CA2946660A1

CA2946660A1 - Thermal liner and thermal container comprising same

Info

Publication number: CA2946660A1
Application number: CA2946660A
Authority: CA
Inventors: Stephane Morasse; Philippe Perron
Original assignee: Cascades Canada ULC
Current assignee: Cascades Canada ULC
Priority date: 2016-05-12
Filing date: 2016-10-26
Publication date: 2017-11-12
Also published as: US20170327298A1

Abstract

A thermal liner comprising a plurality of planar panel sections and being configurable in an operative configuration defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall. Each one of the bottom wall, the side walls and the top wall comprises an inner sheet, an outer sheet and at least one intermediate sheet. A first core layer extends between the inner sheet and a respective one of the at least one intermediate sheet and defines a plurality of geometrically patterned structures inbetween. A second core layer extends between the outer sheet and a respective one of the at least one intermediate sheet and defines a plurality of geometrically patterned structures inbetween.
A
container having a thermal liner such as the one described above is also provided.

Description

THERMAL LINER AND THERMAL CONTAINER COMPRISING SAME
FIELD OF THE INVENTION
[0001] The present invention relates to the field of thermal containers. More particularly, it relates to a thermal liner for a container and to a container including the thermal liner.
BACKGROUND

[0002] It is known in the art to provide a container with an inner thermal liner in order to define a thermal container. For example and without being limitative, such thermal containers can be used for packing perishable goods along with a refrigerant such as ice, frozen gel packs or the like, to maintain the perishable goods in a refrigerated state for temporary storage and/or shipping thereof.

[0003] Numerous material which offer good thermal insulation properties can be used in the construction of the thermal liners. For example and without being limitative, such materials include polystyrene, polyurethane foam, or the like.
However, in many cases, such materials do not allow recycling thereof, once the thermal container has been used, and must be disposed of through landfill or the like, which is undesirable.

[0004] In order to alleviate this problem, it is known to manufacture thermal liners including foldable cellulosic fiber based thermal liners with a single layer of corrugated and/or honeycomb material separating outer sheets. In an embodiment, a surface of the outer sheets can be covered by a reflective layer such as an aluminum foil layer or a metallized film layer. Such thermal liners are commonly initially manufactured as a liner blank in which crease lines are defined between specific planar panel sections, to allow the easy folding between the sections. The liner blank is foldable between an unfolded configuration and a folded configuration and defines a closed inner chamber, when configured in the closed configuration.

[0005] It is also known to provide multiple panels thermal liners, with panels each having a single layer of corrugated and/or honeycomb material and being combined with one another to define the thermal liner. In such multiple panel thermal liners, the sections thereof can be connected with one another such that they collaborate to define a closed inner chamber having a suitable thermal protection.

[0006] Known cellulosic fiber based thermal liners and corresponding thermal containers however also tend to suffer from several drawbacks. For example and without being !imitative, in many cases the thermal protection properties of the cellulosic fiber based thermal liners and the resulting thermal containers have proved unsatisfactory to maintain the goods in a refrigerated state for sufficient time periods.

[0007] In view of the above, there is a need for a thermal liner and a thermal container comprising the thermal liner which would be able to overcome or at least minimize some of the above-discussed prior art concerns.
BRIEF SUMMARY OF THE INVENTION

[0008] In accordance with an embodiment, there is provided a thermal liner.
The thermal liner comprises two panels configurable between an extended configuration and an operative C-shaped configuration. The two panels are engageable with one another when configured in the operative configuration in order to define a closed inner chamber. Each one of the two panels comprises an inner sheet; an outer sheet; and a core separating the inner sheet from the outer sheet. The core comprises at least two core layers separated by a layer separation sheet. Each one of the at least two core layers includes a geometrically patterned structure.

[0009] In an embodiment, each one of the at least two core layers of the two panels has a surface area and the surface area of the at least two core layers of the two panels is substantially the same.

[0010] In an embodiment, each one of the at least two core layers of the two panels has a surface area and the at least two core layers includes an inner core layer.
The surface area of the inner core layer of at least one of the two panels is smaller than the surface area of the other core layers thereof and the inner core layer is inset with regard to the other core layers.

[0011] In an embodiment, the two panels have a thickness and the inner core layer is inset with regard to the other core layers of a distance substantially corresponding to the thickness of the two panels.

[0012] In an embodiment, at least one of the inner sheet and the outer sheet of each one of the two panels comprises a reflective surface.

[0013] In an embodiment, the inner sheet of each one of the two panels has an inner facing surface. The inner facing surface of the inner sheet of each one of the two panels comprises the reflective surface.

[0014] In an embodiment, the layer separation sheet of each one of the two panels comprises an intermediate reflective surface.

[0015] In an embodiment, the layer separation sheet of each one of the two panels comprises an outer sheet facing surface facing the outer sheet and the outer sheet facing surface of the layer separation sheet of each one of the two panels comprises the intermediate reflective surface.

[0016] In an embodiment, the inner sheet and the outer sheet of each one of the two panels comprise a liquid/vapor resistant barrier.

[0017] In an embodiment, each one of the at least two core layers of each one of the two panels comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

[0018] In accordance with another general aspect, there is also provided a thermal liner. The thermal liner comprises a least two panels configurable between an extended configuration and an operative configuration. The at least two panels each include panel sections superposable onto corresponding panel sections of another one of the least two panels when configured in the operative configuration.
The at least two panels define a closed inner chamber delimited by a bottom wall, four side walls and a top wall when configured in the operative configuration and each one of the bottom wall, the side walls and the top wall include at least two core layers. Each one of the at least two panels comprises an inner sheet; an outer sheet; and a core separating the inner sheet from the outer sheet. The core comprises at least one core layer including a geometrically patterned structure.

[0019] In an embodiment, at least one of the inner sheet and the outer sheet of at least one of the at least two panels comprises a reflective surface.

[0020] In an embodiment, the inner sheet of each one of the at least two panels has an inner facing surface. The inner facing surface of the inner sheet of each one of the at least two panels comprises the reflective surface.

[0021] In an embodiment, the outer sheet of each one of the at least two panels has an outer facing surface and the outer facing surface of the layer separation sheet of the outer sheet of each one of the at least two panels comprises the reflective surface.

[0022] In an embodiment, the inner sheet and the outer sheet of at least one of the at least two panels comprises a liquid/vapor resistant barrier.

[0023] In an embodiment, the inner sheet and the outer sheet of each one of the at least two panels comprises a liquid/vapor resistant barrier.

[0024] In an embodiment, the at least one core layer of each one of the at least two panels comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

[0025] In accordance with another general aspect, there is also provided a thermal liner. The thermal liner comprises a plurality of planar panel sections and is configurable in an operative configuration defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall. Each one of the bottom wall, the side walls and the top wall comprises an inner sheet, an outer sheet and at least one intermediate sheet, with a first core layer extending between the inner sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween and a second core layer extending between the outer sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures in between.

