INSULATED PACKAGING

Technical Field

The present invention relates to insulated packaging.

Backg round Insulated packaging solutions have previously been developed with a view to reducing a rate of change of temperature of goods stored therein during storage and/or transportation. Expanded polystyrene {EPS), for example, has been moulded into containers for use as insulated packaging for perishable food products, such as beef and seafood, and perishable medical products, such as vaccines. EPS can be moulded into a vairiety of shapes and sizes and has good insulative properties. However, there are some significant drawbacks with using EPS for insulated packaging, including:

(a) EPS packaging does not come in a flat-pack configuration, which makes for inefficient storage of the packaging before use;

(b) EPS packaging is not easily collapsible after use, which makes for inefficient disposable of the packaging;

(c) EPS packaging is not readily recyclable;

(d) EPS is not an environmentally friendly to produce;

(e) EPS is not biodegradable, which creates environmental problems on its disposal; and

(f) EPS is brittle and containers formed therefrom can fail leading to:

(i) a loss of thermal properties;

(ii) loss of contents of from the container; and/or

(iii) ingress of contaminants into the container.

Other insulated packaging solutions have been developed with a view top addressing one or more of the above-described difficulties with EPS packaging. For example, flat- pack cardboard boxes have been used with different liners to help improve the insulative properties of the packaging. Such liners have included: (a) cardboard inner panels;

(b) panels of waste sheep wool;

(c) bubble wrap;

(d) heavy duty kraft paper;

(e) thermal corrugate cardboard; and

(f) panels comprising hammer-milled off-cut cardboard pieces.

Each of the above solutions provides packaging with unique thermal, environmental and structural properties that may be superior to EPS packaging in one or more ways. However, they can also introduce some additional difficulties, as explained below.

The wool panels, for example, have good insulative properties and they are good for the environment. However, the wool panels can be costly to manufacture when compared with alternative cardboard solutions. In addition, if the wool gets wet, the panels can omit a bad smell.

The hammer-milled panels are formed as blankets of recycled cardboard material. The relative cost of manufacturing the hammer-milled panels is less than the wool panels, for example, and there is little to no odour if they get wet. However, the hammer-milled panels are made up of quite fine cardboard particles, which can have the following drawbacks:

(a) cardboard dust is generated during the hammer-mill process which creates a dusty work space during manufacturing which may have adverse health effects for factory workers; and

(b) during use, dust from the panels can shake loose which results in a messy product to work with and can sully the goods stored therein.

It is generally desirable to overcome or ameliorate one or more of the above described difficulties, or to at least provide a useful alternative. Summary

In accordance with the invention, there is provided an insulated packaging including:

(a) a cardboard container; and (b) a liner for at least partially interfacing between one or more panels of the container and its contents, wherein the liner includes granulated paper material bound with a binder.

Preferably, the liner is formed in one or more flat panels, each being shaped to overlie an inner surface of the assembled container.

The liner is configured in first and second "U" shaped inserts, each being shaped to overlie inner surfaces of three sides of the assembled container. The first and second inserts are configurable to encapsulate the goods stored therein by overlying inner surfaces of all six sides of the assembled container.

The liner is preferably finished with one or more of the following:

(a) a starch solution sprayed over at least one side of the liner;

(b) a paper backing coupled to at least one side of the liner;

(c) synthetic material sprayed over at least one side of the liner; and

(d) secondary oven press.

Preferably, the granulated paper material includes one or more of the following materials:

(a) Kraft paper;

(b) Cardboard; and

(c) Sourced cardboard waste.

Preferably, the granulated paper material is formed in 8 to 10mm pieces.

In accordance with the invention, there is also provided a liner for at least partially interfacing between one or more panels of an insulated container and its contents, wherein the liner includes granulated paper material bound with a binder. Preferably, the liner is formed in one or more flat panels, each being shaped to overlie an inner surface of an assembled container.

Preferably, the liner is configured in first and second "U" shaped inserts, each being shaped to overlie inner surfaces of three sides of the assembled container. The first and second inserts are configurable to encapsulate the goods stored therein by overlying inner surfaces of all six sides of the assembled container.

Preferably, the liner is finished with one or more of the following: (a) a starch solution sprayed over at least one side of the liner;

(b) a paper backing coupled to at least one side of the liner;

(c) synthetic material sprayed over at least one side of the liner; and

(d) secondary oven press. Preferably, the granulated paper material includes one or more of the following materials:

(a) Kraft paper;

(b) Cardboard; and

(c) Sourced cardboard waste.

Preferably, the granulated paper material is formed in 8 to 10mm pieces.

