum insulated panel, wherein the first cover is shaped to include an integral handle; 
 
   (b) a product box, the product box removably disposed within the base cavity; and   (c) one or more temperature-control members removably disposed within the base cavity.   
     
     
         23 . The shipping system as claimed in  claim 22  wherein the integral handle comprises a hinged tab having a cutout. 
     
     
         24 . The shipping system as claimed in  claim 23  wherein the lid assembly further comprises a compressible pad, the compressible pad being disposed between the lid vacuum insulated panel and the first cover. 
     
     
         25 . The shipping system as claimed in  claim 24  wherein the compressible pad comprises a recess and wherein the recess is aligned with the cutout of the first cover. 
     
     
         26 . The shipping system as claimed in  claim 22  wherein the lid assembly further comprises a second cover, the second cover covering the bottom surface of the lid vacuum insulated panel. 
     
     
         27 . The shipping system as claimed in  claim 26  further comprising an outer box, the outer box comprising a box cavity bounded by at least one side wall, at least one bottom closure flap, and at least one top closure flap, and wherein the base and the lid assembly of the insulation unit are removably disposed within the box cavity of the outer box. 
     
     
         28 . The shipping system as claimed in  claim 27  wherein the lid assembly is dimensioned so that the first cover engages the at least one top closure flap of the outer box when the at least one top closure flap is closed, thereby ensuring that the second cover fully closes the base cavity. 
     
     
         29 . The shipping system as claimed in  claim 22  wherein the lid assembly further comprises a support, the support comprising a first portion and a second portion, the first portion being secured to one of the one or more side walls of the base, the second portion being positioned between and secured to each of the lid vacuum insulated panel and the first cover. 
     
     
         30 . The shipping system as claimed in  claim 29  wherein the first portion of the support and the second portion of the support are separated only by a single crease. 
     
     
         31 . The shipping system as claimed in  claim 29  wherein the first portion of the support and the second portion of the support are separated by a pair of creases forming a hinge.