Shipping container for temperature-sensitive products using semi-rigid or flexible foam

Abstract

A shipping container or package for temperature-sensitive products that can ship in a collapsed or flat configuration made up of an unassembled corrugated container or box, laid flat to which is secured a rectangular sheet of semi-rigid or flexible foam that has had three (3) parallel grooves and both ends mitered into it so that the insulating sheet can be folded as the container or box is assembled, yet shipped flat.

1 . A package for temperature-sensitive products comprising: 
 an outside box;    a first rectangular piece of foam insulation, wherein two opposite sides of said rectangular piece are mitered at angles that add up to 90? or less, and wherein three notches whose angles add up to 90? or less, are formed in the insulation parallel to the mitered sides;    a top panel of foam insulation; and    a bottom panel of foam insulation, wherein the first piece, top panel, and bottom panel are sized to fit inside the outside box when assembled.    
   
   
       2 . The package of  claim 1 , wherein the foam is selected according to the criteria that the material must have adequate thermal barrier capability; the material must be stiff enough to hold its shape inside the box; the material must be resistant to moisture and dirt; the material must be non-toxic; the material must have low cost relative to EPS and vacuum bags; and the material must be flexible enough to conform to the shape of the box and for box joints to seal tightly.  
   
   
       3 . The package of  claim 1 , wherein the foam is made of a material selected from the group consisting of closed cell foam and open cell foam.  
   
   
       4 . The package of  claim 1 , the foam having a thickness between 1 inch and 3 inches.  
   
   
       5 . The package of  claim 1 , wherein the thickness of the foam is calculated to maintain the temperature of package contents below ambient temperature for at least 24 hours.  
   
   
       6 . The package of  claim 1 , wherein the thickness of the foam is calculated to maintain the temperature of package contents below ambient temperature for at least 24 hours.  
   
   
       7 . The package of  claim 1 , wherein the outside box is made of corrugated cardboard.  
   
   
       8 . The package of  claim 1 , wherein the gross weight of the package is less than 65 pounds.  
   
   
       9 . The package of  claim 1 , wherein the box and the foam are secured to each other.  
   
   
       10 . The package of  claim 9 , wherein the box and foam are secured to each other by at least one mechanism taken from the group consisting of adhesive and clips.  
   
   
       11 . The package of  claim 1 , wherein the foam is disposed upon the box, both in a flat position for shipping.  
   
   
       12 . The package of  claim 1 , wherein the foam is made of at least one selected from the group consisting of polyurethane and polyethylene.  
   
   
       13 . A method of making a package for temperature-sensitive products comprising the steps of: 
 providing a laid-out and unassembled box, having pre-formed folds;    providing insulating foam of a selected thickness;    cutting a rectangle out of the foam substantially the same size as four linear sides of the box;    cutting three parallel folding notches in the foam at angles adding up to about 90?or less; and    cutting two opposite ends of the rectangle parallel to the notches at angles that add up to 90?; and    securing the foam to the box.    
   
   
       14 . The method of  claim 13 , wherein the securing step is at least one taken from the group consisting of adhering and clipping.  
   
   
       15 . The method of  claim 13 , wherein cutting the three folding notches are positioned to align with the pre-formed folds of the box.  
   
   
       16 . The method of  claim 13 , further comprising the step of aligning the edges of the rectangular foam to the edges of the box before securing them.  
   
   
       17 . The method of  claim 13 , further comprising the step of bending each corner of the unassembled box and securing the edges to form a cube.  
   
   
       18 . The method of  claim 17 , further comprising the step of providing a rectangular piece of insulating foam for the top of the box and a rectangular piece of insulating foam for the bottom of the box.  
   
   
       19 . The method of  claim 18 , further comprising the step of securing a box top and a box bottom onto the box with the foam top and foam bottom enclosed.  
   
   
       20 . The method of  claim 13 , wherein the cutting step is performed with a mitering tool.