The insulated packaging provides value for customers relating to convenient recycling methods, functionality, freight efficiencies and commercial competitiveness.

In accordance with the invention, there is also provided, a system for manufacturing the above described liner, including:

(a) a granulator module for creating granulated material;

(b) an opening and blending line for receiving the granulated material blending the material with binders;

(c) an airlay system module for forming a carpet of liner material;

(d) a thermobonding oven module for heat treating the carpet of material; and

(e) a combined cutting unit module for receiving the heat treated carpet of material and cutting it into discrete panels. Preferably, the system further includes a layering system, including:

(a) first and second spaced apart conveyors that transition a carpet of liner material from the airlay system module towards the thermosbonding oven module; and

(b) upper and lower reels of outer layer material, wherein the upper reel is arranged to feed the outer layer material downwardly onto the liner material as it transitions towards the thermobonding oven module, and wherein the lower reel is arranged to feed the outer layer material upwardly between the spaced apart conveyors so as to be positioned under the liner material as it transitions towards the thermobonding oven module.

These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

Brief Description of the Drawings Preferred embodiments of the invention are hereafter described, by way of nonlimiting example only, with reference to the accompanying drawings, in which:

Figure 1 is a diagrammatic illustration of a perspective view of insulated packaging; Figure 2 is a diagrammatic illustration of a perspective view of the insulated packaging shown in Figure 1 arranged in another condition of use;

Figure 3 is a diagrammatic illustration of a plan view of a blank for forming a container of the insulated packaging shown in Figure 1;

Figure 4 is a diagrammatic illustration of an exploded view of the insulated packaging shown in Figure 1; Figure 5 is an enlarged view of section "A" of the insert shown in Figure 4; Figure 6 is a graph showing examples of performance of the insulated packaging shown in Figure 1 when compared with other insulated packaging solutions;

Figures 7 to lib show component parts of a system used to form the liner for the insulated packaging shown in Figure 1; Figure 12 is a graph showing examples of performance of the insulated packaging shown in Figure 1 when compared with other insulated packaging solutions;

Figure 13 is a diagrammatic illustration of insulated panels of the insulated packaging shown in Figure 1; and

Figures 14a and 14b show component parts of a system used to form the liner for the insulated packaging shown in Figure 1.

Detailed Description of Preferred Embodiments

The insulated packaging 10 shown in Figures 1 to 4, includes a cardboard container 12, including:

(a) four flat panels 14a, 14b, 14c, 14d coupled together in series;

(b) pairs of flaps 16a, 16b coupled to opposed ends of each panel 14a, 14b, 14c, 14d in the series of panels; and (c) a fastening panel 18 for coupling a first panel 14a in the series to a fourth panel 14d in the series when the container 12 is assembled in the manner shown in Figure 1.

For ease of description, only one example of the container 12 is described and shown in the drawings. Flowever, the container 12 can have any suitable size and configuration suitable for insulated packaging. For example, the container 12 may be formed in any one of the following shapes:

(a) hexagonal;

(b) octagonal;

(c) square; and

(d) rectangle.

The insulated packaging 10 also includes a liner 20 for at least partially interfacing between one or more panels 14a, 14b, 14c, 14d of the container 12 and its contents (not shown). As shown in Figure 5, the liner 20 includes granulated paper material 26 that is bound with a binder. As described in further detail below, the liner 20 is made using a granulation machine 52 which produces the granulated paper material 26. The liner 20 is preferably made up of one or more flat panels that are shaped to overlie inner sides 24 of the container 12. As shown in Figure 4, the liner 20 can be configured in first and second "U" shaped inserts 22a, 22b. Each insert 22a, 22b is shaped to overlie inner surfaces 24 of three sides of the assembled container 12. The first and second inserts 22a, 22b are configurable to encapsulate the goods stored therein by overlying inner surfaces 24 of all six sides of the assembled container 12.

The liner 20 is preferably finished with one or more of the following:

(a) a starch solution sprayed over at least one side of the liner;

(b) a paper backing coupled to at least one side of the liner;

(c) synthetic material sprayed over at least one side of the liner; and

(d) secondary oven press.

The size of the particles in particulate material is directly proportionate to how much they are a hazard to human health. The environmental protection agency (EPA) is primarily concerned by particles that are ten micrometers or less in diameter. This is because these particles are likely to be inhaled into the lungs and cause serious health problems. Particulate matter is grouped into both coarse fibres which can be inhaled, and fine particles.

The liner 20 is made of paper material, including sourced cardboard waste, that has been granulated into small 8 to 10mm pieces using granulation machine, for example. As shown in Figure 5, the particulate material 26 of the liner 20 is larger than the corresponding particles of the hammer-milled liner. As such, the liner is less dusty and safer to manufacture and use than the hammer-milled panels, for example.

