Shipping container with compostable insulation
In one aspect, a shipping container includes a plurality of thermally insulating pads positioned in a cavity in a box. Each pad of the plurality of thermally insulating pads includes a solid compostable panel formed primarily of extruded milled sorghum, the panel providing a rectangular plate, and a compostable water-proof film forming a pocket enclosing the panel. The panel is loose within the pocket. At least one of the plurality of thermally insulating pads includes a multi-section panel including a score across its width in at least one location. The score extends partially but not entirely through the thickness of the multi-section panel. The multi-section panel is folded at a right angle at the score such that the panel provides a plurality of rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent.
1. A shipping container to hold an item, comprising:
an exterior box having a floor and a plurality of side walls to define a cavity therein and an opening to the cavity at the top of the box;
a cover to close off the top of the box; and
a plurality of thermally insulating pads positioned in the cavity, the plurality of thermally insulating pads positioned such that each of the floor, plurality of side walls and cover are adjacent to and covered by a pad from the plurality of thermally insulating pads, the plurality of thermally insulating pads shaped to provide an interior space to receive the item, wherein each pad of the plurality of thermally insulating pads includes
a solid compostable panel formed primarily of a starch that holds together as a single unit, the panel providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and
a compostable water-proof film forming a pocket enclosing the panel without being bonded to the panel;
wherein at least one of the plurality of thermally insulating pads includes a plurality of rectangular panel sections, wherein the pad is folded at a right angle along a boundary between the panel sections and each panel section is dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of plates is adjacent, and wherein the film provides both an interior surface of the pad and an exterior surface of the pad where the pad is folded with all of the panel sections enclosed in the same pocket.
2. A thermal insulation assembly for placement in a shipping container to hold an item, comprising:
a plurality of thermally insulating pads shaped to be positioned in a cavity of a rectangular prism shipping container such that each of a floor, plurality of side walls and cover of the container are adjacent to and covered by a pad from the plurality of thermally insulating pads and an interior space is provided to receive the item, wherein each pad of the plurality of thermally insulating pads includes
a solid compostable panel formed primarily of grain starch that holds together as a single unit, the panel providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and
a compostable water-proof film forming a pocket enclosing the panel without being bonded to the panel;
wherein at least one of the plurality of thermally insulating pads is a multi-section pad including a plurality of rectangular panel sections enclosed by the film, wherein the multi-section pad is configured to be foldable at a right angle along a boundary between the panel sections and each panel section is dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the plurality of rectangular panel sections is adjacent, and wherein the film provides both an interior surface of the multi-section pad and an exterior surface of the multi-section pad where the pad is folded with all of the panel sections enclosed in the same pocket.
3. The assembly of claim 2 , wherein an interior of the pocket is evacuated of air.
4. The assembly of claim 2 , wherein the panel is loose within the pocket.
5. The assembly of claim 2 , wherein the at least one of the plurality of thermally insulating pads comprises a score across its width in at least one location on an interior surface of the panel, the score extending partially but not entirely through the thickness of the multi-section pad to divide the panel into the plurality of rectangular panel sections.
6. The assembly of claim 5 , wherein the score comprises a compressed portion of the multi-section body.
7. The assembly of claim 5 , wherein the score comprises a cut out portion of the multi-section body.
8. The assembly of claim 2 , wherein the starch comprises corn starch, wheat starch or milled sorghum.
9. The assembly of claim 2 , wherein the panel of each pad has a uniform homogenous composition.
10. The assembly of claim 2 , wherein the panel of each pad is a unitary body.
11. A thermal insulation article for placement in a shipping container to hold an item, comprising:
a multi-section thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover from two to five of out of a floor, four side walls and cover of the container while leaving an interior space to receive the item, wherein the thermally insulating pad includes
a plurality of solid compostable panel sections formed primarily of grain starch, each panel section holding together as a single unit, each panel section providing a rectangular plate dimensioned to substantially span whichever of the floor, plurality of side walls or cover that the rectangular plate is adjacent, and
a compostable water-proof film forming a pocket enclosing the plurality of panel sections without being bonded to the panel sections;
wherein the multi-section thermally insulating pad is configured to be foldable at a right angle along a boundary between the panel sections, and wherein the film provides both an interior surface of the multi-section thermally insulating pad and an exterior surface of the multi-section thermally insulating pad where the multi-section thermally insulating pad is folded with all of the panel sections enclosed in the same pocket.
12. The article of claim 11 , wherein an interior of the pocket is evacuated of air.
13. The article of claim 11 , wherein the plurality of solid compostable panel sections are slidable within the pocket.
14. The article of claim 11 , wherein the multi-section thermally insulating pad comprises a panel having a score across its width in at least one location on an interior surface of the panel, the score extending partially but not entirely through the thickness of the panel to divide the panel into the plurality of panel sections.
15. The article of claim 11 , wherein the plurality of solid compostable panel sections each have a thickness between of about ¼ and 1 inch.
16. The article of claim 11 , wherein the plurality of solid compostable panel sections each have a density of about 0.6 to 3.5 g/cm 3 .
17. The article of claim 11 , wherein surfaces of each of the plurality of solid compostable panel sections are basically flat.
18. The article of claim 11 , wherein one or more surfaces of one or more of the plurality of solid compostable panel sections are corrugated.
19. The article of claim 11 , wherein the starch comprises corn starch, wheat starch or milled sorghum.
20. The article of claim 11 , wherein the multi-section thermally insulating pad includes a plurality of stacked panels.