[0026] In an embodiment, at least one of the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall comprises a reflective surface.

[0027] In an embodiment, the inner sheet of each one of the bottom wall, the side walls and the top wall has an inner facing surface. The inner facing surface of the inner sheet of each one of the bottom wall, the side walls and the top wall comprises the reflective surface.

[0028] In an embodiment, the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall comprises an intermediate reflective surface.

[0029] In an embodiment, the at least one intermediate sheet comprises an outer sheet facing surface facing the outer sheet. The outer sheet facing surface of the at least one intermediate sheet comprises the intermediate reflective surface.

[0030] In an embodiment, the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall comprises a liquid/vapor resistant barrier.

[0031] In an embodiment, each one of the first core layer and the second core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

[0032] In an embodiment, each one of the bottom wall, the side walls and the top wall comprises at least one intermediary core layer extending between adjacent intermediate sheets and defining a plurality of geometrically patterned structures inbetween.

[0033] In an embodiment, the at least one intermediary core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

[0034] In accordance with another general aspect, there is further provided a thermal container. The thermal container comprises a container comprising: a container bottom wall; and four container side walls extending substantially perpendicularly from the container bottom wall. The thermal container also comprises a thermal liner insertable into the container and comprising a plurality of planar panel sections. The thermal liner is configurable in an operative configuration defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall. Each one of the bottom wall, the side walls and the top wall comprises an inner sheet, an outer sheet and at least one intermediate sheet, with a first core layer extending between the inner sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween and a second core layer extending between the outer sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween. Each one of the bottom wall and the side walls of the thermal liner is superposed respectively to the container bottom wall and the four container side walls when the thermal liner is inserted in the container with the inner chamber being closed at least by the top wall of the thermal liner.

[0035] In an embodiment, at least one of the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises a reflective surface.

[0036] In an embodiment, the inner sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner has an inner facing surface, the inner facing surface of the inner sheet of each one of the bottom wall, the side walls and the top wall comprises the reflective surface.

[0037] In an embodiment, the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises an intermediate reflective surface.

[0038] In an embodiment, the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises an outer sheet facing surface facing the outer sheet, the outer sheet facing surface of the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall comprises the intermediate reflective surface.

[0039] In an embodiment, each one of the first core layer and the second core layer of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

[0040] In an embodiment, each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises at least one intermediary core layer extending between adjacent intermediate sheets and defining a plurality of geometrically patterned structures inbetween.

[0041] In an embodiment, the at least one intermediary core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Other objects, advantages and features will become more apparent upon reading the following non-restrictive description of embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:

[0043] Figures 1 and la are perspective views of a first panel of a thermal liner, according to an embodiment wherein all layers of all the panels of the thermal liner substantially have the same surface area, and wherein the first panel is shown in an extended configuration in Figure 1 and in an operative configuration (or "C"
shaped configuration) in Figure la.

[0044] Figures 2 and 2a are perspective views of a second panel of the thermal liner of the embodiment of Figures 1 and 1a, wherein the second panel is shown in an extended configuration in Figure 2 and in an almost operative configuration (or "C" shaped configuration) in Figure 2a, i.e. the second panel is being folded into the operative configuration.

[0045] Figure 3 is a perspective view of the thermal liner comprising the first panel of Figure 1 and the second panel of Figure 2, wherein the thermal liner is shown with the first and second panels engaged and defining a closed inner chamber (not shown).

[0046] Figure 4a to 4d are perspective views of the successive insertion stages of the thermal liner of Figure 3 in a container to form a thermal container, wherein Figure 4a shows the first panel being inserted in the container, Figure 4b shows the second panel being inserted in the container with the first panel already inserted therein, Figure 4c shows the first panel and the second panel inserted in the container and exposing the inner chamber and Figure 4d shows the container in a closed configuration.

[0047] Figures 5 and 5a are perspective views of a horizontally extending first panel of a thermal liner, according to an alternative embodiment wherein all layers of the first panel substantially have the same surface area and an inner layer of a second panel has a smaller surface area, and wherein the first panel is shown in an extended configuration in Figure 5 and in an operative configuration (or "C"
shaped configuration) in Figure 5a.

[0048] Figures 6 and 6a are perspective views of the second panel of the thermal liner of the embodiment of Figures 5 and 5a, wherein the second panel is shown in an extended configuration in Figure 6 and in an almost operative configuration (or "C" shaped configuration) in Figure 6a, i.e. the second panel is being folded into the operative configuration.

[0049] Figure 7 is a perspective view of the thermal liner comprising the first panel of Figure 5 and the second panel of Figure 6, wherein the thermal liner is shown with the panels engaged and defining a closed inner chamber (not shown).

[0050] Figures 8 to 10 are top plan views of the panels of a thermal liner, according to another alternative embodiment wherein the panels are superposable to define a multi-layer thermal liner, with Figure 8 showing an outer panel, Figure 9 showing an inner panel and Figure 10 showing an annular panel of the thermal liner.

[0051] Figure 11 is a perspective view of the outer panel, inner panel and annular panel of Figures 8 to 10 shown with the panels partially engaged and defining a closeable inner chamber.

[0052] Figure 12 is a graph showing the test results regarding the insulation performance of the thermal container having different thermal liner configurations, as a function of the quantity of humidity.
DETAILED DESCRIPTION

[0053] In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures or described in the present description are embodiments only, given solely for exemplification purposes.

[0054] Moreover, although the embodiments of the thermal liner and thermal container comprising the thermal liner consist of certain components and geometrical configurations, as explained and illustrated herein, not all of the components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, may be used for thermal liner and thermal container comprising the thermal liner, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art.
Moreover, it will be appreciated that positional descriptions such as "above", "below", "left", "right" and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

[0055] In general terms, there is provided a thermal liner and a thermal container, such as a cardboard box or the like, comprising the thermal liner, wherein the thermal liner includes a plurality of insulating and superposed core layers (i.e. the core of the thermal liner includes at least two superposed layers). In an embodiment, each one of the core layers includes geometrically patterned cells and the core layers are separated by at least one layer separation sheet (or intermediate sheet). The thermal liner includes a plurality of planar panel sections, each lining a corresponding wall of the container when the thermal liner is inserted inside the container. The combination of the thermal liner and container defines a thermal container having a thermal liner with at least two layers of geometrically patterned cells lining each wall of the container, thereby providing advantageous thermal properties.

[0056] One skilled in the art will understand that such a thermal liner having a plurality of insulating core layers can have many different configurations.
For example and without being limitative, according to different embodiments, the thermal liner having a plurality of insulating core layers can include only one or a plurality of panels engageable with one another to form the thermal liner.
Some of the possible embodiments are described below, but one skilled in the art will understand that several additional embodiments, different from the ones described below could also be provided.

[0057] Referring generally to Figures 1 to 3, a first embodiment of the thermal liner for providing thermal insulation in a container 15 (see Figure 4) is shown.
The thermal liner 10 includes a first panel 20 and a second panel 40 engageable with one another in order to form the thermal liner 10 defining a closable inner chamber 11 (See Figure 4c). Each one of the first panel 20 and the second panel 40 is formed from a liner blank.

