WO2013063374A1

WO2013063374A1 - Super insulating corrugated cardboard packaging system for food, beverages and perishables

Info

Publication number: WO2013063374A1
Application number: PCT/US2012/062091
Authority: WO
Inventors: Robert James SHOWERS
Original assignee: Showers Robert James
Priority date: 2011-10-28
Filing date: 2012-10-26
Publication date: 2013-05-02

Abstract

The present invention introduces industrially prefabricated corrugated stock to include although not limited to corrugated cardboard for the purpose of forming boxes, cartons, or for packaging hot, cold and/or perishable items. The components making up the corrugated board design are first laminated with polymer-based Aerogel film that is extremely flexible, extremely strong (durable), fireproof, waterproof, hydrophobic as well as super-insulating.Cavities are filled with an insertable/injectable insulation. Once components are laminated with said Aerogel polymer-based film on all main surfaces, these components are next assembled into corrugated stock that soon afterwards is used to form boxes, cartons and, or packaging. The paper for a liners or a medium may be configured in two optional, innovative ways as seen in Figure 8 and Figure 9.

Description

Super Insulating Corrugated Cardboard Packaging System

For Food, Beverages and Perishables

The current application claims a priority of the Provisional Patent Application Number

61/552,596 filed on October 28, 2011.

FIELD OF THE INVENTION

Corrugated cardboard is often used for making boxes, cartons and various packaging (or packaging components) for hot pizza, hot or cold foods and beverages for shipping, carry-out as well as home delivery. Corrugated cardboard is also used as packaging for medications and other temperature sensitive products. The way cardboard is designed creates reinforcement for added strength while the design itself creates pockets of trapped air within layers making up corrugated cardboard. These pockets of trapped air create a mediocre insulating effect.

BRIEF DESCRIPTION OF THE PRIOR ART

The first commercial non-corrugated paperboard box was produced in England in 1817. Robert Gair invented a pre-cut flat paperboard or cardboard that folded into boxes in 1890. The application of this idea to corrugated boxboard was further developed around the turn of the twentieth century. Corrugated paper often referred to as pleated paper was patented in England in 1856. Next corrugated boxboard was used as a shipping material. A patent was issued to a New York businessman by the name of Albert Jones for single-faced or often referred to as a single- sided corrugated board. This inventor used the corrugated board for wrapping glass. A machine for producing larger corrugated board quantities surfaced in 1874 invented by G. Smyth. Soon afterwards, an inventor named Oliver Long improved upon designs by inventing corrugated board with liner sheets on both sides. This is what is known today as corrugated cardboard. The first corrugated cardboard box manufactured in the United States of America (USA) was in 1895. By the early 1900s, wooden boxes and crates were increasingly being replaced by corrugated paper shipping cartons. By 1908, corrugated cardboard and corrugated paper-board became commonplace descriptions used in the paper industry. Since then thousands of different profiles (die-cut designs) have been used and materials used for manufacturing corrugated packaging advanced as technology, manufacturing, and shipping advanced while the practice of layers of suitable materials creating pockets adding reinforcement and strength remained. Once the corrugated assembly was made, it became commonplace for a box or carton designer to create innovative corrugated boxes (containers) and packaging (or components thereof) as they utilized die-cutting systems driven by sophisticated software to include, although not limited to, computer-aided design (CAD) die-cutting programs. This allows the designer to program different box (package) templates (also known as blank designs) often even before

manufacturing begins. The following prior art illustrates various packaging templates (die-cut designs) and designs although many thousands of different templates (designs) currently exist.

United States Patent Number 5,595,339 features a blank for an octagonal box

United States Patent Number D356,254 features a pizza box

United States Patent Number 5,881,948 features an expandable pizza box

United States Patent Number 5,806,755 features a protective pizza carton

United States Patent Number 5,918,797 features a blank for a pizza box

United States Patent Number 5,833,130 features a multi-functional pizza carton

United States Patent Number 6,016,951 features a pizza box with roll-over feature

United States Patent Number 6,065,669 features a slanting-wall type pizza box

United States Patent Number 6,290,122 features a versatile pizza carton

United States Patent Number 5,961,035 features a designer pizza box

United States Patent Number 6,092,715 features an easy use pizza box

Those practiced in the art of packaging, corrugated cardboard packaging and die cutting will appreciate the following. None of the prior art stated herein features a super-insulating design including the integration of nanotechnology, fireproof, hydrophobic, waterproof, super- insulating, bendable, polymer-based Aerogel film as does this present invention. The present invention also features Aerogel film bonded where die-cuts leave exposed edges where cutting has taken place. These edges are also later wrapped with Aerogel film completely sealing in the trapped air created by the flutes (corrugated medium) and outside layers serving as liners. Any remaining seams left unsealed once a package receives its contents shall also be sealed with the Aerogel film and bonding adhesive.

