REFRIGERANT PACKING

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Serial

No. 61/334,797, filed May 14, 2010, entitled "CYLINDRICAL BIODEGRADABLE AND/OR RECYCLABLE REFRIGERANT GEL PACK"; U.S. Provisional Patent

Application No. 61/315,432, filed March 19, 2010; U.S. Patent Application No. 12/120,353, filed May 14, 2008 (published U.S. Patent Application Publication No. 20090283578); and International Patent Application No. PCT/US2009/043972, filed May 14, 2009 (published International Application Publication No. WO/2009/140507). This application also relates to issued U.S. Patent Nos. 7,229,677; 7,094,192; and 6,875,486. The entirety of the

aforementioned patents and applications are incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to gel containing packaging, and more particularly to cooling or heating package inserts for maintaining temperature within a desired range.

BACKGROUND OF THE INVENTION

The ability to ship products, such as food and other goods such as medical and drug supplies, including blood and other biological materials, pharmaceuticals, medicines, cosmetics, confections, and food stuffs, during periods of long transit times, presents problems with respect to degradation of the cargo due to adverse temperature conditions. This is particularly so for long distances requiring extended periods of time for completion and delivery, and is especially difficult when the products are dated or perishable and need to be preserved, or their integrity or efficacy need to be preserved by maintaining the cargo at low temperature during transit.

Low temperatures may be achieved by cooling the entire truck, ship, plane, or railcar cargo area. Alternatively, individual cargo packages, for example crates, boxes, or cases, may be cooled by the introduction of cold or cold-producing items into the cargo package. The cold producing items so introduced are eventually recycled or discarded into the

environment.

An objective technical problem to be solved is therefore to improve upon the cold and or heat producing abilities of temperature maintaining packaging inserts, while providing for recyclability as well as environmentally improved degradation of these inserts and their materials once discarded.

SUMMARY OF THE INVENTION

An embodiment of a device for maintaining a temperature of a package comprises a containment shell fabricated from a mix of polymer and a bio-active material operative to foster microbial degradation of the containment shell; and a gel containable within the containment shell and formed of a substantially cellulosic material and water.

In various embodiments, the containment shell mix further includes a swelling agent operative to increase a hydrophilic property of the containment shell; the bio-active material includes nutrients for microorganisms; the mix was heated and formed into a resin prior to being formed into the containment shell.

In other embodiments, the containment shell further includes a neck having threads, the containment shell sized and dimensioned to be fillable using automated bottle filling equipment; the cellulosic material includes one of hydroxyethyl cellulose or carboxymethyl cellulose; the gel includes between about 1 and about 2% cellulosic material by weight; the gel includes between about 1.2% and about 1.5% cellulosic material by weight; the gel includes about 1.5% cellulosic material by weight; the shell has the form of a cylinder; the shell has a longitudinal axis about which is formed a portion of a cylinder and a

longitudinally extending edge having an acute radius; the shell is formed from about 0.5% to about 5% of the mix, combined with non-mixed polymer; and the shell is formed from about 1% of the mix, combined with non-mixed polymer.

In yet further embodiments, the gel is has a low viscosity and is a pourable liquid for at least 12 hours after the cellulosic material is mixed with water, after which a gel is formed; the mix includes at least one of organic nutrients, esters, proteins, and fatty acids; the mix includes a binding agent; the mix includes an organoleptic swelling agent; and the mix includes a chemo-attractant.

In other embodiments, a device for maintaining a temperature of a package comprises a containment shell fabricated from a mix of polymer, microbial nutrients and a swelling agent together operative to foster microbial degradation of the containment shell; and

a gel containable within the containment shell and formed of with about 1.5% carboxymethyl cellulose by weight and water, the gel operative to function as a phase-change material which absorbs heat at a slower rate than water. Further in accordance with the disclosure, a method for maintaining a temperature of a package comprises partially filling a containment shell fabricated from a mix of polymer, microbial nutrients and a swelling agent together operative to foster microbial degradation of the containment shell, with a gel formed of with about 1.5% carboxymethyl cellulose by weight and water, the gel operative to function as a phase-change material which absorbs heat at a slower rate than water.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present disclosure, in which:

FIG. 1 is a biodegradable container of an embodiment;

FIG. 2 is an alternative form of a biodegradable container;

FIG. 3 is a graph of a temperature maintaining ability of a container containing gel, of the disclosure;

FIG. 4 is an illustration of a process of forming and using a biodegradable container of the disclosure;

FIG. 5 is an alternative container of an embodiment of the disclosure;

FIG. 6 is yet another embodiment of a container, including a gel insert;

FIG. 7 is an embodiment of a container formed with a gel insert;

FIG. 8 is an embodiment of a tear-drop shaped container of the disclosure;

FIG. 9 is a bottom view of the container of FIG. 8;

FIG. 10 is a biodegradable packing pouch of the disclosure;

FIG. 11 is a side cross-section of the pouch of FIG. 10, showing a gusset;

FIG. 11A is an enlargement of an indicated area of FIG. 1 1, illustrating an alternative location for a gusset; and

FIG. 12 is a cross-sectional side view of the pouch of FIG. 10, containing the container of FIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples and that the systems and methods described below can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present subject matter in virtually any appropriately detailed structure and function. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the concepts.

The terms "a" or "an", as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms "including" and "having," as used herein, are defined as comprising (i.e., open language). The term "coupled," as used herein, is defined as "connected," although not necessarily directly, and not necessarily mechanically.

Embodiments

Herein, references to maintaining low temperature apply equally to maintaining an elevated temperature, as is needed by the product application. Lowering temperature is commonly desired for extended time intervals, for example to retard microbial and or chemical decomposition, whereas heat may tend to increase these over time.

Notwithstanding, the embodiments of the disclosure may be used where maintaining heat for an extended time is beneficial or desirable.

Embodiments herein provide a gel containing package insert operative to generate or absorb heat to maintain temperatures near a desired set point. The embodiments may be inserted into common packaging containers, or may be combined with other temperature regulating elements, for example within other packaging materials directed to maintaining temperature, or within cold or heated storage facilities or shipping containers. The embodiments further provide heat or cooling for extended transit periods for goods in shipment.

As examples, the embodiments herein are advantageously used for transporting medical specimens, biological material, and food and other goods under low temperature conditions, while maintaining the physical integrity of the package and the low temperature conditions for an extended period of time, enabling shipment to distant destinations.

With reference to FIGS. 1-2, a package insert 100 includes a liquid tight container or shell 102 containing a gel 200, which is a biodegradable, recyclable, and natural material which decomposes rapidly when exposed to the environment in a landfill. Rapid

decomposition for this embodiment is typically measured in days or weeks, dependent upon the quantity of material, the amount of moisture, and other ambient conditions. In FIG. 1, container 100 is a typical drinking bottle, for example fabricated with plastic, for example PET (polyethylene teraphthalate), although as described herein, embodiments of this disclosure include other materials. Other examples of materials which may be used to enclose a gel of the disclosure include glass, cardboard, wood, metal, rubber, high density polyethylene (HDPE), polyvinyl chloride (PVC), polypropylene (PP), polystyrene (PS), post consumer resin (PCR), and K-resin (SBC). Container 100 has a threadable neck 106, and is sealable with a cap, not shown. Container 100 is thus adapted to be handled and filled by conventional water bottle filling, capping, labeling, and packaging industrial bottling equipment. For example, in one application, 40,000 bottles can be filled with gel of the disclosure in a single 8 hour shift.

FIG. 2 illustrates a container 100B containing gel 200, and an inner container adapted to hold a pourable substance, for example powders or liquids, in an inner container 104, the inner container closed with a cap 108. Container 100B may be sealed, or may be configured to be openable, whereupon gel 200 may be replaced.

