Method of making a thermally insulated shipper

1. A method of making a thermally insulated packaging system for a temperature sensitive payload, the method comprising the steps of:

Step 200 : molding an outer shell, the outer shell having a bottom and sides extending from the bottom;

Step 202 : placing a bottom VIP panel against the bottom of the outer shell and a side VIP panel against each of the sides of the outer shell to create an outer shell assembly, each side VIP having a top edge facing away from the bottom;

Step 204 : transferring the outer shell assembly to a steam chest insert molding machine;

Step 206 : positioning a male plug within the outer shell assembly, leaving a space therebetween;

Step 208 : molding an inner shell into the space between the outer shell assembly and the male plug by high temperature and high pressure steam chest molding, thereby pushing the bottom and side VIP panels against each other, wherein the outer shell and inner shell have adjoining faces; and

Step 210 : applying a sealant between the adjoining faces of the outer shell and inner shell so the VIP panels are completely enclosed.

2. The method of claim 1 wherein:

Step 208 is carried out so that the top edge of each side VIP is covered by the inner shell.

3. A method of making a thermally insulated packaging system for a temperature sensitive payload, the method comprising the steps of:

Step 200 : molding an outer shell, the outer shell having a bottom and sides extending from the bottom;

Step 202 : placing a bottom VIP panel against the bottom of the outer shell and a side VIP panel against each of the sides of the outer shell to create an outer shell assembly, the bottom VIP panel and the side VIP panels forming a five sided housing, each side VIP panel having a top edge facing away from the bottom;

Step 204 : transferring the outer shell assembly to a steam chest insert molding machine;

Step 206 : positioning a male plug within the outer shell assembly, leaving a space therebetween; and

Step 208 : molding an inner shell such that it occupies the space between the outer shell assembly and the male plug and such that it covers the entire top edge of each side VIP panel, wherein during Step 208 the outer shell and the inner shell are sealed together along a perfect seal line so the VIPs are completely enclosed.

4. The method of claim 3 wherein:

during step 208 the bottom VIP panel and the side VIP panels are press fitted against the outer shell and the inner shell.