Insulated bag with handles

Patent metadata

Field	Value
Publication number	US-2020122896-A1
Application number	US-201916721995-A
Country	US
Kind code	A1
Filing date	Dec 20, 2019
Priority date	May 9, 2017
Publication date	Apr 23, 2020
Grant date	—

Abstract

An insulated bag includes a pair of opposing main panels; and a pair of opposing side panels, each side panel attached to each main panel, the main panels and the side panels defining a bag cavity within the insulated bag; the main panels and the side panels defined in an insulated blank, the insulated blank including a first paper layer; and a paper fiber pad coupled to the first paper layer, the paper fiber pad having paper reinforcement fibers interlocked with about 2% to about 25% by weight of a meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly, wherein subjecting the repulpable shipping container to a repulpability test produces greater than 85% fiber yield.

First claim

That which is claimed is:

1 . An insulated bag comprising:
a pair of opposing main panels; and a pair of opposing side panels, each side panel attached to each main panel, the main panels and the side panels defining a bag cavity within the insulated bag; the main panels and the side panels defined in an insulated blank, the insulated blank comprising:
a first paper layer; and
a paper fiber pad coupled to the first paper layer, the paper fiber pad having paper reinforcement fibers interlocked with about 2% to about 25% by weight of a meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly, wherein subjecting the repulpable shipping container to a repulpability test produces greater than 85% fiber yield.

2 . The insulated bag of claim 1 , wherein the meltable PE/PP bi-component thermoplastic binder fiber is a chopped fiber having lengths between about 0.5 to about 16 mm.

3 . The insulated bag of claim 1 , wherein:
the insulated blank further comprises a second paper layer; the first paper layer is coupled to the second paper layer; and the paper fiber pad is at least partially encapsulated between the first paper layer and the second paper layer.

4 . The insulated bag of claim 3 , further comprising a handle assembly comprising a handle portion attached to a base portion, the base portion being laminated between the first paper layer and the second paper layer.

5 . The insulated bag of claim 1 , wherein the insulated batt further comprises one of a recycling-compatible or water soluble adhesive layer disposed between the first paper layer and the paper fiber pad.

6 . The insulated bag of claim 1 , wherein the thermoplastic binder fiber makes up less than 10% by weight of the paper fiber pad.

7 . The insulated bag of claim 1 , wherein the thermoplastic binder fiber makes up about 10% by weight of the paper fiber batt.

8 . The insulated bag of claim 1 , wherein the paper fiber batt has a weight of between 1300 and 1600 GSM.

9 . The insulated bag of claim 8 , wherein the thermoplastic binder fibers have a plurality of different lengths.

10 . An insulated bag comprising:
a pair of opposing main panels; and a pair of opposing side panels, each side panel attached to each main panel, the main panels and the side panels defining a bag cavity within the insulated bag; the main panels and the side panels defined in an insulated blank, the insulated blank comprising:
a first paper layer; and
a paper fiber batt coupled to the first paper layer, the paper fiber batt including paper fibers bound together by thermoplastic binder fibers.

11 . The insulated bag of claim 10 , wherein the thermoplastic binder fibers makeup less than 10% by weight of the paper fiber pad.

12 . The insulated bag of claim 10 , wherein the thermoplastic binder fibers makeup about 10% by weight of the paper fiber batt.

13 . The insulated bag of claim 10 , wherein the thermoplastic binder fibers are meltable PE/PP bi-component thermoplastic binder fibers.

14 . The insulated bag of claim 10 , wherein the paper fiber batt has a weight of between 1300 and 1600 GSM.

15 . The insulated bag of claim 10 , wherein the thermoplastic binder fibers have a plurality of different lengths.

16 . The insulated bag of claim 15 , wherein a first portion of the thermoplastic binder fibers has a length of about 1 mm and a second portion of the thermoplastic binder fibers has a length of about 6 mm.

17 . The insulated bag of claim 10 , wherein subjecting the shipping container to a repulpability test produces greater than 85% fiber yield.

18 . A method for forming an insulated bag, the method comprising:
mixing paper fibers with binder fibers to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; coupling the paper fiber batt to a paper layer to form an insulated batt; and folding the insulated batt to form an insulated bag comprising:
a pair of opposing main panels defined by the insulated batt; and
a pair of opposing side panels defined by the insulated batt, each side panel attached to each main panel, the main panels and the side panels defining a bag cavity within the insulated bag;
wherein the insulated bag has a repulpability of greater than 85%.

19 . The method of claim 18 , wherein the binder fibers are meltable PE/PP bi-component thermoplastic binder fibers.

20 . The method of claim 19 , wherein a first portion of the binder fibers has a length of about 1 mm and a second portion of the binder fibers has a length of about 6 mm.

21 . The method of claim 18 , wherein the paper fiber batt has paper reinforcement fibers interlocked with about 2% to about 25% by weight of a meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly.

Assignees

• Pratt Retail Specialties Llc

Inventors

• Waltermire Jamie
• Ott Paul
• Sollie Greg

Classifications

• B65D33/16 Primary

  End- or aperture-closing arrangements or devices (valves of valve bags {B65D31/14}; closures of filled bags B65D77/10) · CPC title

• A45C11/20

  Lunch or picnic boxes or the like · CPC title

• B65D31/12

  with two or more compartments · CPC title

• B65D33/18

  using adhesive applied to integral parts, e.g. to flaps · CPC title

• B65D81/3897

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