Shipping Container With Compostable Insulation

Abstract

A shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a recyclable film formed primarily of paper. The recyclable film forms a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially, but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.

1 . A thermal insulation article for placement in a shipping container to hold an item, the system comprising:
 a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container while leaving an interior space to receive the item, wherein the thermally insulating pad includes:
 a solid compostable panel formed primarily of starch, the panel holding together as a single unit, the panel providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and 
 a recyclable film formed primarily of paper, the recyclable film forming a pocket enclosing the panel such that when positioned in the cavity of the rectangular prism shipping container adjacent a respective floor, side wall or cover, wherein the recyclable film wraps around the panel and provides both an interior surface of the pad facing the interior space and an exterior surface of the thermally insulating pad facing the respective floor, side wall or cover, and wherein the recyclable film is adhered to a portion of the panel that has become sticky by application of water to the starch. 
   
     
     
         2 . The thermal insulation article of  claim 1 , wherein the recyclable film is coated with a coating of one or more water-retardant materials. 
     
     
         3 . The thermal insulation article of  claim 2  wherein a thickness of the coating applied to the recyclable film is between about 0.001 and 0.090 inch. 
     
     
         4 . The thermal insulation article of  claim 3 , wherein the one or more water-retardant materials include water-resistant materials, water-repellent materials, and water-proof materials. 
     
     
         5 . The thermal insulation article of  claim 1 , wherein the recyclable film is substantially pure paper. 
     
     
         6 . The thermal insulation article of  claim 1 , wherein the recyclable film is formed primarily of paper mixed with one or more water-retardant materials. 
     
     
         7 . The thermal insulation article of  claim 6 , wherein a thickness of the recyclable film is between about 0.001 and 0.090 inch. 
     
     
         8 . The thermal insulation article of  claim 7 , wherein the one or more water-retardant materials include water-resistant materials, water-repellent materials, and water-proof materials. 
     
     
         9 . The thermal insulation article of  claim 1 , wherein the paper comprises a wood pulp paper. 
     
     
         10 . The thermal insulation article of  claim 1 , wherein the recyclable film forms the pocket enclosing the panel without being bonded to the panel. 
     
     
         11 . The thermal insulation article of  claim 10 , wherein an interior of the pocket is evacuated of air. 
     
     
         12 . The thermal insulation article of  claim 1 , wherein the panel is slidable within the pocket. 
     
     
         13 . The thermal insulation article of  claim 1 , wherein the starch comprises corn starch, wheat starch or milled sorghum. 
     
     
         14 . A method of fabricating an insulative insert for placement in a shipping container to hold an item, the method comprising:
 placing a solid compostable panel formed primarily of grain start between two sheets of recyclable film, the panel holding together as a single unit, wherein the two sheets of recyclable film are formed primarily of paper, wherein the recyclable film is adhered to the panel by applying water to the panel; and   heat sealing the two sheets such that the panel is enclosed in a pocket of recyclable film that completely surrounds the panel to form a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container.   
     
     
         15 . The method of  claim 14 , the method comprising:
 forming a plurality of thermally insulating pads according to the method of  claim 14 .   
     
     
         16 . The method of  claim 15 , further comprising a method of insulating a shipping container, the method of insulating a shipping container comprising:
 inserting the plurality of thermally insulating pads into a cavity of the shipping container such that each of the floor, plurality of side walls and cover of a box is adjacent to and covered by a pad from the plurality of thermally insulating pads and the plurality of thermally insulating pads provide an interior space to receive the item, and wherein each rectangular plate is dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent.