Barrier materials and containers made therefrom

Abstract

A barrier structure comprises: a first membrane substantially reflective of electromagnetic radiation; a second membrane spaced apart from the first membrane and bound to the first membrane about an edge thereof to form a bladder, the second membrane resistant to vapor transmission; and a fibrous insert disposed between the first membrane and the second membrane so as to maintain the spaced apart relationship, the fibrous insert defining a space holding an insulating medium resistant to the transmission of thermal energy and interspersed therethough. The first membrane may further comprise a multilayer composite and may include a polymer resistant to vapor transmission, for example including at least one of H 2 O, CO 2 and O 2 . The polymer may be a polyester. The multilayer composite may further comprise a structure substantially reflective of thermal energy. The composite may further comprise one or both of an outer metallization layer and an inner metallization layer. The composite may further comprise a sealing member. The sealing member may be a polyethylene layer. The fibrous insert may comprise randomly oriented fibers of plural deniers bonded together in a crush-resistant structure. The plural deniers may be within a range of 3 to 100 denier. The fibrous insert may further comprise an acrylic binder, an EVCL binder, a polyvinyl acetate (PVA) binder or other polymer binder and combinations thereof. The EVCL binder may be included in the fibrous insert as a percentage of material comprising the fibrous insert of about 35-75% w/w. The first membrane, the second membrane and the fibrous insert may all possess substantially similar melt flow indices. Also shown, a shipping container may comprise plural wall structures according to the thermal barrier structure described, disposed on at least two sides of a payload region, such as a box or envelope. The plural wall structures may be bonded together along at least one edge, for example to form a shipping envelope having an interior payload region surrounded by the bladders of the plural wall structures. The plural structures may further comprise a third membrane resistant to vapor transmission; and another fibrous insert disposed between the second membrane and the third membrane.

1 . A barrier structure, comprising: 
 a first membrane substantially reflective of electromagnetic radiation;    a second membrane spaced apart from the first membrane and bound to the first membrane about an edge thereof to form a bladder, the second membrane resistant to vapor transmission; and    a fibrous insert disposed between the first membrane and the second membrane so as to maintain the spaced apart relationship, the fibrous insert defining a still air space resistant to the transmission of electromagnetic radiation and interspersed therethough.    
   
   
       2 . The structure of  claim 1 , wherein the first membrane further comprises: 
 a multilayer composite.    
   
   
       3 . The structure of  claim 2 , wherein the composite includes a polymer resistant to vapor transmission.  
   
   
       4 . The structure of  claim 3 , wherein the vapor whose transmission the polymer resists includes at least one of H 2 O, CO 2  and O 2 .  
   
   
       5 . The structure of  claim 4 , wherein the polymer is a polyester.  
   
   
       6 . The structure of  claim 2 , wherein the multilayer composite further comprises: 
 a structure substantially reflective of thermal energy.    
   
   
       7 . The structure of  claim 6 , wherein the composite further comprises: 
 one of an outer metallization layer and an inner metallization layer.    
   
   
       8 . The structure of  claim 7 , wherein the composite further comprises: 
 another one of an outer metallization layer and an inner metallization layer.    
   
   
       9 . The structure of  claim 8 , wherein the composite further comprises: 
 a sealing member.    
   
   
       10 . The structure of  claim 9 , wherein the sealing member further comprises: 
 a polyethylene layer.    
   
   
       11 . The structure of  claim 10 , wherein the fibrous insert comprises: 
 randomly oriented fibers of plural deniers bonded together in a crush-resistant structure.    
   
   
       12 . The structure of  claim 11 , wherein the plural deniers are within a range of 3 to 100 denier.  
   
   
       13 . The structure of  claim 12 , wherein the fibrous insert further comprises: 
 at least one of an EVCL binder, an acrylic binder and a PVA binder.    
   
   
       14 . The structure of  claim 13 , wherein the fibrous insert further comprises: 
 an EVCL binder.    
   
   
       15 . The structure of  claim 14 , wherein the EVCL binder is included in the fibrous insert as a percentage of material comprising the fibrous insert of about 35-75% w/w.  
   