The paper material of the liner includes one or more of the following:

- Kraft paper

- Cardboard - Sourced cardboard waste

The online meal kit and grocery market presents a sustainable offering in the insulated packaging space. Many meal kits have been provided in either EPS boxes or single-use plastic satchels, both of which are difficult to recycle. The insulated packaging 10 offers a sustainable, recyclable alternative that requires minimal changes to meal kit companies' operational model.

Figure 6 shows examples of performance of the insulated packaging 10 when compared with EPS boxes and cardboard boxes with hammer-milled liners. The testing was conducted with the boxes packed in ambient room temperature and placed in 35°C. The 5 degree failure point shows that insulated packaging 10:

• Flas a 20% better performance when compared to the EPS box;

• Performs 2 hours longer in hot environments;

• Protects temperature sensitive goods that are in hot (35 degree) environments over a long period.

In addition, the packaging 10 is conveniently curbside recyclable. Whereas the EPS box is not.

System 50 for producing the liner 20

The system 50 shown in Figure 7 to 12 is used to form the liner 20 for the insulated packaging 10. The system 50, includes:

(a) a granulator module 52;

(b) an opening and blending line 100;

(c) an airlay system module 200;

(d) a thermobonding oven module 300; and

(e) a combined cutting unit module 400.

Liner 20 produced by the system 50 preferably has the following properties:

(a) Material max final width: 1120 mm.

(b) Fibers: recycled cardboard + PES bico low melt

(c) Thickness: 25 mm (d) Weights: 900 gsm

A detailed description of the component parts of the system 50 is set out below. (a) Granulator Module 52

The granulator module 100 is preferably the Granulator model ITS 110/58 which has a feeding conveyor belt, vertical distance approx. 6.500 mm, width of the belt approx. 900 mm, motor drive 1.5 kW. Alternatively, the granulator module could be any other suitable machine that can produce granulated paper material.

Technical Characteristics granulator module 100:

Star characteristics Star with 4 blades supports Rotor Diameter 580 mm Rotor Length 1100 mm Total Weight 4.500 Kg Installed Power 75 kW Screen 0 8 mm

Electric Motor 400V, 50Hz, 3 phase IE3

Shaft Speed (adjustable) around 580 RPM The granulator module 100 granulates paper material into into small 8 to 10mm pieces.

(b) The one opening and blending line 100 The one opening and blending line 100 shown in Figures 8a and 8b, receives granulated material from the granulator module and includes:

(c) The airlay system module 200

The airlay system module 200 shown in Figures 9a and 9b, includes:

(i) pneumatic airlay unit 202; and

(ii) weighing system 204.

Fed through machine web and heating oven to melt binder and bond material together.

(i) Pneumatic airlay unit 202

Batt shaping unit through a pressure/suction forming system.

Upper hood with two introducing rollers, which receive the fibers from the buffer silo.

Spiked transport cylinder for fibers opening and scattering.

Pressurized system to convey the fibers from the spiked cylinder to the exit part of the machine.

Perforated upper and lower conveyor belts for fibers collection, complete with suction system.

The upper perforated apron is vertically adjustable, to adapt to the different fabric batt weights requested.

The non-woven formation zone is between the upper and lower aprons. The thickness and other characteristics of the non-woven are influenced by the upper apron position and by the individual adjustment of both air flows. - Dust minimization thanks to the recovery of the process air: the suction air is recovered on top of the machine for the fibers pressurized blowing system.

- Cleaning brush for perforated belts.

- Top and bottom delivery aprons.

(ii) Weighing system 204

Delivery apron with electronic weighing system.

Installed on two weighing devices, each including three loading cells. - The loading cells are complete with spheres for the reduction of the longitudinal and transversal disturbs.

- A control software manages the signal in exit from the weighing devices and adjust the pneumatic former accordingly.

- Including connecting apron to convey the batt to the thermobonding section.

(d) The thermobonding oven module 300

The thermobonding oven module 300 shown in Figures 10a and 10b, includes:

(i) Entry section 302;

(ii) Two heating section 304;

(iii) Cooling section 306; and

(iv) Exit section 308. (i) Entry section 302

- Automatic belt tracking system.

Sloping inlet conveyor to allow the entrance of nonwoven of high thickness.

- Upper and lower glass fiber PTFE coated belts.

(ii) Heating modules 304

The machine is equipped with two heating modules: The distance of the belt can be adjusted up to 300 mm. The adjustment can be altered from the control panel and is effected together with the complete upper blowers bench.

