HK1146022B - Insulated shipping bags - Google Patents

Description

Heat insulation transport bag

Technical Field

The present invention relates to thermally insulated containers, primarily for the transport or storage of goods, food, samples and similar items that must be maintained within a predetermined temperature range for a predetermined period of time to ensure the safety and quality of the items. More particularly, the present invention relates to a foldable insulated bag that maintains articles placed therein at a predetermined temperature, cold or hot, for an extended period of time. Collapsible bags are suitable for transporting perishable items such as food, samples and medical items over long distances, and may also be used in the catering industry, takeaway and traditional cooler functions.

Background

In many industries, it is critical to safely transport and store temperature sensitive products or samples for the preservation of such products or samples. Medical supplies, samples, transplants and the like must be maintained at a controlled temperature during transport from supplier to user, from supplier to patient and during transfer between devices. With the rise of online food stores, there is a need for improvements in thermally insulated packaging for shipping items, such as frozen food products, from a temperature controlled environment to end consumers. Often the package of the delivered item requires that the item be left in a sub-optimal environment for a period of time before the consumer actually obtains the delivered item.

Various methods have been tried to keep the shipped items at an optimum temperature, including foam coolers, dry ice packs or boxes, and insulated storage bags. Each method has disadvantages including limited time to maintain the articles at the optimum temperature, environmental impact or safety factors, and increased shipping costs due to the weight and/or volume of the container or express delivery.

In some instances, the use of a foam freezer in combination with a dry ice package may effectively maintain the articles at an optimal temperature. However, both the supply costs and the additional transportation costs for their use are very expensive. In addition, foam freezers have a negative environmental impact and handling dry ice packaging can increase safety concerns.

Dry ice packaging has been used alone for transporting and delivering perishable items. However, their ability to maintain optimum temperatures for long periods of time in standard carton containers is very poor.

Other bags have been used in the short-haul transport of perishable items. However, they can only be used to transport items and cannot keep the items within the optimum temperature range for a considerable period of time, for example more than 1 to 3 hours or more.

In view of the foregoing, there is a need to provide an insulated shipping container with greater insulating properties to ensure that items, food, medical supplies and samples and other temperature sensitive items can be safely shipped and maintained at the necessary temperature for a longer period of time than is possible using conventional shipping containers.

There is also a need to provide insulated shipping containers that can be compactly arranged to reduce shipping costs without degrading the insulating properties.

Disclosure of Invention

The present invention comprises a flexible or collapsible hot/cold storage or shipping bag that is adapted to be self-forming and/or supporting, but can be conveniently reduced in size to fit into an outer container or box for shipping. In a preferred embodiment, the bag is formed of at least three layers of insulating material, including an outer metal or radiant energy reflective layer, an intermediate open cell foam insulating layer and an inner low thermal convection, food grade plastic layer.

In some embodiments, the fully flexible insulated bag is designed as a stand-up container that can remain in a supported position when placed on a support surface. However, the bag may also be placed or folded into an outer protective structure, such as a cardboard container or box, a plastic bag or box, or other shipping container. Due to the flexible insulation material of the bags, they can conform to the outer container or reduce the space occupied, thereby maximizing shipping efficiency and reducing shipping costs.

In a preferred embodiment of the invention, the inner plastic layer is formed in the shape of a bag with an outwardly folded sleeve at the open portion so that the sleeve frictionally receives and retains the upper free ends of the opposite sides of the intermediate insulating material. In this manner, the intermediate insulating material is mechanically secured to the inner plastic layer so that each layer can be simultaneously inserted into the outer reflective or metal foil layer. The frictional retention of the middle layer in the inner plastic layer cuff also serves to retain the middle insulation layer in the outer layer during use of the composite insulated bag of the present invention. In some embodiments, the upper end of the inner plastic bag layer is welded to the inner surface at or slightly below the upper edge of the outer layer. The outer reflective or foil layer is also formed into the shape of a pocket, with both ends of the foil folded along its length and then the opposite edges welded together.

The composite insulated bag or multi-layer insulated bag of the present invention may also include various closure and handle configurations. In some embodiments, the inner plastic bag-like structure can be heat sealed at its upper open end after the articles are placed in the insulated bag. In other embodiments, the upper open end of the inner plastic bag may be sealed with a mechanical zipper type closure or double sided tape after the article is placed therein. In other embodiments, the inner plastic bag may not be sealed. Preferably the upper end of the outer reflective or foil bag layer has a heat seal or a mechanical zipper or friction lock seal. In some embodiments, the seal is achieved by installing friction locks on the handle that are initially sealed to the upper edges of the opposing sides of the outer reflective or foil layer, including structures that interlock when the handle components are locked together.

In some embodiments of the present invention, to facilitate compact handling and/or folding of the multi-layered insulated shipping and storage bags of the present invention for shipment to wholesalers or end users in subsequent use, the interior of the bag, particularly the intermediate open-cell foam layer, is evacuated by the application of a partial vacuum. The vacuum can be applied to the bag through the opening between the outer reflective layer and the intermediate open cell foam material using a vacuum tube or placing the bag in a low pressure enclosure or physically compressing the bag. When the vacuum tube is withdrawn, or the predetermined low pressure within the bag has been reached, the external opening is closed with a removable sticker or cover to prevent ambient air from entering the bag. The bag can be easily folded into a compact configuration for storage or transport when the bag is at least partially evacuated to allow air to escape from between the open cell foam and the outer reflective layer and foam. When the bag is used by the end user, the sheet or cover is removed, allowing the bag to automatically expand as ambient air enters the vacuum opening. When the bag is inflated, the adhesive tab or cover may be reused to prevent contaminants from entering the opening. In this regard, the vacuum process and the expansion process may be performed in a vacuum enclosure when the insulated shipping and storage bag is used to ship or store items that must be kept sterile.

Compact handling of these multi-layered insulated shipping and storage bags of the present invention for storage and shipment to wholesalers or end users in subsequent use can also be accomplished by placing one or more insulated bags into an outer plastic bag having a sealable open end. The outer bag is then mechanically compressed so that most of the air is vented from the enclosed insulated shipping bag and the outer bag, and the outer bag is then sealed. In some embodiments, a partial vacuum is achieved in the outer bag to reduce the pressure therein and reduce the volume of the entire package.

Further, in some embodiments, the upper edge of the middle foam layer is secured or sealed within a sleeve of the inner plastic layer, the sleeve is sealed within the outer reflective layer, or the upper edge of the inner plastic layer is sealed to the outer reflective layer to isolate the foam layer therein from the surrounding environment, and a reduction in pressure between the foam layer and the outer reflective layer does not affect the sterility of the inner surface of the inner plastic layer.

In addition to the use of collapsible hot/cold insulated shipping and storage bags for food, such as frozen food or heat-treated food service, the bags may be well-suited for other uses, including the shipping of medical items including drugs, blood, samples and organs, and other items that must be strictly maintained at a certain temperature.

The collapsible hot/cold insulated shipping and storage bags can maintain perishable items at their optimal temperatures for longer periods of time. For example, the process of maintaining low temperatures while transporting items from one area to another is known as a cold chain. A cryogenic chain is further defined as a continuous storage and dispensing activity to maintain the temperature of the articles within a given range. The collapsible hot/cold insulated shipping and storage bags of the present invention allow items left to the end user to remain at their optimal temperature, cold or hot, for at least 3 hours.

In addition, the insulated shipping and storage bag of the present invention is designed to be lightweight and flexible to allow the bag to be compressed, folded and placed compactly in a shipping container, avoiding the need to occupy space where other objects may be transported, which may reduce both shipping and storage costs.

Another advantage of the insulated shipping and storage bag of the present invention is that the open cell foam middle layer also serves to cushion the contents of the bag, particularly during shipping, so that damage to the contents of the bag is less than other prior art shipping containers.

Drawings

The invention may be better understood with reference to the following drawings:

FIG. 1 is a top elevational view of an embodiment of the present invention in an open position receiving an article disposed therein;

FIG. 2 is a cross-sectional view 2-2 of FIG. 1 showing the insulation layer of the insulated shipping and storage bag;

FIG. 3 is a top elevational view of the embodiment of the invention shown in FIG. 1 with an article placed therein, illustrating how the insulated shipping and storage bag is self-standing on a support surface;

FIG. 4 is a plan view of the intermediate foam layer showing the cut having a slit to facilitate free standing of the bag in use;

FIG. 5 is a perspective view of the inner plastic layer of FIG. 1 formed into a bag-like configuration and showing the sleeve frictionally engaged with the upper end of the intermediate foam insulation material therein;

FIG. 6 is a view similar to FIG. 1 showing an insulated bag of the present invention having an opening and associated closure structure for emptying and subsequent expansion of the bag so that it may be compactly stored and transported to an end user;

FIG. 7 is a cross-sectional view taken at 7-7 of FIG. 6, showing the tube and open cell foam therein placed through the opening to reduce pressure within the bag;

FIG. 8 is a perspective view of a plurality of insulated bags of the present invention placed within an outer sealable plastic enclosure for shipping to an end user, the bags being compactly held or folded under low internal pressure;

FIG. 9 is a cross-sectional view similar to FIG. 2 showing another embodiment of the present invention.

Detailed Description

With continued reference to the figures, the present invention will be described with respect to several embodiments of insulated and flexible or pliable hot/cold storage and shipping bags. Fig. 1-4 illustrate an insulated bag 10 according to a first embodiment of the present invention. The insulated bag 10 is a multi-layered structure for storing and transporting heat sensitive substances and is made of at least three layers of insulating substances. The outer layer 11 is made of a material known as heat-radiating, which is tear-resistant, non-porous, leak-resistant, heat-sealable or welded or sealed with a sterile polyethylene bagging material, and is compatible with conventional printing techniques. Such materials include, but are not limited to, thermoplastic polymers such as metallic polyethylene terephthalate (METPET) and various metal foils. As previously mentioned, the outer layer 11 may be printed with advertising information or any other desired indicia.

The outer layer is formed of the above materials and is generally rectangular when expanded into a unitary film. The outer layer is preformed in the form of a bag and the film is folded along the central line of the integral film to form the base 12 and the side edges are welded, heat sealed or sealed to form the opposing side seams 13 to form an opening 14 in the outer layer.

As shown in fig. 2, the intermediate heat insulating layer 20 is made of a known low heat conductive material. These materials include, but are not limited to, low density foldable open cell polyurethane foams, including those that have a memory of remolding upon deformation. Thus, the insulation is made of a foldable or compressible memory foam with thermal insulation and cushioning properties. The foam may be die cast (molded) or cut and shaped to prevent the formation of thermal bridges.

When poor insulation is used, thermal bridges are created which allow heat transfer to occur between the materials. To prevent thermal bridging, the insulating foam must be properly applied and placed to insulate the area of the bag that is intended to receive the items contained therein. In view of this, the insulating foam layer 20 is made of polyurethane or polyurethane-based foam to prevent thermal bridges and to maintain the low heat transfer required to maintain the optimum temperature of the perishable items. In addition to the low thermal properties of the foam, the foam is also capable of conforming to the article wrapped therein to form a frame and/or structure for the article. The self-forming foam forms a base or floor, lid and wall for the article when placed therein. The foam also provides a protective cushion for the items placed in the bag to prevent damage to the items.

Referring to fig. 4, the foam insulation layer 20 is between about 0.5 inches and 1.5 inches thick and may have a different density. The foam layer is in the form of a sheet, generally rectangular, with the two ends 21 and 22 being substantially parallel to each other and the long sides 23 and 24 being substantially parallel to each other. Each corner of the insulation layer has a cut-out area 25 at substantially right angles. Each cut-out region is defined by two substantially perpendicularly intersecting edges 26 and 27. The cutout area 25 may include an additional slit 25' extending into the width of the material to facilitate bending. The size of the cut 25 can vary depending on the size of the bag and the function of the cut is to allow the top of the formed bag to be folded at the corners when the layer 20 is folded along the centerline a-a to form the opposing side edges 28 and 29, as shown in fig. 5. Opposite cuts 30 are made in the center of the sides of the middle foam layer, except for the corner cuts. The cuts 30 are linear and may vary in size to facilitate folding of the bottom 12 of the formed insulated bag to form a substantially flat support base for the bag when the bag is placed on a support surface "S" with articles placed therein, as shown in fig. 3. As with the other cutout regions 25, the cutout regions 30 may include additional slits 30 extending into the width of the material to facilitate bending.