   
       16 . The structure of  claim 1 , wherein the first membrane, the second membrane and the fibrous insert all possess substantially similar melt flow indices.  
   
   
       17 . The structure of  claim 1 , wherein the second membrane comprises: 
 a corrosive inhibiting film.    
   
   
       18 . The structure of  claim 17 , wherein the corrosive inhibiting film comprises: 
 a reactive intercept barrier film.    
   
   
       19 . A shipping container comprising: 
 plural wall structures according to the thermal barrier structure of  claim 1 , disposed on at least two sides of a payload region.    
   
   
       20 . The shipping container according to  claim 19 , wherein the plural wall structures are bonded together along at least one edge.  
   
   
       21 . The shipping container according to  claim 20 , wherein the plural structures are bonded together to form a shipping envelope having an interior payload region surrounded by the bladders of the plural wall structures.  
   
   
       22 . The shipping container according to  claim 21 , wherein each of the plural structures further comprises: 
 a third membrane resistant to vapor transmission; and    another fibrous insert disposed between the second membrane and the third membrane.    
   
   
       23 . The shipping container according to  claim 19 , wherein the plural structures are incorporated in walls of a box structure.  
   
   
       24 . The structure of  claim 19 , wherein the one of the outer metallization layer and the inner metallization layer is capable of receiving a static electric discharge to the structure without damage to items carried therein.  
   
   
       25 . The structure of  claim 19 , wherein the second membranes of the plural barrier structures are adjacent a payload region, and the second membranes comprise: 
 a corrosive inhibiting film.    
   
   
       26 . The structure of  claim 25 , wherein the corrosive inhibiting film comprises: 
 a reactive intercept barrier film.    
   
   
       27 . An insert for a shipping container, the shipping container defined by an outer wall, the inset comprising: 
 an inner wall membrane resistant to vapor transmission and defining a payload space;    a fibrous insert disposed between the inner wall and the outer wall, so as to maintain the outer wall and the inner wall in a spaced-apart relationship, the fibrous insert defining a still air space resistant to the transmission of electromagnetic radiation and interspersed therethrough;    wherein closing the shipping container forms a bladder defined by the fibrous insert and the still air space which together surround the payload space.    
   
   
       28 . The insert of  claim 27 , wherein the fibrous insert further comprises: 
 randomly oriented fibers having plural denier within a range of 3 to 100 denier and the insert has a surface resistivity less than about 10 11  Ω/□.    
   
   
       29 . The insert of  claim 28 , wherein the fibers are at least one of polyethylene, polypropylene and polyester.  
   
   
       30 . The insert of  claim 29 , wherein the fibers are hollow.  
   
   
       31 . The insert of  claim 27 , wherein the fibrous insert further comprises: 
 a binder having at least one of anti-bacterial, anti-fungal and anti-static properties.    
   
   
       32 . The insert of  claim 31 , wherein the binder comprises EVCL.  
   
   
       33 . The insert of  claim 27 , wherein the inner wall membrane further comprises: 
 a corrosion inhibiting film.    
   
   
       34 . The insert of  claim 33 , wherein the corrosion inhibiting film comprises: 
 a reactive intercept barrier film.    
   
   
       35 . The insert of  claim 34 , wherein the reactive intercept barrier film comprises: 
 a reactive layer, reactive with inorganic ions; and    an absorber layer, absorptive of organic ions.    
   
   
       36 . The insert of  claim 35 , wherein the reactive intercept barrier film further comprises: 
 a composite including 
 a substrate resistant to transmission of H 2 O or O 2 ,  
 an outer layer of conductive carbon, forming the absorber layer, and  
 an inner layer of a material to which free ions are attracted, forming the reactive layer.  
   
   
   
       37 . The insert of  claim 36 , wherein the reactive intercept barrier film further comprises: 
 a metallized film on the outer layer of conductive carbon.    
   
   
       38 . The insert of  claim 36 , wherein the substrate further comprises: 
 polyethylene teraphthalate.