Shipping Container Packaging with Thermal Regulation

This application claims priority pursuant to Title 35 USC Sec. 119 (e) to U.S. Provisional Application Ser. No. 63/654,369 filed May 31, 2024, the entire context of which are hereby incorporated by reference herein as if fully set forth.

This disclosure relates to shipping container packaging for safe transport of articles, particularly liquid commodities in glass bottles. More particularly it relates to shipping container packaging arranged to maintain an acceptable thermal environment for the commodity during shipment.

The shipping container packaging disclosed in U.S. Pat. Nos. 8,434,620 and 8,844,718 has found significant commercial success in retail transport of bottles of wine. This arrangement is known to meet the requirements of “ISTA Test Procedure 1A-Standard” administrated by the International Safe Transportation Association (ISTA). The entire content of the disclosure and drawings of U.S. Pat. Nos. 8,434,620 and 8,844,718 are hereby incorporated herein by reference, as if fully set forth.

As shown from U.S. Pat. No. 6,910,582 product in shipping containers may be insulated from the surrounding environment and may also include heat absorption material internally of the surrounding carton. Such known packaging however, suffers in that the thermal material is isolated from the product containing articles with no direct heat transfer capability.

This disclosure provides shipping container packaging arranged with all structural protections afforded by the bottle shipment packaging of U.S. Pat. Nos. 8,434,620 and 8,844,718, as well as providing effective thermal regulation with thermally reactive material in direct heat transfer relation with the commodity being shipped.

Referring to the accompanying drawings, there is illustrated a shipping container packaging in accordance with the disclosure of prior U.S. Pat. Nos. 8,434,620 and 8,844,718. The illustrated container packaging is arranged to provide thermal regulation of the interior environment to ensure product integrity. As seen in, the shipping container packaging, designated, is housed in outer surrounding cardboard carton. The packaging ensures safe commercial transport of individual articles, here illustrated as bottlesof liquid, and additionally protects the payload (the liquid) against undesirable elevated temperatures. In this latter regard, the shipping container packaging is considered particularly suitable for shipping bottles containing wine. The shipping container packaging of the disclosure may, of course, be utilized for shipping any suitable commodity contained in a fragile vessel.

Turning now to the drawings where, whenever possible like reference numerals will refer to like elements. Cartonis generally rectangular with longitudinal side wallsand transverse or lateral side walls. Top and bottom walls of the cartonare bound by closure of movable major flapsand minor flaps. The flaps are ultimately sealed with removeable tape (not shown) to close the cartonfor shipping.

The interior surfaces of carton side wallsandand the carton walls formed by top and bottom flapsandare lined with insulation to reduce heat transfer through the carton. Any sustainable insulation, common to commodity packaging is considered appropriate. For example, ClimaCell a product of TemperPack, is considered suitable. ClimaCell and TemperPack are registered trademarks of Temperpack Technologies, Inc., Richmond, VA.

In the illustrated embodiment this is accomplished with two segmentsandof flexible insulation batting. Approximately 1 inch thick, the flexible material segments are formed into engaged “U” shapes positioned against the interior surfaces of carton. One such segmentis arranged to cover the flapsandforming the bottom and top walls of the carton, and one vertical lateral side wall. The other segmentis sized and oriented within the cartonto cover one side walland the two longitudinal side walls. The flexibility of the insulation batting segments permits access to the bottleson opening of the flapsandat the top wall of the carton.

The shipping container packaging, as described in prior U.S. Pat. Nos. 8,434,620 and 8,844,718 the disclosures of which are fully incorporated by reference herein, includes top trayconfigured to secure and support the articles. There is further provided a bottom tray, configured to support individual articlesin a spaced apart configuration. The traysandof the disclosure, made of molded pulp fiber are vertically separated by divider assembly.

As seen in, top trayhas a perimeter edgesized for slight interference fit with the inner surface of insulating batting segmentsandlining the walls of carton. It includes twelve (12) upper article or bottle receiving chambers defined by generally conical cup-like wallsterminating in endsarranged for contact with the inner surface of insulation batting segmentextending under the top wall of cartonformed by major flapsand minor flaps. Each endincludes a crushable protrusion, seen inassociated with the top of each bottleto absorb loads imparted by forces incurred during shipping.