[0058] The liner blank of the first panel 20 includes an inner sheet 22, an outer sheet 24 and a core 26. The core 26 separates the inner sheet 22 from the outer sheet 24 and creates an array of cells therebetween. In the embodiment shown, the core 26 is composed of at least two core layers 27, 28 of geometrically patterned structures, separated by a layer separation sheet 29 (or intermediate sheet). In the embodiment shown, the core 26 includes a first core layer 27 extending between the inner sheet 22 and the layer separation sheet 29 and defining an array of cells therebetween and a second core layer 28 extending between the layer separation sheet 29 and the outer sheet 24 and defining an array of cells therebetween. In the embodiment shown, the two core layers 27, of the thermal liner have substantially the same surface area.

[0059] The liner blank of the second panel 40 also includes an inner sheet 42, an outer sheet 44 and a core 46 separating the inner sheet 42 from the outer sheet 44 to create an array of cells therebetween. Once again, the core 46 is composed of at least two core layers 47, 48 of geometrically patterned structures, separated by a layer separation sheet 49. In the embodiment shown, the core 46 of the second panel 40 once again includes a first core layer 47 extending between the inner sheet 42 and the layer separation sheet 49 and defining an array of cells therebetween and a second core layer 48 extending between the layer separation sheet 49 and the outer sheet 44 and defining an array of cells therebetween.
One skilled in the art will once again understand that, in alternative embodiments (not shown), the core 46 can include more than two core layers, with each additional core layer being separated from an adjacent core layer by an additional layer separation sheet. In the embodiment shown, the two core layers 47, 48 of the thermal liner also have substantially the same surface area.

[0060] One skilled in the art will also understand that, in an alternative embodiment (not shown), the core 26, 46 of the first panel 20 and/or the second panel 40 can include more than two core layers, with each additional core layer being separated from an adjacent core layer by an additional layer separation sheet. Together, the inner sheet 22, 42, the outer sheet 24, 44 and the core 26, 46 of the first panel 20 and the second panel 40 define the thickness of the liner blank of the first panel 20 and the second panel 40 in an expanded (or uncrushed) state.

[0061] In an embodiment, the inner sheets 22, 42 and/or the outer sheets 24, 44 of the first panel 20 and second panel 40 include a reflective surface 17. For example and without being limitative, in an embodiment, the inner sheets 22, 42 and/or the outer sheets 24, 44 can include a metallized film, which can be laminated to a cellulosic fiber based sheet, such as a Kraft liner board paper or the like.
In an embodiment, the metallized film can include a film such as, for example and without being limitative, a polyethylene film, a polypropylene film or the like, onto which aluminum is vaporized. In an alternative embodiment, the inner sheets 22, 42 and/or the outer sheets 24, 44 can rather include a foil layer, or a layer of other material offering reflective characteristics, laminated to a plastic substrate, such as a polyethylene substrate, a polyester substrate or the like which can further be laminated to the cellulosic fiber based sheet. One skilled in the art will also understand that, in other alternative embodiments, other combinations of materials, such as reflective coatings, offering reflective properties can also be used to provide a reflective surface 17 of the inner sheets 22, 42 and/or the outer sheets 24, 44. In an embodiment, the reflective surface 17 is an outer surface (e.g.
the reflective film, layer or coating can line an outer surface of the inner sheets 22, 42 and/or the outer sheets 24, 44, facing away from the core 26, 46). One skilled in the art will however understand that, in an alternative embodiment, the reflective surface 17 can be an inner surface (e.g. the reflective film, layer or coating can line an inner surface of the inner sheets 22, 42 and/or the outer sheets 24, 44, facing towards the core 26, 46).

[0062] One skilled in the art will understand that, in an embodiment, the layer separation sheets 29, 49 can also include a reflective surface (not shown).
One skilled in the art will understand that the reflective surface of the layer separation sheets 29, 49 can be similar to the reflective surface described above regarding the inner sheets 22, 42 and/or the outer sheets 24, 44. Hence, the possible alternatives for the reflective surface described above regarding the inner sheets 22, 42 and/or the outer sheets 24, 44 also apply to the reflective surface of the layer separation sheets 29, 49. It will be understood that the reflective surface of the layer separation sheets 29, 49 can be positioned on either side or on both sides of the layer separation sheets 29, 49.

[0063] In an embodiment, the inner face of the inner sheet 22, 42 and an outer sheet facing surface of the layer separation sheet 29, 49 include the reflective surface. In other words, in such an embodiment the reflective surface is an inner surface provided on the inner sheet 22, 42 of the first panel 20 and second panel 40, and an outer surface provided on the layer separation sheets 29, 49 of the first panel 20 and second panel 40.

[0064] One skilled in the art will understand that, in an embodiment any one of the inner sheets 22, 42, outer sheets 24, 44 and/or layer separation sheets 29, 49 or all of these elements can be free of reflective surface. In such an embodiment, the corresponding ones of the inner sheets 22, 42, outer sheets 24, 44 and/or layer separation sheets 29, 49 can include only a cellulosic fiber based layer, such as a Kraft liner board paper or the like. Moreover, in an embodiment, different types of reflective surfaces can be provided for each one of the inner sheets 22, 42, outer sheets 24, 44 and/or layer separation sheets 29, 49.

[0065] In an embodiment, the inner sheets 22, 42, layer separation sheets 29, and/or the outer sheets 24, 44 of the first panel and second panel can also include a liquid/vapor resistant barrier 18. For example and without being limitative, in an embodiment, the inner sheets 22, 42, layer separation sheets 29, 49 and/or the outer sheets 24, 44 can include a liquid/vapor resistant film laminated to a cellulosic fiber based sheet, such as a Kraft liner board paper or the like.
For example and without being limitative, the liquid/vapor resistant film can be a polyethylene film, a polypropylene film or the like. In an alternative embodiment, the inner sheets 22, 42, layer separation sheets 29, 49 and/or the outer sheets 24, 44 can rather include a liquid/vapor resistant coating applied to the cellulosic fiber based sheet. Numerous types of liquid/vapor resistant coating could be applied to the cellulosic fiber based sheet. For example and without being limitative, coatings including aqueous dispersion of polymers or copolymers which are capable to provide the above mentioned properties could be used, such as MichemeCoat 81 and MichemeCoat 82 which comprise a styrene-butadiene copolymer; VaporCoat 2200R from the company Michelman, the products Spectra-GuardTM 3007BK and Spectra-GuardTM 3003 both from the company Spectra-kote Corp., Tribinder from the company Tri-Tex Co inc., and Aqualene 5050 from Aqua Based Technologies which all are acrylic based products; ESACOTE PU DP 170/N which comprise a polyurethane; or Cartabond SMH Liquid from the company CLARIANT, which is a polyvinylalcohol based aqueous dispersion. In another alternative embodiment, the inner sheets 22, 42, layer separation sheets 29, 49 and/or the outer sheets 24, 44 can also include a liquid/vapor resistant film such as a polyethylene film or the like, without cellulosic fiber based sheet.