The Aerogel film and suitable adhesive may be made available to be optically transparent or translucent whereas any printing beneath it may still be identified. The Aerogel film is die cut to the same pattern as a liner or liners and corrugated medium or mediums are (1 fluted layer or layers).

Cavities created by the medium and the liner are filled with hydrophobic,

insertable/injectable insulation, such as Aerogel powder or granules, depending of cavity size. One manufacturer of this type of insulation is Cabot hydrophobic aerogel branded as Lumira and Enova.

Liners and mediums may also be made by sandwiching polymer based aerogel film between two layers of paper although adhesive will be used to bond both paper layers to said NASA published polymer based aerogel film as seen in Figure 9.

This aerogel film as seen in Figure 9 may also be substituted for an insulating coating such as for example Nansulate (or a suitable insulating coating that includes Enova) a product of nanotechnology as seen in Figure 8.

BACKGROUND OF THE INVENTION

Dominos, Pizza Hut, and thousands of other businesses internationally use cardboard for boxing pizza and other hot foods. Cardboard packaging including packaging components form templates are used for shipping, carry-out and home delivery of hot and cold food as well as many beverages. With the proliferation of fast food side items such as chicken wings, breadsticks, and hot sandwiches and the like as an offshoot of the cardboard box industry continues to flourish internationally. Packaging made of corrugated cardboard is frequently designed to package and keep beverages such as beer cold longer and for protection purposes. Even supermarkets, produce distributors, shopping malls and convenience stores now use corrugated cardboard packaging due to it being such a versatile material that can be easily die- cut as needed. Corrugated cardboard is designed for creating reinforcement for adding strength, insulation and for protective purposes. The design of corrugated cardboard creates pockets of trapped air between layers. The fluted interior design traps air against outside walls that serves as a mediocre insulator. Although corrugated cardboard designs do insulate, they are not highly effective for insulating.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 illustrates a corrugated cardboard profile featuring two outside layers serving as liners bonded by adhesive to an interior corrugated medium (1 fluted layer)

Figure 2 is a magnified view of Figure 1 showing the five layer composition being polymer based aerogel film, water, and heat resistant adhesive, paper, or other suitable material, water and heat resistant adhesive, and polymer based aerogel film.

Figure 3 illustrates a corrugated cardboard profile featuring two outside layers and one inside layer bonded by adhesive to two interior corrugated mediums (2 fluted layers)

Figure 4 is a magnified view of Figure 3 showing the five layer composition being polymer based aerogel film, water and heat resistant adhesive, paper or other suitable material, water and heat resistant adhesive, and polymer based aerogel film.

Figure 5 shows the five layer composition being polymer based aerogel film, water and heat resistant adhesive, paper or other suitable material, water and heat resistant adhesive, and polymer based aerogel film.

Figure 6 shows the five layer composition of the fluted layer where the composition being polymer based aerogel film, water and heat resistant adhesive, paper or other suitable material, water and heat resistant adhesive, and polymer based aerogel film.

Figure 7 illustrates a layer of suitable material with continuous adhesive applied to both of its sides whereas continuous polymer-based Aerogel film is next applied. All side surfaces of each component (layers such as liners or mediums) making up Figure 1 or Figure 2 are laminated with said polymer based Aerogel film (Aerogel film made entirely of polymers). This way before all said components are bonded together by adhesive, one with another in order to form a corrugated assembly that shall later be used to form a box, carton, packaging or component thereof. Figure 8 illustrates a layer that can be used as a liner or later formed as a corrugated medium. The configuration consists of an insulating coating consisting of Nansulate (or a suitable insulating coating or adhesive that includes Cabot Enova aerogel) between two paper layers. This way the insulating coating is between and bonds together the two layers of paper or other suitable material.

