Field

[0001] The invention relates to temperature controlled packaging, in particular, natural fibre composite containers and liners.

Background

[0002] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

[0003] Polystyrene based thermal packaging is currently the industry standard for thermally insulated packaging. This packaging is commonly used in the transportation of hot and cold foods, pharmaceuticals and temperature sensitive goods. The drawbacks of polystyrene packaging include being non-biodegradable, low tensile strength and having limited hydroscopic properties and the decimation of the environment.

[0004] Packaging that is said to be more environmental friendly has been developed. These packages have generally used natural fibres, however, fall short in number of areas.

[0005] Patent application DE 19735662 which discloses a packaging container with a multi-layer sheet comprising one or more layers of fibreboard and/or paper combined with another layer of fibrous material. One shortcoming of this container is that it relies on felting and stitching to attach the fibre to the fibreboard/paper. This reduces the rigidity and protective performance of the board and limits its appropriateness for exposure to liquids.

[0006] US patent application 20180050857 discloses a method and system for producing an insulated mailer and an insulated carton having an insulative paper fibre pad structure. The insulative paper fibre pad has entangled reinforcement fibre. A method of forming an insulative paper fibre pad using recycling-compatible or water-soluble adhesive and paper layers is provided. One disadvantage of this method is that the insulative paper pad structure offers inferior insulative properties to fibre such as wool. Under this application, a watertight (impermeable) liner is not offered limiting use with non-viscous products.

[0007] Patent application WO 2008028222 relates to a laminated material suitable for hot food containers. The first lamination layer is a layer of a material adapted to absorb and retain moisture. The second lamination layer, impervious to fluids there may be comprised of metallic foil; and a third lamination layer, may be comprised of a layer of thermally insulating material. One shortcoming of this container is its thermal retention ability. The R-values are lower than that of composite fibres such as wool. The prior art is engineered for hot food and maintains this temperature for a short period of time. Another shortcoming is the use of materials not easily recyclable or biodegradable.

[0008] US patent application 20170198959 is a multi-container thermally insulated product delivery system. It uses a hollow container to house the fibrous material placed inside a corrugated cardboard carton. One shortcoming of this system is that it requires many different parts and is a labour intensive process to set up the packaging. This system restricts space for packing goods and limits applicability by not being impermeable to water.

[0009] Patent application EP 2727727, GB 2490539, GB 2513287, GB 2537894 and GB 2549777 are various interpretations in which fibrous material (e.g. wool) is attached to a corrugated board. All applications fall short by not providing an impermeable membrane to allow liquid transport and fall short by not finding the most breathable and impermeable membrane.

Object of the Invention

[0010] It is the object of the present invention to substantially overcome, or at least ameliorate, one or more of the disadvantages of the prior art, or to at least provide a useful alternative.

Summary of Invention

[0011] In accordance with a first aspect, the invention provides a thermally insulating container comprising: an outer carton formed of fiberboard defining a carton interior; an insulating liner to be fitted within the carton interior, said liner comprising natural fibers; and a receptacle to be received within the liner, the receptacle having a receptacle wall substantially impermeable to water and moisture.

[0012] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

[0013] Preferably, the outer carton comprises a base wall, at least one side wall and a closable top wall.

[0014] Preferably, the fiber-board is corrugated fiberboard.

[0015] Preferably, the outer carton is formed as one of: a regular slotted carton (RSC); an overlap slotted carton (OSC), full overlap slotted carton (FOL); center special slotted carton; center special overlap slotted carton; center special full overlap slotted carton.

[0016] Preferably, the carton is at least one of: recyclable, compostable, and biodegradable.

[0017] Preferably, the receptacle wall is formed of a polymer, and wherein preferably the polymer is a high density polymer; most preferably the high density polymer includes High Density Polyethylene (HDPE).

[0018] Preferably, the receptacle is at least one of: recyclable, compostable, and biodegradable. [0019] Preferably, the receptacle includes a biopolymer.

[0020] Preferably, the receptacle includes a receptacle wall having a wall thickness of 30 to 100 microns and more preferably a wall thickness of 70 to 80 microns.