In an embodiment, gel 200 is fabricated from a cellulosic material mixed with water to form a gel which sets, or develops a semi-liquid or solid state, within a few hours, for example 12 hours, to within a few days, for example in about 24 hours. Until gel 200 sets, it is a low viscosity pourable liquid which may flow through conventional industrial automated water bottling equipment without substantial modification to such equipment. A specific example of a cellulosic material which may be used is carboxymethyl cellulose (CMC), or cellulose gum, which is also used, among other purposes, as a food viscosity modifier or thickener, and is non-toxic, non-allergenic, which rapidly degrades in the environment. Hydroxyethyl cellulose may also be used. Gel 200 is operative to behave as a phase-change material, and more specifically, to absorb heat in a gradual manner as the gel changes from a solid to a semi-liquid state.

To form a gel in accordance with an embodiment, the following steps may be followed:

1) weigh out 7.4 grams of CMC on a paper pad (to form a 1.5% mixture of solids);

2) weigh out 495 grams of tap water in beaker (softened water is advantageous), and pour into a blender cup;

4) using a variable blender control, begin gentle to moderate agitation of water to form a vortex;

5) slowly add the measured CMC into the water vortex;

6) mix for 2 to 3 minutes to form the gel; 7) pour the gel blender cup contents into a container using a spatula to clean the sides of the blender cup;

8) stir the container contents with a spatula occasionally for up to 30 minutes;

9) pour the gel from the container into a container of the disclosure; and

10) observe for gelling— a firm aqueous gel should be formed within 24 hours.

Scale up for larger quantities may be carried out as would be understood by one skilled in the art. An example of a commercial source of CMC is Unigel 30 CP Polymer (a product of Progressive Polymers, Inc., Prior Lake, Minnesota, USA), whose primary component is an odorless white power of cellulose ether, which complies with FDA regulation 184 (Generally Regarded As Safe). An example of a scale-up mixture is 12.5 pounds of Unigel 30 CP with 100 gallons of water.

A mixture of 1.5% solids has been found to have advantageous properties, particularly with respect to stability during reuse (e.g. refreezing). Lower concentrations, for example 1.2% may also be used, but results for reuse have been found to be substantially less favorable, with a degraded product appearance and or performance in terms of

thermodynamic properties, relative to the higher concentration.

Additionally, it has been found that the Unigel 30 CP Polymer performs better at a 1.5% concentration than Unigel 12-C-Fortifed Polymer Mix (also by Progressive Polymers, Inc.). In particular, an increase in concentration to 1.5% and or the use of Unigel 30 CP produces the advantages of low temperature maintenance for a longer period, and a longer set-up or gelling period, which provides substantially more time for filling containers of this disclosure before hardening. In accordance with various embodiments, as low as 1% and as high as 2% cellulosic material may be used.

In accordance with an embodiment of the disclosure, container 100 (hereinafter including the alternative containers 100, indicated with suffixed letters), may be fabricated using a degradable polymeric material which degrades substantially more rapidly than a pure form of the polymer from which the degradable polymer is based.

The process used in creating the degradable plastic includes adding nutrients and other organic compounds which weaken the polymeric substrate and attract microbial activity, for example by providing requisite microbial nutrients which are lacking in non-treated plastics, or by providing other materials which attract organisms which are capable of degrading the polymeric substrate. The added compounds are admixed into the plastic, and contribute to rapid breakdown of the plastic in the disposal environment, whether aerobic or non-aerobic. Environmental or imposed factors, including light, heat, mechanical stress and moisture, may be combined with the action of the added compounds, to speed decomposition.

More particularly, and with reference to FIG. 4, in step 400 a polymeric material 440 is mixed with an active material which may include a bio-active material 442 such as a nutrient, odor, or chemo-attractive substance, and or an agent 444 operative to cause swelling of the polymeric molecular structure, for example an agent that causes the polymer to be more hydrophilic, together with water or other liquid 446, to form an encapsulated or admixed material 448. This material is heated in step 402 to form a master batch carrier resin 450, which is then advantageously formed into pellets 452 in step 404.