Figure 9 illustrates a layer configuration that can also be used as a substitute for Fig 8. The configuration being made up of a highly reflective film, an adhesive, paper layer (or other suitable material), an adhesive, a polymer based aerogel film, an adhesive, a paper layer, an adhesive, and a highly reflective film. This way the polymer based aerogel film is bonded by adhesive between two layers of paper or other suitable material for making up a corrugated medium or to be used as a liner board.

Figure 10 illustrates a layer similar to the layer in Figure 8 that can be used as a liner or later formed as a corrugated medium. The configuration consists of a highly reflective film, an adhesive, a paper layer, an insulating coating consisting of Nansulate (or a suitable insulating coating or adhesive that includes Cabot Enova aerogel), a paper layer, an adhesive, and a highly reflective film.

DETAIL DESCRIPTIONS OF THE INVENTION

The present invention is an extremely significant improvement to corrugated cardboard (and paper stock) used for packaging. The present invention is a product of nanotechnology whereby a strong, fire proof, highly flexible, bendable, durable, hydrophobic, dust free, water proof, silica free, high heat stable, super insulating polymer-based Aerogel film is integrated (lamination of all surfaces) so that air, heat, cold, water, dirt, dust, or moisture can no longer directly contact the paper or suitable material used as packaging components. Air, heat, cold, fire, water, dirt, dust, moisture only contacts the Aerogel film that is highly resistant to heat, cold, water, dirt, dust and moisture. Even where component edges are exposed (with no Aerogel film protection) from die-cuts during manufacturing, these same component edges would be exposed edges and shall be separately wrapped with the Aerogel film and bonded thereby adhesive. Finished assembled packages (once contents also are packaged), where any open seams still exist, shall be laminated (taped over) with the same Aerogel film and adhesive for a complete seal against air leakage, fire, heat, cold, water, dirt, dust and moisture. If venting is desired, then selected areas shall be left unsealed.

Dominos, Pizza Hut and thousands of others internationally use corrugated board made of various materials for boxing pizza and other hot or cold foods. Industrially prefabricated boxes made up of suitable corrugated board materials are commonly used for packaging hot foods, cold foods, perishable foods, or items and cold or hot beverages. Many brand name beers, such as Sam Adams, Miller, Yuengling, Guinness, Corona, Sarajevsko Pivo, Heineken, Coors, Budweiser and San Miguel Pale Pilsen, are packaged in poorly insulating boxes or cartons made from corrugated board. Cooled beverages or items often get warm far too quickly once they leave coolers and, therefore, become undesirably warm unless they are re-cooled. Often corrugated materials are used to protect products from freezing. Currently, cardboard is not highly resistant against fire unlike the Aerogel film laminated present invention.

Specialists in industry no longer use the term corrugated cardboard due to this description not specifically denoting the actual materials used. Corrugated cardboard is also at times used as packaging for medications, biomedical items as well as many other temperature sensitive products and, or for other purposes. The term cardboard may refer to a variety of heavy paperlike materials, including although not limited to fiberboard, plastics, laminated papers, various paperboards, card stocks as well as other suitable materials. The meaning of the term corrugated box or container packaging often depends on personal choice.

The science, technology, and art of packaging is protecting or enclosing products for storage, sale, distribution and eventual use. Packaging also refers to the process of evaluation design and production of packaging materials and packages. For the purpose of the present invention shall be described as a coordinated system of preparing goods for warehousing, transporting, logistics, marketing, sale, and eventual use. Packaging preserves, protects, contains and assists during transports. Packaging is fully internationally integrated into business, government, industrial, institutional, and personal uses .

The earliest recorded known use of paper packaging dates back to the Persian in 1035 in Cairo where spices, vegetables, and miscellaneous were wrapped in paper for the customers as they were sold. They were not well protected from fire (was highly combustible) and the packaging was very poorly insulated. Corrugated (also called pleated) paper was originally patented in England around the mid 1850s. Corrugated boxboard was used as packaging for shipping material starting around the late 1870s. A patent was issued to a New York City businessman by the name Albert Jones for a single-faced corrugated board. This businessman used the corrugated board for packaging, organizing, protecting, and transporting glass items. This corrugated packaging was not well protected from fire (was highly combustible) or water. The first machine for mass

manufacturing packaging board was built in mid- 1870s, and, soon after, corrugated board with liner sheets on both sides was invented. This is what is commonly referred to today as corrugated cardboard. Corrugated cardboard was still not highly fire resistant at this time as is the present invention. Many wooden boxes and wooden crates were quickly replaced by corrugated paper packaging for economic purposes. By the early 1900s, the trades termed the concept as corrugated paper-board and corrugated cardboard. Since then, many new materials were used to create similar corrugated reinforced packaging designs. Corrugated cardboard was still not highly fire resistant and was considered mediocre in terms of insulating at this time, which is unlike the present invention.

