One-piece insulating container

Abstract

A one-piece insulating container is provided. The container is formed from a container template that includes a generally flat case blank and an insulation template secured to the case blank. The case blank and insulation template may be folded simultaneously to form the three-dimensional container. The insulation template is designed to cushion and insulate an interior volume defined by the formed case blank. When folding, the insulation template conforms to the shape of the folded case blank. The case blank and insulation template may thus be manipulated in tandem to provide a completely enclosed space that is insulated on all sides. The dimensions of the case blank and insulation template may be adjusted to establish containers of varying sizes and dimensions.

What is claimed is: 
     
         1 ) A container template for foldably forming a container having an insulated and cushioned interior, said container template comprising:
 a generally flat case blank adapted to foldably form a three-dimensional container having interior surfaces when folded, wherein the case blank has four sections arranged in a row, wherein each section comprises a side wall subsection and opposing flaps attached to each side wall subsection; and   an insulation template secured to one side of the case blank and shaped to cover the side wall subsections of all four sections and to cover two opposing flaps of one of the four sections, wherein the insulation template is adapted to fold simultaneously with the case blank so that the insulation template covers all interior surfaces of the three-dimensional container when folded.   
     
     
         2 ) The container template of  claim 1 , wherein the insulation template is secured to the case blank by an adhesive. 
     
     
         3 ) The container template of  claim 1 , wherein the insulation template comprises fibers contained within an encapsulating material. 
     
     
         4 ) The container template of  claim 3 , wherein the insulation template further comprises temperature-control elements contained within the encapsulating material. 
     
     
         5 ) The container template of  claim 1 , wherein an end side wall subsection of the case blank has an adhesive tab attached thereto and configured to secure the end side wall subsection to which the adhesive tab is attached to an opposing end side wall subsection. 
     
     
         6 ) A method of forming an insulated container, said method comprising the steps of:
 providing a generally flat case blank adapted to foldably form a three-dimensional container having interior surfaces when folded, wherein the case blank has four sections arranged in a row, wherein each section comprises a side wall subsection and opposing flaps attached to each side wall subsection;   providing a foldable insulation template shaped to cover the side wall subsections of all four sections and to cover two opposing flaps of one of the four sections;   securing the insulation template to one side of the case blank in a position in which the insulation template covers the side wall subsections of all four sections of the case blank and covers two opposing flaps of one of the four sections; and   folding the case blank and the insulation template simultaneously, after the step of securing the insulation template to one side of the case blank, to form a three-dimensional container in which all interior surfaces of the three-dimensional container are covered by the insulation template.   
     
     
         7 ) The method of  claim 6 , wherein the step of securing the insulation template to one side of the case blank comprises applying an adhesive to the case blank or to the insulation template. 
     
     
         8 ) The method of  claim 6 , wherein the insulation template comprises fibers contained within an encapsulating material. 
     
     
         9 ) The method of  claim 8 , wherein the insulation template further comprises temperature-control elements contained within the encapsulating material, and the step of providing an insulation template comprises installing the temperature-control elements within the encapsulating material. 
     
     
         10 ) The method of  claim 6 , wherein an end side wall subsection of the case blank has an adhesive tab attached thereto and configured to secure the end side wall subsection to which the adhesive tab is attached to an opposing end side wall subsection, further comprising the step of securing the end side wall subsection to which the adhesive tab is attached to the opposing end side wall subsection with the adhesive tab.