THERMALLY INSULATING PACKAGING
A thermally insulating packaging to hold an item includes a solid compostable or recyclable shell that is formed primarily of a plant fiber, and a bottom cover. The shell includes a floor, a plurality of inner side walls that are coupled to the floor, a rim coupled to the plurality of inner side walls, and a plurality of outer side walls that are couple to the rim. The floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space. The plurality of inner side walls and plurality of outer side walls have a space therebetween that defines a gap. The gap can be an air-filled cavity, or be filled with a compostable or recyclable core material.
1 . A thermally insulating packaging to hold an item, the thermally insulating packaging comprising:
a solid compostable or recyclable shell that is formed primarily of a plant fiber, wherein the shell includes
a floor,
a plurality of inner side walls that are coupled to the floor,
a rim coupled to the plurality of inner side walls, and
a plurality of outer side walls that are couple to the rim,
wherein the floor and the plurality of inner side walls define an interior space of the shell to receive the item and an opening to the interior space,
wherein the plurality of inner side walls and plurality of outer side walls have a space therebetween that defines an air-filled first gap, wherein the air-filled first gap and shell are sufficiently thick to provide thermal insulation along sides of the packaging,
wherein the floor is continuously coupled to each of the plurality of inner side walls, wherein each of the plurality of inner side walls is continuously coupled to adjacent inner side walls, wherein each of the plurality of inner side walls is continuously coupled to the rim, wherein the rim is continuously coupled to each of the plurality of outer side walls, and wherein each of the plurality of outer side walls is continuously coupled to adjacent outer side walls.
2 . The packaging of claim 1 , further comprising a bottom cover configured to extend below the floor of the shell such that the floor and the bottom cover have a space therebetween that defines an air-filled second gap, wherein the air-filled first second gap and shell are sufficiently thick to provide thermal insulation along a bottom of the packaging.
3 . The packaging of claim 2 , wherein the bottom cover is configured to be detachably secured to bottom edges of the outer walls of the shell.
4 . The packaging of claim 2 , wherein the bottom cover comprises one or more flaps extending off one or more bottom edges of the outer side wall of the shell.
5 . The packaging of claim 2 , comprising a plurality of projections between the floor and the bottom cover.
6 . The packaging of claim 5 , wherein the plurality of projections comprise protrusions from the shell.
7 . The packaging of claim 2 , comprising a top cover configured to be detachably secured to the rim of the shell to cover the interior space.
8 . The packaging of claim 7 , wherein one of the top cover and the rim includes grooves and the other of the top cover and the rim comprises protrusions configured to fit into the grooves.
9 . The packaging of claim 7 , wherein the top cover is formed primarily of the plant fiber.
10 . The packaging of claim 9 , wherein the top cover comprises a solid compostable or recyclable shell.
11 . The packaging of claim 1 , wherein the plurality of outer side walls extend from the rim vertically downward past the floor.
12 . The packaging of claim 11 , comprising a plurality of projections extending downward from the floor of the shell.
13 . The packaging of claim 12 , wherein the plurality of projections comprise protrusions from the shell.
14 . The packaging of claim 1 , wherein the shell is formed primarily from coconut husk, corn husk, linen, or cotton or paper, or combinations thereof
15 . The packaging of claim 1 , comprising a first water-proof, water-resistant or water-repellant layer disposed on the shell and configured to block water penetrating the shell.
16 . The packaging of claim 1 , wherein the shell comprises a first water-proof, water-resistant or water-repellant material mixed with the plant fiber.
17 . The packaging of claim 1 , wherein a thickness of the cavity is between ¼ and 4 inches.
18 . The packaging of claim 1 , wherein a thickness of the shell is between 0.02 and 0.3 inches.
19 . The packaging of claim 1 , wherein the thermally insulating packaging is stackable such that the plurality of inner side walls and plurality of outer side walls of a first thermally insulated packaging substantially fits into the gap between the plurality of inner side walls and plurality of outer side walls of a second thermally insulated packaging.
20 . The packaging of claim 19 , wherein the inner side walls and the outer side are sloped to form an obtuse angle relative to the floor.