The height adjustment is performed by linear actuators: two at the entry of the first heating section, two between one heating section and the other and two at the exit of the last heating section.

For each half section (1000 mm long) the air can be directed: from top to bottom 44 or from bottom to top ††. The air flow direction can be changed manually with oven stopped, by moving the position of four panels.

The oven is equipped with "plenum-panel" nozzles.

Each heating zone is equipped with its own burner, as well as ventilation fan and temperature control system.

The drive of the circulating air fan is inverter controlled, in order to adjust the air capacity (reduced air volume for soft products, which should not be damaged by excessive air pressure).

On both the oven sides, large doors allow access to the transport belts and nozzles: the cleaning and maintenance is particularly easy.

The groups of nozzles can easily be pulled out for cleaning.

Maximum oven temperature: 210°C (depending on the belts)

Including automatic adjustment of the airflow width.

(iii) Cooling section 306

The distance of the top belt can be adjusted between 5 and 300 mm. The adjustment can be altered from the control panel and is effected together with the complete upper blowers bank by a motorized screw jack system.

Suction fans and "plenum-panel" nozzles positioned below the bottom belt, for a cooling effect on the fabric from top to bottom 4,4,. One suction fan for each half section.

Driven compacting rollers to help the material calibration.

(iv) Exit section 308

Automatic belt tensioning system.

One top and one bottom cleaning brushes to clean the conveyor belts. Connections with the outside:

- Three pipes for gas supply (one for each heating section). - Two pipes for the exhaust air (the pipes can be merged into one by the customer).

- Two pipes for the air in exit from the cooling unit (the pipes can be merged into one by the customer).

- One pipe for the exhaust of the excess of air eventually exiting from the two ends of the heating area.

- The supply doesn't include the connecting pipes with the outside, the pipes for gas supply and the eventual fumes thermal treatment unit.

(e) The combined cutting unit module 400

The combined cutting unit module 400 shown in Figures 11a and lib, includes:

(i) Entry section with loop control 402;

(ii) Rotary blade slitting section with three groups 404; (iii) Manual sharpening unit;

(iv) Guillotine cross cutting section 408; and

(v) Exit conveyor belt 410.

(i) Entry section 402

- Loop control for tension control and small accumulation during the crosscut.

(ii) Rotary blade slitting section 404

THREE circular slitting blades, diameter 610 mm. complete with ac motor with inverter.

Each slitting blade is separately mounted on a carriage which runs along a sliding bar across the whole width of the machine.

Manual adjustment of the transversal position of the cutting groups, thanks to knobs which can be reached from the operator catwalk. - Each slitter can be pneumatically lifted and lowered with respect to the anvil surface by pressing a button.

- Anvil surface composed of a series of wires along the working width, slightly movable in case that they are touched by the slitting blades.

(iii) Manual sharpening unit 406

- Carriage with sharpener sliding on a guide along the width of the slitting unit mod. - The carriage is placed in front of the slitters.

- The operator manually moves the sharpener in front of each group to be sharpened.

- Pneumatic system to put the sharpener in contact with the blade.

- Two sharpening discs placed at 90° and driven by a motor.

(iv) Guillotine cross cutting section mod 408

Cut longitude and latitude directions for end pad product: - Feeding calendar, diam. 150 mm each, upper one movable by pneumatic pistons.

Encoder for measuring the product length, installed on the calender roller. As an alternative, the encoder can be installed on a rubber coated measuring wheel in direct contact with the product. - Transversal cut by tempered steel guillotine blade, driven by a connecting rod- crank- mechanism and self-braking AC gearmotor.

- The blade cuts against an anvil bar made of hard plastic (8 useful sides).

- Parallel to the cutting blade two pressing bars are assembled, controlled by pneumatic cylinders anchored to the structure. - Adjustment of the pressure of the pressing bars.

- Pre-setting of cut length from electric control panel.

In one embodiment, the system 50 includes the layering system 500 shown in Figures 14a and 14b located between the above described airlay system module 200 and the thermobonding oven module 300. The layering system 500 includes: (a) first and second spaced apart conveyors 502, 504 that transition a carpet of liner material 506 from the airlay system module 200 towards the thermosbonding oven module 300; and (b) upper and lower reels 508, 510 of outer layer material 512.

The upper reel 508 is arranged to feed the outer layer material 512 downwardly onto the liner material 506 as it transitions towards the thermobonding oven module 300. The lower reel 510 is arranged to feed the outer layer material upwardly between the spaced apart conveyors 502, 504 so as to be positioned under the liner material 506 as it transitions towards the thermobonding oven module 300. The layering system 500 thereby applies top and bottom layers of material 512 to the liner material 506.