[0066] One skilled in the art will understand that, in an embodiment, the above described reflective surface 17 can operate as liquid/vapor resistant barrier (i.e. the reflective surface 17 can provide the desired liquid/vapor resistant properties).

Therefore, in an embodiment, no specific liquid/vapor barrier 18 is required along the inner sheets 22, 42, layer separation sheets 29, 49 and/or the outer sheets 24, 44, when a reflective surface 17 is provided thereon. Hence, in an embodiment where the inner sheets 22, 42 include the reflective surface 17, no additional liquid/vapor resistant barrier 18 is required along the inner sheets 22, 42, the reflective surface operating as a liquid/vapor resistant barrier 18.

[0067] In an embodiment, the inner sheet 22, 42 and the outer sheet 24, 44 include the liquid/vapor resistant barrier 18. As mentioned above, in an embodiment, the liquid/vapor resistant barrier provided along the inner sheet 22, 42 can be provided by the reflective surface 17 thereof.

[0068] In an embodiment, the geometrically patterned structures of each core layer 27, 28, 47, 48 of the core 26, 46 of the first panel 20 and second panel 40 include a plurality of cellulosic fiber based structures extending between the corresponding one of the inner sheet 22, 42, the outer sheet 24, 44 and the layer separation sheet 29, 49. For example and without being limitative, in an embodiment, the plurality of cellulosic fiber based structures are honeycomb structures (or honeycomb cells) formed by cellulosic fiber based walls, such as Kraft paper walls or the like, extending transversely between the inner sheet 22, 42 and the layer separation sheet 29, 49 for the first layer 27, 47 and between the layer separation sheet 29, 49 and the outer sheet 24, 44 for the second layer 28, 48. One skilled in the art will understand that, in alternative embodiments, other structures providing the array of cells between the corresponding one of the inner sheet 22, 42, outer sheet 24, and layer separation sheet 29, 49 could also be provided.

[0069] In the course of the present document, the term "honeycomb structure"
is understood to mean a three-dimensional geometrically patterned structure defining a grid of hexagonal open-ended core cells and providing an enhanced strength for supporting and protecting loads. As will be easily understood, the honeycomb structure creates an air space as a result of the three-dimensional geometrically patterned structure.

[0070] As will be described in more details below, in the embodiment shown in Figures 1 to 3, each one of the first panel 20 and the second panel 40 is configurable between an extended configuration, where the panels 20, 40 extend substantially straight (see Figures 1 and 2), and an operative configuration (see Figures la and 2a) where the panels 20, 40 have a substantially "C" shaped configuration. In order to allow such folding of the panels 20, 40 between the extended configuration and the operative configuration, in an embodiment, each panel has crease lines formed in the corresponding liner blank, thereby defining a plurality of planar panel sections.

[0071] In the embodiment shown in Figures 1 to 3, the first panel 20 includes a central section 30, a first end section 32, and a second end section 34. The first panel 20 has a first crease line 36 defined between the central section 30 and the first end section 32, and a second crease line 38 defined between the central section 30 and the second end section 34. Each one of the first crease line 36 and the second crease line 38 extends between a first longitudinal edge 33 and a second longitudinal edge 35 opposed to the first longitudinal edge 33 of the first panel 20, with the first crease line 36 being substantially parallel to the second crease line 38. The first crease line 36 and the second crease line 38 are also substantially parallel to the first lateral edge 37 and the second lateral edge 39 of the second panel 40. One skilled in the art will understand that, in an alternative embodiment (not shown), each one of the first crease line 36 and the second crease line 38 can extend between the first lateral edge 37 and the second lateral edge 39, rather than between the first longitudinal edge 33 and the second longitudinal edge 35.

[0072] The second panel 40 also includes a central section 50, a first end section 52 and a second end section 54. Once again, the second panel has a first crease line 56 defined between the central section 50 and the first end section 52, and a second crease line 58 defined between the central section 50 and the second end section 54. Once again, each one of the first crease line 56 and the second crease line 58 extends between a first longitudinal edge 53 and a second longitudinal edge 55 opposed to the first longitudinal edge 53 of the second panel 40, with the first crease line 56 being substantially parallel to the second crease line 58. The first crease line 56 and the second crease line 58 are also substantially parallel to the first lateral edge 57 and the second lateral edge 59 of the second panel 40.
One skilled in the art will understand that, in an alternative embodiment (not shown), each one of the first crease line 56 and the second crease line 58 can extend between the first lateral edge 57 and the second lateral edge 59, rather than between the first longitudinal edge 53 and the second longitudinal edge 55.

[0073] In the embodiment shown in Figures 1 to 3, each one of the central section 30, first end section 32 and second end section 34 of the first panel 20 and the central section 50, first end section 52 and second end section 54 of the second panel 40 has a square shape with substantially the same surface area. Hence, the resulting thermal liner 10 and defined inner chamber 11 thereof (formed by engaging the first panel 20 and the second panel 40) is of substantially cubical shape (see Figure 3).

[0074] One skilled in the art will however understand that, in an alternative embodiment (not shown) where the thermal liner 10 is of a cuboid shape (i.e.
defining a closed (or closeable) inner chamber 11 with six faces but of a shape different than a cubic shape), the central section 30 of the first panel 20 can have a different size and shape than the first end section 32 and the second end section 34 thereof and the central section 50 of the second panel 40 can have a different size and shape than the first end section 52 and the second end section 54 thereof. Moreover, the first end section 32 and the second end section 34 of the first panel 20 can have a different size and shape than the first end section 52 and the second end section 54 of the second panel 40.

[0075] In an embodiment, each crease line 36, 38, 56, 58 of the first panel 20 and second panel 40 is formed into the liner blank from the inner sheet 22, 42 and defines a "V" shaped channel therein. In an embodiment, the angle between the walls of the "V" shaped channel is such that the walls of the "V" shaped channels defined by the crease lines 36, 38, 56, 58 are substantially pressed against one another when the panels 20, 40 are configured in the operative configuration.
Such contact of the walls of the "V" shaped channels against one another prevents the formation of thermal bridges between adjacent sections 30, 32, 34, 50, 52, 54, when the thermal liner 10 is used inside the container for providing thermal insulation. In other words, the "V" shaped channels are sized and shaped in accordance with the thickness of the core 26, 46 of the first panel 20 and the second panel 40, to allow folding of the panels 20, 40, between adjacent ones of the sections 30, 32, 34, 50, 52, 54, while substantially preventing thermal exchange at these junctions when the panels 20, 40 are configured in the operative configuration.