As described in the above-mentioned patents, top trayincludes structural elements to sustain the top tray against loads imparted during transport. Best seen in, top trayincludes pillarspositioned along perimeter edgeand between and conical wallshaving contact surfacesfor load transferring contact with the interior surface of insulation batting segment.

Shown in, the opposite ends of pillars, are formed with intersecting channelsaligned to engage with divider assemblyas discussed further below. Channelsare best seen in.

Bottom tray, best seen in, has a perimeter edgesized for slight interference fit with the inner surface of batting segmentsandlining wall of carton. It includes twelve (12) article or bottle receiving chambersdefined by generally cylindrical cup-like wallseach with a bottom wall. In an assembled shipping containerbottom wallsare supported upon the inner surface of insulation battingpositioned over major flapsand minor flapsforming the bottom wall of the carton. Each top wallincludes a crushable circular protrusion, seen into absorb loads imparted to bottlesduring shipping.

As described in prior U.S. Pat. Nos. 8,434,620 and 8,844,718 bottom trayincludes adequate structural elements to sustain the bottom tray against loads imparted during transport of the shipping container. Best seen in, bottom trayincludes pillarsalong perimeter edgeand between and conical wallshaving contact surfacesfor load transferring contact with the interior surface of insulation batting segment.

Shown in, the opposite ends of pillars, are formed with intersecting channelsaligned to engage with divider assemblyas discussed further below.

Integrated between molded pulp formed top trayand bottom tray, divider assemblyprovides columnar strength to shipping container packaging. Made of cardboard, with flutes running horizontally, longitudinal and lateral divider panelsandisolate the product containing bottlesfrom the adverse effects of shipping and handling mishaps. In this disclosure, the divider panelsanddelineate separate voids or chambers designatedinthat separately surround each article or bottle.

With reference to, the illustrated embodiment includes two longitudinal divider panelsextending horizontally between vertical edges. The vertical edges contact the inner surface of insulation batting segmentsandadjacent opposing lateral side walls. The longitudinal divider panels extend vertically between horizontal edgesdisposed in channelsandformed by top trayand bottom tray.

As seen in, longitudinal divider wallsinclude a central vertical narrow slothaving a width about the thickness of the cardboard divider panels, extending vertically from top edgeto about midway of the panel. Slotincludes “T” shaped slitat its distal end and resides in, and engages with lateral divider panelas discussed further below.

In addition, longitudinal divider panelsinclude wide slotsextending vertically from an upper horizontal edgehaving bottom edgesdisposed nearly to, but spaced from lower or bottom edge. The wide slots having a width discussed below, are spaced from central lateral panel narrow slotin alignment with channelsandof top and bottom traysand.

In the illustrated embodiment, with reference to, divider assemblyincludes one lateral, or transverse divider panelextending laterally between vertical edgesin contact with the inner surface of insulation batting segmentoverlying longitudinal side wallsof carton. Divider panelextends vertically between upper and lower horizontal edgesdisposed in channelsandof top trayand bottom trayas seen in.

Referring to, lateral divider panelinclude a pair of narrow slotsextending from lower or bottom horizontal edgeupward to about midway of the panel. Slotsmay include “T” shaped slitsat their distal end. The slots are positioned to engage narrow slotsand slitin longitudinal divider panelsto maintain lateral spacing of longitudinal divider panelswithin divider assembly.

In accordance with the disclosure and with reference to, divider assemblyincludes thermal regulation elementssupported within wide slotsof longitudinal divider panels. Thermal regulation elementsextend between vertical edgesand horizontal upper and lower horizontal edgesto define vertical planar heat transfer surfaces.

As shown in, thermal regulation elements, reside in wide slotsof longitudinal divider panels. In the embodiment of, vertical edgescontact the inner surface of insulation batting segmentcovering longitudinal side wallsof cartons. Lower horizontal edgeof thermal regulation elementsis in supporting contact with the bottom edgeof wide slotsof longitudinal divider panels. Upper horizontal edgeis in contact with aligned channelsof top tray.

