U.S. patent application number 12/779912 was filed with the patent office on 2010-12-16 for thermal containment system providing temperature maintaining shipping package with segmented flexible pcm panels.
Invention is credited to Arnold Charles Hillmann, Preston Noel Williams.
Application Number | 20100314397 12/779912 |
Document ID | / |
Family ID | 43085339 |
Filed Date | 2010-12-16 |
United States Patent
Application |
20100314397 |
Kind Code |
A1 |
Williams; Preston Noel ; et
al. |
December 16, 2010 |
Thermal Containment System Providing Temperature Maintaining
Shipping Package with Segmented Flexible PCM Panels
Abstract
A packaging system having an outer container and a segment panel
defining a plurality of phase change material (PCM) segments, with
said segments being aligned with sides of the outer container
interior upon wrapping around a payload and insertion into the
outer container. The segmented panels may include edge tapers which
facilitate the wrapping process with adjacent edge tapers being
brought together during the wrapping process. A method of packaging
using PCM-containing segments which are wrapped around a portion of
a payload is also disclosed.
Inventors: |
Williams; Preston Noel;
(Minneapolis, MN) ; Hillmann; Arnold Charles;
(Prior Lake, MN) |
Correspondence
Address: |
BRIGGS AND MORGAN P.A.
2200 IDS CENTER, 80 SOUTH 8TH ST
MINNEAPOLIS
MN
55402
US
|
Family ID: |
43085339 |
Appl. No.: |
12/779912 |
Filed: |
May 13, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61177998 |
May 13, 2009 |
|
|
|
Current U.S.
Class: |
220/592.01 ;
53/440 |
Current CPC
Class: |
Y02E 60/145 20130101;
F25D 2303/0843 20130101; B65D 81/3823 20130101; F28D 2020/0008
20130101; F25D 3/08 20130101; Y02E 60/14 20130101; F28D 20/02
20130101; F25D 2303/085 20130101; F25D 2303/08222 20130101; F25D
2303/0844 20130101; F25D 2303/0845 20130101 |
Class at
Publication: |
220/592.01 ;
53/440 |
International
Class: |
B65D 81/18 20060101
B65D081/18; B65B 63/08 20060101 B65B063/08 |
Claims
1. A transport package for a temperature sensitive payload
comprising: an outer container having an interior defined by at
least three sides; a panel defined by a plurality of interconnected
segments containing phase change material and at least one insert;
and a payload section adapted to receive the temperature sensitive
payload, with the panel being wrapped around the payload prior to
insertion into the outer container, and with at least three of said
plurality of interconnected segments being aligned with said at
least three sides of the outer container.
2. The package of claim 1 wherein the panel includes a pair of
intermittently joined film layers defining cavities into which said
phase change material is received.
3. The package of claim 2 wherein the panel includes a plurality of
voids defined by a plurality of inserts.
4. The package of claim 3 wherein some of the voids are defined by
flutes of a corrugated paper product.
5. The package of claim 3 wherein edges of the plurality of inserts
taper, and when the panel is folded into form, said edges of
adjacent pairs of inserts are brought together.
6. The package of claim 5 wherein the at least one insert includes
a plurality of sheets of corrugated product.
7. The package of claim 6 wherein said plurality of sheets includes
multiple sheets of decreasing size.
8. A method of packaging a temperature sensitive product
comprising: thermally preconditioning a flexible phase change
material-containing panel, said panel including a plurality of
segments containing at least one insert; wrapping the panel around
at least a portion of the temperature sensitive product; and
inserting the temperature sensitive product wrapped with the panel
into an outer container, with said plurality of segments being
aligned with a plurality of inside surfaces of said outer
container.
9. The method of claim 8 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 inserting.
10. The method of claim 8 wherein said at least one insert is a
corrugated product.
11. The method of claim 8 wherein said at least one insert has
tapered edges and wherein said wrapping brings together a pair of
tapered edges of an adjacent pair of inserts to define a
corner.
12. The method of claim 8 wherein said panel includes 6 segments
and wherein said wrapping aligns the 6 segments with 6 interior
sides of the outer container.
