Thermally insulating packaging

Abstract

A thermally insulating packaging to hold an item includes a solid compostable or recyclable shell that is formed primarily of a plant fiber, and a bottom cover. The shell includes a floor, a plurality of inner side walls that are coupled to the floor, a rim coupled to the plurality of inner side walls, and a plurality of outer side walls that are couple to the rim. The floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space. The plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap. The gap can be an air-filled cavity, or be filled with a compostable or recyclable core material.

What is claimed is: 
     
         1 . A thermally insulating packaging to hold an item, the thermally insulating packaging comprising:
 a solid compostable or recyclable shell that is formed primarily of a first material that is a molded and compressed plant fiber, wherein the shell includes
 a floor, 
 a plurality of inner side walls that are seamlessly and continuously coupled to the floor along first common edges and each seamlessly and continuously coupled to two adjacent inner side walls along second common edges 
 wherein the floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space; 
   a plurality of outer side walls formed primarily of plant fiber, wherein the plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap;   a rim extending between the inner side wall and the outer side wall and over the gap;   a bottom cover attached to bottom edges of the outer side walls and extending below the floor of the shell, the bottom cover including a flap; and   a compostable or recyclable core positioned in the first gap, the core formed primarily of a starch, a plastic, a plant fiber, or a combination thereof.   
     
     
         2 . The packaging of  claim 1 , wherein the floor and the bottom cover have a space therebetween that defines a second gap. 
     
     
         3 . The packaging of  claim 2 , wherein a portion of the core is positioned in the second gap. 
     
     
         4 . The packaging of  claim 1 , wherein the core fills the first gap. 
     
     
         5 . The packaging of  claim 1 , wherein a thickness of the core is between ¼ and 4 inches. 
     
     
         6 . The packaging of  claim 1 , wherein a thickness of the shell is at least 0.02 inch. 
     
     
         7 . The packaging of  claim 6 , wherein the thickness of the shell is between 1/32 and 1 inch. 
     
     
         8 . The packaging of  claim 6 , wherein the thickness of the shell is between 0.02 and 0.3 inches. 
     
     
         9 . The packaging of  claim 1 , wherein core is primarily a plant fiber material. 
     
     
         10 . The packaging of  claim 9 , wherein core is primarily shredded plant fiber. 
     
     
         11 . The packaging of  claim 9 , wherein the core is primarily paper. 
     
     
         12 . The packaging of  claim 11 , wherein core is primarily shredded paper. 
     
     
         13 . The packaging of  claim 1 , wherein the bottom cover includes a pair of flaps extending from edges of opposite outer side walls. 
     
     
         14 . The packaging of  claim 13 , wherein the pair of flaps are seamlessly and continuously coupled to the opposite outer side walls. 
     
     
         15 . The packaging of  claim 1 , further comprising a lid to cover the opening to the interior space, the lid formed of a compostable or recyclable material. 
     
     
         16 . The packaging of  claim 1 , wherein the inner side walls include one or more projections extending inwardly toward the interior space. 
     
     
         17 . The packaging of  claim 16 , wherein the projections extend vertically along the inner surface of the inner side walls. 
     
     
         18 . The packaging of  claim 17 , wherein the rim is coupled to the outer side walls. 
     
     
         19 . The packaging of  claim 18 , wherein the rim is continuously and seamlessly coupled to the inner side walls. 
     
     
         20 . The packaging of  claim 1 , comprising a layer of a moisture barrier material disposed on the shell and configured to block water penetrating the shell. 
     
     
         21 . The packaging of  claim 1 , comprising a moisture barrier material mixed with the molded and compressed plant fiber in the shell. 
     
     
         22 . A thermally insulating packaging to hold an item, the thermally insulating packaging comprising:
 a solid compostable or recyclable shell that is formed primarily of a first material that is a molded and compressed plant fiber, wherein the shell includes
 a floor, 
 a plurality of inner side walls that are seamlessly and continuously coupled to the floor along first common edges and each seamlessly and continuously coupled to two adjacent inner side walls along second common edges 
 wherein the floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space; 
   a plurality of outer side walls formed primarily of plant fiber, wherein the plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap;   a rim extending between the inner side wall and the outer side wall and over the gap;   a bottom cover attached to bottom edges of the outer side walls and extending below the floor of the shell, the bottom cover including a flap, wherein the floor and the bottom cover have a space therebetween that defines a second gap; and   a compostable or recyclable core that is formed primarily of shredded paper and that is positioned in the first gap and the second gap.   
     
     
         23 . The packaging of  claim 22 , wherein the core fills the first gap and the second gap. 
     
     
         24 . The packaging of  claim 22 , wherein a thickness of the core is between ¼ and 4 inches. 
     
     
         25 . The packaging of  claim 22 , wherein a thickness of the shell is at least 0.02 inches. 
     
     
         26 . The packaging of  claim 25 , wherein a thickness of the shell is at least 0.02 between 0.02 and 0.3 inches. 
     
     
         27 . The packaging of  claim 25 , wherein the thickness of the shell is between 1/32 and 1 inch. 
     
     
         28 . The packaging of  claim 22 , wherein the bottom cover includes a pair of flaps extending from edges of opposite outer side walls.