U.S. patent application number 12/325871 was filed with the patent office on 2009-09-17 for temperature maintaining shipping package.
Invention is credited to Henry Adolph Cousineau, III, Arnold Charles Hillmann, Christian Peter Kramer, David Nicholas Legas, Eric Robert Lindquist, Preston Noel Williams.
Application Number | 20090230138 12/325871 |
Document ID | / |
Family ID | 41061900 |
Filed Date | 2009-09-17 |
United States Patent
Application |
20090230138 |
Kind Code |
A1 |
Williams; Preston Noel ; et
al. |
September 17, 2009 |
Temperature Maintaining Shipping Package
Abstract
A package and method of use for packaging temperature sensitive
payloads during transport through environments having extreme
temperatures. The package includes a segmented, flexible panel
containing a plurality of phase change material segments. A pair of
such panels may be used, with each panel being separately thermally
preconditioned as a function of anticipated ambient temperature
during transport. The panels may be formed by retaining phase
change material segments between a pair of flexible sheets.
Inventors: |
Williams; Preston Noel;
(Richfield, MN) ; Cousineau, III; Henry Adolph;
(Minneapolis, MN) ; Hillmann; Arnold Charles;
(Prior Lake, MN) ; Lindquist; Eric Robert;
(Medina, MN) ; Kramer; Christian Peter; (Saint
Louis Park, MN) ; Legas; David Nicholas;
(Bloomington, MN) |
Correspondence
Address: |
BRIGGS AND MORGAN P.A.
2200 IDS CENTER, 80 SOUTH 8TH ST
MINNEAPOLIS
MN
55402
US
|
Family ID: |
41061900 |
Appl. No.: |
12/325871 |
Filed: |
December 1, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60991658 |
Nov 30, 2007 |
|
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|
Current U.S.
Class: |
220/592.26 ;
53/473 |
Current CPC
Class: |
B65D 81/3895
20130101 |
Class at
Publication: |
220/592.26 ;
53/473 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65B 1/04 20060101 B65B001/04 |
Claims
1. A transport package for a temperature sensitive payload
comprising: an outer container; a panel defined by a plurality of
interconnected segments of phase change material; and a payload
section adapted to receive the temperature sensitive payload, and
with the panel being wrapped around the payload prior to insertion
into the outer container.
2. The package of claim 1 wherein the panel includes a pair of
intennittently joined film layers defining cavities into which
phase change material is contained.
3. The package of claim 2 wherein the panel includes a plurality of
voids.
4. The package of claim 3 wherein the voids are generally linearly
aligned.
5. The package of claim 1 wherein the panel is provided with
enhanced flexibility in a direction beneficial for wrapping the
payload.
6. The package of claim 1 wherein the panel includes a plurality of
segmented sheets.
7. The package of claim 6 wherein said plurality of segmented
sheets includes a pair of sheets, with each of the pair of sheets
being thermally preconditioned differently than the other prior to
wrapping the pair of panels around the payload.
8. A transport package for a temperature sensitive payload
comprising: a plurality of segmented panels containing phase change
material within an interior volume, with said interior volume being
defined between a pair of fluid impervious layers; and a payload
section adapted to receive the temperature sensitive payload, and
with the plurality of panels being wrapped around the payload prior
to insertion into an outer container.
9. The package of claim 8 wherein the pair of fluid impervious
layers are intermittently joined together to define a plurality of
volumes containing phase change material.
10. The package of claim 9 wherein the pair of fluid impervious
layers are joined together via a thermal bonding process.
11. The package of claim 8 wherein at least some of the plurality
of segmented panels are preconditioned differently from each other
prior to wrapping the payload.
12. A method of packaging a temperature sensitive product
comprising: thermally preconditioning a flexible phase change
material-containing panel, said panel including a plurality of
segment portions; wrapping the panel around the temperature
sensitive product; and inserting the temperature sensitive product
wrapped with the panel into an outer container.
13. The method of claim 12 flither comprising: sealing the outer
container prior to shipment.
14. The method of claim 12 further comprising: thermally
preconditioning a second flexible phase change material-containing
panel and wrapping the second flexible phase change
material-containing panel around the temperature sensitive product
prior to said insertion.