13. The method of claim 8 wherein said panel includes 12 segments
and wherein said wrapping aligns the 12 segments with 6 interior
sides of the outer container.
14. A method of packaging a temperature sensitive payload
comprising: wrapping the payload in a first flexible, segmented
panel containing an insert and 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 an insert and 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, with panels of said segmented panels being aligned
with inside surfaces of said container.
15. The method of claim 14 further comprising: wrapping the payload
with thermal insulation prior to said inserting.
16. The method of claim 14 wherein at least some phase change
material has been preconditioned by adding heat energy to the at
least some phase change material until the at least some phase
change material is liquid.
17. The method of claim 14 wherein at least some phase change
material has been preconditioned by removing heat energy from the
at least some phase change material until the at least some phase
change material is solid.
18. The method of claim 14 wherein the segmented panels are
thermally preconditioned based on anticipated ambient temperatures
during payload transportation.
19. The method of claim 14 wherein at least two different thermal
preconditioning processes are used to prepare the segmented
panels.
20. The method of claim 14 wherein said wrapping the payload in the
first flexible, segmented panel includes providing the first panel
in flat form and folding the first panel into a box form prior to
inserting the payload.
Description
RELATED APPLICATIONS
[0001] This application claims priority to pending U.S. Ser. No.
61/177,998, filed May 13, 2009, and hereby incorporated by
reference in its entirety.
TECHNICAL FIELD
[0002] The present invention is directed to a thermal containment
system providing a package for a temperature sensitive product 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 carriers, such as United States Postal
Service, United Parcel Service, FedEx, etc.
BACKGROUND OF THE INVENTION
[0003] The conventional means of shipping temperature sensitive
materials such as blood and medical products involves the use of an
insulated box along with some cooling agent. These cooling agents
are typically a frozen gel, dry ice, or glistening (wet) ice.
[0004] There are, however, several problems with the conventional
approach. First, the insulation material often does not degrade
readily, leading to disposal problems. These problems are so severe
that many countries ban the use of styrofoam, thus severely
restricting international shipments of biological materials.
Second, the cooling agents also present numerous practical problems
in field use. Specifically, gel systems are often too expensive for
routine use and disposal. As for dry ice, the carbon dioxide gas
evolved during shipment may be dangerous to shipping personnel. Wet
ice poses handling problems in packing, as well as leakage and
product soaking problems.
[0005] Many previously existing shipping systems also suffer the
disadvantage that they are not capable of maintaining the shipped
product or payload within a target temperature range. Various
biological products, such as platelets, whole blood, semen, organs
and tissue, must be maintained above a predetermined minimum
temperature and below a predetermined maximum temperature.
Pharmaceutical products are also commonly required to be kept
within a specified temperature range. Food products, flowers and
produce frequently have preferred storage temperature ranges as
well. Many known methods and systems for shipping such products are
not able to keep temperatures within the desired range. The result
of this practice is excessive cooling, frequently resulting in
damage to the product.
[0006] Previously known methods and systems which are capable of
maintaining a payload within a specified temperature range have
been found to be unsuited to certain applications, unduly complex
in practice, and/or prohibitively expensive. For example,
refrigerated containers require associated compressors, coils,
crystals, or other equipment, which adds to the apparatus' expense,
weight and size. Additionally, this type of equipment generally
requires batteries or connection to an external power source.
Refrigerated containers also require ventilation, so that heat from
the payload can be rejected to the ambient. Sufficient ventilation
for the proper operation of these devices is generally unavailable
in the closely-packed cargo compartments of common carrier
transport vehicles. Refrigerated transport vehicles exist, but are
substantially more expensive than unrefrigerated transport, and are
not as readily available.
[0007] Another problem often observed with conventional systems is
failure to maintain the proper temperature over time, due to
inadequate insulation and/or inadequate cooling pack capacity.
Again, the end result is product damage.
[0008] The consequence of these observed shortcomings of
conventional shipping systems is damage to the material being
transported. For biomedical materials such as blood, blood
products, pharmaceuticals, etc., loss of these products due to heat
damage is critical because of the intrinsic financial value of
these items and because of the potential health hazards that the
use of compromised materials presents. Likewise, heat damage to
various foods also presents both financial and health
consequences.
