CROSS-REFERENCE TO RELATED APPLICATIONS,

[0001] This application claims benefit under 35 U.S.C. § 1 19(e) of United States provisional patent application no. 61/356,401 , filed Jane 18, 2010 and United States provisional patent application no. 61/442,276, filed February 13, 2011, which are hereby incorporated by reference in their entireties.

FIELD OF THE INVENTION

[0002] The present invention relates to insulating inserts, containers comprising them, and methods for assembling them. The present invention also relates to methods for transporting or insulating pay loads using them.

BACKGROUND OF THE INVENTION

[0003] Thermal insulated containers are typically used to transport temperature sensitive products, i.e., products that can be damaged or otherwise rendered unusable if subjected to changes in temperature. As used here in, temperature sensitive products include, but are not limited to, food products, specialty chemicals, pharmaceutical and life science products, biomedical products, test specimens, blood, organs, tissues, and electronics.

[0004] Currently, there are several different types of containers for transporting temperature sensitive products. One type of thermal insulated container is a molded cooler made from a thermally insulating material. Examples of thermally insulating materials used in molded coolers include expanded polystyrene and molded polyurethane. Because molded coolers requite extensive capital equipment to manufacture the molds, they can have high manufacturing costs. In addition, molded coolers are not space efficient to ship from their point of manufacture to their intended user since (he payload spaces are empty until used. Molded coolers are also not space efficient for shipping multiple payloads.

[0005] Another type of thermal insulated container is a box lined with insulating panels, such as vacuum insulation panels (VIPs). As used herein, a VIP comprises a core material contained within a sealed enclosure, from which air has been evacuated. Assembly of the VIPs for this type of container can be time-consuming and expensive. In particular, assembly requires complex placement of six panels, one panel is placed at each side of the container, one on the bottom and one on the top. External forces, such as tape or an outer corrugated box, are often needed to hold the panels in place. In addition, VIP-lined containers transfer heat through each of their twelve seams. Al each seam, heat transfer occurs at a rate thai is higher than that through the area comprising the VIPs. In addition, at each seam, the length of beat transfer depends on the thickness of the VIP. Heat transfer can also occur through gaps formed in the seams between adjoining VIPs because the contacting surfaces are short and, most often, rough.

10006] Known thermal insulated containers can be expensive and /or impractical when transporting small payloads. Frequently, these containers are not space efficient and cannot be used to transport multiple products within a single container.

SUMMARY OF THE INVENTION

[0007] The present invention provides insulating inserts and containers comprising them for use in transporting or insulating a payload. The insulating inserts comprise at least two VIPs and at least one thermal insulating material, with a cavity for the payload and optionally, a cooling or heating source and an internal protective liner. The thermal insulating material lies between two VIPs.

[0008] The present invention also provides methods for assembling the insulating inserts of the present invention. [0009] The present invention also provides methods of transporting a payload to a desired location using any of the insulating inserts of the present invention.

[0010] The present invention also provides methods of insulating a payload using any of the insulating inserts of the present invention. BRIEF DESCRIPTION OF THE FIGURES

[0011] Fig. 1 is a perspective view of an insulating insert according to an embodiment of the present invention.

[0012] Fig. 2 is a perspective view of an assembled insulating insert according to an embodiment of the present invention.

[0013| Fig.3A is a top view of a thermal insulating material for use in an insulating insert of the present invention.

[0014| Fig. 3B is a top view of a thermal insulating material for use in an insulating insert of the present invention.

[0015] Fig.3C is a top view of a thermal insulating material for use in an insulating insert of the present invention.

[0016] Fig.3D is a top view of a thermal insulating material for use in an insulating insert of the present invention.

[0017| Fig.4 is a perspective view of an insulating insert according to an embodiment of the present invention.

[0018] Fig.5 is a perspective view of an assembled insulating insert according to an embodiment of the present invention.

[0019] Fig.6 is a perspective view of a container comprising an insulating insert according to an embodiment of the present invention.

[0020| Fig.7 is a perspective view of a container comprising an insulating insert according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] In order that the invention herein described may be fully understood, the following detailed description is set forth.

[0022| Unless defined otherwise, all technical and scientific terms used herein have the same meaning as those commonly understood by one of ordinary skill in the an to which this invention belongs. Although methods and materials similar or equivalent (o those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. The materials, methods and examples are illustrative only, and are not intended to be limiting. All publications, patents and other documents mentioned herein are incorporated by reference in their entirely.

[0023] Throughout this specification, the word "comprise" or variations such as "comprises" or "comprising" will be understood to imply the inclusion of a slated integer or groups of integers but not the exclusion of any other integer or group of integers.

[0024] The terms "include " "includes," "including," "have," "has," or "having"

will be understood as open-ended and non-limiting unless specifically slated otherwise.

[ 0025] The term "a" or "an" may mean more than one of an item.