As illustrated, particularly in, assembled divider assemblydivides the space or volume between top trayand bottom trayinto voids or chamberssurrounding a major portion of each of the product containing articles or bottles. Significantly each such void or chamberis partially defined by a portion of a vertical planar heat transfer surfaceof thermal regulation elements. Thus, there exists direct, un-obstructed radiant heat transfer between thermal regulation elementsand each articlewithin shipping container. This relationship, with direct exposure of each bottleto an associated heat transfer surfacemaximizes effectiveness of the thermal regulation elementsas well as providing for direct exposure of the articles being shipped to the thermal regulation elements.

Any suitable thermal regulation elementmay be employed. For example, Glacier Foam Bricks, foam-filled refrigerant blocks from Pelton Shepherd Industries, Stockton, CA have been found effective. In the embodiment illustrated, the thermal regulation element may have the following approximate dimensions: height 7½ inches, width 13¾ inches, depth 1 inch. Each thermal regulation element may include a quantity of refrigerant, for example fifty-two (52) ounces. The illustrated foam bricks are a water based semi-solid that maintain their shape during freezing and thawing and contribute to the structural rigidity of the divider assembly. It is also contemplated that “phase-change” material may be successfully used to form the thermal regulation element.

In the embodiment illustrated, the shipping container packaging is configured to receive twelve (12) bottles within the twelve voidsdefined by the divider assembly. The disclosure is merely illustrative, and not limiting. As can be appreciated, the shipping container packagingcan be configured for 6, 9 or 15 bottles without departing form the principles of the disclosure. Moreover, the protected product need not be wine. The disclosed shipping container packaging is useful to provide the disclosed benefits to articles shipped to, or within elevated temperature environments.

illustrates a slightly modified configuration of the disclosed arrangement. For ease of understanding, pulp formed top trayis not shown.

generally illustrates the assemblyas seen inwith the insulation batting segmentsandeliminated. That is to say, the wallsandof cartondirectly surround the top and bottom traysandand interposed divider assembly. The shipping container packaging is unchanged, and as illustrated, retains and protects liquid containing bottlesin voidsas previously described above. Such an arrangement, complete in the manner disclosed herein except with the absence of internal insulation batting elementsand, is deemed suitable to provide safe transit with adequate thermal regulation advantages in less arduous environments.

Turning now tothere is illustrated a modified form of the shipping container packaging of the present disclosure. Here there is illustrated a configuration for shipping six (6) articles with the advantageous features of structural integrity disclosed in U.S. Pat. Nos. 8,434,620 and 8,844,718 as well as providing the thermal regulation advantages of the present disclosure.

show a carton, having longitudinal side wallsand transverse or lateral side wallsdefining a space to receive shipping container packaging. Cartonincludes top and bottom closure flaps similar to the cartonof the embodiment ofbut not shown here for ease of description.

Flexible insulation batting segmentsandmay be positioned within cartonsubstantially is illustrated. A top portion of segmentmay be raised to a vertical position to provide access to the interior of the carton. (Top portion of segmentis cutaway for ease of description) When fully assembled, and the cartonclosed, the insulation battingandcompletely surround the shipping container packagingand the articlesshipped within carton. Optionally, for shipments to less demanding environments a carton, such as illustrated inmay be employed with the shipping container packagingin direct contact with carton wallsand.

As illustrated, a pulp-formed bottom trayis similar in configuration to bottom traybut sized to receive six (6) articles for transit rather than twelve (12). A top tray, not shown, is also a component of shipping container packaging. It is similar in structure and function to top traybut, again, sized to transport six (6) articles.

As best illustrated in, a divider assemblyextends between the top tray and bottom trayand in functionally equivalent to the divider assemblyof. Divider assemblydivides the space between top trayand bottom trayinto six (6) article surrounding chambers or voids.