[0009] Packages incorporating phase change materials 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 rises 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 liquid material
falls, the PCM solidifies, 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.
[0010] 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 materials from hotter ambient
temperatures. 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
[0011] The present invention relates to a package and method of
encasing a payload with phase change materials 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 with each segment including a generally rigid insert for
lightweight, structural stability.
[0012] An embodiment of the present invention includes a package
defined by an outer container, such as a container, which contains
insulated panels and 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
film thermal bonding procedure. One embodiment of the present
invention utilizes multiple panels of generally similar form to
define a plurality of segmented PCM portions.
[0013] It is desired to have a lightweight, highly reliable,
portable container that maintains the temperature of pharmaceutical
products or other temperature sensitive materials over a relatively
long or given period of time. For pharmaceutical products/materials
for example, it is desired to maintain thermal stability to allow
the material to ultimately be administered to patients many hours
or days after they were first placed into the container.
[0014] An embodiment of the present invention includes a thermal
management system. The thermal management system includes a
plurality of PCM-containing panels connected together to form a
segmented PCM module. The system further includes a phase change
material occupying voids of corrugated panels within an interior of
the plurality of panels, and a liquid container, such as film, to
at least prevent the phase change material from leaking out of the
interior of the plurality of PCM-containing panels.
[0015] Another embodiment of the present invention includes a
method of manufacturing a thermal management system. The method
utilizes a horizontal fill-and-seal machine. The method comprises
securing a bottom film layer into a cavity form, such as via a
vacuum, and dispensing PCM fluid into the formed cavity. Corrugated
paper insert elements are then placed into the cavity and
physically held in place to allow air to escape the flutes of the
corrugated paper elements while the PCM fluid saturates the
corrugated paper elements. A top film layer is then placed above
the cavity and the top and bottom film layers are heat sealed
together to provide a fluid-tight cavity. The method further
provides forming a plurality of PCM-containing cavities
simultaneously wherein a step includes sealing the phase change
material and plurality of corrugated insert panels within a
plurality of cavities to define a segmented PCM panel.
[0016] A further embodiment of the present invention includes a
method of using insert panels within each PCM-containing cavity and
wherein the insert panels are cut in complimentary manner that
facilitates the fit between the PCM-containing panels and cavities.
In one such embodiment, the multiple insert panels may be pre-cut
with an edge taper to define a plurality of tapered edges. These
tapered edges permit closer engagement between adjacent PCM panels
once formed into a desired shipping configuration.
[0017] A further embodiment of the present invention includes a
method of using multiple insert panels within each PCM-containing
cavity and wherein the multiple insert panels are of different size
relative to each other. In one such embodiment, the multiple insert
panels may be decreasing in size to define a plurality of tapered
edges. These tapered edges permit closer engagement between
adjacent PCM panels once formed into a desired shipping
configuration.
[0018] A further embodiment of the present invention includes a
method of using a pair of segmented PCM panels, with each panel
being defined by three PCM-containing segments. The PCM panels are
formed into a generally C-shaped form once inserted into an outer
container. The pair of PCM panels can thus cover all six sides of a
rectangular form.
[0019] A further embodiment of the present invention includes a
method of using a single segmented PCM panel. The PCM panel is
formed into a generally rectangular form prior to insertion into an
outer container. Segments of the PCM panel cover all six sides of a
rectangular form. Some or all of the segments of the PCM panel may
include an insert panel to provide lightweight, structural
stability.
[0020] A further embodiment of the present invention comprises a
method of using a thermal management system. The method comprises
thermally preconditioning a container at a preconditioning
temperature for a predefined period of time. The container is
designed to include a plurality of segmented PCM panels, a phase
change material occupying voids within the interiors of the
plurality of panel segments and voids within an insert panel(s),
and a liquid barrier to at least prevent the phase change material
from leaking out of the interior of the plurality of panel
segments. The method further includes opening the container,
placing at least one pharmaceutical product or material into the
container, and closing the container. The method also comprises
shipping the container to a destination location during a
predetermined time period such that a temperature of the at least
one product stays within a predetermined temperature range over the
predetermined time period due to the design of the container.