15. A method of packaging a temperature sensitive product
comprising: wrapping the payload in a first flexible, segmented
panel containing phase change material preconditioned based on an
anticipated ambient temperature during transport of the payload;
wrapping the payload in a second flexible, segmented panel
containing phase change material preconditioned based on another
anticipated ambient temperature during said transport; and
inserting the payload wrapped with the segmented panels into an
outer container.
16. The method of claim 15 further comprising: wrapping the payload
with thermal insulation prior to said inserting.
17. The method of claim 15 wherein at least some phase change
material has been preconditioned by adding heat energy to phase
change material until the phase change material is liquid.
18. The method of claim 15 wherein at least some phase change
material has been preconditioned by removing heat energy from phase
change material until the phase change material is solid.
19. The method of claim 15 wherein the segmented panels are
thermally preconditioned based on anticipated ambient temperatures
during payload transportation.
20. The method of claim 15 wherein at least two different thermal
preconditioning processes are used to prepare the segmented panels.
Description
RELATED APPLICATIONS
[0001] This applications claims priority from U.S. Provisional
Patent Application No. 60/991,658, filed Nov. 30, 2007, and hereby
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention is directed to a package, such as used
during transport, for a temperature sensitive payload and a method
of use. More particularly, the present invention relates to a
package and method of use for shipping temperature sensitive
materials via common carrier.
BACKGROUND OF THE INWENTION
[0003] Packages incorporating phase change materals for transport
of temperature sensitive payloads are well known. A phase change
material (PCM) is a substance with a high heat of fusion which,
upon melting and solidifying at certain temperatures, is capable of
storing or releasing large amounts of energy. Initially,
solid-liquid PCMs perform somewhat like conventional storage
materials: their temperature nrses as they absorb heat. Unlike
conventional storage materials, however, when such PCMs reach their
phase change temperatures (i.e., melting point temperature) they
absorb large amounts of heat without a significant rise in
temperature. When the ambient temperature around a lquid material
falls, the PCM solidifiesv releasing its stored latent heat.
Certain PCMs store 5 to 14 times more heat per unit volume than
conventional storage materials such as iron, masonry, or rock.
[0004] Transporting temperature sensitive materials through
environments having extreme ambient temperatures in a manner that
does not require a power source or other mechanical device is
desirable. Various methods have been advanced for this purpose. For
example, prior known devices have employed phase change materials
in liquid form to encase a payload to protect materials from colder
ambient temperatures and phase change materials in solid form to
encase a payload to protect materals from hotter ambient
temperatures.
[0005] PCMs can be broadly grouped into two categories: "Organic
Compounds" (such as polyethylene glycol) and "Salt-based Products"
(such as Glauber's salt). The most commonly used PCMs are salt
hydrides, fatty acids and esters, and various paraffins (such as
octadecane). Ionic liquids have also been investigated as novel
PCMs.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention relates to a package and method of
thermally protecting a payload with phase change materals and an
outer container, wherein the PCM material is provided in segmented
panels. In one embodiment, a payload is surrounded with phase
change material contained within segmented PCM panels that are
wrapped around a payload. A package in accordance with the present
invention may include multiple segmented panels of phase change
material.
[0007] It is particularly desirable to have a storage or shipping
container capable of thermally protecting a payload such as, but
not limited to, a bottle or bottles of pills. An embodiment of the
present invention relates includes a package defined by an outer
container, such as an envelope, which contains one or more
flexible, segmented PCM panels surrounding a payload. In one
example, the segments are defined by bondings between panel
surfaces. Such a bond can be formed via a thermal bonding
procedure. One embodiment of the present invention utilizes
multiple panels of generally similar form to define a plurality of
segmented PCM portions.
[0008] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the invention
will be described hereinafter which form the subject of the claims
of the invention. It should be appreciated by those skilled in the
art that the conception and specific embodiment disclosed may be
readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes of the present
invention. It should also be realized by those skilled in the art
that such equivalent constructions do not depart from the spirit
and scope of the invention as set forth in the appended claims. The
novel features which are believed to be characteristic of the
invention, both as to its organization and method of operation,
together with further objects and advantages will be better
understood from the following description when considered in
connection with the accompanying figures. It is to be expressly
understood, however, that each of the figures is provided for the
purpose of illustration and description only and is not intended as
a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present invention,
reference is now made to the following descriptions taken in
conjunction with the accompanying drawing, in which:
[0010] FIG. 1 is an view of a package assembly in a disassembled
state in accordance with the present invention.