The outer layer material 512 is preferably a paper based material. For example, a paper based material having grammages in the range of 5 grams per square metre (GSM) up to 300 GSM. Alternatively, the outer layer material 512 is a suitable synthetic material. For example, the outer layer material 512 is a non-woven interlining material made up of: (a) 68% Polyethylene terephthalate; and

(b) 32% polyethylene.

As would be understood by one skilled in the relevant art, the system 500 can be configured to include the upper reel 508 or the lower reel 510 so as to produce an outer layer on one side of the lining material 506 only.

The combined liner material 506 and outer layer material 512 is aesthetically pleasing and improves handling of the product when packing into a box and folding the material itself. Further, by encasing the insulation material 506, there are the following advantages:

(a) reduced risk of dusty material flaking off the insulation;

(b) an additional layer to absorb moisture from the goods been packed that may generate condensation; (c) opportunities for instructional information (assembly or recycling guides) and/or marketing material to be printed onto the material 512.

Preferred Additional Features of the System 50:

(a) Secondary press oven 54 shown in Figure 15, for example, to seal liner pads and reduce loose material or dust from pad.

(b) Chemical Emulsion Spraying Machine for spray coating used to reduce loose materia:

Stainless steel tank capacity 300 litres.

Pneumatic pump.

Emulsion mist application set composed of one automatic spraying gun installed in a section of duct lm long, complete with electro-valve for the immediate stop of the spray when the feed conveyor of the upstream machine stops.

(c) An additional set of rollers that apply paper to the top and bottom of the material so that only the pad edges are exposed.

(d) Metal detector for the automatic interception and rejection of metal impurities, composed of detecting probe, high speed electro pneumatic diverter valve, trash collecting box with access door and control panel with the electronic hardware.

The Press Oven 54 is used to heat and compress the non-woven fabric made by controlled cylinders and electrical resistances. The press oven 54 includes special plates designed to be heated:

- With electric resistances

- With diathermic oil

- Hot air

The oven 54 includes a plurality of fields, each comprising 14 motorized cylinders and 7 pairs of heated plates. Each plate is adjustable in height and diagonally, the entry module in particular has a section with double inclination. The oven 54 include the following features: - Special lower and upper conveyor belts, in Teflon-coated glass fiber

- Automatic temperature regulation by PLC with P.I.D.

- Cooling and calibration performed by controlled cylinders and water-cooled plates - Adjustment of the distance between the belts up to 300mm

- Complete with belt tensioning and centering systems

- High pressing capacity in a reduced dimensions machine thanks to the complete motorization

- The cooling section is the same as the hot one with 7 calenders and 14 plates

Other properties of the liner 20:

• Cushioning applications

• Moisture absorbency · Anti bacterial - Solutions that can be applied to the material via specific coatings

The liner 20 has the following for dust and flaked material reduction: · Sprayed starch on material once leaving the oven

• Paper lining on material once leaving the oven

• Secondary oven press

• Cardboard backing sheet covering granulated material 26 for stability The liner 20 is shown, by way of non-limiting example, with reference to the "U" shaped sections 22a, 22b. However, the liner 20 can be varied in one or more of the following ways:

• Density · Thickness

• Various sizes

• Weight

• Binder material is also being investigated with the intention to use poly waste materials as binders

• Material type could range in kraft to recycled material percentages • The R value ( thermal performance) can be scaled to suit certain supply chain requirements of target markets

Preferably, the liner 20 is formed in blankets that can be folded into the "U" shaped inserts 22a, 22b during assembly of the packaging 10.

Insulated packaging 10 v's EPS packaging

As shown in Figure 13, for 6 hours:

• EPS chilled chicken - Started at 8°C and reached 21.5°C

• Insulated packaging 10 chilled chicken - Started at 8°C and reached 15°C

• EPS frozen meal - frozen chicken maintained temperatures below -12°C

• Insulated packaging 10 frozen mean - frozen chicken maintained temperatures below -12°C

Additional markets Insulated packaging 10 could be applicable for:

Fruit 8i produce

Wine

Diary

Meat

Pharma

Construction insulation Pet bedding

Commercial eskies - current market eskies are $12 ranging up to $100 o Fishing o Camping o Festivals - Food, music, etc o Bottles shops o Supermarkets o Food markets o Fast food deliveries / transport vessel lining coustic repellency (needs to be assessed)

Temporary living - Camping, supporting homeless bedding initiatives Preferably, the liner 20, 506 has a thickness range of 5mm to 30mm.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.