In step 404, the pellets 452 are fabricated into containers 100 as described herein, using methods known in the art, or hereinafter developed, for converting pelletized material into containers. Such methods include extrusions, for example blown or cast sheets, blow molding, for example stretch blow molding, injection molding, or rotomolding. The aforedescribed process of steps 400-402 does not prevent such methods from being carried out. In step 404, gel 200 may be added to containers 100 using any known method, including conventional bottle filling automated equipment. Such filling is advantageously performed prior to gel 200 setting up, for example prior to 24 hours elapsing from mixing of the constituents of gel 200, as described herein.

The quantity of admixed material 448 used is advantageously an amount which is just sufficient to foster microbial growth to form a coating upon container 100, whereby an optimal environment of microbial growth becomes self sustaining. Additionally, the coating enables the formation of an anaerobic layer, where anaerobic digestion may take place together with aerobic digestion.

In an embodiment, admixing about 0.5% to about 5% of pellets 452 into conventional plastic has been found to be sufficient to produce biodegradation as described herein, and advantageously about 1% of admixed material 448 is combined with non-admixed polymer to produce a polymeric mix which biodegrades at a greatly accelerated rate due to

biodecomposition. Pellets as described may be purchased from Enso Bottles, LLC of Mesa, Arizona, USA, although other biodegradable plastics may be found, for example by Shields Bag & Printing Co. of Yakima, Washington, USA.

Cotnainer 100 is not filled completely with gel 200, as space must be allocated for expansion of gel 200 within container 100 due to a phase change of gel 200 from a viscous liquid to a solid, for example when frozen. Container 100 may include extension spaces, for example disposed on either side of a filler neck, into which frozen gel 200 may expand during the freezing process.

In step 406, containers 100, possibly together with gel 200, are reused, or are deposited for recycling or disposal. During recycling, gel 200 may be separated from container 100, and the materials recycled separately, or they may be recycled and mechanically decomposed together. Step 406 illustrates a single user or consumer discarding container 100, although it should be understood that many containers 100 may be recycled or disposed together, for example as part of a commercial process.

Ultimately, in step 408, some portion of the containers 100 and gel contents 200 will be deposited in a landfill as waste. In the landfill, the biodegradable active materials 442, 444, 446 cooperate to enable microorganisms 454, advantageously in the presence of water 456, to digest or degrade the plastic resin from which container 100 is formed, as shown in step 410. Digestion may be determined, for example, in the ASTM D551 1 anaerobic biodegradation test. One such plastic resin, for example, may be based upon polyethylene terephthalate (PET or PETE). Microbial digestion may take place in either aerobic or anaerobic conditions, for example by bacteria.

In the landfill, additive 444 renders normally water-repellent polymers more hydrophillic, thus attracting and promoting the intimate adhesion of the prerequisite biofilm. The additives 442 then facilitates the growth of syntrophic colonies of diverse

microorganisms 454 that degrade hydrocarbon polymers through, for example, an enzymatically catalyzed oxidative process, as well as by oxidative ring-opening. In aerobic conditions, biodegradation reduces the long hydrocarbon chains of the polymer to carbon dioxide and water, and in the case of anerobic biodegradation, carbon dioxide, methane, and water. As the decomposition of the polmer in accordance with this disclosure is not based on photo degradation or thermal degradation, the shelf life and usable life of container 100 is not adversely affected.

An advantage to the aforedescribed process that is not exhibited by oxo-degradable or PLA starch or corn-based containers, includes, in addition to biodegradability, containers 100 formed with a base of PET, may be mixed into a standard PET recycling stream. Further, PET in particular may be caused to be biodegradable in an organic, non-starch based manner, which is non-destructive to the environment. Containers 100 of the disclosure may further be heated to 140 degrees Celcius, and may be reused, whereas PLA containers cannot be heated or reused in this manner. Containers formed by the process described in steps 400-410 maintain the same or substantially similar physical properties, including for example shelf life, texture, clarity, appearance, and oxygen transfer rate, as non-treated conventional polymeric containers. However, after the microbial and environmental degradation in the landfill, the bioactive containers 100 of the disclosure break down into bio-gases and bio-mass 458, otherwise known as inert humus, and leave behind no harmful materials.

