Insulated shipping container and method of making
An insulating shipping container includes an exterior box formed of paper defining a cavity and an interior box formed of paper and positioned within said cavity. The interior box defines a product cavity. A compressed mass of compostable insulating plant material is received in the cavity and around the interior box and covered by a collar.
1 . A thermally insulating shipping container, comprising:
an outer container that is a box formed of paper and having a floor and a plurality of sidewalls;
an inner container that is a box formed of paper and having a floor and a plurality sidewalls, a space interior to the plurality of sidewalls of the inner container defining an inner cavity to hold a product for shipping in the shipping container;
a recyclable or compostable thermal insulation material formed primarily of plant fiber disposed between the sidewalls of the inner container and the sidewalls of the outer container; and
a barrier formed of paper positioned to cover at least a portion of a top surface of the thermal insulation material between the sidewalls of the inner container and the sidewalls of the outer container, the barrier comprising
a horizontal collar positioned substantially co-planar with and surrounding an upper rim of the plurality of sidewalls of the inner container and below an upper rim of the plurality of sidewalls of the outer container,
a first plurality of overhanging sections extending from a rectangular inner edge of the collar, each overhanging section of the first plurality of overhanging sections folded downwardly to extend partially but not entirely along a height of a corresponding sidewall of the inner container, and
a second plurality of overhanging sections extending from a rectangular outer edge of the collar.
2 . The shipping container of claim 1 , wherein the collar completely covers a top surface of the thermal insulation material.
3 . The shipping container of claim 1 , wherein the first plurality of overhanging sections are attached to corresponding sidewalls of the inner container.
4 . The shipping container of claim 3 , wherein the first plurality of overhanging sections are adhesively attached to corresponding sidewalls of the inner container.
5 . The shipping container of claim 4 , wherein the second plurality of overhanging sections are not adhesively attached to corresponding sidewalls of the outer container.
6 . The shipping container of claim 1 , wherein the second plurality of overhanging sections are attached to corresponding sidewalls of the outer container.
7 . The shipping container of claim 6 , wherein the second plurality of overhanging sections are adhesively attached to corresponding sidewalls of the outer container.
8 . The shipping container of claim 7 , wherein the second plurality of overhanging sections are not adhesively attached to corresponding sidewalls of the inner container.
9 . The shipping container of claim 1 , wherein the first plurality of overhanging sections are attached to corresponding sidewalls of the inner container and the second plurality of overhanging sections are attached to corresponding sidewalls of the outer container.
10 . The shipping container of claim 9 , wherein the first plurality of overhanging sections are adhesively attached to corresponding sidewalls of the inner container and the second plurality of overhanging sections are adhesively attached to corresponding sidewalls of the outer container.
11 . The shipping container of claim 1 , comprising a rectangular insert of insulative material that fits inside the plurality of sidewalls on the barrier and above the inner cavity.
12 . The shipping container of claim 11 , wherein the rectangular insert of insulative material fits below the upper rim of the plurality of sidewalls of the outer container.
13 . The shipping container of claim 11 , wherein the outer container includes one or more flaps extending from the upper rim of the plurality of sidewalls of the outer container, the one or more flaps foldable to cover the rectangular insert and close the shipping container.
14 . The shipping container of claim 1 , wherein the outer container and inner container are cardboard or paperboard.
15 . The shipping container of claim 14 , wherein the barrier is cardboard.
16 . The shipping container of claim 1 , wherein each overhanging section of the first plurality of overhanding sections is rectangular.
17 . The shipping container of claim 16 , wherein each overhanging section of the second plurality of overhanding sections is rectangular.
18 . The shipping container of claim 1 , wherein each overhanging section of the first plurality of overhanging sections extends downwardly on a side of the corresponding sidewall farther from the insulating material.
19 . The shipping container of claim 18 , wherein the first plurality of overhanging sections are adhesively attached to corresponding sidewalls of the inner container, and the second plurality of overhanging sections are not adhesively attached to corresponding sidewalls of the outer container.
20 . The shipping container of claim 19 , wherein the second plurality of overhanging sections contact corresponding sidewalls of the outer container.
21 . The shipping container of claim 1 , wherein the rectangular outer edge of the collar is vertically stabilized relative to the outer container.
22 . The shipping container of claim 1 , wherein the plant fiber is formed from cotton fiber, corn stalks, or coconut husk.
23 . The shipping container of claim 1 , wherein the first plurality of overhanging sections comprises four overhanging sections and the plurality of sidewalls of the inner container comprises four sidewalls, and wherein each overhanging section of the four overhanging sections extends from a different side of the rectangular inner edge of the collar and is secured to a different one of four sidewalls.
24 . The shipping container of claim 1 , wherein the barrier is a single unitary paper part and the inner container and outer container are not part of the single unitary paper part.
25 . The shipping container of claim 1 , comprising a layer of insulating material between the floor of the outer container and the floor of the inner container.
26 . The shipping container of claim 1 , wherein the barrier is not adhesively attached to the inner container and not adhesively attached to the outer container.