Method and Apparatus for Providing an Insulated Shipping Container

Abstract

Disclosed is an insulated shipping container for transporting temperature-controlled materials and method of making the same. In a preferred embodiment, the insulated shipping container comprises an outer box or housing and a plurality of insulated inserts configured to be snugly and removably received in the outer box or housing. The plurality of insulated inserts are shaped to define a rectangular cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps. The insulated inserts as well the outer box or housing of the disclosed device can be stored flat and reused.

I claim: 
     
         1 . An insulated shipping container for temperature-sensitive transport, the container comprising:
 an outer box or housing and a plurality of insulated inserts configured to be snugly and removably received in the outer box or housing;   the plurality of insulated inserts being shaped to define a rectangular cavity of the outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps;   each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides;   the polystyrene core further comprising a scoring at ends thereof to form a thermal packaging product when the core is encapsulated within a metallized polyethylene material; and   wherein the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.   
     
     
         2 . An insulated shipping insert for a temperature-sensitive transport container, the insulated insert comprising:
 a polystyrene core encapsulated within a metallized polyethylene material on all sides;   the insulated insert is removably inserted into a rectangular cavity of an outer box or housing, the cavity bounded by a bottom wall and a plurality of rectangular side walls and top closure flaps;   each of the plurality of insulated inserts comprising a polystyrene core encapsulated within a metallized polyethylene material on all sides;   the polystyrene core further comprising a scoring at ends thereof to form a thermal packaging product when the core is encapsulated within a metallized polyethylene material; and   wherein the thermal packaging product may bend or crack at a predetermined spot to minimize voids in packaging and to ensure a snug fit in the outer box or housing.   
     
     
         3 . A method of providing an insulated shipping container for temperature-sensitive transport, the method comprising the steps of:
 providing an outer box or housing;   removably inserting a first insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the insulated insert forms a bottom wall, a first rectangular side wall and a top closure flap; and   removably inserting a second insulated insert into a rectangular cavity of the outer box or housing, wherein a portion of the second insulated insert forms a second, third and fourth rectangular side wall, thereby creating all insulated cavity.   
     
     
         4 . The method of  claim 3  further comprising the step of inserting a transportable 
     
     
         5 . The method of  claim 3  further comprising the closing of the top closure flap to house a transportable item. 
     
     
         6 . The method of  claim 5  further comprising sealing the outer box or housing for shipment.