[0076] In an embodiment and as can be seen more clearly in Figure 3, the first panel 20 and second panel 40 are sized such that when the first panel 20 and the second panel 40 are configured in the operative configuration and engaged together to form the thermal liner 10, the edges 33, 35, 37 and 39 of the first panel 20 abut against the inner sheet 42 of the second panel 40. Such abutment of the edges 33, 35, 37 and 39 of the first panel 20 against the inner sheet 42 of the second panel results in the first panel 20 and the second panel 40 defining a closed (or closeable) inner chamber 11 therebetween. One skilled in the art will understand that, in an alternative embodiment (not shown), the first panel 20 and second panel 40 can also be sized such that when the first panel 20 and the second panel 40 are configured in the operative configuration and engaged together to form the thermal liner 10, the edges 53, 55, 57 and 59 of the second panel 40 abut against the inner sheet 22 of the first panel 40 to define the closed (or closeable) inner chamber 11.

[0077] In view of the above, the closed (or closeable) inner chamber 11 is defined by a bottom wall 11a, four side walls 1 1 b and a top wall 11c. Each one of the bottom wall 11a, side walls lib, and the top wall 11c includes an inner sheet 22, 42, an outer sheet 24, 44 and a layer separation sheet 29, 49. Moreover, a first core layer 27, 47 extends between the inner sheet 22, 42 and the layer separation sheet 29, 49 and defines a plurality of geometrically patterned structures inbetween. A second core layer 28, 48 extends between the outer sheet 24, 44 and the layer separation sheet 29, 49 and defines a plurality of geometrically patterned structures inbetween. One skilled in the art will understand that, in alternative embodiments (not shown), additional core layers and corresponding layer separation sheets can also be provided.

[0078] In an embodiment (not shown), the bottom wall 11a, four side walls lib and top wall 11c can each include a different amount of core layers. For example and without being limitative, in an embodiment, the bottom wall 11a can include more core layers than the four side walls lib and top wall 11c.

[0079] Now referring to Figures 4a to 4d, a sequence of successive insertion stages of the thermal liner 10 of Figures 1 to 3 into a container 15, in accordance with an embodiment, will be described in more details below. In the embodiment shown, the second panel 40 is initially inserted in the container 15, with the first end section 52 lining the bottom of the container 15 (i.e. the first end section 52 being juxtaposed to the bottom wall of the container 15), the central section lining one of the sides of the container 15 (i.e. the central section being juxtaposed to one of the container side walls), and the second end section 54 unfolded away from the entrance of an inner cavity of the container 15 to allow access therein (see Figures 4a and 4b). Subsequently, the first panel 20 is inserted in the container 15, with each one of the sections 34, 30, 32 lining a corresponding one of the sides of the container 15 (i.e. each one of the sections 34, 30, 32 being juxtaposed to one of the container side walls) (see Figure 4b and 4c).
Finally, the second end section 54 of the second panel 40 is folded to close the thermal liner (i.e. to define the closed inner chamber 11) and the container flaps are closed over the second end section 54 to close the container 15 with the second end section 54 lining the container flaps (i.e. the second end section 54 being juxtaposed to the closed container flaps). One skilled in the art will understand that, in alternative embodiments (not shown), other insertion sequences can be performed in order to insert the above-described thermal liner 10 into the container 15 where the thermal liner 10 substantially lines the inner surface of the walls of the container 15.

[0080] One skilled in the art will understand that, as mentioned above other panel assemblies or configuration thereof, different from the above-described assembly defining the thermal liner 10 can be foreseen in order to provide a thermal liner 10 defining the closed inner chamber delimited by a bottom wall 11 a, four side walls 11 b and a top wall 11c, each having multiple core layers. For example and without being limitative, alternative embodiments are described below.

[0081] Referring to Figures 5 to 7, there is shown an alternative embodiment of the thermal liner 110 wherein similar features are numbered using the same reference numerals in the 100 series. In the alternative embodiment of Figures 5 to 7, the thermal liner 110 once again includes a first panel 120 and a second panel 140 engageable with one another in order to define the thermal liner 110. The first panel 120 and second panel 140 of this alternative embodiment are similar to those of the above-described embodiment and the teachings regarding the above-described first panel 20 and second panel 40 and components thereof also apply and need not be repeated herein.

[0082] The first panel 120 of this alternative embodiment is similar to the first panel 20 of the previously described embodiment and includes an inner sheet 122, an outer sheet 124 and a core 126 composed of at least two core layers 127, 128 of geometrically patterned structures, separated by a layer separation sheet 129.
The first panel 120 also includes a first crease line 136 defined between the central section 130 and the first end section 132 and a second crease line 138 defined between the central section 130 and the second end section 134. As can be seen in Figures 5 and 5a, the two layers 127, 128 of the core 126 of the first panel 120 have substantially the same surface area.

[0083] The second panel 140 also includes an inner sheet 142, an outer sheet and a core 146 having at least two core layers 147, 148 of geometrically patterned structures, separated by a layer separation sheet 149. The second panel 140 also includes a first crease line 156 defined between the central section 150 and the first end section 152 and a second crease line 158 defined between the central section 150 and the second end section 154. In this alternative embodiment and as can be seen in Figures 6 and 6a, the surface area of the inner layer 147 is smaller than the surface area of the outer layer 148 of the core 146, such that the inner layer 147 is inset with regard to the outer layer 148 (i.e. the peripheral edge of the inner layer 147 is inwardly offset from the peripheral edge of the outer layer 148).

[0084] In an embodiment, the distance of which the inner layer 147 is inset with regard to the outer layer 148, substantially corresponds to the thickness of the first panel 120, such that the edges 133, 135, 137 and 139 of the first panel 120 abut against the layer separation sheet 149 of the second panel 140 rather than onto the inner sheet 122. In such an embodiment, the resulting thermal liner 110 once again has a double layer core along substantially the entire bottom wall 111a, four side walls 111b and top wall 111c defining the inner chamber 111. As will be understood, the peripheral sections of the bottom wall 111a, side wall 111b and/or top wall 111c where the core 146 of the second panel 140 includes only the outer layer 148, has the first panel 120 juxtaposed thereon, such that no single layer section is provided along the bottom wall 111a, four side walls 111b and top wall 111c defining the inner chamber 111.

[0085] One skilled in the art will understand that, in an alternative embodiment (not shown), the first panel 120 can have an inner core layer 127 inset with regard to the outer layer 128, while the two core layers 147, 148 of the core 146 of the second panel 140 have substantially the same surface area. In another alternative embodiment (not shown), both the first panel 120 and the second panel 140 can have an inner core layer 127, 147 inset with regard to the outer layer 128, along opposed connecting edges (i.e. the inner core layer 127, 147 of one of the first panel 120 and the second panel 140 can be inset along a portion thereof, with the inner core layer 127, 147 of the other one of the first panel 120 and the second panel 140 being inset along a complementary portion thereof).

[0086] The first panel 120 and second panel 140 can also include a reflective surface 117 and/or a liquid/vapor resistant barrier 118, similarly to the above described embodiment of Figures 1 to 3.