In the early part of the 20th century, engineers began to use many different material compositions for manufacturing corrugated board stock although the concept and actual designs are still often quite similar.

Polymers also advanced in years more recent and at times are used although designs having an outer layer or layers with a fluted interlayer or layers. Creating cavities for

reinforcement creating strength is still commonplace. Various corrugated board used at this time was still not fire proof (were highly combustible), water proof or super-insulating as is the present invention.

For the purpose of describing the present invention, corrugated board stock is used more to define a packaging design than the actual materials or combination of materials making up the design due to so many modern, suitable materials. Packaging made of said corrugated board stock is often designed for use as packaging while providing protection and insulation while organizing and for transporting.

Corrugated board boxes, cartons, and packaging are used for both carry-out and home delivery of hot or cold food and beverage items. With the proliferation of fast food side items, such as chicken wings, breadsticks, hot sandwiches, and the like as an offshoot of corrugated packaging, this industry continues to evolve and flourish until the present day. Supermarkets, shopping malls, and convenience stores now use corrugated packaging due to it being such a versatile packaging option. Said corrugated stock designs create pockets of trapped air, and this air does currently serve as a mediocre insulator for allowing items to stay hot, warm, cold, or colder for a longer period of time. Said corrugated stock is not really as effective for insulating items as is frequently desired. A far better insulating design is therefore desirable and would therefore benefit the packaging industry. Even corrugated cardboard packaged explosives would be far safer as the present invention is fire proof. In fact, the polymer based aerogel film may be made thicker to add even additional fire protection and additional insulation. Other products, such as flowers, also require temperature controlling packaging systems for the purpose of storing and/or shipping. Therefore, the present invention would be ideal for this purpose as well as many other temperature sensitive products.

A significant amount of fast food intended for home delivery is packaged in said corrugated stock made into packaging for food and beverages and other products. Many pizza boxes serve as packaging and are manufactured to be square. Non-square pizza boxes reduce pizza-sliding if a pizza is round. Many non-square pizza box die-cut blanks made of corrugated stock have been patented, including although not limited to a heptagon, pentagon, and hexagon pizza boxes. An example of a non-square pizza box is the shape of an octagon, 8-sided pizza box. Domino's Pizza used such a box. Dominoes more recently adopted a patented D-style hexagon box.

Corrugated stock made into packaging for pizza and other hot foods are commonly made in many different shapes while the actual material used to make the corrugated stock frequently varies from manufacturer to manufacturer. By far, thick paper is most often the material of choice for a majority of corrugated board boxes due to being economical and so readily available while having substantial strength for resistance against crushing especially when packages are stacked. The present invention adds value especially in regard to significantly reducing air leakage, air circulation, especially heat transfer or retaining cold, retaining heat or significantly resisting water, fire, dirt, dust and moisture.

More recently, recycled materials have become more and more acceptable rather than using new raw materials to manufacture corrugated stock. Corrugated board often used for pizza boxes is known as single wall corrugated box material consisting of two separate outer sheets of flat paper known as facings that are bonded with adhesive to a corrugated (fluted) inner layer, often known as a medium. Architects for thousands of years have used an arch with a curve for strengthening and supporting a span of space. Corrugated fiberboard uses this same principle with paper arranged as arches forming a corrugated medium although cardboard is highly combustible unlike the present invention , which is fire proof. These arches are often referred to as flutes that are bonded to linerboard with adhesive for resistance against pressure from all directions and against bending. When corrugated board is placed on end, the arches form strong columns. These columns are capable for supporting a significant amount of weight. Undesirably, the ends of columns are traditionally left unsealed thereby reduce much needed insulating value, which is unlike the present invention because the Aerogel film seals, fire proofs, and super- insulates these end openings. This protects exposed component edges and internal cavities from fire, air leakage, heat transfer, and water/moisture damage. With the present invention, the Aerogel laminated vertical linerboard also serves as to further protect the flutes from fire, heat transfer, moisture, and damage. Corrugated fiberboard can be specified by means of its construction such as for example single face, single- wall, double- wall as well as edge crush strength, burst strength, flat crush, flute size, weight of components, surface treatments, and coatings. ASTM and TAPPI testing methods are standardized in this industry. The size of the corrugated medium, flute size, combining adhesive, and linerboards can be varied for engineer desired properties for matching a wide range of uses. Double- and triple- wall corrugated board is produced for a higher stacking strength and better resistance against puncture. A corrugated design provides additional impact protection, additional stacking strength and adds mediocre insulating properties by means of the hollow cavities filled with trapped air that tends to have said mediocre insulating effect. The present invention is far more insulating (super insulating) and fire proof.