[0021] Preferably, the receptacle is formed of food-safe materials.

[0022] Preferably, the receptacle is a flexible bag. [0023] Preferably, the insulating liner includes natural wool fibres.

[0024] Preferably, the insulating liner comprises a composite blend of natural wool and other natural fibers.

[0025] Preferably, the insulating liner comprises a first layer of insulating material and a second layer of a polymer film.

[0026] Preferably, the second layer is a high density polymer, more preferably the second layer is a High Density Polyethylene (HDPE).

[0027] Preferably, the second layer is at least one of: recyclable, compostable, and biodegradable.

[0028] Preferably, the second layer includes a biopolymer.

[0029] Preferably, the second layer has a thickness of 10 to 50 microns and more preferably a thickness of around 20 microns.

[0030] Preferably, the second layer is formed of food-safe materials.

[0031] Preferably, the second layer includes micro-perforations therethrough allowing the passage of moisture.

[0032] Preferably, the liner further includes a third layer of a polymer film and wherein the first layer is arranged between the second and third layers.

[0033] Preferably, the third layer is a high density polymer and more preferably the third layer is a High Density Polyethylene (HDPE).

[0034] Preferably, the third layer is at least one of: recyclable, compostable, and biodegradable.

[0035] Preferably, the second layer includes a biopolymer. [0036] Preferably, the third layer has a thickness of 10 to 50 microns and more preferably a thickness of around 20 microns.

[0037] Preferably, the third layer is formed of food-safe materials.

[0038] Preferably, the second and third layers substantially encapsulate the first layer.

[0039] Preferably, the insulating liner is formed from a thermal insulating sheet material.

[0040] Preferably, the second and third layers are connected along at least one peripheral edge of said sheet.

[0041] Preferably, the liner is formed as a floor panel and a plurality of peripheral side panels connected thereto.

[0042] Preferably, the second layer includes micro-perforations therethrough allowing the passage of moisture.

[0043] Preferably, the third layer includes micro-perforations therethrough allowing the passage of moisture.

[0044] Preferably, the liner absorbs and adsorbs moisture.

[0045] Preferably, the container is adapted for use as a seafood carton, wine carton or pallet cover.

[0046] According to a third aspect of the invention as presently contemplated there is provided a thermally insulating liner for a packaging container having: a first layer comprising insulating natural fibers; a second layer of a polymer film; and a third layer of a polymer film, wherein the first layer is arranged between the second and third layers.

[0047] According to a third aspect of the invention as presently contemplated there is provided a thermally insulating container with the container laminate comprising: a first layer resistant to liquid; a second layer, arranged between the first and the second layer, comprising insulating natural fibers a third layer impermeable to liquid.

[0048] In the specification the terms “outer” and “inner” are used in respect of the other layers disclosed herein. The outer layer is not necessarily the “outer most” layer and the container may comprise one or more layers surrounding the outer layer. Likewise, the inner layer is not necessarily the innermost layer. Furthermore, each of the layers disclosed herein may comprise one or more sub- layers, such a laminate.

Brief Description of Drawings

[0049] Preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings, in which:

[0050] Figure 1 is a perspective view of a thermally insulating packaging container;

[0051] Figure 2 is an exploded view of the thermally insulating packaging container;

[0052] Figure 3 is a cross sectional view of an assembled thermally insulating packaging container of Figure 1 in an open configuration;

[0053] Figure 4 is a cross sectional view of the container of Figure 3 in a closed configuration;

[0054] Figure 5 is a perspective view of the thermally insulating packaging container of Figure 4;

[0055] Figure 6 is a cross sectional portion view of an insulating liner to be fitted within the carton interior, in accordance with the invention;

[0056] Figure 7 is a cross sectional portion view of an insulating liner and carton wall, in accordance with the invention; and [0057] Figure 8 is a cross sectional portion view of an insulating liner to be fitted within the carton interior, in accordance with another embodiment of the invention.