[0087] Now referring to Figures 8 to 11, there is shown another alternative embodiment of the thermal liner 210 wherein similar features are numbered using the same reference numerals in the 200 series. In the alternative embodiment of Figures 8 to 11, the thermal liner 210 includes an assembly of three panels engageable with one another to form the thermal liner 210. The assembly includes an outer panel 260, an inner panel 270 and an annular panel 280.

[0088] Each one of the outer panel 260, inner panel 270 and annular panel 280 is formed from a liner blank including an inner sheet 262, 272, 282, an outer sheet 264, 274, 284 and a core 266, 276, 286 separating the inner sheet 262, 272, and the outer sheet 264, 274, 284 to create an insulating space therebetween.
The core 266, 276, 286 of each panel 260, 270, 280 is composed of at least one layer of geometrically patterned structures such as, for example, a plurality of cellulosic fiber based structures. For example, the plurality of cellulosic fiber based structures can once again be honeycomb-shaped cells formed by cellulosic fiber based walls or the like, extending transversally between the inner sheets 262, 272, 282 and outer sheets 264, 274, 284 (and any layer separation sheet if more than one core layer is provided).

[0089] Similarly to the above-described embodiment, the inner sheets 262, 272, 282 and/or the outer sheets 264, 274, 284 of the outer panel 260, inner panel and annular panel 280 can include a reflective surface 217. Once again the teaching of the above-described embodiments regarding possible reflective surface 217 can be applied herein and will not be repeated.

[0090] Moreover, similarly to the above-described embodiment, the inner sheets 262, 272, 282 and/or the outer sheets 264, 274, 284 of the outer panel 260, inner panel 270 and annular panel 280 can include a liquid/vapor resistant barrier (not shown). Once again the teaching of the above-described embodiments regarding possible liquid/vapor resistant barriers can be applied herein and will not be repeated.

[0091] Once again, each one of the outer panel 260, the inner panel 270 and the annular panel 280 is configurable between an extended configuration, where the panels 260, 270, 280 extend substantially straight (see Figures 8 to 10), and an operative configuration (see Figure 11). In order to allow such folding of the panels 260, 270, 280 between the extended configuration and the operative configuration, each panel has crease lines 268, 278, 288 formed in the corresponding liner blank, thereby defining a plurality of planar panel sections for each panel 260, 270, 280.

[0092] In the embodiment shown, each panel 260, 270, 280 includes a central section 261, 271, 281, two intermediate sections 263, 265, 273, 275, 283, 285 and two end sections 267, 269, 277, 279, 287, 289. Crease lines 268, 278, 288 are defined between each adjacent sections of each one of the panel such that the central sections 261, 271, 281 are pivotally connected to the corresponding ones of the intermediate sections 263, 265, 273, 275, 283, 285 and the intermediate sections 263, 265, 273, 275, 283, 285 are pivotally connected to the corresponding ones of the end sections 267, 269, 277, 279, 287, 289. Once again, each crease line 268, 278, 288 extends between longitudinal edges of the corresponding panels 260, 270, 280, with the crease lines of each panel being substantially parallel to one another.

[0093] As can be seen in Figure 11, when the outer panel 260, the inner panel and the annular panel 280 are engaged with one another in order to define the inner chamber 211, the panels are configured to be arranged such that they combine to provide at least two layers for each one of the bottom wall 211a, side walls 211b, and the top wall 211c defining the inner chamber 211.

[0094] More particularly, the outer panel 260 and the inner panel 270 are arranged crosswise, with the annular panel 280 being subsequently inserted transversally in the cavity formed by the outer panel 260 and the inner panel 270, to line the side walls thereof. Hence, when the outer panel 260, the inner panel 270 and the annular panel 280 are engaged with one another in order to form the thermal liner 210 and define the inner chamber 211, the central sections 261, 271 of the outer panel 260 and the inner panel 270 are superposed to define the bottom wall 211a, with the intermediate sections 263, 265, 273, 275 extending substantially perpendicularly therefrom to define one of the side walls 211b. The central section 281 and end sections 287, 289 of the annular panel 280 are superposed to the intermediate sections 263, 265, 273, 275 of one of the outer panel 260 and the inner panel 270. The intermediate sections 283, 285 of the annular panel 280 are superposed to the intermediate sections 263, 265, 273, 275 of the other one of the outer panel 260 and the inner panel 270. The end sections 267, 269, 277, 279 of the outer panel 260 and the inner panel 270 are superposed to define the top wall of the liner 210.

[0095] In view of the above, each one of the bottom wall 211a, the side walls 211b and the top wall 211c defining the inner chamber 211 includes two superposed planar sections of two of the outer panel 260, the inner panel 270 and the annular panel 280. Since each section has a core of at least one core layer, the resulting thermal liner 210 defines an inner chamber 211 with walls having at least two core layers each. As will be easily understood, in such an embodiment, the superposed inner sheet and outer sheet of the planar sections of the corresponding ones of the two of the outer panel 260, the inner panel 270 and the annular panel 280 are located between the two core layers and hereby define intermediate sheets extending between the core layers.

[0096] One skilled in the art will once again understand that the size and shape of the sections of the outer panel 260, the inner panel 270 and the annular panel can be varied from the embodiment shown, in order to provide a thermal liner of a different cuboid shape than the one of the embodiment shown.

[0097] In view of the above, it will be understood that a thermal liner 10, 110, 210, having multiple core layers advantageously improves the thermal protection properties of the thermal liner 10, 110, 210. Moreover, in an embodiment, the above described thermal liner and associated thermal container are substantially entirely made of recyclable cellulosic fiber based material, such as paper, and therefore provides a thermal liner and corresponding thermal container offering a sustainable packaging solution which substantially avoids the need of sending waste to landfill once the thermal and/or container has been used and is no longer required.
EXAMPLE

[0098] Tests were conducted on a thermal liner of an exemplary embodiment (not shown), which includes the above described characteristics and, as can be seen in the test results presented below, the thermal liner of the exemplary embodiment showed improved thermal properties.

[0099] The thermal liner of the exemplary embodiment included a double layer core of about 1/2 inch each, with a reflective surface on the outer facing surface of the layer separation sheet and the inner facing surface of the inner sheet. In the exemplary embodiment, the reflective surface 117 was a metallized film laminated to the cellulosic fiber based sheet of the layer separation sheet and the inner sheet.
Moreover, the thermal liner of the exemplary included a liquid/vapor resistant barrier on the inner and outer sheets. In the exemplary embodiment, the metallized film of the inner facing surface of the inner sheet operated as a liquid/vapor resistant barrier and a polyethylene film was laminated to the cellulosic fiber based sheet of the outer sheet.

