GB2501863A

GB2501863A - Packaging including insulating material comprising bubble layers between reflective layers

Info

Publication number: GB2501863A
Application number: GB1121878.1A
Authority: GB
Inventors: Geoffrey Peter Lyon; Russell William Harrison
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-10-20
Filing date: 2011-12-20
Publication date: 2013-11-13
Also published as: GB201118141D0; GB2501053A; GB201121877D0; GB201121878D0

Abstract

An insulating thermal material comprises a heat bonded, 'crown to crown', double layer, air retention, barrier air sealed, circular bubble closed cell structure (1, 2). This structure (1,2) is preferably constructed of co-extruded plastic bubble film comprising [linear low density polyethylene (LLDPE) or low density polyethylene (LDPE)], high density polyethylene (HDPE) and nylon (polyarnide (PA)) laminated to and interposed between two outer reflective layers (3, 4). Both of the outer reflective layers (3, 4) comprise vacuum applied aluminium metallised co-extruded bioriented polypropylene (BOPP). The double layer barrier sealed circular bubble closed cell structure comprises a plurality of cells (5) which contain air.

Description

PACKAGING

The present invention relates to thermal packaging. The thermal packaging has application in the transportation of foodstuffs and other goods which are temperature sensitive.

Home delivery of goods purchased via the internet is now commonplace in the UK and elsewhere. Temperature sensitive groceries/goods delivered to the home are generally packaged in containers called totes which are generally made largely of rigid plastics material. The totes are filled with temperature sensitive goods to be delivered and are then stacked in a refrigerated/temperature controlled compartment of a delivery vehicle.

The refrigeration units of these vehicles are expensive to purchase and to operate. As the units are powered by the vehicle's engine their operation has a negative effect on the environment.

The present invention has been made from a consideration of this.

According to the present invention there is provided packaging comprising a tote in combination with a layer of thermal insulation.

The use of insulation within the individual tote thermally insulates the contents of the tote and thus reduces or eliminates the need for refrigeration of the temperature sensitive goods packed within the totes within the delivery vehicle by the refrigeration unit of the delivery vehicle. The tote may be made of a rigid material. The insulation layer may be flexible. This is useful in that the insulation layer may be engaged closely with the contents of the tote whatever the capacity or volume of the temperature sensitive goods inside the tote.

The insulation layer may be fixed to the tote, reteasably securable to the tote or completely separate. Removable insulation layers are useful as a damaged insulation layer may be more readily replaced whilst reusing the relatively expensive tote. Also such insulation layers may be retro-fitted to existing totes.

One form of insulation would comprise sealed gas bubble packaging, one form of which is commonly referred to as bubble wrap. The most common form is air bubble wrap. In one embodiment of the invention this would be coated or laminated with a layer of reflective material such as aluminium. In another embodiment of the invention the insulation comprises two such materials laminated together so as to form a double gas bubble amalgamation sandwiched between outer reflective surfaces. This material is lightweight, flexible, strong, stain resistant and has virtually no impact on the capacity of the tote.

The insulation material requires a top, bottom and sides so as to wrap the contents of the tote. This may be achieved with one piece of material with a base from which extend a number of flaps or alternatively more than one piece of insulation may be used, such as two rectangular pieces of insulation which overlay each other at the base of the tote, with one rectangle forming the base, flaps for two sides of the tote liner and two top overlaying sections and the other forming a second base, flaps for the other two sides of the tote liner and two further/optional overlaying top sections.

According to a further aspect of the present invention there is provided packaging comprising an insulation material comprising upper and lower reflective surfaces and at least one layer of gas filled bubbles. Ideally two layers of gas filled bubbles are provided.

According to a further aspect of the present invention there is provided the use of a material for insulation in packaging, the material comprising upper and lower reflective surfaces and at least one layer of gas filled bubbles.

Again, ideally two layers of gas filled bubbles are provided.

Multiple totes may be stacked one on top of the other by way of custom designed retractable supports/arms/rails present in the tote when charged with goods and optionally nested with the retractable supports in the rest position for storage within one another when empty. The insulation material may remain in the tote when the totes are stacked in nested fashion for storage or otherwise removed and stored elsewhere.