The insulated bag 10 includes an innermost plastic layer 32 made of one or more known materials having low heat transfer properties. These materials include polyurethane, polypropylene, elastomeric materials and the like which are leak proof, non-porous and food grade and which may be heat sealed or otherwise secured or welded to the outer radiation layer 11.

In the preferred embodiment of the invention shown in fig. 1, the inner plastic layer 32 is formed in a bag shape and is open only at the top opening 34, as shown in fig. 2. The pouch has an annular outwardly folded sleeve 35 at the opening, the sleeve 35 being sized to frictionally receive and retain the upper free ends 36 and 37 of the opposite side edges 28 and 29 of the middle insulating foam. In this manner, the intermediate thermal insulation material is mechanically secured to the inner plastic layer 32 so that each layer can be simultaneously inserted into the outer reflective or metal foil layer. The frictional retention of the middle layer in the inner plastic layer cuff also serves to retain the middle insulation layer in the outer layer when the composite insulated bag of the present invention is used, and also to seal the volume or region 38 between the inner layer 32 and the outer layer 11 sufficiently from the interior volume 40 of the insulated bag 10 to avoid contamination of the interior volume 40. In some instances, an adhesive or other agent may completely seal the upper ends 36 and 37 of the intermediate foam within the sleeve 35 of the inner layer 32.

In some examples as shown in fig. 2, the upper end of the inner plastic bag layer 32 is welded at 41 to the inner surface 42 of the outer layer at or slightly below the upper edge of the outer layer, sealing the insulated bag 10 between the inner layer 32 and the outer layer 11.

Although not shown in the drawings, in some embodiments, the inner plastic bag-like structure of the inner layer 32 can be heat sealed at its upper open end 44 after the items are placed in the insulated bag 10. In other embodiments, a zipper type closure device or double sided tape may be used to seal the upper end 44 of the inner plastic bag after the article is placed therein. In other embodiments, the opening 34 of the inner plastic bag may not be sealed.

Preferably, the upper end of the outer reflective or foil bag layer 11 has a heat seal or zip or friction lock seal. In some embodiments, the sealing may be by friction lock members 50 and 51, the friction lock members 50 and 51 being initially sealed at 52 to the upper edges of the opposite sides of the outer foil or reflective layer. The friction lock member 50 comprises a handle 53, which handle 53 can be inserted into an opening 55 of the lock member 51. The lock member 51 has a substantially U-shaped cross-section, see fig. 2, the width of which is such that the lock member 50 can be frictionally secured thereto to seal the components together when the handle 53 is inserted through the opening 55 to seal the bag 10, see fig. 3.

The insulated bag 10 may also be closed by other known conventional means, such as pressure sealing, tape sealing, flaps with resealable tape means, flaps with peel-off tape means, plastic zippers and the like.

Although not shown in the reference numerals, in some embodiments, one or more additional foam layers may be inserted between the inner bag or layer 32 and the outer layer 11 to enhance the insulating properties of the insulated bag, thereby extending the time that the articles are maintained at the optimum temperature.

As previously mentioned, one advantage of the present invention is that the insulated bags can be compactly arranged and stored for storage or shipment to wholesalers/end users, thereby reducing the volume of shipping packaging and thus the associated costs of shipping and storing the bags. Referring to fig. 8, a first embodiment of the present invention for reducing the packaging volume of the insulated bag 10 is shown in detail. As shown, one or more insulated bags 10 may be placed in an outer plastic bag 60 having an end, the outer plastic bag 60 having a sealable opening 62. The outer bag is then mechanically compressed in the direction of arrow 65 so that most of the air exits the enclosed insulated shipping bag 10 and outer bag 60. The outer bag is then sealed. In some embodiments, a partial vacuum is achieved in the outer bag to reduce the pressure therein and reduce the volume of the entire package, followed by sealing the outer bag 60.