Many internationally order Pizza Hut's or Domino's pizza for home delivery through the internet or by telephone. Some in the pizza industry have kept pace with technological advancements while the technology of corrugated packaging that is able to better insulate has not advanced. GPS, driving instructions, and routing software for pizza delivery enables the most efficient routes and delivery times, although keeping pizza hot or even warm enough continues to be a huge and constant problem. Some have even installed tracking technology on delivery vehicles to monitor actual delivery time for maximum efficiency in order to more effectively ensure that packaged temperature sensitive items once received are more efficiently managed. Some pizza shops guarantee a minimal amount of time for delivery although it is far less practical to guarantee that a delivered pizza will be hot enough once a customer actually receives it. There have been numerous international lawsuits arising from hurried delivery drivers causing automobile accidents as they rush hot pizza to its final destination before it cools. The longer that the pizza takes to deliver, the less heat will be retained by a less insulating corrugated pizza box. One attempt for keeping pizza hot longer is an insulated thermal-bag. This solution comes with many new and different problems while, at the same time, adding to cost and increasing management and accounting responsibilities. Some insulating thermal-bags are even heated using electricity although this undesirable complication requires a plug in and cord assembly as well as an electrical system. Thermal-bags have limited cost-verses-value benefits while often causing unwanted condensation. Keeping these thermal-bags sanitary is another constant concern, and, not to mention, the initial cost and eventually reoccurring replacement costs.

Corporations customarily prefer simplicity and efficiency instead of complications and added cost expenditures.

The United States Bureau of Labor Statistics categorizes fast food delivery drivers as drivers-sales workers. Drivers are ranked as the fifth most dangerous job category. Pizza delivery statistically has proved to expose drivers to serious risks. Having an insulating thermal- bag to manage and focus can be a distraction when compared to dropping off a corrugated box, which is more simple and quick. A thermal-bag takes far more time, attention, and can create a distraction from what might be going on in the background, which could be dangerous to the delivery person while constantly delivering to so many unfamiliar neighborhoods as they deliver pizzas to stranger after stranger. By eliminating the insulated thermal-bag while reducing multitasking drivers may at times, under certain circumstances be more prone to avoid robbery, assault, being raped, or being even killed.

A finished piece of corrugated stock for forming a box or carton (packaging) is often made of a single corrugated layer sandwiched between two liner layers and is highly

combustible. The medium is sent through a roller system called a single-facer adhesive station. One layer of liner is bonded with adhesive to the internal medium. Adhesive is applied to the corrugated edges of the medium, and the first layer of liner is applied. Although manufacturing technology varies, often from the single-facer system, the medium and liner together go to a double-backer adhesive station whereas the other layer of liner from the bridge is added.

Continuing through the corrugating systems, often the stock is passed over heat that then cures the bonding adhesive. Once the corrugated assembly was created, it has become commonplace that box or carton designers create extremely innovative corrugated boxes (containers) as they utilize die-cutting systems driven by sophisticated software to include although not limited to computer-aided design (CAD) programs. This allows the designer to program different box (package) templates (also known as blank designs) often even before manufacturing begins. Many CAD programs can even call up past manufacturing designs with or without modifications adding efficiency to the desired corrugated box (carton) design.