In order that the present invention may be more readily understood a specific embodiment will now be described with reference to the accompanying drawings in which:-Fig. 1 is a schematic perspective view of the insulating material of the packaging of the present invention; Fig. 2 is a schematic view of the metalhsed reflective insulation of the insulating material of Fig. 1: Fig. 3 is a cross section of the material along the line A-A of Figure 1; * Fig. 4 is a fragmentary cross section of the material along the line A-A of Figure 1; Fig. 5 is a first perspective view of packaging in accordance with the present invention; Fig. 6 is a second perspective view of the packaging of Fig. 5; and Fig. 7 is a perspective view of the packaging of Figs. 5 and 6 when charged with goods.

Referring to Figs. 1 to 4 a thermal insulation material 10 comprises a heat bonded crown to crown, double layer of air retention, barrier air sealed, circular bubble closed cell structure. This comprises two sheets 11, 12 of air bubble packing laminated together via the crowns 15, 16 of the bubbles 13, 14 of the two sheets 11, 12. The bubble packaging 10 is co-extruded bubble film, possibly comprising linear low density polyethylene (LDPE), linear high density polyethylene (LHDPE) and polyamide (PA), such as NYLON (trade mark). The non bubbled sides 17, 18 of the air bubble packing are each laminated to a sheet of high brilliance reflective film 19, 20. The reflective film may comprise metallised film, such as aluminium. Here this is metallised OPP Laminate, co-extruded heat-sealable bi-oriented polypropylene film adhesive laminated to a one-side metallised 2Opm co-extruded heat-sealable bi-oriented polypropylene film with the metal layer sandwiched between the two polypropylene film layers.

The air retention barrier air sealed bubble material of the invention is a hundred times more resistant to the passage of air than a thicker single layer of polythene bubble material. Every bubble is sealed against air loss and is resistant to compression degeneration and bursting. This heat bonded crown to crown' amalgamation of two layers of bubble film is laminated to and interposed between two outer high brilliance reflective layers, both of which comprise metalhsed OPP (orientated polypropylene) Laminate co-extruded heat-sealable bi-oriented polypropylene film adhesive laminated to a one-side metallised 2Opm co-extruded heat-sealable bi-oriented polypropylene film with the metal layer sandwiched between the two polypropylene film layers. Each film is a 3-layer structure with a core layer of polypropylene and two outside layers of heat-sealable film made from two or more polymers. The two outer layers of the laminated sandwich' may comprise a different co-extruded material such as, but not limited to, for example, aluminium foil with a bonded anti corrosion film/lacquer or polycarbonate sheet applied to the outer exposed lace. Different materials may be provided on one side to the other dependent on application demands or functional requirements. The double layer heat bonded barrier air sealed circular bubble closed cell structure comprises a plurality of cells which contain air. The dimensions of the width/diameter of the cell is related to the depth of the cell and will increase or decrease as applications dictate but without adverse effect on the overall thermal capability except if the cells were of greater diameter than 32mm whereas there is a tendency for the exterior metallised layers to fall into each other' and to come into contact with each other between the cells forming a negative thermal abridgment Colourless barrier sealed closed cell double bubble material may be produced from film of low and high density polypropylene and polyamide (LDPE/HDPE & PA). It may be laminated on both exterior sides to a reflective, high brilliance, co-extruded metallised OPP Laminate film. This combination provides for a high degree of prevention of emissive heat or cold thermal transfer by conduction and extremely high degrees of prevention of radiative heat or cold thermal iransfer from either side of the insulation material incorporating a high barrier to humidity and to the forming of condensation.

The high surface tension and inter-ply bond strength of the metallised exterior film affords enhanced tensile strength to the laminated sandwich'. The exterior metallised brilliant film can have a colour applied to tone down the reflective glare characteristic should applications dictate.

Referring to Figs. 5 to 7 two sheets 21, 22 of the material 10 are provided for insertion in a rigid plastic tote 30. The side walls and floor of the tote 30 define a basket receptacle 33 for the storage of goods, such as groceries arid the like. Retractable PVC coated metal bars 31, 32 are provided at the top of the tote. These are movable from a first working position as shown in Fig. 7 in which the bars 31, 32 overlap the basket receptacle area 33 in order to facilitate stacking of similar totes 30 thereon when the totes 30 are charged with goods. Here the bars engage with recesses (not shown) in the base of the tote 30 stacked above. The bars 31, 32 are movable to a second resting position as shown in Fig. 5 in which the bars 31, 32 lie to the ends of the tote 30 and do not therefore prevent nesting of totes 30 one inside the other when the totes 30 are not charged with goods. Such a bar arrangement for totes is known in the industry.