Containers 100 in one embodiment have been shown to fully biodegrade in 9 months to 5 years, and will biodegrade in either aerobic or anaerobic conditions. Biodegrading may take place in a landfill, commercial or residential compost, burial, litter site, and in agricultural and erosion-control settings. Further, containers 100 do not contain heavy metals, for example as are used to promote oxodegradation.

In one embodiment, container 100 is formed with a polyester copolymer with additive ingredients 444 including one or more of scissoring agents (to break bonds), organic chemo- attractants, and or organoleptic swelling agents. Nutrients 442 may include various organic nutrients, esters, proteins, and fatty acids. A reactor grade binding agent (PETE) or other binding agent may also be used. Particular examples may be found in U.S. Patent Application Publication No. 2008/0103232, published May 1, 2008, the contents of which are incorporated by reference herein, which discloses formulations that can be used for forming degradable plastics which may be formed into containers as described herein.

The assembly of container 100 and gel 200 produces a product which has a high standard (typically class 1) of recyclability for PET plastics. Containers 100 may be advantageously formed, for example, in sizes of 17, 39.9, 48 and 93 fluid ounces, although sizes at least within the range of 4 fluid ounces to 128 fluid ounces would be useful for a variety of applications. Specialized applications could benefit from sizes much smaller, or much larger, than the foregoing. In addition, containers 100 may be formed to be clear or transparent, translucent, opaque, solid colored, or tinted with a color. Similarly, gel 200 may be clear or colored with an additive. During cooling or freezing, it is advantageous for space to be provided within container 100 for expansion of gel 200.

Tests for degradability in a landfill environment, including ASTM 5511 and 5526, have shown the assembly of containers and gels of the disclosure exhibit an increase in biodegradation of 95-99.5% over conventional materials. In particular, the 5526 test is a landfill replication using actual landfill leachate.

Referring now to FIG. 3, it may be seen that a container of the disclosure is capable of maintaining a reduced temperature for an extended period of time. In particular, a cylindrical 2 pound 6 ounce (38 oz.) bottle, having the form illustrated in FIG. 8, and containing a frozen gel as described herein, exhibited a rise of less than 4 degrees Celsius, measured upon a surface of the container, in ambient conditions that would normally be experience by cargo in transit.

Referring now to FIG. 5, an alternative container 100B is illustrated, having a cylindrical shape, and being filled with gel 200. Without being bound by a particular theory, a cylindrical shape is advantageous, as compared with a container having flat surfaces, in that there is less surface area for heat exchange for a given volume. Moreover, rectangular-shaped gel packs typically taper to a flat heat seal on two sides, creating areas where a contained refrigerant material is disposed in a thin layer. Accordingly, temperature exchange is excessively rapid in this area, beginning in this thinner region. Accordingly, with a circular or cylindrical container in accordance with the disclosure, there is less surface area exposed to ambient heat, and there are further no thin edges, whereby the contained gel may therefore maintain a lower temperature for longer periods, relative to containers with flat sides.

In a test conducted by the inventor, a cylindrical-shaped container of the disclosure was compared to a conventional, flat, rectangular-shaped gel pack of the same weight (2 lbs.), in identical insulated containers. The container of the disclosure maintained 2-8°C for 48 hours under a constant ambient temperature of 24°C, whereas the conventional gel pack of the same weight and under the same ambient temperature lasted only 38 hours before reaching 8°C.

In FIG. 6, a container lOOC includes an outer shell 102 houses a solid, for example frozen, core 1 10 formed of gel 200. Core 1 10 may alternatively advantageously be formed inside a flexible container, for example a plastic bag. A reservoir 1 12 is formed within the core, for example by inserting a reservoir shaped object into core 1 10 before it becomes solid. The object may be left in place, particularly if it is open at an end, whereby objects may be contained therewithin. An insulating cap 108 may advantageously be placed upon container 100B to facilitate maintenance of a temperature within core 1 12, and or to retain materials within core 1 12. Core 110 may additionally be formed within shell 102.