[0021] Another embodiment of the present invention comprises a
thermal management system. The thermal management system comprises
a plurality of insert panels formed as structurally porous panels
and connected together to form a container. A phase change material
occupies voids or gaps within an interior of the plurality of
structurally porous panels. The system further includes a liquid or
fluid barrier material, such as a film layer, to at least prevent
the phase change material from leaking out of the interior of the
plurality of structurally porous panels.
[0022] In one preferred form, the present invention provides a
system and method for maintaining a payload within a temperature
range, between a minimum temperature and a maximum temperature. The
invention includes a first temperature control material having a
first phase change temperature sufficiently above the minimum
temperature in the range to ensure the payload does not fall below
the minimum temperature in the range, and a second temperature
control material having a second phase change temperature
sufficiently below the maximum temperature in the range to ensure
the payload does not rise above the maximum temperature in the
range. In one embodiment, the first material exists as a liquid
within the target temperature range, and the second material as a
solid. The first material changes from its liquid phase to its
solid phase at a temperature sufficiently above the minimum
temperature in the range to ensure the payload does not fall below
the minimum temperature in the range, and the second material that
changes from its solid phase to its liquid phase at a temperature
sufficiently below the maximum temperature in the range to ensure
the payload does not rise above the maximum temperature in the
range. In this manner, the latent heats associated with the
respective phase changes assist in maintaining the temperature of
the payload within the range. Virtually any desired target
temperature range may be accommodated by appropriate selection of
the first and second materials.
[0023] The present invention further includes heat transfer devices
which can take any of a number of forms, including without
limitation: flexible plastic pouches, rigid or semi-rigid panels,
and/or blister packs. The heat transfer devices comprise one or
more reservoirs for containing the first and second materials.
Separate heat transfer devices can be provided for each of the
first and second materials or, alternatively, a single heat
transfer device can be segmented into separate reservoirs for each
of the first and second materials. Baffles or other separation
means can be provided within the heat transfer devices for
maintaining the first and second materials in position.
[0024] 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
[0025] 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:
[0026] FIG. 1 is an view of a package of a thermal containment
system in accordance with the present invention.
[0027] FIGS. 2 through 6 are perspective views of the package of
FIG. 1 depicting progressively disassembled states.
[0028] FIG. 7 is a view of a segmented PCM-containing panel of FIG.
1.
[0029] FIG. 8 is a detailed view of the segmented PCM-containing
panel of FIG. 7.
[0030] FIG. 9 is a detailed cross-sectional view of a segmented
PCM-containing panel of FIG. 7.
[0031] FIG. 10 is a detailed view of a segmented PCM-containing
panel of FIG. 7 as formed to define a corner, such as around a
payload section.
[0032] FIG. 11 is a perspective view of a segmented PCM-containing
panel provided in flat form.
[0033] FIG. 12 is a perspective view of the PCM panel of FIG. 11 as
manipulated into a generally rectangular form.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The packaging system of the present invention was developed
for shipments of goods which must be kept within narrow temperature
ranges over a period of days under uncontrolled ambient temperature
conditions. Such goods include biological products, blood products,
vaccines, pharmaceuticals, chocolate products, latex paints, etc.
The system described herein can be configured to maintain
controlled product temperatures under both high and low ambient
temperature conditions.
[0035] This system uses phase change materials for tight
temperature control and minimum shipping weight and volume. These
phase change materials are reusable, and can save significantly on
shipping costs. Various numbers of layers of phase change material
may be used based upon time requirements, ambient temperature
requirements, thermal insulation factor of the outer container, and
the degree of temperature control required for the product.
Descriptions of various phase change materials, parameters and
engineering constraints are provided in U.S. Pat. Nos. 5,899,088;
6,482,332; and 7,328,583, the disclosure of each being incorporated
herein by reference.
[0036] With reference to FIG. 1, there is shown one embodiment of a
thermal management system including a package 10 in an assembled
state. Package 10 includes an outer container 11 having a top wall,
bottom wall and side walls. Package 10 includes outer container 11
containing an arranged plurality of insulation panels and segmented
PCM panels. In the illustrated embodiment, container 11 is a
rectangular box. 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.