[0026] The terms "and" and "or" may refer to either the conjunctive or disjunctive and mean "and/or".

[0027] The term "about" means within plus or minus 1 % of a stated value. For example, "about 100" would refer to any number between 90 and 110.

[0028] It should be understood that the order of steps or ordering for performing certain actions is immaterial so long as the present invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.

[0029] The present invention provides insulating inserts and containers comprising them for use in transporting or insulating a payload. The insulating insert comprises at least two vacuum insulation panels and at least one thermal insulating material, with a cavity for the payload and optionally, a cooling or heating source and an internal protective liner. The thermal insulating material may comprise a cut cavity or an uninterrupted cavity. The thermal insulating material ties between two vacuum insulation panels. The insulating inserts and the containers of the present invention have important properties for

commercialization purposes. Such properties include, but are not limited to, ease and flexibility of manufacture, reduced manufacture and assembly costs, capability of transporting single or multiple payloads (thus eliminating the need for multiple sized containers), and important performance characteristics. [0030] The insulating inserts of the present invention have efficient heat transfer characteristics. The specific performance of the insulating inserts increases as the ratio of the surface area of the thermal insulating material to thickness increases. The insulating inserts of the present invention have only 8 seams (in contrast to the known VlP-conlainers, which have 12 seams). With the reduced number of seams, the heat transfer length can be increased by changing the size or dimensions of the panels and the pay load cavity, and not just by changing the thickness of the panel, as is the case with known VIP-containers. The insulating inserts of the present invention also have less heat transfer through gaps in the seams because of the increase in surface area contact with the VlPs. In addition, the insulating inserts of the present invention have less heat transfer because the thermal insulating material, which can optionally be made with, more or less elastic materials, more easily conforms to each VIP.

[0031] FIG. 1 and FIG. 2 illustrate an insulating insert according to an embodiment of the present invention. The insulating insert 10 comprises a first VIP 12, a second VIP 16, and a thermal insulating material 14. As illustrated, the thermal insulating material 14 lies between the first and the second VIPs 12 and 16. The thermal insulating material 14 contains a cavity in which a payload and optionally, a cooling or heating source and an internal protective liner may be placed. FIG. 2 illustrates an assembled insulating insert for use in a container to transport a payload. The insulating insert may be assembled by placing the thermal insulating material 14 on top of the first VIP 12 and then placing the second VIP 16 on top of the thermal insulating material 14.

[0032| Vacuum insulation panels (VIPs) are well known in the art and comprise a core material contained within a sealed enclosure, from which air has been evacuated. The core material may be made from any open cell material including, but not limited to, polystyrene, polyurethane, fiberglass, silica, and various forms of organic foams. Suitable core materials include, but are not limited to,

AEROCORE (available from American Aerogel Corporation), NANOGEL (available from Nanopore), and those disclosed in U.S. patent 7,521,485, U.S. patent 6,344,240, U.S. patent 6,315,971, U.S. patent 6,090,439, and U.S. patent 5,877,100, the contents of each of which are incorporated by reference. [0033] The VIPs may further comprise getters or desiccants to absorb gases and moisture. Getters and desiccants are well known in the art and any may be used in the insulating inserts of the present invention.

[0034] The enclosure is a membrane or barrier film that keeps out gases and vapors. Suitable membranes or barrier films include, but are not limited to, metal sheet, plastics, metal foil polymeric film, and combinations thereof.

[0035] The VIPs used in the insulating inserts of the present invention may be the same or different Preferably, the VIPs are (he same.

[0036] While the VIPs are shown in the figures in rectangular form, each VIP can have a variety of shapes and forms. The VIPs may be square, circular, oval or any irregular shape. The surface of the VIP may be flat or non-flat.

[0037] The thermal insulating material used in the insulating inserts of the present invention include, but are not limited to, polystyrene, polyurethane, polyisocyanurate, polyethylene, polypropylene, rubber and silicones.

[0038] While the thermal insulating materials are shown in the figures in rectangular form, each thermal insulating material can have a variety of shapes and forms. The thermal insulating materials may be square, circular, oval or any irregular shape. The surface of the thermal insulating material may be flat or non- flat.

[0039] The size and shape of the VIPs and the thermal insulating material used in an insulating insert of the present invention may be the same or different The VIPs and thermal insulating material may be any combination of size and shape. As illustrated in the figures, the VIPs and the thermal insulating materials may have the same size and shape. Alternatively, the VIPs and the thermal insulating materials may have different sizes and shapes. For example, the VIP may have a rectangular form and the thermal insulating material may have an irregular shape.

[0040] The thermal insulating material lies between two VIPs. The thermal insulating material may lie fully or partially between the VIPs. As illustrated in the figures, the thermal insulating material may lie fully between two VIPs.

