Repulpable insulating liners, bags, and mailers, and methods of making and using the same
A repulpable insulated shipping liner, bag, or mailer includes a flexible sealed volume having a first layer and second layer sealed together to form a housing. An insulating layer made from repulpable cellulosic material is located within the housing and is configured to be folded so as to line the interior of a box or a container, and form an insulated container for shipping and/or storage.
1 . A repulpable insulating liner 10 comprising:
pliable first and second layers 11 / 12 that are bonded together so as to form a bag configuration 150 or an envelope configuration 150 ′ having (i) a bottom 151 , (ii) walls 152 , (iii) an opening 15 opposite the bottom 151 , (iv) a first major outer liner surface 13 , (v) a second major outer liner surface 14 opposite said first major outer liner surface 13 , (vi) a first major inner liner surface 16 , (vii) a second major inner liner surface 18 opposite said first major inner liner surface 16 , said first major inner liner surface 16 and said second major inner liner surface 18 (a) being positioned between said first major outer liner surface 13 and said second major outer liner surface 14 , and (b) forming an article receiving pouch 19 of said liner 10 accessible via said opening 15 , said article receiving pouch 19 having a pouch volume 197 , and (viii) a liner housing volume 191 of a first size between said pliable first and second layers 11 / 12 ; and
a repulpable insulating layer 20 positioned within the liner housing volume 191 and being of a size smaller than the first size and being movable relative to the pliable first and second layers 11 / 12 , the repulpable insulating layer 20 comprising one or more layers 21 of shaped, non-planar paper material 22 having (a) a first insulating material end portion 26 positioned along said opening 15 and extending within a first space 192 between (i) said first major outer liner surface 13 and (ii) said first major inner liner surface 16 , and (b) a second insulating material end portion 27 positioned along said opening 15 and extending within a second space 193 between (i) said second major outer liner surface 14 and (ii) said second major inner liner surface 18 .
2 . The repulpable insulating liner 10 of claim 1 , wherein the liner 10 is configured to be convertible into a substantially rectangular box form 250 having a bottom wall 151 , two pair of opposing side walls 152 and a liner top wall 153 , said liner top wall 153 being foldable over the two pair of opposing side walls 152 whereby, when the liner 10 is inserted into an open box outer shipping or storage container 112 , the liner 10 conforms to an interior configuration of the outer box shipping and storage container 112 and thereby provides an insulated covering for all inner surfaces of the outer shipping or storage container 112 , when inserted into the outer box shipping or storage container 112 , including the bottom wall 160 , opposite side walls 161 , and top wall 162 of the outer box shipping or storage container 112 when the liner top wall 153 is closed.
3 . The repulpable insulating liner 10 of claim 1 , wherein the repulpable insulating layer 20 is positioned within the liner housing volume 191 but otherwise unattached to the pliable first and second layers 11 / 12 .
4 . The repulpable insulating liner 10 of claim 1 , wherein the repulpable insulating layer 20 has a rectangular shape with said first insulating material end portion 26 and said second insulating material end portion 27 being along opposite edges of the rectangular shape.
5 . The repulpable insulating liner 10 of claim 1 , wherein said repulpable insulating layer 20 further comprises opposing cut outs 24 centrally along opposite side edges 28 / 29 of said repulpable insulating layer 20 so as to form a middle portion 210 between two side portions 280 / 290 , said opposing cut outs 25 enabling a free standing configuration whereby said repulpable insulating layer 20 is folded centrally thereof so that said middle portion 210 becomes the bottom 151 , and said side portions 280 / 290 become the walls 152 .
6 . The repulpable insulating liner 10 of claim 1 , wherein said repulpable insulating layer 20 has a rectangular shape with cut outs 25 at each of four corners of said rectangular shape.
7 . The repulpable insulating liner 10 of claim 1 , wherein said repulpable insulating layer 20 comprises from 4 to 50 layers 21 of shaped, non-planar paper material 22 .
8 . The repulpable insulating liner 10 of claim 1 , wherein each layer 21 of shaped, non-planar paper material 22 (i) comprises shaped, non-planar paper 22 , (ii) has an average paper layer thickness of from 0.1 millimeters (mm) to 5.0 mm, and (iii) has a paper layer density between 15 g/m 3 and 65 g/m 3 .
9 . The repulpable insulating liner 10 of claim 1 , wherein each layer 21 of shaped, non-planar paper material 22 comprises at least 80% by weight of reclaimable paper pulp.
10 . The repulpable insulating liner 10 of claim 1 , wherein each layer 21 of shaped, non-planar paper material 22 comprises crepe paper, embossed paper, embossed tissue paper, or any combination thereof.
11 . The repulpable insulating liner 10 of claim 1 , wherein said repulpable insulating layer 20 has an overall thickness t 1 of from 0.25 inches (in) (6.35 mm) to 3.0 in (76.20 mm).
12 . The repulpable insulating liner 10 of claim 1 , wherein said repulpable insulating layer 20 has (i) an overall thickness t 1 of 0.5 in (12.70 mm), and (ii) an R-value equal to or greater than an R-value of a 1 lb per cubic foot density polyurethane foam insulating layer having a foam layer thickness of 1.0 in (25.40 mm).
13 . The repulpable insulating liner 10 of claim 1 , wherein the pliable first and second layers 11 / 12 each independently comprises a paper layer comprising at least 80% by weight of reclaimable paper pulp.
14 . The repulpable insulating liner 10 of claim 1 , wherein said first major outer liner surface 13 extends beyond said opening 15 to form a liner flap 110 .
15 . The repulpable insulating liner 10 of claim 14 , wherein said liner flap 110 extends a length F L beyond said opening 15 , and length F L is equal to or greater than a box form depth D BF of the repulpable insulating liner 10 when configured into a substantially rectangular box configuration 150 .
16 . The repulpable insulating liner 10 of claim 14 , wherein said first insulating material end portion 26 extends into said liner flap 110 .
17 . The repulpable insulating liner 10 of claim 1 , wherein said pliable first and second layers 11 / 12 are portions of a continuous recyclable and repulpable liner substrate (not shown) that is folded over onto itself to form (i) said first major outer liner surface 13 , (ii) said second major outer liner surface 14 opposite said first major outer liner surface 13 , (iii) said first major inner liner surface 16 , and (iv) said second major inner liner surface 18 opposite said first major inner liner surface 16 .
18 . The repulpable insulating liner 10 of claim 1 , further comprising: a liner closure 30 capable of at least partially closing said opening 15 of said liner 10 .
19 . An insulated shipping and storage container 100 comprising:
an outer box shipping and storage container 112 comprising at least a planar bottom wall 160 , two sets of opposing planar side walls 161 and at least one top panel 162 ; and
the repulpable insulating liner 10 of claim 1 .
20 . A method of maintaining an item at a desired temperature, said method comprising:
positioning the item within an insulated shipping and storage liner, the insulated shipping and storage liner comprises the repulpable insulating liner 10 of claim 1 .