Packaging with Insulative Walls Having Condensation Wicking Layer and Bubble Foil Insulation Layer

Abstract

A packaging may include at least one insulating wall and at least one cooling device embedded into the at least one wall. A method of forming at least one insulating wall of a package may include placing a cooling device into a form, closing the form, injecting a liquid form of an expansive foam, and curing the foam.

What is claimed is: 
     
         1 . A packaging comprising:
 at least one insulating wall;   at least one cooling device embedded into the at least one wall, the cooling device and at least one insulating wall forming a monolithic piece;   a bubble foil insulation layer formed on an outside surface of the at least one insulating wall; and   a condensation wicking layer formed on an inside surface of the at least one insulating wall.   
     
     
         2 . The packaging of  claim 1 , wherein the at least one insulating wall comprises six walls. 
     
     
         3 . The packaging of  claim 1 , wherein the bubble foil insulation layer is laminated onto the outer surface of the at least one insulating wall. 
     
     
         4 . The packaging of  claim 1 , further comprising a cardboard layer exterior to the at least one insulating wall forming an outside layer of the packaging. 
     
     
         5 . The packaging of  claim 1 , wherein the at least one cooling device includes a plurality of cooling devices embedded into a plurality of insulating walls. 
     
     
         6 . The packaging of  claim 1 , wherein the condensation wicking layer is laminated onto the interior surface of the at least one insulating wall. 
     
     
         7 . The packaging of  claim 1  further comprising a plurality of bubbles formed in the bubble foil insulation layer to maintain a polyatomic gas therein. 
     
     
         8 . The packaging of  claim 1 , wherein the at least one cooling device is embedded into the at least one insulating wall using a form to receive a liquid form of expansion foam through access holes defined trough one of the bubble foil insulation layer and condensation wicking layer. 
     
     
         9 . A method of forming at least one insulating wall of a package, comprising:
 placing a cooling device into a form, the form including a plurality of wells defined by a number of chamfered walls and ribs to form a plurality of insulating walls of an insulating package and hinges between the plurality of the insulating walls;   placing a bubble foil insulation layer on a first side of the form;   placing a condensation wicking layer on a second side of the form closing the first side of the form onto the second side of the form;   injecting a liquid form of an expansive foam between the bubble foil insulation layer and condensation wicking layer and into the wells; and   curing the foam to create the plurality of insulating walls having the cooling device embedded in at least one of the plurality of insulating walls, the cooling device and the at least one of the insulating walls forming a monolithic piece.   
     
     
         10 . The method of  claim 9  further comprising forming holes into one of the bubble foil insulation layer and condensation wicking layer through which the liquid form of the expansive foam may be passed into the wells. 
     
     
         11 . The method of  claim 10  further comprising trimming a portion of the bubble foil insulation layer and the condensation wicking layer from a portion of the insulating wall. 
     
     
         12 . The method of  claim 9 , wherein the form forms at least two sides of a cube. 
     
     
         13 . The method of  claim 9  further comprising forming a plurality of walls in the form to form a cube having a hollow portion to hold an object and forming a cardboard box around the plurality of walls. 
     
     
         14 . The method of  claim 9 , wherein at least one edge of a plurality of abutting insulating walls have a 47-degree chamfer. 
     
     
         15 . A shipping container, comprising:
 a box;   six insulating walls, at least one side of each of the insulating walls laid against the surface of at least one wall of the box, each of the insulating walls comprising:
 four chamfered edges; and 
 at least one hinge between one of the four chamfered edges of a first insulating wall and a chamfered edge of a second insulating wall, the chamfered edge being a 47-degree chamfer; 
   a bubble foil insulation layer formed onto an outer surface of each of the insulating walls; and   a condensation wicking layer formed onto an inner surface of each of the insulating walls.   
     
     
         16 . The shipping container of  claim 15 , wherein the six insulating walls forms a cube within the box, the cube comprising an interior cavity to hold an object. 
     
     
         17 . The shipping container of  claim 15 , wherein closing of the box causes pressure to be exerted on each of the interfaces between each of the six insulating walls creating a forced fit between each of the six insulating walls. 
     
     
         18 . The shipping container of  claim 15 , wherein the box is made of cardboard. 
     
     
         19 . The shipping container of  claim 15 , where each of the six insulating walls is made of a mixture of a polyether polyol resin and a polymeric isocyanate. 
     
     
         20 . The shipping container of  claim 20  further comprising forming holes into one of the bubble foil insulation layer and condensation wicking layer through which the liquid form of the expansive foam may be passed into the wells. 
     
     
         21 . The shipping container of  claim 21  further comprising a plurality of bubbles formed in the bubble foil insulation layer to maintain a polyatomic gas therein.