The present invention is a corrugated stock with integrated nanotechnology that has been dubbed by NASA as polymer-based Aerogel film. This Aerogel film is made entirely of polymers and was originally invented by NASA and their associates. NASA has documented polymer based Aerogel film as a superior insulating film, and therefore said Aerogel film shall be used to significantly increase insulating and fire proofing properties of said components making up a box, carton, or package. The components making up the corrugated stock design are laminated with said polymer-based Aerogel film on all main surfaces using a suitable heat resistant, waterproof adhesive. Once cured the components are next bonded together by the waterproof and heat resistant adhesive for the purpose of forming the corrugated stock as seen in Figure 1 through Figure 7 and other corrugated designs. By completely laminating each component's main side surfaces with said polymer-based Aerogel film, before bonding

(adhesive) components together, one with one another. This results in far superior fire proofing, water proofing, super-insulating corrugated packaging system. The present invention also features Aerogel film bonded where die-cuts leave exposed edges and cutting has taken place. These exposed edges also are wrapped with Aerogel film completely sealing in the trapped air (or fire proof, hydrophobic Aerogel power or Aerogel granules such as Cabot aerogel

manufacturers) in cavities that are created by the flutes (corrugated medium) and outside layers serving as liners. Any remaining seams left unsealed once a package receives its contents shall also be sealed with the Aerogel film and bonding adhesive. The polymer based Aerogel film and suitable adhesive may be made available when desirable to be optically transparent or translucent whereas any printing beneath it may still be identified. Some manufacture packaging made up of just one single flat layer of stock that does not include a corrugated design. In this case, both sides of the paper layer shall be laminated with Aerogel film. This single paper layer may also be configured differently as two paper layers with insulation between them as seen in Figure 8 and Figure 9. The paper facing the package interior cavity may still be laminated with highly reflective (reflects radiant heat) food safe film when desirable based upon the packaging circumstances. Just one example of a traditional one layer box design is one that is commonly known as a pizza box most often accompanied by a pizza box lid know as a die-cut out pizza box blank.

Again, Aerogel film can be bonded (adhesive) where die-cuts leave cut component edges exposed, allowing heat transfer, and far more susceptible to fire. The present invention can be exposed to far higher heat unlike a conventional plain paper packaging. These exposed die-cut component edges can be separately wrapped with said fire resistant NASA polymer, super- insulating Aerogel film, and bonded in place with said water proof, heat resistant adhesive. Once a package receives its contents, any remaining seams that are left unsealed shall also be separately sealed with the Aerogel film and waterproof, heat resistant bonding adhesive. The Aerogel film and suitable adhesive as an option may be made available to be optically transparent or translucent whereas printing beneath it if such exists may still be identified.

NASA's Glenn Research Center and associates has developed said Aerogel polymer- based film to be 85-95% porous, flexible, extremely strong, waterproof, extremely resistant to heat, highly flexible, and bendable as a super-insulating film. This film is made entirely of engineered polymers (polymer-based Aerogel film). Polymer-based Aerogel film made entirely of engineered polymers doesn't dust or shed insulation particles, which is unlike the previously developed NASA polymer-reinforced silica Aerogels (X-aerogels). NASA's publication of July 28, 2011 acknowledges that there are no hazards or mess when said Aerogel film is handled by users. The film has been confirmed to be extremely effective for preventing heat transfer according to NASA publication of July 28, 2011 and, therefore, is well suited for the present invention. NASA publication of said polymer-based Aerogel film on July 28, 2011 explains how the Glenn Research Center and associates developed the polymer-based Aerogel films to be extremely flexible, fire proof, durable, water proof, bendable, super- insulating, highly heat resistant and very strong. Said Aerogel film as a manufactured component used for the present invention is extremely low in bulk density compared to most all other solids. It is derived from a gel whereas the liquid component is replaced with a highly-insulating gas resulting is a low- density solid that is extremely effective as a thermal insulation when formed into a film. Aerogel was originally discovered by Samuel Stephens Kistler in the early 1900s and was far too fragile for creating such suitable flexible super-insulating film. NASA improved upon past Aerogel technology resulting in said suitable polymer-based Aerogel having no silica that is extremely flexible and can be made in the form of a film. Originally, Aerogels by themselves were hydrophilic although some polymer-based Aerogel film can be engineered to be hydrophobic and, therefore, are not subject to premature degradation in more extreme conditions. Said polymer-based Aerogel film almost nullifies all three methods of heat transfer commonly referred to as conduction, radiation, and convection. Polymer-based Aerogel film is a very poor conductor of heat while serving as good convective inhibitors because air cannot circulate through the lattice.