[0011] FIG. 2 is a view of a portion of the package assembly of
FIG. 1.
[0012] FIG. 3 is a cross-sectional view of the package assembly
taken along lines A-A of FIG. 1.
[0013] FIG. 4 is a cross-sectional view of the package assembly
taken along lines B-B of FIG. 2.
[0014] FIG. 5 is a view of a portion of the package assembly of
FIG. 1 during an assembly process.
[0015] FIG. 6 is a view of the package assembly of FIG. 5 during
the assembly process.
[0016] FIG. 7 is a view of the package assembly of FIG. 1 in a
ready-to-ship state.
[0017] FIGS. 8-11 are views of another embodiment of a package
assembly in accordance with the present invention.
[0018] FIGS. 12-14 are graphs of test data collected during actual
shipments of packages in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] With reference to FIG. 1, there is shown one embodiment of a
package 10 in a disassembled state. Package 10 includes outer
container 11 and a pair of phase change material (PCM) panels 13. A
payload is provided, which in this example, is a pair of bottles
16. As disclosed hereinafter, payload 16 is contained within rolled
PCM panels 13 and container 11 upon assembly.
[0020] In the illustrated embodiment, container 11 is an envelope.
Container 11 may be insulated or uninsulated. In other embodiments,
container 11 may assume alternative forms, including, but not
limited to, nonrectangular forms. Container 11 may be of plastic or
polymer material, corrugated paper or corrugated plastic or other
suitable material.
[0021] PCM panels 13 may assume different shapes or forms in
alternative embodiments. Panels 13 contain a plurality of PCM
segments 18. In the illustrated embodiments of FIGS. 1-11, a pair
of flexible, segmented PCM panels 13 are employed in package 10. In
the embodiment of FIGS. 1-7, panels 13 are segmented in two
generally orthogonal directions, for simplicity sake referred to
herein as "horizontal" and "vertical" directions. In comparison,
the embodiment of FIGS. 8-11 utilize panels 13 which are segmented
in a single directions, e.g., vertical. As shown in FIGS. 1 and 2,
panels 13 of are segmented in both horizontal and vertical
directions.
[0022] Panels 13 are defined by a plurality of separated
PCM-containing segments 18. These segments 18 are separated by
linear voids 19. Voids 19 may be defined during a thermal bonding
manufacturing process. For example, the voids 19 and cavity forming
segments 18 may be formed from a pair of thermoplastic sheet
material brought together during a thermal bonding/filling process.
Voids 19 may be continuous, that is to say each segment 18 is
separated from each other and PCM is prevented from flowing from
one segment 18 to an adjacent segment 18. In another embodiment,
voids 19 may be non-continuous and PCM is able to flow from one
segment into another segment 18 when an external force is supplied.
In short, the interior volumes of segments 18 may be either
separated or provided in fluid communication with each other.
[0023] FIGS. 3 and 4 represent cross-sectional views taken along
lines A-A and B-B in FIGS. 1 and 2, respectively. Each segment 18
contains a quantity of PCM held between upper and lower films 20,
21. In one embodiment, segments 18 are defined between pairs of
void regions 19 wherein film layers 20, 21 are brought together
during a sealing/filling process. PCM is held within volumes
contained between film layers 20, 21. The size of segments 18 could
depend on a variety considerations including, but not limited to,
temperature constraints of payload and/or anticipated ambient
temperature during shipping, size of payload, size or weight
limitations of shipper, etc. It should be appreciated that
alternative segment 18 designs could also be utilized depending,
for example, on the geometry of the payload, thermal constraints,
etc. As suggested by FIG. 5, slits or perforations may be formed in
upper and/or lower segment portions such as indicated by numeral
29. Such slits or perforations 29 may be beneficial during a panel
13 rolling process as further disclosed herein. Slits or
perforations 29 are shown in phantom line to indicate that for
other embodiments of panel 13, slits or perforations 29 may or may
not be present.