[00100] Tests were conducted between a thermal container having a thermal liner with a multiple layer core and a thermal container having a thermal liner with a single layer core to compare the time required for a protein of a meal placed therein to reach 4 Celsius. In the test, each layer of the core was a 1/2 inch honeycomb structure layer and a Kraft liner board paper was used as a layer separation sheet between each one of the core layer. The container content remained the same for each one of the tests and corresponded to approximately two meals for two adults with the ice initially added being at approximately -Celsius. The results of the test are shown in the table below:
Content Ice Time to reach 4 Celsius Time to reach 4 Celsius of the quantity (hours) (hours) container (pounds) Single Layer Core Double layer core 2 13.1 15.8 4 21.5 26.8 6 27.9 33.1 meal 8 29.75 36.5 38.7 12 41.5 56.2

[00101] As can be seen from the test results above, for a same thickness, the thermal liner having a double layer core significantly outperformed the thermal liner having a single layer core for every ice quantity. The difference between the two thermal liners increases with the quantity of ice provided in the thermal liner inserted in the container. It should be noted that the test results for the thermal liner having a double layer core with an ice quantity of 10 pounds have not been included in the present test results, given that the container has been damaged during the test and therefore the results obtained were not accurate.

[00102] More importantly, additional tests were performed in order to measure the thermal conductivity and thermal resistivity of a section of honeycomb cardboard panel depending on the thickness thereof and the amount of layer cores.

[00103] In a first test, sections of honeycomb cardboard panels of different thicknesses (but always having a single core) were tested. The results are presented in the table below:
single material diameter conductivity resistivity # of added thickness (in) (W / mK) (Km / W) layers (in) 0.75 0.442 0.0670 14.945 1 0.75 0.462 0.0690 14.493 1 0.75 0.927 0.1110 8.979 1 0.75 0.945 0.0951 10.520 1 0.75 1.413 0.1101 9.083 1 0.75 2.483 0.1600 6.246 1 0.75 2.496 0.1322 7.564 1 0.75 3.772 0.1498 6.676 1

[00104] As can be seen, these tests show that the thermal conductivity increases along with increase in thickness of the panel core. This is an unexpected result given that the increase of the thickness increases the air quantity in the core (air having low thermal conductivity of approximately 0.026W (m K)-1). Hence, in view of these tests, it appears that simply increasing the thickness of the panels forming the thermal liner would not result in an increase in thermal protection properties.

[00105] Additional tests were performed in order to measure the thermal conductivity as a function of the amount of layers of the core.

[00106] The table below shows the test results for core layers of about 1 inch diameter thickness conductivity resistivity # of added in (in) (W / mK) (Km / W) layers 0.75 0.945 0.0951 10.520 1 0.75 1.878 0.1000 10 2 0.75 2.823 0.1036 9.653 3 0.75 3.76 0.1046 9.560 4

[00107] The table below shows the test results for core layers of about 1/2 inch:
diameter thickness conductivity resistivity # of added in (in) (W / mK) (Km / W) layers 0.75 0.442 0.0670 14.945 1 0.75 0.462 0.0690 14.493 1 0.75 0.908 0.0720 13.960 2 0.75 0.925 0.0735 13.605 2 0.75 1.366 0.0740 13.484 3 0.75 1.378 0.0752 13.298 3 0.75 1.824 0.0750 13.371 4 0.75 1.713 0.0759 13.175 4 0.75 3.681 0.07803 12.82 8

[00108] The table below shows the test results for core layers of about 1/4 inch:
diameter thickness conductivity resistivity # of added in (in) (W / mK) (Km / W) layers 0.625 0.256 0.05735 17.437 1 0.625 0.528 0.0607 16.464 2 0.625 1.059 0.06452 15.499 4 0.625 2.110 0.06842 14.616 8 0.625 4.055 0.06999 14.288 16

[00109] In view of the above, the tests have shown that superposition of multiple layers of smaller thicknesses yields a better insulating capacity (smaller thermal conductivity) than a corresponding panel with a single layer of a greater thickness matching the overall thickness of the multiple layers. Hence, in view of the above, it appears that it is advantageous to provide the thermal liner with a multiple layer core, in order to increase the thermal capacities thereof.

[00110] Furthermore simulations were conducted in order to verify that the position of a reflective surface within the core of a honeycomb cardboard panel, as is the case in the exemplary embodiment, impacted on the thermal conductivity thereof.

[00111] In the simulations, four surfaces within the core of a double layer honeycomb cardboard panel were tested (i.e. tests were performed with reflective surfaces on the different surfaces of an inner sheet, outer sheet and layer separation sheet of the panel). The table below provides the results of the simulations wherein the surfaces are indicated as follows: (1) the inner facing surface of an outer sheet (i.e. the surface of the outer sheet facing towards the inner sheet); (2) the outer facing surface of the layer separation sheet (i.e.
the surface of the layer separation sheet facing towards the outer sheet); (3) the inner facing surface of the layer separation sheet (i.e. the surface of the layer separation sheet facing towards the inner sheet); and (4) the inner facing surface of the inner sheet (i.e. the surface of the inner sheet facing towards the outer sheet).
Reflective surfaces keff (W (m K)1) None 0.0598 1, 2, 3, 4 0.0436 1,2 0.0510 1,3 0.0499 1,4 0.0494 2, 3 0.0496 2, 4 0.0493 3, 4 0.0498

[00112] In view of the above, it is understood that simulations confirmed that the combination which yields the best results is to provide a reflective surface on the outer facing surface of the layer separation sheet and the inner facing surface of the inner sheet.

[00113] Finally, referring to Figure 12, tests were also conducted in order to measure the insulation performance of the thermal container having different thermal liner configurations, as a function of the quantity of humidity. Three thermal liner configurations were tested. In the first configuration (indicated by hatched dots in Figure 12), the thermal liner included a Monaxially Oriented Polypropylene (MOPP) film (providing liquid/vapor resistant properties) on the inner sheet and outer sheet of the thermal liner, in the second configuration (indicated by black dots in Figure 12), the thermal liner included a MOPP film (providing liquid/vapor resistant properties) on the inner sheet and a Polyethylene film (also providing liquid/vapor resistant properties) on the outer sheet of the thermal liner, and in the third configuration (indicated by white dots in Figure 12), the thermal liner included a MOPP film (providing liquid/vapor resistant properties) on the inner sheet and an uncoated cellulosic fiber based sheet (substantially not providing liquid/vapor resistant properties) as outer sheet.

[00114] As can be seen in Figure 12, both the first configuration and the second configuration of the thermal liner (including liquid/vapor resistant barriers on the inner sheet and outer sheet of the thermal liner) perform substantially equally and offer no substantial insulation performance variation even when the quantity of humidity increases. However, the third configuration (where a liquid/vapor resistant barrier is provided on the inner sheet only) shows a significant decrease in insulation performance when the quantity of humidity increases. Indeed, the test results show that the insulation performance decreases of about 40% between a quantity of humidity of about 10 g/kg of dry air and about 20 g/kg of dry air, which is significant. In view of the above, the test results that the presence of a liquid/vapor resistant barrier on the inner and outer sheets improves the insulation performance of the thermal liner as opposed to only providing a liquid/vapor resistant barrier on the inner sheet.

[00115] Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person skilled in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person skilled in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the scope of the invention as defined in the appended claims.

