Shipping product with thermal and mechanical insulation features

Abstract

A fillable gel pack includes a first film layer having an area and a liquid permeable layer bonded in a region equal to or smaller than the area of the first film layer to define a gel chamber. The fillable gel pack also includes a gel material in dry or powdered form disposed in the gel chamber and a second film layer bonded to at least a portion of the liquid permeable layer or the first film layer to define a liquid chamber.

What is claimed is: 
     
         1 . A fillable gel pack comprising:
 a first film layer having an area;   a liquid permeable layer bonded to a region of the first film layer equal to or smaller than the area of the first film layer to define a gel chamber;   a gel material in powder form disposed in the gel chamber; and   a second film layer bonded to at least a portion of the liquid permeable layer or the first film layer to define a liquid chamber.   
     
     
         2 . The fillable gel pack of  claim 1  wherein the first film layer, the liquid permeable layer, and the second film layer are heat sealed to define the gel chamber and the liquid chamber. 
     
     
         3 . The fillable gel pack of  claim 1  wherein the liquid chamber includes a fill port disposed between at least one of the first film layer or the liquid permeable layer and the second film layer. 
     
     
         4 . The fillable gel pack of  claim 1  wherein the first film layer comprises a bottom film layer. 
     
     
         5 . The fillable gel pack of  claim 1  wherein the second film layer comprises a top film layer. 
     
     
         6 . The fillable gel pack of  claim 1  wherein at least one of the first film layer or the second film layer comprise a multilayer stack. 
     
     
         7 . The fillable gel pack of  claim 6  wherein the multilayer stack comprises at least two different layers of polyethylene. 
     
     
         8 . A fillable gel pack, comprising:
 a first non-permeable layer;   a second non-permeable layer coupled with the first non-permeable layer, the first and second non-permeable layers cooperating to define both an exterior surface of the fillable gel pack and an opening leading into a first interior portion of the fillable gel pack;   a powdered gel material carried within a second interior portion of the fillable gel pack; and   a liquid permeable layer disposed within the fillable gel pack that forms a barrier between the first and second interior portions of the fillable gel pack.   
     
     
         9 . The fillable gel pack as recited in  claim 8 , wherein a peripheral portion of the liquid permeable layer is heat sealed to peripheral portions of both the first and second non-permeable layers. 
     
     
         10 . The fillable gel pack as recited in  claim 9 , wherein the first and second non-permeable layers comprises polymer film layers that are not permeable to liquid water. 
     
     
         11 . The fillable gel pack as recited in  claim 8 , wherein the liquid permeable layer comprises polypropylene. 
     
     
         12 . The fillable gel pack as recited in  claim 8 , wherein the powdered gel material is adhesively coupled with the liquid permeable layer. 
     
     
         13 . The fillable gel pack as recited in  claim 8 , wherein the powdered gel material comprises a polymer or copolymer containing acrylic acid or acrylamide monomers. 
     
     
         14 . The fillable gel pack as recited in  claim 8 , wherein the second interior portion is defined by the liquid permeable layer and the second non-permeable layer. 
     
     
         15 . The fillable gel pack as recited in  claim 14 , wherein the first non-permeable layer defines a cutout region that enlarges the opening leading into the first interior portion. 
     
     
         16 . A fillable gel pack, comprising:
 a first film layer;   a second film layer joined to the first film layer to form an interior volume;   a fill port defined by one or both of the first film layer and the second film layer; and   a liquid permeable layer disposed within the interior volume that separates the interior volume into a first region and a second region, the first region being in communication with an exterior environment through the fill port.   
     
     
         17 . The fillable gel pack as recited in  claim 16 , wherein the fill port is defined only be the first film layer and wherein the liquid permeable layer is coupled to an interior facing surface of the first film layer and is disposed across the fill port. 
     
     
         18 . The fillable gel pack as recited in  claim 16 , wherein the fill port is defined by both the first film layer and the second film layer. 
     
     
         19 . The fillable gel pack as recited in  claim 18 , wherein the liquid permeable layer is folded so that an open end of the liquid permeable layer is oriented towards the fill port and a creased end of the liquid permeable layer is oriented towards the bottom of the interior volume. 
     
     
         20 . The fillable gel pack as recited in  claim 16 , wherein the liquid permeable layer is substantially the same size as both the first film layer and the second film layer.