Alternatively, the thermal insulating materially may lie partially between two VIPs. [0041] The thermal insulating material contains a cavity for receiving the payload and optionally, a cooling or heating source and an internal protective liner. The cavity may be prepared by milling, cutting or forming directly while making the thermal insulating material. The size and shape of the cavity depend on the payload, and the optional cooling or healing source and protective liner.

Preferably, the cavity is small in volume and in thickness,

[0042] FIG. 3A-D illustrate thermal insulating materials for use in the insulating inserts of the present invention. Thermal insulating material 14 contains a cavity 17 in which a payload and optionally, a cooling or heating source and an internal protective liner may be placed. As illustrated in FIG. 3A, the thermal insulating material 14 may comprise an uninterrupted cavity. Alternatively, as shown in FIG.3B-D, the thermal insulating material 14 may comprise a cut cavity.

[0043] Preferably, the thermal insulating material comprises a cut cavity.

[0044] When the thermal insulating material comprises a cut cavity, the cavity may be cut into multiple pieces. Preferably, the cavity is cut into two pieces. The pieces may be the same size or different sizes. Preferably, the pieces are different sizes. When the cavity is cut into multiple pieces, one piece may serve as a lid. The cuts in the cavity may be made in a step, zigzag, jagged, diagonal, angled, or straight fashion, or combinations thereof. The cuts in the cavity may be made at the same time as those made in preparing the payload cavity. Alternatively, the cuts may be made before or after preparing the payload cavity.

[0045] Preferably, the cuts in the cavity are made at the same lime as those made in preparing the payload cavity.

[0046] Referring to FIG. 1 and FIG. 2, while these figures illustrate a thermal insulating material comprising an uninterrupted cavity, in other embodiments, the thermal insulating material comprises a cut cavity.

[0047] The geometries of the VIPs and the thermal insulating material may be varied to optimize heat transfer through the insulating insert and depend on factors including, but not limited to, the particular application of the insulating insert, the size of the payload, the number of payloads, the temperature requirements of the payload and the duration of shipping. The geometries may be varied by changing the surface area of the VTP or the thickness of the thermal insulating material. Preferably, the VIPs have a surface are a in the range of about 4 square inches to about 3600 square inches. In some embodiments, the surface area is in the range of about 9 square inches to about 120 square inches. In other embodiments, the surface area is in the range of about 15 square inches to about 1296 square inches. Preferably, the thermal insulating material has a thickness in the range of about 0.5 inches to about 48 inches. More preferably, the thickness is in the range of about 0.75 inches to about 24 inches. Yel even more preferably, the thickness is in the range of about 1 inch to about 8 inches. In alternate embodiments, the ratio of the surface area of the ViP to the thickness of the thermal insulating material is in the range of about 20 to about 50.

[0048] The paytoad may be any temperature sensitive product. Examples of temperature sensitive products that may be used include, but are not limited to, food products, specialty chemicals, pharmaceutical and lite science products, biomedical products, test specimens, blood, organs, tissues, and electronics.

[0049] The optional cooling or heating source functions to maintain, raise or lower the temperature of the payload in the insulating insert. Suitable sources include, but are not limited to, dry ice, wet ice, gel packs, reusable ice packs, heating packs and other phase change materials. Alternatively, the source may be an active heating or cooling device, such as a battery powered refrigeration or heating unit

[0050] The optional internal protective liner functions to protec the VIPs from exposure and puncture. Suitable internal protective liners are well known in the art, and include, but are not limited to, chip board and corrugated liners.

[0051] When assembling the insulating insert of the present invention, the payload and the optional cooling or heating source and internal protective liner may be placed into the payload cavity before or after the second VIP is placed on top of the thermal insulating material. When the insulating insert comprises a thermal insulating material having a cut cavity, the payload and the optional cooling or heating source and internal protective liner may be placed into the payload cavity by first removing one piece of the cut cavity (which serves as a lid) and then replacing it. [0052] FIG. 4 and FIG.5 illustrate an insulating insert according to an embodiment of the present invention. The insulating insert 18 comprises a first VIP 12, a second VIP 16, a third VIP 22, a first thermal insulating material 14 and a second thermal insulating material 20. As illustrated, the thermal insulating materials 14 and 20 lie between VIPs 12, 16 and 22. Both thermal insulating materials 14 and 20 contain a cavity in which a payload and optionally, a cooling or heating source and an internal protective liner may be placed. The payloads may be the same or different.

[0053| While FIG.4 and FIG. 5 illustrate a thermal insulating material comprising an uninterrupted cavity, in other embodiments, one or more of the thermal insulating materials comprises a cut cavity.

[0054] FIG. 5 illustrates an assembled insulating insert for use in a container to transport two payloads. The insulating insert may be assembled by placing the thermal insulating material 14 on top of the first VIP 12, placing the second VIP 16 on top of the thermal insulating material 14, placing the second thermal insulating material 20 on top of the second VIP 16, and placing the third VIP 22 on top of the second thermal insulating material 20.