[0024] FIGS. 2 and 4-6 depict the process of assembling package 10.
In FIG. 2, payload 16 has been placed upon upper film surface 20 of
segmented panel 13. Prior to assembly, panels 13 have desirably
been thermally conditioned. Assuming the same PCM material is used
in the pair of panels 13, one the panels may be preconditioned to
be solid and the other panel may be preconditioned to be liquid.
Panels 13 are preconditioned depending on the temperature
constraints of a given package. In other embodiments, more than two
PCM panels 13 could be used.
[0025] FIG. 4 depicts rolling one of the PCM panels 13 around
payload 16. Next the other PCM panel 13 is rolled around the first
PCM panel 13. FIG. 5 depicts the combination of PCM panels and
payload 16 as inserted into container 11. Flap 30 of container 11
is subsequently folded into adhesive contact with a panel surface.
FIG. 7 depicts package 10 as assembled and ready to ship. Package
10 may be adapted to be mailed as-is, or alternatively package 10
or a plurality of packages 10 may be contained in yet another
larger package (not shown), such as a box. Container 11 may be
adapted to directly receive a label, stamps or other indicia
utilized during the shipping process.
[0026] Referring to FIGS. 5 and 6, because payload 16 does not
extend to edges of panel 13, end portions of panels 13 may be
folded over to fully enclose payload 16. In comparison, the panels
13 of a second embodiment as shown in FIGS. 8-11 are not folded
over.
[0027] FIGS. 8-11 illustrate another embodiment of package 100.
FIG. 8 depicts a disassembled package 100 including a pair of
flexible, PCM panels 13 and container 110. In comparison to package
10 of the first embodiment, PCM panels 13 are defined by a
plurality of vertical voids 190. As shown in FIGS. 9 and 10,
payload 160 extends substantially across panel 130. When panels 13
are wrapped around payload 160, ends of payload 160 may be visible
as shown in FIG. 11.
[0028] The present invention is also directed to a package and
method for encasing a payload cavity with flexible, segmented
panels 13 containing phase change material. In one example, a water
based phase change material is combined with another phase change
material to provide thermal protection for the payload. By properly
selecting the phase change materials, a package can be configured
to provide maximum thermal protection for a temperature sensitive
product during delivery. Employing a combination of solid and
liquid phase change materials in the container can provide
protection from both hotter and colder ambient temperatures during
delivery, and a beneficial reduction in the amount of certain phase
change materials can result.
[0029] Embodiments of the present invention may include two or more
different phase change materials. In one embodiment, a water-based
phase change material is utilized along with a 2.sup.nd,
non-water-based phase change material. In one embodiment, a
temperature sensitive product is protected against thermal damage
from the water-based phase change material by an intermediate phase
change material. Depending on the desired temperature range, a
variety of different phase change materials may be utilized to keep
a temperature sensitive product warm or cold during shipment
through an environment having substantially different temperatures
than desired. For example, prior to shipment one or both of the
phase change materials 13 can be preconditioned so that phase
change material is in liquid form or solid form. Depending on the
anticipe mate a e eeture profile, the most effective combination of
solid and liquid phase change material can be selffecte combination
is needed, auxiliary phase change material in solid, liquid, or
solid and liquid phase can be added to augment the thermal
capabilities of the container.
[0030] FIGS. 12-14 illustrate test data associated with three test
shipments of a package in accordance with the present invention.
Three packages were transported to either Florida or New York from
Minneapolis using ordinary available shippers. Temperature of the
payload was monitored as well as the ambient temperature as felt by
the outer container. Data was measured by two temperature
sensing/recording devices contained within container. Temperature
and time as collected during the tests are provided in graph form.
Each test package maintained the payload within a 5 deg. C.
temperature band (25.0-20.0 deg. C.) over at least a two day period
while the ambient temperature dipped above or below the temperature
band. Test success for a package was defined by the package
maintaining the payload within the desired temperature band for at
least two days during the transport process.
[0031] Selection of the phase change materials may include
consideration of multiple factors including, but not limited to,
the desired protected temperature range, anticipated ambient
temperatures during shipment, thermal properties of the different
phase change materials, thermal properties of the container and/or
insulation panels, and thermal properties of the temperature
sensitive product being shipped. The design and sizing of
containers of for the phase change material and the insulation
panels could vary depending on these factors as well.