Another example to illustrate the extreme value and improvement of the present invention is how frozen meat and frozen seafood is often shipped. It is customary to use large amounts of ice and/or expensive cooling systems in trucks, airplanes, cargo planes, ships and trains that transport frozen foods. It would not always be practical to use corrugated cardboard packaging because these foods would at times start melting or spoil. The present invention is extreme in its ability to add super-insulation as a super-insulating packaging system and the cost savings and benefits are highly beneficial in said frozen food packaging and shipping industry.

In fact, as an option and a CLAIM of the present invention, the cavities, where air is trapped and completely encapsulated by the Aerogel film, shall be instead filled with

hydrophobic, insertable/injectable insulation (replacing air) to add significant insulation and fire resistance. This option of filling cavities with insulation is a CLAIM of the present invention although the trapped air is a mediocre insulator whereas the hydrophobic, insertable/injectable insulation are by far a better insulator. For example, Cabot hydrophobic Lumera Aerogel is commonly used for filling between panes in windows or hollow polycarbonate glazing cavities and are commercially and readily available from Cabot Corporation. Larger cavities have enough room for Lumera granules whereas smaller cavities shall be filled with Cabot ENOVA Aerogel powder.

In any packaging situation, if a manufacturer specifies the polymer-based Aerogel film not to be in direct contact with contents that are being packaged, then the Aerogel film can receive a layer of food safe plastic film that is bounded by adhesive to the Aerogel film. A highly reflective food safe film may also be used (in place of plain plastic) should a highly reflective film be desired to cover the Aerogel film. Preferable this highly reflective film shall be BoPET (Biaxially-oriented polyethylene terephthalate), which is a polyester film made from stretched polyethylene terephthalate having high tensile strength, chemical resistance and dimensional stability reflectivity, aroma barrier and gas properties, and above all reflecting thermal radiation. Highly reflective food safe films are commonplace in food packaging and are well known for being highly effective for reflecting radiant heat. For example, this would be an excellent choice for a Pizza Box lid. Radiant heat would be reflected back into a hot pizza for example.

Temperature sensitive live fish could also be packaged with the present invention then shipped where an airtight, waterproof, super- insulating packaging material is practical.

Many military supplies are packaged for supplies, foods, ammunition, transport material, electronics, and etc. to endure the extreme distribution and storage situations. Military packaging problems led to what is known as "mil spec" (Military Standard) regulations being applied to packaging, designating it "military specification packaging" around 1940, due to critical losses from bad packaging systems. Far more stringent quality and performance are currently requires although expensive. The present invention is ideal for many applications where a waterproof, airtight, fire proof, and super insulating packaging systems is desirable.

It is to be especially noted and a CLAIM of the present invention that liners or corrugated mediums may be a single layer of paper or other suitable materials although may be made two optional ways as follows and as seen in Figure 8 and Figure 9.

In Figure 8, the first way is configuration consisting of a paper layer, Nansulate insulating coating (or a suitable insulating coating that includes Cabot Enova aerogel) and a paper layer. This way the insulating coating is between and bonds together the two layers of paper or other suitable material for use as a corrugated medium or liner board. Also in Figure 10, the first configuration additionally consists of a highly reflective film, an adhesive, a paper layer, an insulating coating consisting of Nansulate (or a suitable insulating coating or adhesive that includes Cabot Enova aerogel), a paper layer, an adhesive, and a highly reflective film.

Regarding the isolative coating Nansulate as a preferred embodiment as seen in Figure 8 other suitable emerging aerogel coatings such as although not limited to suitable Cabot Enova coatings may also be used. According to the manufacturer Cabot Enova can be used as a key ingredient for high performance thermally insulating coating and adhesive formulations. This also may be used for reducing thermal conductivity. Cabot claims the film is expected to have excellent moisture resistance consisting of highly hydrophobic aerogel. Cabot offers Enova aerogel in a range of particle sizes (8μιη to 4mm) to accommodate various film thicknesses and Cabot claims it can be used in suitable water-based formulation. Again, the isolative coating Nansulate is preferred although all others emerging, suitable aerogel coatings may also be used. According to the manufacturer Industrial NanoTech, Nansulate is patented nanocomposite insulation made with Hydro-NM-Oxide, a product of nanotechnology, and is well documented as a high quality insulation coating. The manufacturer states Nansulate when fully cured contains approximately 70% Hydro-NM-Oxide and 30% acrylic resin and performance addaitive. The manufacturer states Nansulate energy saving, clear coating technology is used worldwide to insulate buildings, equipment and machinery. The manufacturer has coating instructions clearly published. In the event Nansulate is used for the present invention as seen in Figure 8, each coat applied is to be firm although not fully cured before a next coat is applied although for the present invention the very last coat once applied the paper as a cover shall be immediately applied so as to bond to the paper layer. However, should the last coat be left to get firm to the point it would not bond as effectively with the paper layer this coat may be left to get firm and a suitable adhesive may be used to bond the coating to the paper layer. If the suitable material does not effectively bond with the coating or Nansulate (or suitable aerogel coating or aerogel adhesive) the last coat shall be permitted to get reasonably firm (although not fully cured) and an adhesive for bonding the paper to the coating is most practical.