Detailed Description of Embodiments

[0058] Figure 1 shows a perspective view of a thermally insulated packaging container 10. The container 10 includes an outer carton 20, and as is best seen with reference to Figure 2, comprising a base wall 22, a peripheral side wall 24 and a closable top wall 26. The base wall 22, side wall 24 and top wall 26 define a carton interior 28.

[0059] While the outer carton may take a variety of shapes, for instance, feasibly the carton may have any number of straight or curved side walls, typically, and as shown in the figures the container is a rectangular box such that the side wall 24 includes a pair of opposite side panels 24a and a pair of opposite end panels 24b.

[0060] In this embodiment, the outer carton 20 is constructed from one or more cut, scored and folded corrugated fiberboard blanks. While fiberboard may be used, corrugated fiberboard is preferred since it typically imparts greater stiffness to the carton walls and corresponding structural integrity to the carton, thereby, allowing stacking and the like while protecting the contents within.

[0061] Methods of constructing carton from cardboard blanks is well known in the art and many different variations on this method may be applied to the invention. For instance, the figures depict a regular slotted carton (RSC) wherein the base wall is formed from a plurality of base flaps each base flap connected to a respective lower edge of an associated side/end panel. An opposing pair of base flaps are each one-half the container's width so they can meet in the center and be joined by tape, or staples to close the base of the carton. Similarly, the top wall is formed of a plurality of top flaps 26a where each top flap is connected to a respective upper edge of an associated side/end panel. However other types of carton construction may be used including but not limited to overlap slotted carton (OSC), full overlap slotted carton (FOL); center special slotted carton; center special overlap slotted carton and center special full overlap slotted carton.

[0062] In this embodiment, both the outer carton 20 and is capable of being recycled or are substantially biodegradable, compostable or any combination thereof. Furthermore, the outer carton 20 includes a coating or treatment to provide water resistance and/or water repellant qualities. Water-resistant / repellant coatings and treatments may comprise an acrylic copolymer. For example, water-based printing ink & coatings such as Esteprint Waterborne Ink which comprises:

CAS RN %

Ethanolamine 141-43-5 <1% Acrylic Copolymer Proprietary 35-55% Acrylic Monomers Proprietary 0-02% Cyclic Halogenated Biocide Proprietary 0-01% Isopropyl Alcohol 67-63-0 <3%

[0063] Referring to the Figures, a receptacle which in this embodiment takes the form of a flexible bag 40 is fitted within the carton interior 28. The bag is made from a high density polymer, preferably a High Density Polyethylene (HDPE) or a biopolymer. Bag sidewalls typically have a wall thickness of between 40 and 100 microns although thickness of between 70 and 80 are preferred.

[0064] The receptacle 40 is at least one of: recyclable, compostable, and biodegradable and preferably formed of food safe materials.

[0065] Interposed between the outer container 20 and the bag 40 is a thermal insulating layer or liner 50. As can be seen with reference to Figure 2, in this embodiment the insulating liner 50 substantially surrounds the entire compartment 28 including the top, bottom and all sides. The liner includes wool fibers, which provide the container 10 with thermally insulative properties. Preferably, in addition to insulation, the wool fibre composite also provides a degree of cushioning to cargo in the container and, as will be seen, hygroscopic and/or hydroscopic properties to soak up fluids and moisture in the container.

[0066] With reference to Figure 2, the thermal insulating layer 50 may include multiple pieces of insulative sheet material. In this embodiment a first sheet 52 includes first, second and third portions (52a, 52b, & 52c respectively). The first portion 52a is sized and shaped to cover the base wall 22 of the container 10, the second portion 52b, covers one of the side walls of the container 10 while the third portion 52c covers the top wall. The second sheet 54 also includes first, second and third portions (54a, 54b, & 54c respectively) each for covering a respective side wall of the container. In some embodiments the insulating layer may be preconstructed so that portions 52a, 52b, 54a, 54b and 54c are conjoined at respective peripheral edges to form a container shaped soft walled bag for convenient assembly of the package.