In this embodiment the divider assembly has a simplified configuration. Divider assemblycomprises a unitary cardboard sheet having two lateral divider portionsjoined by a central webwhich, when installed, resides against insulation battingalong longitudinal side wallof carton.

The lateral divider portionsare formed by bending the divider portionsninety degrees (90°) at dashed lines, at central web. (See) Divider portionshave a length to extend to insulation battingalong opposite longitudinal side wallsof the carton. The vertical heights of divider portionsin such that they extend between the top tray and bottom traydividing the intervening space into three separate sections. Each divider portionincludes a vertical slotopen adjacent its top end and terminating at a bottom edge. The slotsare equidistant between longitudinal side wallsof carton.

In accordance with the disclosure, a thermal regulation elementis held in slotsof divider portionsand extends between insulation batting segmentsandalong lateral side wallsof carton. It is sized to extend between top tray and bottom tray. Thermal regulation elementpresents a vertical planar heat transfer surfaceon each vertical side wall, and with divider portionsdivides the space within the interior of the carton between top tray and bottom trayinto six (6) article surrounding chambers or voidssurrounding a major portion of each product containing article. Significantly each such chamberis partially defined by a portion of a vertical planar heat transfer surfaceof thermal regulation element. This relationship provides for direct radiant heat transfer between the contained articlesand the thermal regulation element.

In this embodiment, seen inthe thermal regulation elementmay have dimensions substantially the same as the thermal regulation elementof the embodiment of. Notably, the embodiment illustrated may also be used in a carton such as illustrated inwhere no insulation battingoris present.

In an exemplary process, product containing articles such as bottles of wine, possibly 750 mL are often shipped to consumers from distribution centers. Shipments may include delivery into environments where ambient temperature of 100° F. or more exist. The length of time a loaded carton may reside in transit may be two (2) to three (3) days. As an example, to load a shipment, a carton, such as cartonofis unfolded from a flattened condition and the bottom longitudinal major flapsand lateral minor flapsfolded together and sealed in place.

Flexible insulation batting segmentsandmay be first positioned within cartonsubstantially is illustrated inwith one segmentfolded vertically to provide access to the interior of the carton. A top portion of segmentmay be raised to a vertical position to provide access to the interior of the carton. When fully assembled, and the cartonclosed, the insulation battingandcompletely surrounds the shipping container packagingand the articlesshipped within carton. Optionally, for shipments to less demanding environments, a carton, such as illustrated inmay be employed with the shipping container packagingin direct contact with carton wallsand.

A bottom trayis placed into the carton adjacent the assembled bottom cardboard flaps supported upon insulation segment. A divider assembly, including interconnected cardboard longitudinal divider panelsand lateral divider panelmay be inserted with bottom edges supported in channelof bottom tray. Twelve articles in the form of bottlescontaining wine or other liquid may then be inserted, one in each article surrounding chamber.

Thermal regulation elementsnormally stored at about zero degrees Fahrenheit (0° F.) may then be inserted into wide slotsin longitudinal divider panels. The thermal regulation panels rest upon bottom edgesof slotsand extend upwardly to the horizontal edgeof each divider panel.

When so positioned each article surrounding chamberincludes a portion of the vertical planar heat transfer wall surfaceof one of the thermal regulation elements. These surfaces reside in direct radiant heat transfer relation to the articles.

The top trayof the shipping container packagingmay then be positioned above the divider assemblywith the vertical edgesof longitudinal divider panelsandof lateral divider panelpositioned within channels. The portion of insulated segmentmay then be folded to a horizontal position covering the top of top tray. Flapsandat the top of cartonmay then be closed and sealed making the cartonand its contents, articles, ready for shipment.

The mechanisms disclosed herein and the processes involved include some well known components, features and operating parameters commonly associated with article shipping containers. Though not specifically discussed, or shown in the accompanying drawings, these elements are considered inherent to the disclosure and fully understood by persons of ordinary skill in the art.

Various features of the present invention have been described with reference to the illustrative embodiments. It should be understood, however, that modifications may be made without departing from the scope of the disclosed subject matter.

Preferred embodiments of this invention are described therein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.