Claims

CLAIMS:

1. A thermal liner comprising:
two panels configurable between an extended configuration and an operative C-shaped configuration, the two panels being engageable with one another when configured in the operative configuration in order to define a closed inner chamber, each one of the two panels comprising:
an inner sheet;
an outer sheet; and a core separating the inner sheet from the outer sheet, the core comprising at least two core layers separated by a layer separation sheet, each one of the at least two core layers including a geometrically patterned structure.

2. The thermal liner of claim 1, wherein each one of the at least two core layers of the two panels has a surface area and wherein the surface area of the at least two core layers of the two panels is substantially the same.

3. The thermal liner of claim 1, wherein each one of the at least two core layers of the two panels has a surface area and wherein the at least two core layers includes an inner core layer, the surface area of the inner core layer of at least one of the two panels being smaller than the surface area of the other core layers thereof and the inner core layer being inset with regard to the other core layers.

4. The thermal liner of claim 3, wherein the two panels have a thickness and wherein the inner core layer is inset with regard to the other core layers of a distance substantially corresponding to the thickness of the two panels.

5. The thermal liner of any one of claims 1 to 4, wherein at least one of the inner sheet and the outer sheet of each one of the two panels comprises a reflective surface.

6. The thermal liner of claim 5, wherein the inner sheet of each one of the two panels has an inner facing surface, the inner facing surface of the inner sheet of each one of the two panels comprising the reflective surface.

7. The thermal liner of any one of claims 1 to 6, wherein the layer separation sheet of each one of the two panels comprises an intermediate reflective surface.

8. The thermal liner of claim 7, wherein the layer separation sheet of each one of the two panels comprises an outer sheet facing surface facing the outer sheet and wherein the outer sheet facing surface of the layer separation sheet of each one of the two panels comprises the intermediate reflective surface.

9. The thermal liner of any one of claims 1 to 8, wherein the inner sheet and the outer sheet of each one of the two panels comprise a liquid/vapor resistant barrier.

10. The thermal liner of any one of claims 1 to 9, wherein each one of the at least two core layers of each one of the two panels comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

11. A thermal liner comprising:
a least two panels configurable between an extended configuration and an operative configuration, the at least two panels each including panel sections superposable onto corresponding panel sections of another one of the least two panels when configured in the operative configuration, the at least two panels defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall when configured in the operative configuration and each one of the bottom wall, the side walls and the top wall including at least two core layers, each one of the at least two panels comprising:
an inner sheet;

an outer sheet;
a core separating the inner sheet from the outer sheet, the core comprising at least one core layer including a geometrically patterned structure.

12. The thermal liner of claim 11, wherein at least one of the inner sheet and the outer sheet of at least one of the at least two panels comprises a reflective surface.

13. The thermal liner of claim 12, wherein the inner sheet of each one of the at least two panels has an inner facing surface, the inner facing surface of the inner sheet of each one of the at least two panels comprising the reflective surface.

14. The thermal liner of claim 12 or 13, wherein the outer sheet of each one of the at least two panels has an outer facing surface and wherein the outer facing surface of the layer separation sheet of the outer sheet of each one of the at least two panels comprises the reflective surface.

15. The thermal liner of any one of claims 11 to 14, wherein the inner sheet and the outer sheet of at least one of the at least two panels comprises a liquid/vapor resistant barrier.

16. The thermal liner of claim 15, wherein the inner sheet and the outer sheet of each one of the at least two panels comprises a liquid/vapor resistant barrier.

17. The thermal liner of any one of claims 11 to 16, wherein the at least one core layer of each one of the at least two panels comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

18. A thermal liner comprising a plurality of planar panel sections and being configurable in an operative configuration defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall, wherein each one of the bottom wall, the side walls and the top wall comprises an inner sheet, an outer sheet and at least one intermediate sheet, with a first core layer extending between the inner sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween and a second core layer extending between the outer sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween.

19. The thermal liner of claim 18, wherein at least one of the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall comprises a reflective surface.

20. The thermal liner of claim 19, wherein the inner sheet of each one of the bottom wall, the side walls and the top wall has an inner facing surface, the inner facing surface of the inner sheet of each one of the bottom wall, the side walls and the top wall comprising the reflective surface.

21. The thermal liner of any one of claims 18 to 20, wherein the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall comprises an intermediate reflective surface.

22. The thermal liner of claim 21, wherein the at least one intermediate sheet comprises an outer sheet facing surface facing the outer sheet, the outer sheet facing surface of the at least one intermediate sheet comprising the intermediate reflective surface.

23. The thermal liner of any one of claims 18 to 22, wherein the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall comprises a liquid/vapor resistant barrier.

24. The thermal liner of any one of claims 18 to 23, wherein each one of the first core layer and the second core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

25. The thermal liner of any one of claims 18 to 24, wherein each one of the bottom wall, the side walls and the top wall comprises at least one intermediary core layer extending between adjacent intermediate sheets and defining a plurality of geometrically patterned structures inbetween.

26. The thermal liner of claim 25, wherein the at least one intermediary core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

27. A thermal container comprising:
a container comprising:
a container bottom wall; and four container side walls extending substantially perpendicularly from the container bottom wall;
a thermal liner insertable into the container and comprising a plurality of planar panel sections, the thermal liner being configurable in an operative configuration defining a closed inner chamber delimited by a bottom wall, four side walls and a top wall, wherein each one of the bottom wall, the side walls and the top wall comprises an inner sheet, an outer sheet and at least one intermediate sheet, with a first core layer extending between the inner sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween and a second core layer extending between the outer sheet and a respective one of the at least one intermediate sheet and defining a plurality of geometrically patterned structures inbetween, wherein each one of the bottom wall and the side walls of the thermal liner is superposed respectively to the container bottom wall and the four container side walls when the thermal liner is inserted in the container with the inner chamber being closed at least by the top wall of the thermal liner.

28. The thermal container of claim 27, wherein at least one of the inner sheet and the outer sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises a reflective surface.

29. The thermal container of claim 28, wherein the inner sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner has an inner facing surface, the inner facing surface of the inner sheet of each one of the bottom wall, the side walls and the top wall comprising the reflective surface.

30. The thermal container of any one of claims 27 to 29, wherein the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises an intermediate reflective surface.

31. The thermal container of claim 30, wherein the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises an outer sheet facing surface facing the outer sheet, the outer sheet facing surface of the at least one intermediate sheet of each one of the bottom wall, the side walls and the top wall comprising the intermediate reflective surface.

32. The thermal container of any one of claims 27 to 31, wherein each one of the first core layer and the second core layer of each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.

33. The thermal container of any one of claims 27 to 32, wherein each one of the bottom wall, the side walls and the top wall defining the inner chamber of the thermal liner comprises at least one intermediary core layer extending between adjacent intermediate sheets and defining a plurality of geometrically patterned structures inbetween.

34. The thermal container of claim 33, wherein the at least one intermediary core layer comprises a honeycomb structure defining a grid of hexagonal open-ended core cells.