REUSABLE CONTAINER

TECHNICAL FIELD

This disclosure relates to reusable containers for refrigerating products such as food products.

BACKGROUND

The importance of keeping products refrigerated or frozen is well understood. For example, food products must be refrigerated to prevent spoilage or growth of undesirable organisms. Products such as organs for transplant must be kept refrigerated so they can maintain their viability for transplant. Some pharmaceutical products must be kept refrigerated to maintain their efficacy. Typically, these products are refrigerated at refrigerating temperatures just above freezing, e.g., greater than 32°F to 4FF (greater than 0 ⁰ C to 5°C). In addition, products such as food products may be stored and transported frozen to maintain long term freshness, e.g., from -10 ⁰ F to less than 32°F (-23 ⁰ C to less than 0 ⁰ C). There is a need for reusable containers that not only keep products refrigerated or frozen but that are also able to keep products refrigerated or frozen for 4 hours or more.

SUMMARY

A reusable container for storing or transporting a product to be refrigerated or frozen such as a food product is provided, comprising an inner wall, an outer wall, and a wall space provided between the inner wall and the outer wall that comprises a slurry. The wall space is substantially separated from the environment outside of the reusable container. For example, the inner wall and the outer wall can be connected together such that the wall space is fully contained. In some embodiments, the slurry is loose within the wall space and allowed to move freely within the wall space. In some embodiments, 50-99% or 75-95% of the wall space comprises the slurry. The slurry can include, for example, a salt of 2-propenoic acid and/or a glycol material.

In some embodiments, the container is generally rectangular, the inner wall is a first inner wall and the outer wall is a first outer wall; and the container further comprises second, third and fourth inner walls and second, third and fourth outer walls; a bottom; and a top. In some embodiments, the container is generally Attorney Docket No.: 23291-0015WO1

cylindrical and further comprises a bottom and a top. In some embodiments, the container can include a bottom and the bottom can include an inner bottom wall and an outer bottom wall with a bottom space therebetween, wherein the bottom space includes the slurry. In some embodiments, the container can include a top and the top can include an inner top wall and an outer top wall with a top space therebetween, wherein the top space includes the slurry. In some embodiments, at least one of the inner wall and the outer wall is formed from steel or an insulating plastic material.

In some embodiments, the container is stackable. For example, the container can include protrusions on a top end of the container and corresponding indentions on a bottom end of the container. The container can, in some embodiments, include a hinged lid, the lid including a lid space therein and comprising a slurry within the lid space. In some embodiments, a chamber is formed by the interior surface of the inner wall and an interior surface of a bottom. In some embodiments, the container includes an assembly that allows the container to be locked. In some embodiments, the container can include a single chamber for storing products to be refrigerated within said inner wall. In some embodiments, the container can include two chambers for storing products within said inner wall and two lids, wherein each lid corresponds to a particular chamber. The container can include a chamber defined by an interior surface of the inner wall of the container that is capable of maintaining a refrigerating temperature of greater than 32 to 41 ⁰ F for 4 or more, or even 8 or more hours in a room temperature environment. Alternatively, the chamber is capable of maintaining a freezing temperature of -10 to less than 32°F for 4 or more, or even 8 or more hours in a room temperature environment. In some embodiments, the inner wall and the outer wall have substantially the same thickness. A secondary insulating material such as a secondary container can be used to surround the reusable container.

A method of shipping a product to be refrigerated in a reusable container is also provided. The method comprises refrigerating a reusable container comprising an inner wall, an outer wall, a wall space provided between the inner wall and the outer wall, the wall space being substantially separated from the environment outside of the reusable container, and a slurry provided in the wall space. A product to be refrigerated can be inserted into the reusable container and then stored in the reusable container until it can be used or consumed. In some embodiments, the product to be refrigerated in the reusable container can be stored at a refrigerating temperature (e.g. Attorney Docket No.: 23291-0015WO1

at a temperature of greater than 32 to 41 ⁰ F) or a freezing temperature (e.g. at a temperature of -10 to less than 32°F) for 4 or more or 8 or more hours.

A method of producing a reusable container for storing or transporting a product to be refrigerated or frozen is also provided. The method comprises first forming a container comprises a side inner wall, a side outer wall, a side wall space provided between the inner wall and the outer wall, a bottom inner wall, a bottom outer wall, a bottom wall space provided between the bottom inner wall and the bottom outer wall, and an aperture in communication with the bottom wall space, wherein the bottom wall space is in fluid communication with the side wall space. The container can then be inverted and a slurry provided through the aperture to allow the slurry to flow into the bottom wall space and the side wall space such that the total bottom wall space and the side wall space is at least 50% filled with the slurry. The aperture can then be sealed such as through sonic welding to prevent the slurry from leaking out of the container. The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a reusable container that is generally rectangular.

Figure 2 is a view drawn along line 2-2 of Figure 1 that illustrates a wall space between inner and outer walls.

Figure 3 is a perspective view of a reusable container that is generally rectangular and includes a lid or top portion. Figure 4 is a perspective view of the reusable container of Figure 3 with a portion cutaway.

Figure 5 is a perspective view of only the lid or top portion of a reusable container further illustrating a plug.

Figure 6 is a perspective view of only the lid or top portion of a reusable container.

Figure 7 is a perspective view of a bottom portion of a reusable container further illustrating a plug. Attorney Docket No.: 23291-0015WO1

Figure 8 is an alternative perspective view of the reusable container of Figure 7.

Figure 9 is a front view of a reusable container that is generally cylindrical.

Figure 10 is a front view of the reusable container of Figure 9 with portions cut away and the lid opened.

Figure 11 is a side view of two generally rectangular containers stacked upon each other.

Figure 12 is a side partial cutout view of the containers in Figure 11 stacked upon each other. Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

The term "comprising" and variations thereof as used herein are used synonymously with the term "including" and variations thereof and are open, non- limiting terms. A reusable container for storing or transporting a product to be refrigerated or frozen is provided. Any product to be refrigerated or frozen can be used with the reusable container. For example, a food product or a beverage can be provided in the container. Alternatively, a pharmaceutical product, a transplantable organ, or other products to be refrigerated or frozen can be stored and transported in the container. The reusable container comprises an inner wall, an outer wall, a wall space provided between the inner wall and the outer wall, the space being substantially separated from the environment outside of the reusable container, and a slurry provided in the wall space. In some embodiments such as the embodiment in Figure 1, the reusable container 10 can be generally rectangular in shape and can include rounded corners. The reusable container in Figure 1 includes inner walls 12, 22, 32 and 42 and corresponding outer walls 14, 24, 34, and 44, respectively. The inner walls 12, 22, 32 and 42 and respective outer walls 14, 24, 34 and 44 can include a wall space therebetween. For example, as shown in Figure 2, the inner wall 12 and outer wall 14 can include a wall space 16 and the wall space can further include a slurry 18. Although not shown in Figure 1, wall spaces can also exist between inner wall 22 and outer wall 24, inner wall 32 and outer wall 34, and/or inner wall 42 and outer wall 44, and can further include the slurry. For example, Figure 4 illustrates a Attorney Docket No.: 23291-0015WO1

wall space 26 in phantom between inner wall 22 and outer wall 24, a wall space 36 between inner wall 32 and outer wall 34 and a wall space 46 between inner wall 42 and outer wall 44. In some embodiments, at least two, at least three, or all four of the respective inner and outer walls include a wall space and can further include a slurry in the wall space.

The wall space 16 is substantially separated from the environment outside of the reusable container 10. For example, the wall space 16 can be separated from the outside environment during normal use so the slurry 18 is not exposed to the environment as it could affect the performance of the slurry. However, the wall space 16 may be accessible to the outside environment if the slurry 18 in the wall space 16 needs to be replaced or replenished. In some embodiments, the wall space 16 can be separated from the outside environment and can be fully contained by connecting the inner wall 12 and outer wall 14 together, for example, at locations 50 and 52 shown in Figure 2. In some embodiments, the reusable container 10 includes a top portion. For example, as shown in Figure 3, the top portion 58 can include two lids 60 and 62. The lid (e.g. lid 60) can include an inner lid wall or inner top wall 64 and an outer lid wall or outer top wall 66 with a inner lid space or inner top space 68 between the inner lid wall 64 and the outer lid wall 66 as shown in Figure 4. The inner top space 68 can further include a slurry. Although not shown in Figure 3 or 4, the lid 62 can have the same configuration as the lid 60. Furthermore, although the top portion 58 of the reusable container in Figure 3 includes two lids 60 and 62, one lid can alternatively be used or more than two lids can be used. In some embodiments, the lids 60 and 62 have the ability to be locked to the container 10 using holes 70 and 72 and by using a lock or a metal or plastic security seal (not shown). This allows the reusable container 10 to be tamper proof.

Figures 5 and 6 further illustrate the lids 60 and 62. As shown these figures, the lids 60 and 62 can be hinged and rotate along axis 74. The lids 60 and 62 can also include a plug 76 that substantially separates the lid space 68 from the environment outside of the reusable container. This plug 76 is provided at a location where a hole is provided in the lid 60 so the slurry can be provided in the lid space 68. Once the slurry is provided, the plug 76 can be sonic welded so the slurry is contained within the lid space 68. This prevents leakage of the slurry outside of the lid space 68. Attorney Docket No.: 23291-0015WO1

As shown in Figures 3 and 4, the reusable container 10 can further include a bottom portion 80 such as bottom 82. The bottom 82 can include a bottom inner wall 84 and a bottom outer wall 86. A bottom space 88 can be provided between the bottom inner wall 84 and the bottom outer wall 86, and can further include a slurry. Figure 7 provides an additional view of the reusable container 10 that illustrates the bottom portion 80 and bottom 82. As shown in Figure 7, the bottom 82 can include a plug 90 that provides a hole 92 where the slurry can be provided to the bottom space 88 and the wall spaces (16, 26, 36 and 46), which can communicate with the bottom space 88. The container 10 can be inverted, the slurry provided through the hole 92 and then the plug 90 can be sonic welded to contain the slurry within the bottom space

88 and the wall spaces (16, 26, 36 and 46) to prevent leakage of the slurry and to separate the bottom space 88 and the wall spaces (16, 26, 36 and 46) from the outside environment. A drainage hole (not shown) can optionally also be included to facilitate cleaning or to otherwise remove liquids from the container 10 by providing access to the outside environment.

As shown in the figures, a chamber 100 is defined by the respective interior surfaces of the inner walls 12, 22, 32, and 42, the interior surface of the top 58 and the interior surface of the bottom 82. As shown in Figure 8, the bottom of the chamber 100 (or the inner bottom wall 84) can be sloped along directions 94 to allow liquids to collect in one location in the container 10, particularly when a drainage hole is used.

Alternatively, the bottom of the chamber 100 can be substantially flat. Although the container 10 is drawn with a single chamber, multiple chambers can be included. For example, a chamber could correspond to each of the lids 60 and 62 and an additional interior wall (not shown) provided to separate the chambers. The interior wall could further include a space and a slurry in some embodiments. Although not shown, the container can also include one or more integral handles to facilitate transportation of the container.

The inner walls 12, 22, 32 and 42 and the outer walls 14, 24, 34 and 44 can have thicknesses of between about 1/4 and about 3/4 inch (e.g. 1/2 inch). In some embodiments, the inner walls 12, 22, 32 and 42 all have approximately the same thickness (e.g. within about 10%) and the outer walls 14, 24, 34 and 44 all have approximately the same thickness. In some embodiments, the inner walls 12, 22, 32 and 42 and the outer walls 14, 24, 34 and 44 all have approximately the same Attorney Docket No.: 23291-0015WO1

thickness. The wall spaces 16, 26, 36 and 46 can have widths of about 1/2 and about 1 1/4 inches (e.g. 7/8 inch). The lid inner wall 64 and the lid outer wall 66 can have thicknesses of about 1/4 and about 3/4 inch (e.g. 1/2 inch) with the space 68 therebetween having a width of about 1/2 and about 1 1/4 inches (e.g. 7/8 inch). The bottom inner wall 84 and the bottom outer wall 86 can have thicknesses of about 1/4 and about 3/4 inch (e.g. 1/2 inch) and the bottom wall space 88 can have a width of about 1/2 and about 1 1/4 inches (e.g. 7/8 inch).

In some embodiments such as the embodiment in Figures 9 and 10, the container 110 can be generally cylindrical. The cylindrical container can include an inner wall 112 and an outer wall 114, with a wall space 116 therebetween. The wall space 116 can include a slurry 118. As with the embodiments illustrated in Figures 1- 8, the wall space 116 can be substantially separated from the environment outside of the reusable container 110. The container 110 further includes a top portion 120 such as top 121 and a bottom portion 122 such as bottom 123. The top 121 can include a lid 124 and the lid can be hinged. The lid can include an outer lid wall 126 and an inner lid wall 128 and a space 130 therebetween that can further include a slurry. A chamber 132 can be formed by the interior surface of the inner wall 112, the interior surface of the top 121 and the interior surface of the bottom 123 for the product to be refrigerated. The bottom 123 can include a bottom inner wall 136, a bottom outer wall 138, and a bottom space 140 therebetween that can further include a slurry.

Although not shown in Figures 9 and 10, a hole can be provided in the bottom outer wall 138 to access the bottom space 140 and the wall space 116 and the container 110 inverted and the slurry fed through the hole. The hole can then be sealed as described herein. A hole can also be provided in the lid inner wall 128 that accesses the lid space 130 for providing the slurry and the hole can be sealed as described herein. The thicknesses of the walls and the widths of the spaces between the walls can be in the same ranges described for the generally rectangular container 10. Although the container is illustrated in the figures to be either generally rectangular or generally cylindrical, it can be provided with different shapes if desired. In some embodiments such as the embodiment illustrated in Figures 11 and

12, the reusable container can be stackable. Figures 11 and 12 illustrate two containers 150 and 152 stacked upon one another. The reusable containers 150 and 152 can include any features that allow the containers to be stacked. For example, as Attorney Docket No.: 23291-0015WO1

illustrated by top container 150 in Figures 11 and 12, a top end 154 of the container 150 can include protrusions 156 and 158. The top container 150 can also include indentions 160 and 162 on a bottom end 164 of the container. The bottom container 152 can include protrusions 166 and 168 at the top end 170 that correspond to the indentions 160 and 162 of the top container 150.

The reusable container 10 can be formed of any suitable material. Exemplary materials include steel and insulating plastic material and the entire container can be made of the same material or different materials can be used for different portions of the container. In some embodiments, all or a portion of the container can be formed of a polycarbonate, a polyethylene polymer or copolymer, or a hexene copolymer material. An exemplary hexene copolymer is a linear low density hexene copolymer sold by ExxonMobil as a LL 8555 series LLDPE. The insulating plastic material can be formed of a food grade chemical and can have inherent fire retardance or UV stability or can further include additives such as a fire retardants, mold inhibitors and UV stabilizers. The plastic material can also include a filler material such as fibers or filler particles. In some embodiments, the use of an insulating plastic material results in a container that is dishwasher safe and/or that has low warpage. In some embodiments, the material used for the container can have a shelf life of 5 or more years and can be suitable for approval by the National Sanitation Foundation (NSF). As discussed above, a slurry can be provided in a wall space (e.g. slurry 18 in wall space 16). The slurry can include a polymer latex and/or a glycol material. For example, a latex such as LUQUASORB FP 800 latex (BASF Corporation) comprising a 2-propenoic acid homopolymer, sodium salt (93.6%), water (5%) and propylene glycol (1%) can be used as the latex material in the slurry. An exemplary glycol material includes a CARBOWAX polyethylene glycol or methoxypolyethylene glycol material (Dow/Union Carbide). Other glycols can also be used including ethylene glycol, diethylene glycol, propylene glycol, and polymers or copolymers of these glycols, and the like. In some embodiments, the slurry can be modified by adding liquid nitrogen to the above components. For example, the liquid nitrogen can be injected into the slurry composition, e.g., in an amount of 1-10%, 2-8% or 5% by weight of the slurry composition. Once provided in the composition to form the slurry, the liquid nitrogen can become a dissolved gas within the slurry. The chemicals used in the slurry can be food grade chemicals such as the LUQUASORB Attorney Docket No.: 23291-0015WO1

FP 800 latex discussed above so possible leakage of the slurry does not cause health issues. The chemicals used in the slurry can also, in some embodiments, also provide fire retardance to the container. In some embodiments, the slurry can be provided in more concentrated form to increase the ability of the slurry to maintain the refrigerating or freezing temperature.

In some embodiments, the slurry is allowed to move freely within the wall space (and also the top space and bottom space where included in the container). For example, the slurry can be provided loose within the wall space and contained only by the inner and outer walls. Thus, the slurry is not confined by other means such as by being provided in a gel pack. The slurry can occupy 50-99%, 75-95% or 80-90% of the total space (i.e., the total wall space, top space and bottom space). The amount of slurry used can depend on the level of refrigeration desired for the container (e.g. refrigerating temperatures or freezing temperatures) and the products to be provided therein. In some embodiments, the chamber 100 is capable of maintaining a refrigerating temperature of greater than 32 to 41 ⁰ F for 2 or more, 4 or more, 6 or more, 8 or more, or even 10 or more or 12 or more hours in a room temperature environment (outside of the container). In some embodiments, the chamber 100 is capable of maintaining a freezing temperature of -10 to less than 32°F for 2 or more, 4 or more, 6 or more, 8 or more, or even 10 or more or 12 or more hours in a room temperature environment. In some embodiments, the temperature in the container increases less than 0.5°, less than 0.75°, or less than 1°F per hour. In some embodiments, the container can include a temperature gauge to provide the temperature of the chamber 100. Although not shown, a cooling blanket can further be used within the container to further increase the refrigeration of the container. In some embodiments, a secondary insulating material (not shown) can surround the container to further increase the ability of the container to maintain refrigerating temperatures for longer periods of time and can limit condensation on the exterior of the container. The secondary insulating material can, for example, be in the form of a secondary container such as a MYLAR bag, cardboard or an insulated, optionally foamed, plastic container that surrounds the reusable container.

For example, ROXUL mineral wool insulation available from Roxul, Inc., which comprises 94-99% mineral fiber bound using a cured urea extended phenolic formaldehyde binder (1-6%) can be used as the secondary insulating material. The Attorney Docket No.: 23291-0015WO1

mineral wool insulation can be provided as an insulated blanket that is customized to cover all the side of the container 10 and then the covered container can be placed in corrugated cardboard case for storage or transport. Although able to maintain a refrigerating or freezing temperature, the reusable container can, in some embodiments, still be heated to temperatures exceeding 100 ⁰ F without damage to the container or slurry.

The reusable container can be produced by various methods. In some embodiments, particularly where a plastic material is used to form the container, the container can be formed in a mold such as a rotational mold (rotomold) by providing the plastic material as a powder, heating the powder to allow it to flow within the mold, and casting the mold. Holes provided in the container to provide the slurry composition can be sealed using a sonic spin weld.

A method of shipping a product to be refrigerated in a reusable container is also provided. The method comprises refrigerating a reusable container as described above. For example, the reusable container can be provided in a standing refrigerator or freezer to provide the desired initial temperature. In some embodiments, the container can be refrigerated at a temperature of -30 to 41 ⁰ F, with temperatures greater than 32°F typically used for products to be stored at refrigerating temperatures and less than 32°F used for products to be stored at freezing temperatures. A product to be refrigerated or frozen can be inserted in the reusable container and then stored in the reusable container until it can be used or consumed. As mentioned above, the product can be kept in the container in a refrigerating or freezing environment for the periods of time discussed above.

Depending on the particular level of refrigeration desired for the reusable container, certain parameters in the container can be modified. For example, the number of wall, top or bottom spaces and how many of these spaces include slurry can affect the level of refrigeration for the container (at a refrigerating or freezing temperature). The percentage of the total space occupied by the slurry can also affect the level of refrigeration . The container materials selected, the inner wall thicknesses, the outer wall thicknesses, the wall space widths, the slurry composition and the slurry viscosity can all be selected or modified to provide a particular level of refrigeration. For example, the wall thicknesses and/or the space widths can be Attorney Docket No.: 23291-0015WO1

increased to increase the ability of the container chamber to maintain the desired temperature.

A number of embodiments have been described. Nevertheless, it will be understood to one skilled in the art that various modifications may be made. Further, while only certain representative combinations of the formulations, methods, or products are disclosed herein are specifically described, other combinations of the method steps or combinations of elements of a composition or product are intended to fall within the scope of the appended claims. Thus a combination of steps, elements, or components may be explicitly mentioned herein; however, all other combinations of steps, elements, and components are included, even though not explicitly stated.