In another embodiment shown in fig. 6 and 7, to facilitate compact handling and/or folding of the multi-layered insulated shipping and storage bags of the present invention for storage or shipment to wholesalers or end users in subsequent use, the interior of the bag 10, and in particular the intermediate open-cell foam layer 20, is evacuated by application of a partial vacuum. Vacuum can be applied to the bag through the opening 70 between the outer reflective layer 11 and the intermediate open cell foam 20 using vacuum tube 72 or by placing the bag 10 into a low pressure enclosure. When the vacuum tube is withdrawn, or a predetermined low pressure has been reached in the bag, the external opening 70 is closed with a removable adhesive tab or cover 74 to prevent ambient air from entering the bag. The lid or sheet includes a self-adhesive glue 75 on the inside for sealing the opening to prevent accidental expansion of the space in the bag. When the bag is at least partially evacuated to allow air to escape from between the open cell foam and outer reflective layer and the inner plastic layer or bag, the bag can be easily stacked or folded into a compact configuration for storage or transport. When the bag is to be used by the end user, the sheet or cover is removed and ambient air enters the vacuum opening so that the bag automatically expands. When the bag is inflated, the adhesive tab or cover may be reused to prevent contaminants from entering the opening. In this regard, when the insulated shipping storage bag 10 is used to ship or store items that must be kept sterile, the vacuum process and the inflation process may be performed in a vacuum enclosure.

Referring to fig. 9, yet another embodiment or yet another insulated bag 10' of the present invention is disclosed wherein the sleeve on the inner layer or bag 32 of the embodiment of fig. 1 and 2 is absent. In this embodiment, the inner layer or bag 32 ' includes an upper free edge 76, and the upper free edge 76 is sealed or welded at 78 to the inner surface of the outer reflective layer 11 ' below the opening of the bag 10 '. The bag of this embodiment may be opened and sealed using the vacuum previously described, and the same materials and compact means of transport or storage may be used, including the use of an outer packaging container or bag.

Claims (9)

1. An insulated shipping and/or storage bag having a bottom, a sidewall extending upwardly from the bottom, and a top attached to the sidewall generally opposite the bottom, the top covering an opening generally opposite the bottom, the bag comprising:

an external radiant energy reflecting layer;

a middle foam layer formed from a single piece of sheet material having first cuts at all four corners thereof and oppositely disposed second cuts approximately midway along opposite side edges of the sheet material, the second cuts facilitating formation of a free standing configuration of the bag, wherein the middle foam layer has a substantially rectangular shape such that the middle foam layer extends continuously along the top, side walls and bottom of the bag;

an inner plastic layer forming an article receiving pocket; and

sealing means for sealing the opening into the bag.

2. The insulated shipping and/or storage bag of claim 1 wherein said inner plastic layer includes a sleeve in which an upper portion of said intermediate foam layer is received, securing said intermediate foam layer to said inner plastic layer.

3. The insulated shipping and/or storage bag of claim 1 further comprising venting means for venting air from between said inner plastic layer and said outer radiant energy reflecting layer to allow the shipping and/or storage bag to be formed into a compact configuration for shipping to an end user without allowing air to enter the interior of said bag.

4. The insulated shipping and/or storage bag of claim 3 further comprising a covering means for covering said evacuation means.

5. The insulated shipping and/or storage bag of claim 1 wherein said intermediate foam layer is between 0.5 inches and 1.5 inches thick.

6. The insulated shipping and/or storage bag of claim 1 wherein said sheet of material further comprises a slit extending inwardly from each of said first and second cuts.

7. The insulated shipping and/or storage bag of claim 1 wherein said inner plastic layer is secured to an inner surface of said outer radiant energy reflecting layer adjacent the bag opening.

8. The insulated shipping and/or storage bag of claim 1 wherein said sealing means comprises a handle.

9. The insulated shipping and/or storage bag of claim 1 wherein said intermediate foam layer is formed of open cell foam.