The second way is a layer being made up of a highly reflective film, an adhesive, a paper (or other suitable material), an adhesive, a polymer based aerogel film, an adhesive, another paper layer, an adhesive, and a last highly reflective film. This way the polymer based aerogel film is bonded by adhesive between said two layers of paper or other suitable material for configuring a corrugated medium or liner board.

Although the invention has been explained in laymen's terms in relation to its preferred embodiments, it is to be understood that many other possible modifications, variations and materials (including although not limited to emerging Aerogel technologies such as insulating, aerogel coating) may be utilized without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

1. The invention is a Super Insulating, Fireproof, Airtight, Waterproof Corrugated Cardboard Packaging System For Packaging Food, Beverages and Perishables comprises of:

A continuous polymer-based Aerogel film layer that is fire proof, water proof, super- insulating, strong, durable, flexible, and extremely bendable;

A continuous water proof, heat resistant adhesive layer;

A continuous liner layer;

A continuous water proof, heat resistant adhesive layer;

A continuous polymer-based Aerogel film layer that is fire proof, water proof, super- insulating, strong, durable, flexible and extremely bendable;

and

A continuous water proof, heat resistant adhesive layer;

A continuous layer later arranged as a medium (Fluted);

A continuous water proof, heat resistant adhesive layer;

and

A continuous water proof, heat resistant adhesive layer;

A continuous liner layer;

A continuous water proof, heat resistant adhesive layer;

and

The polymer based Aerogel film laminated components are next bonded together by water proof, heat resistant adhesive while the center layer serving as a medium it being fluted;

The design creates pockets of trapped air that are fully encapsulated in the Aerogel film for an air tight seal;

and The assembly being die-cut into a desired pattern;

Therefore the Aerogel film layers being die cut at the same time and to the same pattern as a liner or liners and the corrugated medium or mediums (1 fluted layer or layers);

Sealing over (wrapping) cavity at one end with polymer film and leaving the other end to fill with hydrophobic, insertable/injectable insulation;

Insertable/injectable insulation to replaced trapped air as an option also is therefore claimed;

Sealing over (wrapping) the reverse side of each cavity end with polymer film and leaving the other end to fill with insertable/injectable insulation;

All exposed edges where die-cut are therefore wrapped with the polymer based Aerogel film and bonded in place by the water proof, heat resistant adhesive;

Therefore ends of each cavity are air tight, fire proof, waterproof where the die-cut otherwise traditionally leave open ends leading into interior cavities;

Food safe plastic film as an option to laminate (using waterproof, heat resistant adhesive) all Aerogel film as an option therefore also is claimed;

Food safe highly reflective film as an option to laminate (using waterproof, heat resistant adhesive) over all Aerogel film as an option therefore also is claimed.

2. The process of packaging of products comprises:

Once items (products) are packaged any unsealed seams are separately covered over with the polymer based Aerogel film and bonded in place by a waterproof, heat resistant adhesive;

This results in a seam that is effectively sealed for the purpose of fire proofing, waterproofing, and super-insulating the seam as well as resulting in an airtight seal;

This water proof, heat resistant adhesive may be self sticking (like self stick tape strips) or waterproof, heat resistant adhesive may be separately applied;

It is further claimed that Figure 8 and Figure 9 can be used for liners or for configuring as the medium and these can be laminated on the outside with the NASA polymer based aerogel film with a last food safe film that keeps the aerogel film from being directly contacted. This last film may be a food safe film that is highly reflective and reflects radiant heat.