US 11,040,818 C1 (12,932nd)
Compostable insulation for shipping container
Darrell Jobe, Pleasanton, CA (US)
Filed by Vericool, Inc., Livermore, CA (US)
Assigned to VERICOOL WORLD, LLC, San Ramon, CA (US)
Reexamination Request No. 90/019,578, Jul. 15, 2024.
Reexamination Certificate for Patent 11,040,818, issued Jun. 22, 2021, Appl. No. 16/585,974, Sep. 27, 2019.
Application 90/019,578 is a continuation of application No. 15/932,239, filed on Feb. 16, 2018, granted, now 10,807,788.
Claims priority of provisional application 62/460,023, filed on Feb. 16, 2017.
This patent is subject to a terminal disclaimer.
Ex Parte Reexamination Certificate issued on Jun. 5, 2025.
Int. Cl. B65D 81/38 (2006.01); B31D 5/00 (2017.01); B32B 3/28 (2006.01); B32B 9/02 (2006.01); B32B 9/04 (2006.01); B32B 9/06 (2006.01); B65D 65/46 (2006.01); B31B 50/26 (2017.01); B31B 120/40 (2017.01)
CPC B65D 81/3858 (2013.01) [B31D 5/0004 (2013.01); B32B 3/28 (2013.01); B32B 9/02 (2013.01); B32B 9/045 (2013.01); B32B 9/06 (2013.01); B65D 65/466 (2013.01); B31B 50/26 (2017.08); B31B 2120/402 (2017.08); B31B 2247/00 (2013.01); B32B 2255/12 (2013.01); B32B 2255/24 (2013.01); B32B 2262/062 (2013.01); B32B 2307/304 (2013.01); B32B 2307/7265 (2013.01); B32B 2439/00 (2013.01)]
OG exemplary drawing
AS A RESULT OF REEXAMINATION, IT HAS BEEN DETERMINED THAT:
The patentability of claims 1-29 is confirmed.
New claims 30-100 are added and determined to be patentable.
1. A thermal insulation article for placement in a shipping container to hold an item, comprising:
a thermally insulating pad shaped to be positioned in a cavity of a rectangular prism shipping container to be adjacent to and cover one or more of a floor, four side walls and cover of the container while leaving an interior space to receive the item, wherein the pad includes:
a panel formed primarily of starch that holds together as a single unit, wherein the panel comprises one or more rectangular plates dimensioned to substantially span whichever of the floor, plurality of side walls or cover of the container that the one or more rectangular plates are adjacent, and
a compostable or recyclable film formed of paper, wherein the film sandwiches the panel and provides both an interior surface of the pad to face the interior space and an exterior surface of the pad to face the respective floor, plurality of side walls or cover.
[ 30. The article of claim 11, wherein the panel comprises a score on an interior surface of the panel, and wherein the score comprises a compressed region formed by applying compression to the panel.]
[ 31. The article of claim 11, wherein the panel comprises a score across its width, and wherein compression of the panel at the score forms a recess in the panel that extends through about 50% to about 75% of the thickness of the panel.]
[ 32. The article of claim 31, wherein the score includes the recess defined on an interior surface of the panel.]
[ 33. The article of claim 32, wherein the score divides two rectangular plates of the plurality of rectangular plates.]
[ 34. The article of claim 11, wherein the panel comprises a score across its width on an interior surface of the panel, wherein the score comprises a compressed portion of the panel, and wherein the compressed portion defines a recess in the interior surface of the panel that extends along the score.]
[ 35. The article of claim 11, wherein the panel comprises multiple components that are primarily formed of starch, wherein the panel comprises a score on an interior surface of the panel, and wherein the multiple components are compressed together at the score.]
[ 36. The article of claim 35, wherein the multiple components comprise multiple layers that are each formed primarily of starch.]
[ 37. The article of claim 35, wherein the multiple components comprise a first component and a second component, and wherein the first component is pressed partially into the second component at the score.]
[ 38. The article of claim 12, wherein the panel comprises a portion formed primarily of starch that is deformed by compression at the score.]
[ 39. The article of claim 12, wherein the panel comprises a portion that spans the score and is compressed at the score such that a thickness of the portion is reduced by the compression at the score.]
[ 40. The article of claim 12, wherein the score is formed by compressing the panel at the score without cutting the panel at the score.]
[ 41. The article of claim 11, wherein the panel has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 42. The article of claim 11, wherein the panel has a Young's modulus from 0.01 GPa to 1 GPa.]
