Repulpable container

Patent metadata

Field	Value
Publication number	US-11780666-B2
Application number	US-202217834999-A
Country	US
Kind code	B2
Filing date	Jun 8, 2022
Priority date	Aug 16, 2016
Publication date	Oct 10, 2023
Grant date	Oct 10, 2023

Abstract

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

First claim

That which is claimed is:

1. A modular box assembly comprising:
a box formed of a paper blank, the box comprising multiple side box panels and a bottom box panel and defining an interior and a bottom;
an insulation liner positioned within the box interior, the insulation liner constructed of a length of a batt assembly, the batt assembly comprising an insulation batt in facing contact with a first paper layer and with a second paper layer, the insulation liner defining multiple sections,
wherein at least one section of the insulation liner contacts a side box panel of the multiple side box panels, and wherein another section of the multiple sections of the insulation liner contacts the bottom box panel; and
wherein the insulation batt is formed from a mixture of cellulose reinforcement fibers interlocked with thermoplastic binder fibers distributed substantially randomly within the cellulose reinforcement fibers, the thermoplastic binder fibers making up about 0.5% to 25% by weight of the insulation batt, the insulation batt having a thickness that is at least about 1/16 of an inch,
wherein the thermoplastic binder fibers are comprised of a bi-component fiber comprised of polyethylene (PE) and polypropylene (PP),
wherein a ratio of PE to PP ranges from 50/50 to about 65/35.

2. The modular box assembly of claim 1 , wherein the first paper layer is sealed to the second paper layer such that the insulation batt is encapsulated between the paper layers.

3. The modular box assembly of claim 2 , wherein each edge of the first paper layer is heat sealed to one edge of the second paper layer.

4. The modular box assembly of claim 1 , wherein the second paper layer is a portion of the paper blank such that the insulation batt is in facing contact with at least one portion of the box.

5. The modular box assembly of claim 1 , wherein the insulation batt is adhered to at least one portion of the box.

6. A modular box assembly comprising:
a box formed of a paper blank, the box comprising multiple side box panels and a bottom box panel and defining an interior and a bottom;
an insulation liner positioned within the box interior, the insulation liner constructed of a length of a batt assembly, the batt assembly comprising an insulation batt in facing contact with a first paper layer and with a second paper layer, the insulation liner defining multiple sections,
wherein at least one section of the insulation liner contacts a side box panel of the multiple side box panels, and wherein another section of the multiple sections of the insulation liner contacts the bottom box panel; and
wherein the insulation batt is formed of a mixture of paper fibers and thermoplastic binder fibers distributed substantially randomly within the paper fibers, the thermoplastic binder fibers making up about 0.5% to 25% by weight of the insulation batt, the insulation batt having a thickness that is greater than or equal to about 1/16 of an inch, the thermoplastic binder fibers being adhered to the paper fibers by melting.

7. The modular box assembly of claim 6 , wherein the thermoplastic binder fibers are comprised of at least one of polyethylene, polyester, polypropylene, and polyvinyl alcohol (PVOH).

8. The modular box assembly of claim 7 , wherein the thermoplastic binder fibers are comprised of a bi-component fiber comprised of polyethylene (PE) and polypropylene (PP).

9. The modular box assembly of claim 8 , wherein a ratio of PE to PP ranges from 50/50 to about 65/35.

10. The modular box assembly of claim 6 , wherein the first paper layer is sealed to the second paper layer such that the insulation batt is encapsulated between the paper layers.

11. The modular box assembly of claim 10 , wherein each edge of the first paper layer is heat sealed to one edge of the second paper layer.

12. A modular box assembly comprising:
a box formed of a paper blank, the box comprising multiple side box panels and a bottom box panel and defining an interior and a bottom;
an insulation liner positioned within the box interior, the insulation liner constructed of a length of a batt assembly, the batt assembly comprising an insulation batt in facing contact with a first paper layer and with a second paper layer, the insulation liner defining multiple sections,
wherein at least one section of the insulation liner contacts a side box panel of the multiple side box panels, and wherein another section of the multiple sections of the insulation liner contacts the bottom box panel; and
wherein the insulation batt is formed of a mixture of paper fiber and between about 0.5% and about 25% thermoplastic binder fiber distributed substantially randomly within the paper fiber, said thermoplastic binder fiber being adhered to the paper fiber, wherein the thermoplastic binder fiber has a length of between about 0.5 mm to about 16 mm,
wherein the thermoplastic binder fibers are comprised of a bi-component fiber comprised of polyethylene (PE) and polypropylene (PP),
wherein a ratio of PE to PP ranges from 50/50 to about 65/35.

13. The modular box assembly of claim 12 , wherein the first paper layer is sealed to the second paper layer such that the insulation batt is encapsulated between the paper layers.

14. The modular box assembly of claim 13 , wherein each edge of the first paper layer is heat sealed to one edge of the second paper layer.

Assignees

• Pratt Retail Specialties Llc

Inventors

• Collison Alan B
• Borgman Reid

Classifications

• B65D81/3823 Primary

  formed of different materials, e.g. laminated or foam filling between walls · CPC title

• B29C70/08

  comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers · CPC title

• B29C70/12

  using fibres of short length, e.g. in the form of a mat {(non-woven fabrics per se D04H1/00)} · CPC title

• B29C70/508

  and first forming a mat composed of short fibres · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title