Method of filling an insulated shipping container with loose-fill organic insulation
A recyclable, thermally insulated shipping container is entirely constructed from organic fiber materials in such a manner that the container is curbside recyclable without separation of component materials. The container includes a corrugated cardboard outer box having a bottom wall, a plurality of sidewalls and a top wall, a corrugated cardboard inner liner assembly comprising a corrugated cardboard inner box having a bottom wall and a plurality of sidewalls, and a corrugated cardboard lid assembly. The outer box, inner liner assembly and lid assembly cooperate to create a plurality of thermally insulated cavities which are sequentially filled and uniformly packed with pre-portioned, predetermined volumes of loose-fill cellulose (organic fiber) insulation to create a consistent insulating value throughout the container.
1. A method of filling a shipping container with loose-fill organic fiber insulation comprising the steps of:
providing a shipping container comprising:
an outer box having a plurality of sidewalls; and
an inner liner assembly comprising (i) an inner box having a plurality of sidewalls and (ii) a flange securing the inner box to the outer box via a plurality of securing tabs, each securing tab extending along a substantially entire corresponding edge of the flange,
said outer box sidewalls and said inner liner assembly defining a side fill cavity;
portioning a first predetermined volume of loose-fill organic fiber insulation;
dispensing the first predetermined volume of loose-fill organic fiber insulation into the side fill cavity of the shipping container; and
packing the first predetermined volume of loose-fill organic fiber insulation within the side fill cavity to provide a first packed volume of organic fiber insulation having a predetermined density and insulating value.
2. The method of claim 1 wherein the outer and inner boxes further define a bottom cavity adjacent a bottom wall of said inner box,
said method further comprising the step of:
repeating the steps of portioning, dispensing and packing for a second predetermined volume of loose-fill organic fiber insulation into said bottom cavity to provide a second packed volume of organic fiber insulation having said predetermined density and insulating value.
3. The method of claim 2 wherein the first predetermined volume of loose-fill organic fiber insulation is portioned in a dispensing device comprising a generally cone-shaped portioning receptacle and wherein the steps of portioning comprise blowing the loose-fill organic fiber insulation into the receptacle.
4. The method of claim 3 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
5. The method of claim 2 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
6. The method of claim 1 further comprising the steps of
providing a strengthening panel disposed in adjacent facing relation to a bottom wall of the inner box, said outer box and said strengthening panel further defining a bottom cavity; and
repeating the steps of portioning, dispensing and packing for a second predetermined volume of loose-fill organic fiber insulation into said bottom cavity to provide a second packed volume of organic fiber insulation having said predetermined density and insulating value.
7. The method of claim 6 wherein the first predetermined volume of loose-fill organic fiber insulation is portioned in a dispensing device comprising a generally cone-shaped portioning receptacle and wherein the steps of portioning comprise blowing the loose-fill organic fiber insulation into the receptacle.
8. The method of claim 7 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
9. The method of claim 6 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
10. The method of claim 1 wherein the first predetermined volume of loose-fill organic fiber insulation is portioned in a dispensing device comprising a generally cone-shaped portioning receptacle.
11. The method of claim 10 wherein the step of portioning comprises blowing the loose-fill organic fiber insulation into the receptacle.
12. The method of claim 11 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
13. The method of claim 10 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
14. The method of claim 1 further comprising the step of
repeating the steps of portioning, dispensing and packing for a second predetermined volume of loose-fill organic fiber insulation into said side fill cavity to provide a second packed volume of organic fiber insulation having said predetermined density and insulating value.
15. The method of claim 14 wherein the first predetermined volume of loose-fill organic fiber insulation is portioned in a dispensing device comprising a generally cone-shaped portioning receptacle and wherein the steps of portioning comprise blowing the loose-fill organic fiber insulation into the receptacle.
16. The method of claim 15 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
17. The method of claim 14 wherein the step of dispensing comprises dropping the loose-fill organic fiber insulation by gravity into the shipping container.
18. The method of claim 14 wherein said first and second predetermined volumes of loose-fill organic fiber insulation are the same.