[ 43. The article of claim 11, wherein the thermally insulating pad is compostable.]
[ 44. The article of claim 1, wherein the panel has 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 a plurality of rectangular plates.]
[ 45. The article of claim 44, wherein the score comprises a compressed portion of the panel.]
[ 46. The article of claim 44, wherein the panel comprises a portion that spans the score and is compressed at the score such that a thickness of the portion is reduced by the compression at the score.]
[ 47. The article of claim 44, wherein the score is formed by compressing the panel at the score without cutting the panel at the score.]
[ 48. The article of claim 1, wherein the panel extends through a fold between a plurality of rectangular plates of the thermally insulating pad.]
[ 49. The article of claim 48, wherein the film covers an interior surface of the panel and an exterior surface of the panel at the fold.]
[ 50. The article of claim 1, wherein the panel comprises a score on an interior surface of the panel, and wherein a compressed portion of the panel at the score defines a recess in the panel that extends partially through but not entirely through the thickness of the panel.]
[ 51. The article of claim 50, wherein the recess extends through about 50% to about 75% of the thickness of the panel.]
[ 52. The article of claim 1, wherein the thermally insulating pad is compostable, wherein the panel comprises a foam material, and wherein the panel has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 53. The article of claim 22, wherein the panel has 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 a plurality of rectangular plates.]
[ 54. The article of claim 53, wherein the score comprises a compressed portion of the panel.]
[ 55. The article of claim 53, wherein the panel comprises at least one layer formed primarily of starch that spans the score and is compressed at the score such that the compression at the score reduces a thickness of the at least one layer at the score compared to a thickness of the at least one layer located adjacent to the score.]
[ 56. The article of claim 53, wherein the score is formed by compressing the panel at the score without cutting the panel at the score.]
[ 57. The article of claim 22, wherein the panel extends through a fold between a plurality of rectangular plates of the thermally insulating pad.]
[ 58. The article of claim 57, wherein the film covers an interior surface of the panel and an exterior surface of the panel at the fold.]
[ 59. The article of claim 22, wherein the panel comprises a score on an interior surface of the panel, and wherein the score comprises a compressed region of the panel formed by applying compression to the panel.]
[ 60. The article of claim 22, wherein the thermally insulating pad is compostable.]
[ 61. The article of claim 60, wherein the panel has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 62. The article of claim 61, wherein the panel comprises a foam material.]
[ 63. The article of claim 62, wherein at least 85% of the panel by weight is starch.]
[ 64. The article of claim 63, wherein the panel has a Young's modulus from 0.01 GPa to 1 GPa.]
[ 65. The shipping container of claim 21, wherein the panel has 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 a plurality of rectangular plates.]
[ 66. The shipping container of claim 65, wherein the score comprises a compressed portion of the panel.]
[ 67. The shipping container of claim 65, wherein the score comprises a recess formed by compressing the panel at the at least one location on the interior surface of the panel.]
[ 68. The shipping container of claim 21, wherein the panel comprises a score on an interior surface of the panel, and wherein a compressed portion of the panel at the score defines a recess in the panel that extends partially through but not entirely through the thickness of the panel.]
[ 69. The shipping container of claim 68, wherein the recess extends through about 50% to about 75% of the thickness of the panel.]
[ 70. The shipping container of claim 21, wherein the thermally insulating pad is compostable, wherein the panel comprises a foam material, and wherein the panel has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 71. The shipping container of claim 23, wherein the thermally insulating pad is compostable, wherein the layer of starch comprises a foam material, and wherein the layer of starch has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 72. The shipping container of claim 71, wherein the layer of starch has a Young's modulus from 0.01 GPa to 1 GPa.]
[ 73. The shipping container of claim 24, wherein the layer of starch has a score at the boundary between the plurality of rectangular plates, wherein the score is located on an interior surface of the layer of starch, the score extending partially but not entirely through the thickness of the layer of starch, and wherein the score comprises a compressed portion of the layer of starch.]
[ 74. The shipping container of claim 73, wherein the score comprises a recess formed on the interior surface of the layer of starch by compressing the layer of starch.]
[ 75. The shipping container of claim 74, wherein the recess extends through about 50% to about 75% of the thickness of the layer of starch.]
