Insulated packaging system using cellulose materials
The present disclosure relates to temperature insulated packaging systems and related methods of manufacture and use that can be used for shipping perishable materials. An insulative insert is formed by folding one or more pieces of stock cellulose material along predetermined fold lines and folding slots to form an insert in a folded configuration suitable for insertion as an insulative liner within a container for use in shipment.
1 . A packaging insert formed from a cellulose material and configured for insulating a container, the packaging insert comprising:
a single panel of cellulose material having an upper edge and a lower edge defining a vertical direction extending therebetween;
a left edge and a right edge defining a lateral direction extending therebetween; and
a plurality of internal folding slots, wherein each folding slot begins at the lower edge and extends toward the upper edge until reaching a folding slot terminus,
each folding slot defining a vertical fold line extending from the terminus toward the upper edge in the vertical direction,
each folding slot defining a primary lateral fold line extending from the terminus toward the left or right edge in the lateral direction,
wherein sections below respective primary lateral fold lines are defined as a plurality of contiguous bottom sections and sections above respective primary lateral fold lines are defined as sidewall sections,
wherein the plurality of internal folding slots are arranged with successively shorter or longer lengths such that the primary lateral fold lines are successively lower or higher,
wherein the insert is configured such that folding along the primary lateral fold lines and along the vertical fold lines forms a folded configuration with a sidewall formed by the sidewall sections and a bottom formed by sequentially layering the contiguous bottom sections, the insert being insertable into a container when in the folded configuration.
2 . The packaging insert of claim 1 , wherein the primary lateral fold lines enable corresponding bottom sections to layer with each other when the insert is folded along the primary lateral fold lines and the vertical fold lines, and wherein when the insert is formed into the folded configuration, the bottom of the insert has at least 3-layers.
3 . The packaging insert of claim 1 , further comprising one or more cutouts, wherein the one or more cutouts are each vertically aligned with a corresponding folding slot and along a corresponding vertical fold line.
4 . The packaging insert of claim 3 , wherein the one or more cutouts are each disposed to be positioned at a corner edge of the sidewall when the insert is formed into the folded configuration.
5 . The packaging insert of claim 3 , wherein the one or more cutouts are disposed between the primary lateral fold lines and the upper edge of the insert.
6 . The packaging insert of claim 3 , wherein the one or more cutouts have a lower edge, an upper edge, and a length in the vertical direction, and wherein for each cutout, a distance between the upper edge of the cutout and the upper edge of the insert is equal to or less than the length of the cutout and a distance between the lower edge of the cutout and a corresponding primary lateral fold line is equal to or less than the length of the cutout.
7 . The packaging insert of claim 1 , further comprising at least two secondary lateral fold lines, wherein each secondary lateral fold line extends between the left edge and the right edge of the insert.
8 . The packaging insert of claim 7 , wherein the secondary lateral fold lines enable the resulting sidewall sections to have multiple layers, wherein the sidewall sections include at least 3 layers when the insert is formed into the folded configuration.
9 . The packaging insert of claim 8 , wherein the sidewall includes two adjacent sections when formed into the folded configuration.
10 . The packaging insert of claim 1 , wherein the insert consists of three internal folding slots.
11 . The packaging insert of claim 1 , wherein the cellulose material comprises at least one flat sheet and at least one embossed sheet.
12 . The packaging system of claim 11 , wherein the cellulose material is arranged
in alternating layers of embossed sheets and flat sheets.
13 . The packaging insert of claim 1 , further comprising a coating at least partially disposed on inner surfaces of the insert when formed into the folded configuration.
14 . An insulative packaging system, comprising:
a packaging container; and
at least one packaging insert, the packaging insert comprising:
a single panel of cellulose material having an upper edge and a lower edge defining a vertical direction extending therebetween;
a left edge and a right edge defining a lateral direction extending therebetween; and
a plurality of internal folding slots, wherein each folding slot begins at the lower edge and extends toward the upper edge until reaching a folding slot terminus,
each folding slot defining a vertical fold line extending from the terminus toward the upper edge in the vertical direction,
each folding slot defining a primary lateral fold line extending from the terminus toward the left or right edge in the lateral direction,
wherein sections below respective primary lateral fold lines are defined as a plurality of contiguous bottom sections and sections above respective primary lateral fold lines are defined as sidewall sections,
wherein the plurality of internal folding slots are arranged with successively shorter or longer lengths such that the primary lateral fold lines are successively lower or higher,
wherein the insert is configured such that folding along the primary lateral fold lines and along the vertical fold lines forms a folded configuration with a sidewall formed by the sidewall sections and a bottom formed by sequentially layering the contiguous bottom sections, the insert being insertable into a container when in the folded configuration.
15 . The packaging system of claim 14 , wherein multiple inserts are arranged within the container to form a complete liner.
16 . The packaging system of claim 14 , wherein the packaging insert comprises at least two packaging inserts, wherein each packaging insert is configured to form a folded configuration including a sidewall formed by sidewall sections, and wherein the at least two packaging inserts are configured to form a combined insert having a sidewall with four sections and a combined bottom having four layers formed from bottom sections of the at least two packaging inserts.
17 . The packaging system of claim 14 , the system comprising a single insert.