In FIG. 7, container lOOC is formed of a solid gel core 110, for example with frozen gel, without shell 102. As with the embodiment of FIG. 6, core 1 10 may be formed within a bag, whereupon gel material may be retained upon melting.

In FIG. 8, a container 100E is formed in accordance with any of the embodiments disclosed herein, and includes an extending edge 114, deviating from a cylinder in order to form an angular longitudinal profile. More particularly, edge 114 extends radially outward from a longitudinal axis of a cylindrical core shape of container 100E, and continues along at least a portion of the longitudinal length of container 100E. Edge 1 14 therefore forms a longitudinal edge having a radius smaller than a cylindrical portion of container 100E, for example an acute radius. In one embodiment, edge fosters the maintenance of container 100E in an upright position within a box, for example by placing container 100E with edge 1 14 extending into a folded edge of the box. Advantageously urged into a box corner by the payload contained within the boxy, or by other packing materials, container 100E has an increased likelihood of maintaining a position within the container during transshipment, as compared with a cylindrical container. It is advantageous for container 100E to maintain a position with respect to the payload, for example, in order to promote a temperature transfer between the payload and container 100E, to thereby maintain a temperature of the payload. Further, maintaining a position of container 100E reduces a potential for container 100E to strike the payload, thereby potentially causing damage to either the payload or container 100E. The foregoing advantages may additionally be realized if container 100E is positioned to lie flat within a box, with edge 114 extending into a lower folded edge of the box.

With reference to FIGS. 10-12, a mailing pouch 500 is advantageously composed of materials that are biodegradable. Outer cover 502 of pouch 500 includes a biodegradable film or paper that extends laterally so its lateral edges or margins 504 can be heat sealed together. At the bottom of the pouch 500, outer cover 502 is folded at fold 506. At the top of pouch 500, the front top edge 508 terminates at opening 510, and a back side of cover 502 continues upwardly to form flap 512, enabling pouch 500 to be sealed by folding flap 512 over the front of pouch 500, sealing opening 510. Flap 512 has a lateral stripe of adhesive 514

advantageously covered with a removable protecting covering 516. The inner surface of the pouch 500 includes a gusset 518. A thermal insulating material 520 lines an inner surface of cover 502.

FIG. 12 illustrates container 100E positioned within pouch 500. Edge 114 is advantageously employed to open an interior of pouch 500, and more particularly, to expand gusset 518, creating an expanded and efficient space for the deposition of payload. Edge 114 may be positioned within or near a crease in cover 502, and thereby stabilize container 100E from rolling within pouch 500.

Thus, the use of a container 100 (including 100A-E) provides at least the following advantages: pouch 500 is held in an upright and open for easy loading; as at least a portion of container 100, and particularly 100E is tucked within gusset 518, valuable payload space is avoided, and further useful payload space is made available within pouch 500; the cylindrical shape of container 100 maintains a lower temperature for a longer period than a flat or pouch shaped refrigerant container that may otherwise have been placed within pouch; and provided pouch 500 is made from biodegradable or recyclable materials, the assembly of both pouch 500 and container 100 together are biodegradable and or recyclable. FIG. 1 1A illustrates an alternative location of gusset 518, formed to extend inwards from an end of pouch 500.

Non-Limiting Examples

Although specific embodiments of the subject matter have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the disclosed subject matter. The scope of the disclosure is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover any and all such applications, modifications, and

embodiments within the scope of the present disclosure.

Whereas the specific dimensions are given above, it will be appreciated that variations in dimensions of these elements that do not adversely affect the performance of the gel pack for any particular application, will be apparent to those skilled in the art, from the teachings herein, and are deemed to be included within the purview of the invention. In this regard, although the invention has been shown and described in terms of preferred embodiments, nevertheless, such changes and modifications can be made by those skilled in the art without departing from the teachings herein. The embodiments as disclosed herein, and such examples, illustrations, and theories are for explanatory purposes and are not intended to limit the invention.