[ 76. The shipping container of claim 24, wherein the thermally insulating pad is compostable, wherein the layer of starch comprises a foam material, and wherein the layer of starch has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 77. The article of claim 25, wherein the layer of starch has a score at a boundary between a plurality of rectangular plates of the thermally insulating pad, wherein the score is located on an interior surface of the layer of starch, the score extending partially but not entirely through the thickness of the layer of starch, and wherein the score comprises a compressed portion of the layer of starch.]
[ 78. The article of claim 77, wherein the score comprises a recess formed on the interior surface of the layer of starch by compressing the layer of starch.]
[ 79. The article of claim 78, wherein the recess extends through about 50% to about 75% of the thickness of the layer of starch.]
[ 80. The article of claim 25, wherein the thermally insulating pad is compostable, wherein the layer of starch comprises a foam material, and wherein the layer of starch has a thickness of at least ¼ of an inch and not more than 3 inches.]
[ 81. The article of claim 1, wherein the panel has a score across its width in at least one location on the panel, the score extending partially but not entirely through the thickness of the panel to divide the panel into a plurality of rectangular plates;
wherein the score comprises compression of the panel at the score that reduces the thickness of the panel at the score;
wherein the panel comprises a foam material; and
wherein at least 85% of the panel by weight is starch.]
[ 82. The article of claim 45, wherein the panel comprises a foam material, and wherein at least 85% of the panel by weight is starch.]
[ 83. The article of claim 45, wherein the compressed portion includes a compressed portion formed using a compression applied to the panel while the panel is located between layers of the compostable or recyclable film.]
[ 84. The article of claim 45, wherein the compressed portion includes a compressed portion formed using a compression of the panel applied while the panel is enclosed in the compostable or recyclable film.]
[ 85. The article of claim 1, wherein the panel comprises multiple components that are primarily formed of starch, wherein the panel comprises a score on an interior surface of the panel, and wherein the multiple components are compressed together at the score.]
[ 86. The article of claim 45, wherein the multiple components comprise a first component and a second component, and wherein the first component is pressed partially into the second component at the score.]
[ 87. The article of claim 1, wherein the compostable or recyclable film formed of paper forms a pocket enclosing the panel, and wherein an interior of the pocket includes air; and
wherein a portion of the panel within the pocket is affixed to the compostable or recyclable film formed of paper.]
[ 88. The article of claim 87, wherein the panel has a surface within the pocket, and the compostable or recyclable film formed of paper is affixed at portions of the surface of the panel without being affixed across the entire surface of the panel.]
[ 89. The article of claim 88, wherein the portions where the compostable or recyclable film is affixed to the surface of the panel are spaced apart from an edge of the panel.]
[ 90. The article of claim 88, wherein the portions where the compostable or recyclable film is affixed to the surface of the panel are located at a central portion of the panel and do not extend to one or more edges of the panel.]
[ 91. The article of claim 88, wherein the compostable or recyclable film formed of paper is affixed to the panel at opposing surfaces of the panel.]
[ 92. The article of claim 11, wherein the panel has a score across its width in at least one location on the panel, the score extending partially but not entirely through the thickness of the panel to divide the panel into a plurality of rectangular plates;
wherein the score comprises compression of the panel at the score that reduces the thickness of the panel at the score;
wherein the panel comprises a foam material; and
wherein at least 85% of the panel by weight is starch.]
[ 93. The article of claim 13, wherein the panel comprises a foam material, and wherein at least 85% of the panel by weight is starch.]
[ 94. The article of claim 13, wherein the compressed portion includes a compressed portion formed using compression applied to the panel while the panel is located between layers of the compostable or recyclable film.]
[ 95. The article of claim 13, wherein the compressed portion includes a compressed portion formed using compression of the panel applied while the panel is enclosed in the compostable or recyclable film.]
[ 96. The article of claim 11, wherein an interior of the pocket includes air; and
wherein a portion of the panel within the pocket is affixed to the compostable or recyclable film formed of paper.]
[ 97. The article of claim 96, wherein the panel has a surface within the pocket, and the compostable or recyclable film formed of paper is affixed at portions of the surface of the panel without being affixed across the entire surface of the panel.]
[ 98. The article of claim 97, wherein the portions where the compostable or recyclable film is affixed to the surface of the panel are spaced apart from an edge of the panel.]
[ 99. The article of claim 97, wherein the portions where the compostable or recyclable film is affixed to the surface of the panel are located at a central portion of the panel and do not extend to one or more edges of the panel.]
[ 100. The article of claim 97, wherein the compostable or recyclable film formed of paper is affixed to the panel at opposing surfaces of the panel.]