A first rectangular piece 21 of insulation material is inserted in the tote such that flaps extend outside the basket receptacle area 33, the flaps both being of sufficient length such that their free ends overlap one another when the tote is minimally loaded or fully charged to its top and the flaps are folded over the totes contents. Similarly a second rectangular piece 22 of insulation material is inserted at right angles in the tote such that flaps extend outside the basket receptacle area, the flaps again being of sufficient length so that their free ends overlap one another when the tote is minimally loaded or fully charged to its top.

In use the packaging as shown in Figs. 5 and 6 is charged with items, such as frozen groceries and the flaps are closed over the items and the bars 31, 32 folded over the insulation material into the first position as shown in Fig. 7.

Similar arrangements of charged totes 30 may then be stacked in a vehicle for transportation/delivery in non refrigerated vehicles, whilst transporting the goods in hygienic conditions.

In one test using this arrangement the temperature within the thermally insulated tote warmed only two degrees in eight hours in ambient conditions with temperatures in excess of 20°C. Hence temperature sensitive goods can be transported in the confines of the packaging of the invention in delivery vehicles without the benefit of mechanically produced temperate/cooled air provided by costly refrigeration units. This represents a huge energy cost saving to the supplier of the delivered goods and has an enormous environmental impact due to the zero production of Carbon (Co2) emissions.

It is to be understood that the above described embodiment is by way of illustration only. Many modifications and variations are possible.

For example, the insulation material may be in the form of a sealable bag, which might provide moisture resistance as well as insulation.

Claims

CLAIMS1. Packaging comprising a tote in combination with a layer or layers of thermal insulation.
2. Packaging as claimed in claim 1, wherein the thermal insulation comprises at least two layers of sealed bubbles, the bubbles having a closed cell structure, the layers being provided between outer layers of reflective material.
3. Packaging as claimed in claim 2, comprising a crown to crown double layer of sealed bubbles.
4. Packaging as claimed in claim 2 or claim 3, wherein the bubbles comprise air.
5. Packaging as claimed in any of claims 2 to 4, wherein one layer of bubbles is heat bonded to another layer of bubbles.
6. Packaging as claimed in any of claims 2 to 5, wherein the bubble layers are a heat bonded, crown to crown double layer of air retention barrier air sealed, circular bubble, closed cell structure.
7. Packaging as claimed in claim 6, wherein the bubble layers are constructed of co-extruded plastic bubble film comprising linear low density polyethylene (LOPE) and linear high density polyethylene (HDPE) and polyamide (PA).
8. Packaging as claimed in any of claims 2 to 7, wherein the bubble layers are laminated to and interposed between two outer optionally high brilliance, reflective layers.
9. Packaging as claimed in claim 8, wherein the reflective layers comprise multiple laminated layers of optionally high brilliance, vacuum applied aluminium, metallised film co-extruded with bioriented polypropylene (OPP) upper and lower treated adhesive sealing films.
10. Packaging as claimed in claim 9, wherein four laminated layers of film are co-extruded with the OPP,
11. Packaging as claimed in claim 2, wherein the heat bonded crown to crown amalgamation of two layers of air retention barrier air sealed circular bubble closed cell structure comprises a plurality of cells which contain air.
12. Packaging as claimed in claim 2, wherein at least one of the two outer layers of the laminated sandwich' comprises aluminium foil, optionally with a bonded anti corrosion film or polycarbonate sheet applied to the outer exposed face of the aluminium foil.
13. Packaging as claimed in claim 2, wherein every bubble is sealed against air loss and is resistant to compression degeneration/bursting.
14. Packaging as claimed in claim 2, in which the material is anti-static.
15. Packaging as claimed in claim 2, in which the material is non toxic, irritant and CFC free.
16. Packaging as claimed in claim 2, in which the material is 100% water resistant.
17. Packaging as claimed in claim 2, in which the material is resistant to fungal attack such as mildew.
18. Packaging as claimed in claim 2, in which the material is retardant to rodent attack.