[0032] A temperature maintaining packaging system in accordance
with the present invention includes an insulated or non-insulated
outer container, including but not limited to a box or envelope
made of plastic film, metallic foil or other suitable material, a
phase change material panel or panels consisting of a sealed cavity
or cavities within a plastic film or other suitable material that
is/are preconditioned to be solid, liquid, or solid and liquid in
varying predetermined combinations covering or mostly covering the
interior of the outer container or envelope, and possibly a
secondary phase change material sealed within a plastic film or
other suitable material having a single cavity or multiple cavities
that is/are preconditioned to be solid, liquid, or solid and liquid
in varying predetermined combinations covering or mostly covering
the interior of the first phase change material panel or panels all
to thermally protect a payload within the center of the
package.
[0033] A temperature maintaining packaging system in accordance
with the present invention includes an outer rigid or semi-rigid
tube or hollow container made of paper, plastic or other suitable
material along with suitable caps for enclosing the package, a
suitable insulation such as a plastic foam capable of wrapping
around a phase change material panel or panels and a payload
container, a phase change material panel or panels consisting of a
sealed cavity or cavities within a plastic film or other suitable
material that is/are preconditioned to be solid, liquid, or solid
and liquid in varying predetermined combinations covering or mostly
covering the interior of the outer container, and possibly a
secondary phase change material sealed within a plastic film or
other suitable material having a single cavity or multiple cavities
that is/are preconditioned to be solid, liquid, or solid and liquid
in varying predetermined combinations covering or mostly covering
the interior of the first phase change material panel or panels all
to thermally protect a payload within the center of the
package.
[0034] The temperature maintaining package system in accordance
with the present invention includes PCM panels wherein the phase
change materials are preconditioned to be solid, liquid, or both
solid and liquid.
[0035] The invention is directed to a method of preparing,
packaging and shipping a container or envelope to thermally protect
a payload of temperature sensitive materials including: wrapping
the payload material to be thermally protected in a phase change
material panel with one or more segments of phase change material
conditioned to be solid or liquid; wrapping the payload and initial
phase change material panel in a secondary phase change material
panel with one or more segments of phase change material
conditioned to be solid or liquid; as needed, wrapping the payload
and panels with successive layers of phase change material panels
as space and temperature protection demands; placing the payload
wrapped with phase change material panels into the outer container
or envelope; and sealing the payload and phase change material
panels inside the container and performing any necessary operations
to complete the package such as but not limited to placing shipping
information on the package, placing postage and instructions on the
package, or puncturing a vacuum sealed outer envelope to allow
expansion of the insulation material.
[0036] Another method of preparing, packaging and shipping a
container to thermally protect a payload of temperature sensitive
materials includes: wrapping the payload material to be thermally
protected in a phase change material panel with one or more
cavities of phase change material conditioned to be solid or
liquid; wrapping the payload and initial phase change material
panel in a secondary phase change material panel with one or more
cavities of phase change material conditioned to be solid or
liquid; as needed, wrapping the package in successive layers of
phase change material panels as space and temperature protection
demands; wrapping the payload wrapped with phase change material
panels inside the with suitable insulation such as foam insulation;
and sealing the payload, phase change material panels, and
insulation inside the container and performing any necessary
operations to complete the package such as but not limited to
attaching end caps to the container, placing shipping information
on the package, or placing postage and instructions on the
package.
[0037] The PCM panels may include phase change materials that have
been preconditioned separately to be solid and liquid by adding
heat energy to phase change material containers until the phase
change material is completely liquid and conditioning the liquid
phase change material to be at an acceptable temperature for
packaging; or removing heat energy from phase change material
containers until the phase change material is completely solid and
conditioning the solid phase change material to be at an acceptable
temperature for packaging.
[0038] Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alterations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one of
ordinary skill in the art will readily appreciate from the
disclosure of the present invention, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized according to the present invention. Accordingly, the
appended claims are intended to include within their scope such
processes, machines, manufacture, compositions of matter, means,
methods, or steps.
* * * * *