[0055| While FIG.4 and FIG. 5 illustrate an insulating insert configured for two payloads, in other embodiments, the insulating insert is configured for a plurality of payloads. In these other embodiments, the insulating insert comprises a plurality of VIPs and thermal insulating materials stacked one on top the other to accommodate the plurality of payloads. The plurality of payloads may be the same or different. The plurality of thermal insulating materials may comprise an uninterrupted cavity or a cut cavity.

[0056] The present invention also provides a container comprising any of the insulating inserts described above. For example, the container may comprise an insulating insert for transporting a single payload Alternatively, the container may comprise an insulating insert for transporting a plurality of payloads. In each embodiment, the insulating insert may comprise a thermal insulating material comprising an uninterrupted cavity or a cut cavity.

[0057| When the thermal insulating material comprises a cut cavity, the container may be assembled by placing the insulating insert inside the container in such a way that the top and the bottom VIPs are oriented against the side walls of the container. One piece of the cut cavity in the thermal insulating material serves as a lid. The pay toad, and the optional cooling or heating source and internal protective liner may be placed within the cavity either before the container is assembled, or after the coniainer has been assembled Preferably, Ihe payload, and the optional cooling or heating source and internal protective liner are placed into the cavity after the container has been assembled. The payload, and the optional cooling or heating source and internal protective liner may be placed into the cavity afte r the container has been assembled by removing one piece of the cut cavity (which serves as the lid) and men replacing it. By placing the payload and the optional cooling or heating source and internal protective liner into the cavity after assembly of the container, the VIPs can be protected from exposure, handling and puncture.

[0058] The container may be any size or shape, depending on the size and shape of the payload and the number of payloads. The container may be paper, pressboard, composition board, cardboard, wood, metal, plastic or any other suitable material.

[0059] FIG.6 is a perspective view of a container 24 for transporting a single payload Container 24 comprises a first vacuum insulation panel 12, a second vacuum insulation panel 16 and a thermal insulating material 14. The thermal insulating material 14 contains a cavity for receiving a payload and optionally, a cooling or heating source and an internal protective liner.

[0060] FIG. 7 is a perspective view of a container 24 for transporting two payloads. Container 24 comprises a first vacuum insulation panel 12, a second vacuum insulation panel 16, a third vacuum insulation panel 22, a first thermal insulating material 14 and a second thermal insulating material 20. Both thermal insulating materials 14 and 20 contain a cavity for receiving a payload and optionally, a cooling or heating source and an internal protective liner. The payloads may be the same or different

[0061] While FIG. 7 illustrates a container for transporting two payloads, in other embodiments, the container is configured to transport a plurality of payloads. In these other embodiments, the container comprises an insulating insert, which comprises a plurality VIPs and thermal insulating materials stacked one on top the other to accommodate the plurality of payloads. The plurality of pay loads may be the same or different.

[0062] The present invention also provides methods of transporting a payload to a desired location. This method comprises providing an insulating insert comprising a payload and optionally, a cooling or heating source and an internal protective liner; placing the insulating insert within a container; closing the container and transporting it to the desired location. The insulating inser may be any of insulating inserts described above.

[0063| The present invention also provides a method of insulating a payload. This method comprises providing an insulating insert comprising at least two VIPs and at least one thermal insulating material with a cavity for receiving a payload and optionally, a cooling or heating source and an internal protective liner, and placing a payload, a cooling or heating source, and optionally an internal protective liner within the cavity. The method may further comprise placing the insulating insert into a container. The insulating insert may be any of the insulating inserts described above.

[0064] In order mat this invention be more fully understood, the following examples are set forth. These examples are for the purpose of illustration only and are not to be construed as limiting the scope of the invention in any way.

Examples

[0065] Insulating inserts of the present invention were prepared by placing a thermal insulating material with a preformed cavity on top of an AEROCORE VIP and then placing a second AEROCORE VIP on top of the thermal insulating material. The specific thermal insulating materials and their dimensions are indicated in Table 1 below.

The following abbreviations are used in Table 1. "Poly Iso" refers to

polyisocyanuraie. "Low Density Poly Iso" has a density of 3 Ibs./ft ³ and "High Density Poly Iso" has a density of 4 lbs./ft\ "Soft Grey Foam" refers to reticulated polyurethane.

[0066| The insulating inserts were men tested to determine heat transfer. In these tests, the rate of sublimation of dry ice was measured. This rate is useful for comparing thermal performances of different boxes because it is directly related to heat load and therefore insulation of the box as a whole system.

[0067] While particular materials, formulations, operational sequences, process parameters, and end products have been set forth to describe and exemplify this invention, they are not intended to be limiting. Rather, it should be noted by those ordinarily skilled in the art that the written disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention.