CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 63/379,496 filed on October 14, 2022, and entitled “Interlocking Panels and Assembled Boxes”; U.S. Provisional Application No. 63/380,487 filed on October 21, 2022, and entitled “Crimped Seam for Packaging Materials”; U.S. Provisional Application No. 63/380,534 filed on October 21, 2022, and entitled “Perforated and Crimped Seam for Packaging Materials”; and U.S. Provisional Application No. 63/385,852 filed on December 2, 2022, and entitled “Geometric Containers With Paper-Foam -Paper-Crimp Technology”, each of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

[0002] The present disclosure relates generally to the field of shipment packaging, and in particular but not exclusively, relates to foam material paneling providing internal thermal control and shock protection for contents of the container, such as shipping boxes, bins, or the like.

BACKGROUND

[0003] Shipping packaging containers are essential for the safe and efficient transportation of various goods. These containers must protect their contents not only from external physical impacts but also from temperature variations that can adversely affect the quality and integrity of certain products, such as perishable food items, electronics, pharmaceuticals, and chemicals. Achieving efficient thermal control to provide content protection within a packaging solution is a complex challenge that has been the focus of considerable research and development efforts. [0004] Current technology solutions include blow-molded plastics formed into customized shapes, which are limited in terms of versatility for different packaging configurations, foam embedded in a flexible packaging material, which is intended to conform to various packaging configurations, but causes gaps in the foam at corners and between pieces of flexible packaging material, and other solutions with significant drawbacks in cost, waste, versatility, performance, etc. Traditionally, insulating packaging included materials such expanded polystyrene (EPS), polyurethane foam, or vacuum- insulated panels to maintain temperature control during shipping, while cushioning materials, such as bubble wrap, air pillows, and foam pieces have been utilized to protect fragile items from physical shocks and vibrations during transit.

[0005] Therefore, a need exists for shipment packaging that provides internal thermal control and shock protection for the contents of the container, with improved versatility and performance over conventional shipment packaging technology, among other benefits. Embodiments of the present disclosure are directed to these and other improvements.

DESCRIPTION OF THE DRAWINGS

[0006] The foregoing aspects and many of the attendant advantages of the claimed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0007] FIGURE 1A depicts an isometric view of a shipment packaging assembly, in which technologies and/or methodologies of the present disclosure may be employed;

[0008] FIGURE IB is a front view of a panel of the shipment packaging assembly of FIGURE 1A; [0009] FIGURE 1C is a perspective view of a panel having a backing layer and configured for use in a shipment packaging assembly, in accordance with an embodiment of the present disclosure;

[0010] FIGURE ID is an isometric view of a shipment packaging assembly constructed from the panel of FIGURE IB, in accordance with an embodiment of the present disclosure;

[0011] FIGURE 2A is a front view of a panel configured for use in a shipment packaging assembly, in accordance with an embodiment of the present disclosure;

[0012] FIGURE 2B is an isometric view of a shipment packaging assembly constructed from the panel of FIGURE IB and the panel of FIGURE 2A, in accordance with an embodiment of the present disclosure;

[0013] FIGURE 3A is a front view of panels configured for use in a shipment packaging assembly, in accordance with an embodiment of the present disclosure;

[0014] FIGURE 3B is an isometric view of a shipment packaging assembly constructed from the panels of FIGURE 3A, in accordance with an embodiment of the present disclosure;

[0015] FIGURES 4A and 4B are exploded and assembled perspective views, respectively, of the shipment packaging assembly of FIGURE 3B inserted into a shipment container, in accordance with an embodiment of the present disclosure;

[0016] FIGURE 5 A is a perspective view of panels configured for use in a shipment packaging assembly, showing spacer members operably coupled to an outer surface of the panels, in accordance with an embodiment of the present disclosure;

[0017] FIGURE 5B is an isometric view of a shipment packaging assembly constructed from the panels of FIGURE 5A and inserted into a shipment container, in accordance with an embodiment of the present disclosure;

[0018] FIGURE 6A is a perspective view of a shipment packaging panel assembly, in accordance with an embodiment of the present disclosure; [0019] FIGURE 6B is a perspective view of the shipment packaging panel assembly of FIGURE 6A, shown in a folded configuration with corner portions extending inward;

[0020] FIGURE 6C is a perspective view of the shipment packaging panel assembly of FIGURE 6A, shown in a folded configuration with corner portions extending outward;

[0021] FIGURE 6D is a perspective view of the folded configuration of the shipment packaging panel assembly of FIGURE 6B, shown with a lid portion and a base portion, in accordance with an embodiment of the present disclosure;

[0022] FIGURE 6E is a perspective view of the folded configuration of the shipment packaging panel assembly of FIGURE 6C, shown with a lid portion and a base portion, in accordance with an embodiment of the present disclosure;

[0023] FIGURE 7A is a perspective exploded view of a packaging panel, in accordance with an embodiment of the present disclosure;

[0024] FIGURE 7B is a perspective exploded view of the packaging panel of FIGURE 7A, shown with a thermal coupling tool aligned with an edge of the packaging panel;

[0025] FIGURE 7C is a perspective view of the packaging panel of FIGURE 7A, showing thermally crimped edges of the packaging panel after use of the thermal coupling tool; and

[0026] FIGURES 8A and 8B are perspective views of shipment packaging containers having thermally crimped portions, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0027] The detailed description set forth above in connection with the appended drawings, where like numerals reference like elements, are intended as a description of various embodiments of the present disclosure and are not intended to represent the only embodiments. Each embodiment described in this disclosure is provided merely as an example or illustration and should not be construed as preferred or advantageous over other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed.

[0028J As will be described in more detail below, the present disclosure provides examples of shipment packaging, such as foam material paneling and thermally crimped paneling providing internal thermal control and shock protection for contents of a container. The containers suitable for use with the embodiments of the present disclosure can be shipping boxes, bins, or the like. Disclosed herein are embodiments of systems of interlocking panels, which can be made from foam and combined together to create a gap- free or minimized gap interior space within an outer package (e.g., a shipping box, carton, etc.). The gap-free or minimized gap configurations maximizing thermal insulation properties, while allowing different container sizes to be insulated with the modular panel systems. Although the following description and the FIGURES show various configurations of the modular panel systems shown as shipment packaging assemblies, these are intended as example embodiments, and other configurations are also within the scope of the present disclosure.

[0029] FIGURES 1A and ID depict isometric views of a shipment packaging assembly 110 (“assembly 110,” FIGURE 1A) and a shipment packaging assembly 112 (“assembly 112,” FIGURE ID), in which technologies and/or methodologies of the present disclosure may be employed. FIGURE IB is a front view of a panel 102 of the assembly 110. FIGURE 1C is a perspective view of a panel assembly 114 with the panel 102 (e.g., a foam panel) having a stiffening backing layer 108 (e.g., cardboard, paper, card stock, plastic, film, etc.), the panel assembly 114 being configured for use in a shipment packaging assembly, such as the configuration of the assembly 100, in accordance with an embodiment of the present disclosure. As shown in FIGURE 1A, the assembly 110 includes a configuration of six of the panels 102 arranged in a generally cubic shape, and as shown in FIGURE ID, the assembly 112 includes a configuration of ten of the panels 102 arranged in a generally cuboid shape, with two of the panels 102 arranged in parallel lengthwise to lengthen the assembly 112. In other embodiments, the panels can be sized and shaped to form a cone, a cylinder, a pyramid, or other suitable shapes. The panel 102 includes projection and recess features that allow the panels 102 to be interlocked when assembled into the shape of the assemblies 110 and 112, among other possible assembled configurations. The panels 102 and the assemblies 110 and 112 are intended to be inserted into shipment packaging, such as a shipping box or container as will be described below with reference to FIGURES 4A and 4B, and provide internal thermal control and shock protection for contents of the container.

[0030] Each panel 102 can include the projection and recess features to allow interlocking with other panels 102 into assemblies for shipment. In the illustrated embodiment shown in FIGURE IB, a first edge of the panel 102 includes a first recess 103, a first projection 104, a second recess 105, and a second projection 106. Each of the other edges of the panel 102 similarly include these recesses and projections so that all sides of the panel 102 can be interlocked with other panels 102 by inserting a projection into a recess. Although a substantially square panel is shown, other panel shapes are within the scope of the present disclosure, e.g., rectangular (see FIGURE 2A), triangular, cylindrical, circular, etc.

[0031] As shown, the recesses 103 and 105 and the projections 104 and 106 of the panel 102 can have depths/lengths that generally correspond to the thickness of the panel so that in an assembly, e.g. the assembly 110, the corners of the assembly are flush as shown in FIGURE 1A. In this regard, the depth/length of the recesses 103 and 105 and projections 104 and 106 is shown as dimension a, which corresponds to the thickness of the panel 102. The first recess 103 can have a width shown as dimension b, which in some embodiments can be about three times the dimension a. The first projection 104 can have a width shown as dimension c, which in some embodiments can be about three times the dimension a. The second recess 105 can have a width shown as dimension d, which in some embodiments can be about three times the dimension a. The second projection 106 can have a width shown as dimension e, which in some embodiments can be about two times the dimension a. In other embodiments, any number of recesses and projections can be used with the panel 102 to interlock with other panels, for example, only a single recess and projection on each edge of the panel, or more than two recesses and projections on each edge of the panel, etc. Further, although the depth/length of the recesses and projections are about the same dimension as the thickness of the panel, in other embodiments, the depth/length of the recesses and projections may not correspond to the thickness of the panel.

[0032] In some embodiments, the panel 102 is made of expanded polystyrene, expanded polyethylene, expanded polyurethane, expanded polyvinyl chloride, expanded material that may or may not be petroleum based, expanded starch and/or expanded starch derivatives, mushroom foam, or the like. In other embodiments, the material of panel 102 contains starch, chitosan, and/or fibers in any suitable combination. In some embodiments, the panel 102 can be formed by an extrusion process, can be vacuum formed, can be expanded in a mold, or can be die cut, laser cut, or otherwise cut to form the shape of the panel 102.

[0033] FIGURE 2 A is a front view of a rectangular panel 120 configured for use in a shipment packaging assembly 116 (“assembly 116”) as shown in FIGURE 2B, in accordance with an embodiment of the present disclosure. The assembly 116 can be constructed from the panels 102 for the ends of the assembly 116, and the panels 120 for the sides of the assembly 116. In this configuration, the shape of the assembly 116 can be similar to the assembly 114, except that the side panels 120 are a single piece rather than two of the panels 102 arranged in a parallel configuration. The panels 120 can have similar recesses and projections as the panels 102, or can include a different recess and projection configuration, such as having a fewer or greater number of recesses and projections than what is depicted in FIGURES 2A and 2B. For example, the longer edge of the panel 120 has four recesses and four projections; however, in other embodiments, the panel can have fewer or more than four recess and projection pairs. The panel 120 can have a recess and projection configurations such that, when assembled, the corners of the assembly 116 do not have gaps like the comers of, e.g., the assemblies 110 and 112. The panels 120 can be made from the same materials as the panel 102, described above.

[0034] FIGURE 3 A is a front view of first panels 202, second panels 204, and third panels 206 configured for use in a shipment packaging assembly 210 (“assembly 210”) as shown in FIGURE 3B, in accordance with an embodiment of the present disclosure. The first, second, and third panels 202, 204, and 206 can have different recess and projection configurations such that, when assembled, the corners of the assembly 210 do not have gaps like the corners of, e.g., the assemblies 110 and 112. As shown, the assembly 210 can include two of each of the first, second, and third panels 202, 204, and 206, with each pair of panels being arranged on opposite sides of the cube-shaped assembly 210. In other embodiments, the first, second, and third panels 202, 204, and 206 can be arranged to form other shapes, such as an elongated assembly similar to the assembly 114.

[0035] FIGURES 4A and 4B are exploded and assembled perspective views, respectively, of the assembly 210 inserted into a shipment container 220, in accordance with an embodiment of the present disclosure. As shown, the panel 206 can include a stiffening backing layer 208 to form a panel assembly 214 (similar to the panel assembly 114 of FIGURE 1C). Although not shown, the panels 202 and 204 can similarly have a stiffening backing layer, or can be assembled into the shipment container 220 without a stiffening backing layer. In some embodiments, only the topmost panel 206 includes the stiffening backing layer 208. When assembled into the shipment container 220, the assembly 210 can be sized and shaped to closely correspond to the internal surfaces of the shipment container 220 such that the assembly 210 does not substantially move relative to the shipment container 220 during transit. In some embodiments, the panels 202 and 204, and the bottommost panel 206 can be secured to the shipment container 220, e.g. by adhesive, such that the panels do not shift with respect to the shipment container 220 during removal of the topmost panel 206 upon receipt of the package. In other embodiments, the size of the assembly 210 relative to the shipment container 220 may cause a secure friction fit of the panels 202 and 204 such that these panels do not shift with respect to the shipment container 220 during removal of the topmost panel 206.

[0036] FIGURE 5A is a perspective view of the panels 202, 204, and 206 configured for use in a shipment packaging assembly, showing spacer members operably coupled to an outer surface of the panels 202, 204, and 206, in accordance with an embodiment of the present disclosure. For example, the panel 202 can include a spacer member 203a or a spacer member 203b, each in a general “X” configuration. The panel 204 can include spacer members 205a and 205b in a general “+” configuration, or a spacer member 205c arranged parallel to two of the edges of the panel 204. The panel 206 can include a spacer member 207a or a spacer member 207b, each arranged parallel to two of the edges of the panel 206. The configuration of the spacer members is intended as one example of spacer members that can be added to the panels to space the panels away from the internal surfaces of the shipment container. In this regard, other spacer member configurations are also within the scope of the present disclosure.

[0037] In use, the spacer members can position a panel in a spaced apart configuration with respect to the internal surface of the shipment container. FIGURE 5B is an isometric view of a shipment packaging assembly, such as the assembly 210, constructed from at least one of the panels of FIGURE 5 A and inserted into the shipment container 220, in accordance with an embodiment of the present disclosure. Although the configuration shown in FIGURE 5B only includes the spacer member 203b on one of the panels 202, any number of the panels in the assembly can have spacer members, such as all of the panels when the entire assembly of panels is intended to be spaced apart from the internal surfaces of the shipment container 220. [0038] FIGURE 6A is a perspective view of a shipment packaging panel assembly 300 (“assembly 300”), in accordance with an embodiment of the present disclosure. The assembly 300 can include a foldable panel 302, such as a foam panel having materials described above with reference to the panel 102. The foldable panel 302 can include a stiffening layer 304 of cardboard, paper, card stock, plastic, fdm, etc. In some embodiments, the stiffening layer 304 can include any corrugated cardboard configuration and can be applied using any suitable adhesive. The assembly 300 can include folding regions 306a, 306b, and 306c where corners of the folded configuration of the assembly 300 are intended to be located. In these embodiments, the folding regions 306a, 306b, and 306c may have first, second, and third fold lines including perforations, indentations, or the like to urge the corners to be formed in the folding regions. In this regard, FIGURE 6B shows a perspective view of the assembly 300 (referenced as assembly 300a) in a folded configuration with corner portions formed in the folding regions 306a, 306b, and 306c and extending inward, while FIGURE 6C shows a perspective view of the assembly 300 (referenced as assembly 300b) in a folded configuration with comer portions formed in the folding regions 306a, 306b, and 306c and extending outward. In this folded configuration shown in FIGURES 6B and 6C, the fourth corner of the folded shape can be an overlap region 310 where the ends of the assembly 300 abut. In further embodiments, a moisture barrier layer can be added to the assembly 300 to prevent, e.g., moisture from escaping the internal chamber and wetting the outer shipping container. In these embodiments, a spray-type moisture barrier, such as ECOSHIELD® by CORTEC® Corporation located at 4119 White Bear Parkway, St. Paul, MN 55110, can be applied to the internal surface of the assembly 300.

[0039] FIGURES 6D and 6E are perspective views of the folded configuration of the assemblies 300a and 300b, respectively, shown with a lid portion 320 and a base portion 330, in accordance with an embodiment of the present disclosure. The lid portion 320 can include a panel 322, such as a foam panel having materials described above with reference to the panel 102, and a stiffening layer 324 of cardboard, paper, card stock, plastic, film, etc. the lid portion 320 can be sized and configured to cover the upper opening of the assemblies 300a and 300b such that the contents of the package are surrounded for thermal insulation and/or shock protection. The base portion 330 can include a panel 332, such as a foam panel having materials described above with reference to the panel 102, and a stiffening layer 334 of cardboard, paper, card stock, plastic, film, etc. the base portion 330 can be sized and configured to cover the lower opening of the assemblies 300a and 300b such that the contents of the package are surrounded for thermal insulation and/or shock protection and such that the inner chamber is fully surrounded. In some embodiments, the assembly 300, lid portion 320, and base portion 330 are sized and configured to fit within a standard shipping box, such as a 12”xl2”xl2” box, but any size and configuration is within the scope of the present disclosure. The lid portion 320 can include a foldable handle 326 configured to be grasped by a user to remove the lid portion 320 from the shipment container during opening. In other embodiments, the lid portion can have a cutout or other suitable feature to assist the user in opening the shipment container.

[0040] FIGURE 7A is a perspective exploded view of a packaging panel 404 having a first layer 402a and second layer 402b, in accordance with an embodiment of the present disclosure. FIGURE 7B is a perspective exploded view of the packaging panel 404, the first layer 402a, and the second layer 402b, shown with a thermal crimping tool CR aligned with an edge of the packaging panel 404, and FIGURE 7C is a perspective view of a packaging panel assembly 400 (“assembly 400”) having the packaging panel 404, the first layer 402a, and the second layer 402b, and showing thermally crimped portions 406 (in the embodiment of assembly 400, the thermally crimped portions 406 are the edges) of the packaging panel after use of the thermal crimping tool CR. In these embodiments, the assembly 400 can have a first crimped edge 406a, a second crimped edge 406b, a third crimped edge 406c, and a fourth crimped edge 406d. These crimped edges are formed by the thermal crimping tool CR heating the packaging panel 404 such that the material of the packaging panel 404 forms a mechanical bond with the first and second layers 402a and 402b, sealing the packaging panel 404 therebetween. The foam packaging panel 404 can include chitosan and starch to provide both the binding mechanism between the first and second layers 402a and 402b and also provides mechanical protection and thermal insulation. In some embodiments, the assembly 400 can be manufactured in a strip configuration with multiple assemblies 400 connected together at their respective thermally crimped shared edge, and can include perforations or other separation assistance feature.

[0041] FIGURES 8A and 8B are perspective views of shipment packaging containers 410 and 420 having thermally crimped portions 406, in accordance with an embodiment of the present disclosure. As shown, the container 420 of FIGURE 8A can be sized and configured to at least partially surround a pint-sized container P of ice cream, or other frozen or thermally sensitive good. The container 420 includes various thermally crimped portions 406 to form the shape suitable for partially surrounding the pint-sized container P. Similarly, the container 410 of FIGURE 8B can be sized and configured to at least partially surround a gallon-sized container G of ice cream, or other frozen or thermally sensitive good, and can include various thermally crimped portions 406 to form the shape suitable for partially surrounding the gallon-sized container G. Other thermally crimped shapes are within the scope of the present disclosure. In other embodiments, the thermally crimped container is can be foldable to fit in various shapes and sizes, and can be used with or without a shipping container. In these embodiments, the thermally crimped container can be a foam-lined envelope, box, or sleeve that houses, holds, contains, or nests around the product within.

[0042] In the foregoing description, specific details are set forth to provide a thorough understanding of exemplary embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that the embodiments disclosed herein may be practiced without embodying all of the specific details. In some instances, well-known process steps have not been described in detail in order not to unnecessarily obscure various aspects of the present disclosure. Further, it will be appreciated that embodiments of the present disclosure may employ any combination of features described herein.

[0043] The present application may reference quantities and numbers. Unless specifically stated, such quantities and numbers are not to be considered restrictive, but exemplary of the possible quantities or numbers associated with the present application. Also in this regard, the present application may use the term “plurality” to reference a quantity or number. In this regard, the term “plurality” is meant to be any number that is more than one, for example, two, three, four, five, etc. The terms “about,” “approximately,” “near,” etc., mean plus or minus 10% of the stated value. For the purposes of the present disclosure, the phrase “at least one of A and B” is equivalent to “A and/or B” or vice versa, namely “A” alone, “B” alone or “A and B ”. Similarly, the phrase “at least one of A, B, and C,” for example, means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C), including all further possible permutations when greater than three elements are listed.

[0044] It should be noted that for purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “fore,” “aft,” “inner,” “outer,” “front,” “rear,” etc., should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings.

[0045] Throughout this specification, terms of art may be used. These terms are to take on their ordinary meaning in the art from which they come, unless specifically defined herein or the context of their use would clearly suggest otherwise.

[0046] The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure, which are intended to be protected, are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the present disclosure as claimed.