[0037] FIGS. 2 through 6 illustrate perspective views of package 10
and depict disassembly of the package 10 of FIG. 1 to reveal a
payload section. In FIG. 2, the top walls of container 11 are
opened to reveal a plurality of insulation panels 12. Separate
insulation panels 12 are provided adjacent each of the six sides of
container 11. FIG. 3 depicts the package 10 with the top insulation
panel 12 removed. A PCM panel 13 is thereby exposed.
[0038] FIG. 4 depicts the package 10 with the top segment of the
PCM panel 13 opened to reveal a payload section. A second segmented
PCM panel 13 is also shown to wrap around 3 sides of the payload
section. FIG. 5 depicts the package 10 of FIG. 4 with the second
segmented PCM panel 13 removed. FIG. 5 illustrates the first
segmented PCM panel 13 wrapping around the payload section along
top, side and bottom portions thereof. FIG. 6 shows the package of
FIG. 5 with both PCM panels 13 removed. One of the insulation
panels 12 is also depicted as removed from the interior of package
10. Insulation panels 12 can include vacuum insulation panels.
While insulation panels 12 in the embodiment of FIG. 1 are
generally rectangular in form, panels 12 can assume a variety of
other shapes and forms in alternative embodiments of the invention.
Six generally identical insulation panels 12 are employed in the
embodiment of package 10 of FIG. 1.
[0039] As described hereinafter, the PCM panels 13 include a
plurality of inserts, such as corrugated material, for lightweight,
structural stability. The inserts are preferably contained within
each PCM segment and provided in direct contact with the phase
change material.
[0040] FIG. 7 illustrates a pair of segmented PCM panels 13. PCM
panels 13 may assume different shapes or forms in alternative
embodiments of the invention. Panels 13 each contain a plurality of
PCM segments 18. In the illustrated embodiments of FIGS. 1-7, a
pair of flexible, segmented PCM panels 13 are employed in package
10 and are defined by three 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 materials 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 13 may be either separated or
provided in fluid communication with each other.
[0041] FIG. 7 illustrates an insert 20 contained within PCM
segments 18. FIG. 8 illustrates a side perspective view of a pair
of PCM-containing segments 18 of a PCM panel 13. FIG. 9 depicts a
cross-sectional view taken through one of the segments 18 of the
PCM panel 13. As shown, a plurality of inserts 20 are contained
within each segment 18. Inserts 20 are described in U.S. Pat. No.
7,328,583, entitled Thermally Stable Containment Device and
Methods, assigned to Entropy Solutions, Inc., and incorporated by
reference herein for all purposes.
[0042] Inserts 20 may be corrugated, porous or fibrous panels which
provide lightweight, structural stability to the panel segments 18.
In one embodiment, inserts 20 are formed of a corrugated paper
material adapted to be saturated by liquid PCM within the segment
18. As shown in FIG. 8, the edges of the panel segments 18 are
generally tapered. This tapering effect results from stacking
progressively smaller inserts 20 as shown in FIG. 9. FIG. 10
illustrates one benefit of the tapered edges whereby an adjacent
pair of panel segments forms a relatively tight corner containing
PCM from both panel segments 18.
[0043] In accordance with an embodiment of the present invention,
the PCM comprises a material which melts and solidifies within a
certain temperature range profile and, in doing so, is capable of
storing or releasing energy. As a result, the PCM can be used to
help maintain or regulate the temperature of materials within the
container (e.g., pharmaceutical products or blood). For example, a
PCM may be designed to change phase (i.e., melt or solidify) in a
temperature range conducive for storing bags of human blood. If for
a particular application, thermal protection at a given temperature
is required and there is no PCM that changes phase at that
temperature, it is possible to mix two or more PCMs and arrive at
the desired phase change temperature of the mixture.
[0044] As shown in FIGS. 9 and 10, each segment 18 contains a
quantity of PCM held between upper and lower films 24, 26. In one
embodiment, segments 18 are defined between film layers 24, 26
brought together during a sealing/filling process. PCM is held
within segments 18 defined by film layers 24, 26. 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.