[0067] The thermal insulating sheet material 60 may include a first layer 61 of wool fiber composite comprising a blend of wool and other natural fibers. The wool and natural fibers improve hygroscopic and thermal insulative properties while remaining compostable. Advantageously the wool blend also retains insulative properties when wet. The wool used is scoured, felted compressed and cut to size. Fibrous strands are aligned by felting and the compression holds the composite in a compressed state. This allows the material to be easily cut to size. Wool fiber composite is only one example of an insulating natural fiber layer.

[0068] The wool fibres are interwoven into a flat planar layer, and creases may be provided in a predetermined pattern to facilitate folding of the layer. As will be explained the wool fiber layer may be sandwiched between layers of a micro perforated high density polymer film or encapsulated by micro perforated high density polymer film.

[0069] The process to produce the first insulating layer includes the steps of blending and feeding wool fibres from a feed hooper, opening and carding the wool fibres, cross lapping the wool fibres, needle punching to form the matting; and cutting then sealing the fibres.

[0070] The wool is typically pre-consumer (waste) sheep wool comprised of long wool fibres which offer coarse, crimped, medullated fibres with the highest thermal insulation capacity. The waste wool if first washed and scoured through a set of 5 or more scouring baths. The wool is then placed in a mild detergent and heat up to 73 degrees centigrade. The wool is then passed through a dryer of temperatures up to 100 degrees centigrade. This process is compliant to both ISO 9001 and ISO 14001 standards.

[0071] The wool then goes through the following process steps:

Blending and feeding of the wool fibres from a feed hooper; -Opening and carding;

-Cross lapping; -Needle punching to form the matting; and -Cutting sealing

[0072] The insulative properties lie in attaining the correct GSM to loft ration. Prefereably between 400 GSM/7mm to 1600 GSM/25mm weight. This provides optimum insulation and cushioning.

[0073] The wool layer may be held together by needle punching the wool fibres together without the need for bonding polymers, providing a uniform wool layer.

[0074] With reference to Figure 6, the thermal insulating sheet material may include a second polymer layer 62. Preferably the polymer is a high density polymer film and more preferably a High Density Polyethylene (HDPE) or a biopolymer film. The micro perforated high density polymer film layer preferably has a thickness of between 10 and 50 microns and more preferably a thickness of around 20 microns. In this embodiment the second polymer layer is micro- perforated to allow transmission of fluids and/or moisture therethrough, particularly to allow fluids and / or moistureto be sorbed into the first layer.

[0075] In some embodiments, as can be seen in Figure 7, the liner, in the form of a sheet material may be bonded to internal walls of the outer carton by means of the first layer such that the second layer forms an interior face of the insulated compartment.

[0076] In other embodiments, as shown in Figure 8, in addition to the first insulating layer, the thermal insulating sheet material may include second and third polymer layers (62 & 63 respectively) wherein the first layer is arranged between the second and third layers. Preferably the polymer of each layer is a high density polymer film and more preferably a High Density Polyethylene (HDPE) or a biopolymer film. Each layer preferably has a thickness of between 10 and 50 microns and more preferably a thickness of around 20 microns. In this embodiment at least one of the second and third polymer layers are micro-perforated to allow transmission of fluids and/or moisture therethrough, particularly to allow fluids and / or moisture to be sorbed into the first layer.

[0077] In this embodiment, as can be seen in Figure 8, the second and third layers are joined at at least one peripheral edge 65 to encapsulate the first layer. [0078] Figure 3 shows a cross sectional view of the container 10 when assembled. The container 10 in this embodiment is open and has the bag 40 held within. The bag may contain contents such as fish for example. Figure 4 shows the same cross sectional view of the container 10 of Figure 3 but in a closed configuration. Figure 5 shows a perspective view of the container 10 of Figure 4.

[0079] The container 10 seeks to provide safe transportation of seafood and other liquid products, as liquid will not penetrate through. Impermeability of the bag 40 helps the structural integrity of the container.

[0080] The insulating layer is breathable allowing for hygroscopic and/or hydroscopic properties to take effect (absorption and adsorption of moisture).

[0081] The container 10 is also compatible with temperature loggers to log temperatures of the container 10 or an item placed in the bag 40. In addition, it is compatible with GPS tracking devices and is tamper-evident.

[0082] All components of the container 10 are biodegradable compostable or recyclable.