[0045] FIG. 10 is an exemplary illustration of an embodiment of a
layered structure of corrugated panel inserts 20 used to form a
side of the passive thermal management system of FIG. 1, in
accordance with various aspects of the present invention. The
layered structure comprises multiple corrugated layers. Each
corrugated layer includes flutes, gaps and voids, which are filled
with PCM. FIG. 10 illustrates that a pair of tapered edge
structures of adjacent pairs of segments 18 are brought together
during a wrapping process, with said pair of edge structures
cooperating to define a corner. By so tapering the edges of the
segments 18, a relatively air-tight and energy-efficient corner
structure is provided upon wrapping the segments 18 about a
payload. While the edge structures are illustrated as generally 45
degree tapers, alternative box shapes may utilize edge structures
which are angled differently as compared to that of FIG. 10.
[0046] FIGS. 11 and 12 illustrate another embodiment of the present
invention wherein a segmented flexible PCM-containing panel 13 is
used. Panel 13 is defined by a pair of outer layers, such as
plastic film, which are segmented to contain PCM. Panel 13 includes
a plurality of PCM-containing segments 18 designated A, B, C and D.
Some of the segments 18 may include panel inserts 20. For example,
central segments 18 A, B, C and D may contain a panel insert 20 and
the end segments 18 A.sub.i, B.sub.i, C.sub.i, D.sub.i and/or 18
A.sub.ii, B.sub.ii, C.sub.ii, D.sub.ii would not contain an insert
20. In the illustrated embodiment, panel 13 includes a plurality of
cuts between A.sub.i and B.sub.i, B.sub.i and C.sub.i, C.sub.i and
D.sub.i, A.sub.ii and B.sub.ii, B.sub.ii and C.sub.ii and C.sub.ii
and D.sub.ii to facilitate the folding of the panel into a three
dimensional temperature protection package.
[0047] Another aspect of the embodiment of FIGS. 11 and 12 is the
provision that the segmented PCM panel 13 can be manipulated from a
flat form, as shown in FIG. 11, into a box form 120 as shown in
FIG. 12. In this manner, all six sides of the box 120 are provided
with a PCM segment 18. Ends 122 of the box 120 include overlapping
PCM segments 18. The ends 122 may be secured together to define a
closed box using an adhesive, hook and loop fastener, or other
mechanical or chemical fastening means. The adhesive or fastener
may be provided upon the PCM panel 13 during manufacturing or
placed during assembly into the box form 120.
[0048] A method of using the embodiment of FIGS. 11 and 12 would
include providing a PCM panel 13 in flat form, preconditioning the
PCM panel 13 at a desired temperature, folding the PCM panel 13
into a box form 120, placing a payload within the PCM box 120, and
inserting the PCM box 120 into an outer container 124. During the
folding step, adhesives or other fasteners may be used to seal
sides of the PCM box. Also during the folding step, inserts 20
within one or more of the panel segments 18 promote folding of the
panel 13 along pre-configured linear voids 19.
[0049] In accordance with various embodiments of the present
invention, more than two corrugated layers may be used to form a
layered structure of corrugated panels for use in a thermal
management system. In general, the design of each layer (thickness,
PCM, trigger agent, barrier material, etc.) and the number of such
layers determines the thermal performance of the panel and,
therefore, of the overall resultant container (i.e., thermal
management system). Numerical simulations and/or algorithms may be
used to determine the design of the thermal management system for a
desired thermal performance (i.e., maintaining a desired
temperature range over a desired period of time). The algorithms
may also take into account cost, allowing a designer to balance
cost versus number of PCM layers and insulation layers, for
example.
[0050] 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. In another
embodiment, the phase change material may include thermodynamically
effective quantities of octyl laurate. 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.
[0051] 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 second,
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 can be preconditioned so that phase change
material is in liquid form or solid form. Depending on the
anticipated ambient temperature profile, the most effective
combination of solid and liquid phase change material can be
selected. If additional protection 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.
[0052] 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 for the phase change material and the insulation panels
could vary depending on these factors as well.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] The invention is also 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.
[0057] 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 with suitable insulation such as foam insulation; placing
the payload wrapped with phase change material panels and
insulation into the outer container or envelope; 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.
[0058] 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.
[0059] 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.
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