U.S. patent application number 13/410494 was filed with the patent office on 2013-09-05 for passive thermally regulated knockdown shipping container.
The applicant listed for this patent is William T. Mayer. Invention is credited to William T. Mayer.
Application Number | 20130228583 13/410494 |
Document ID | / |
Family ID | 47826951 |
Filed Date | 2013-09-05 |
United States Patent
Application |
20130228583 |
Kind Code |
A1 |
Mayer; William T. |
September 5, 2013 |
PASSIVE THERMALLY REGULATED KNOCKDOWN SHIPPING CONTAINER
Abstract
A stackable, passive thermally regulated, knockdown shipping
container. The container includes (i) a pair of separate and
independent interchangeable end panels, each carrying a detachable
panel of fragile thermal insulation, and (ii) a plurality of
separate and independent sidewall components each having at least
two hingedly interconnected structural panels which carry a
detachable panel of fragile thermal insulation. The end panels are
each configured and arranged with (a) an external set of
projections operable for stably supporting the container on a
planar surface, and (b) an external set of depressions. The
depressions are configured and arranged such that each projection
on the panel, if inverted, would nest within a corresponding
depression on the panel upon rotation of the inverted set of
projections a defined angular distance about a longitudinal axis of
the container relative to the set of depressions.
Inventors: |
Mayer; William T.; (Stacy,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mayer; William T. |
Stacy |
MN |
US |
|
|
Family ID: |
47826951 |
Appl. No.: |
13/410494 |
Filed: |
March 2, 2012 |
Current U.S.
Class: |
220/592.27 ;
220/4.29; 220/666 |
Current CPC
Class: |
B65D 21/0223 20130101;
B65D 81/3862 20130101; B65D 11/1893 20130101 |
Class at
Publication: |
220/592.27 ;
220/666; 220/4.29 |
International
Class: |
B65D 6/10 20060101
B65D006/10; B65D 6/18 20060101 B65D006/18; B65D 81/38 20060101
B65D081/38 |
Claims
1. A sidewall component suitable for use in construction of a
passive thermally regulated knockdown shipping container,
comprising at least two hingedly interconnected structural panels
each carrying a detachable panel of fragile thermal insulation.
2. The sidewall component of claim 1 wherein the panels of thermal
insulation are precisely aligned on the structural panels such that
the panels of thermal insulation do not contact one another when
the structural panels are disposed in a planar storage
configuration, and abut one another along a length of a border area
thereof when the structural panels are disposed in a
three-dimensional use configuration by pivoting the structural
panels about the interconnecting hinge until further pivotal
movement is inhibited by the structure of the component.
3. The sidewall component of claim 1 wherein the structural panels
are comprised of a plastic material and are interconnected by a
live hinge.
4. The sidewall component of claim 1 wherein the component has two
structural panels.
5. The sidewall component of claim 1 wherein the panels of fragile
thermal insulation are vacuum insulated panels.
6. The sidewall component of claim 1 wherein the panels of fragile
thermal insulation are attached to the structural panels with hook
and loop tape.
7. The sidewall component of claim 1 wherein the panels of fragile
thermal insulation are adhesively attached to the structural
panels.
8. A passive thermally regulated knockdown shipping container,
comprising: (a) a pair of separate and independent interchangeable
end panels, each carrying a detachable panel of fragile thermal
insulation, (b) a plurality of separate and independent sidewall
components in accordance with claim 2, (c) a plurality of primary
connection mechanisms, each operable for affecting border to border
interconnection of a pair of sidewall components pivoted into the
use configuration to form an encircling sidewall assembly, and (d)
a plurality of secondary connection mechanisms, each operable for
attaching one of the end panels to the sidewall assembly over an
open end of the assembly to form an enclosure defining a thermally
regulated payload retention chamber.
9. The thermally regulated shipping container of claim 8 further
including panels of phase change material lining the payload
retention chamber.
10. The thermally regulated shipping container of claim 8 wherein
the structural panels are comprised of a plastic material and are
interconnected by a live hinge.
11. The thermally regulated shipping container of claim 8 wherein
each sidewall component has two structural panels.
12. The thermally regulated shipping container of claim 8 wherein
the panels of fragile thermal insulation are vacuum insulated
panels,
13. The thermally regulated shipping container of claim 8 wherein
the panels of fragile thermal insulation are attached to the
structural panels with hook and loop tape.
14. The thermally regulated shipping container of claim 8 wherein
the panels of fragile thermal insulation are adhesively attached to
the structural panels.
15. An article of commerce, comprising a stackable panel having
longitudinally spaced first and second major surfaces, the panel
configured and arranged with a set of projections extending
longitudinally from the first major surface of the panel operable
for stably supporting the panel on a planar surface and a set of
longitudinally inset depressions in the first major surface
configured and arranged such that each projection on the panel
would nest within a corresponding depression in the panel upon
rotation of an inverted set of projections a defined angular
distance about a longitudinal axis of the panel relative to the set
of depressions.
16. A stackable container defining a longitudinal axis and a
payload retention chamber, and comprising one or more sidewalls
longitudinally separating identically configured and arranged top
and bottom panels, each panel configured and arranged with an
external set of projections operable for stably supporting the
container on a planar surface and an external set of depressions
configured and arranged such that each projection on the panel
would nest within a corresponding depression on the panel upon
rotation of an inverted set of projections a defined angular
distance about the longitudinal axis of the container relative to
the set of depressions.
Description
BACKGROUND
[0001] Thermally labile goods are frequently transported or shipped
in passive thermally regulated shipping containers (i.e., a
thermally insulated container containing a thermally conditioned
phase change material such as ice). While generally effective for
maintaining an object to be shipped at a nominally heated or cooled
temperature, the storage and return transport of empty containers
remains an ongoing issue.
[0002] Efforts to construct foldable or knockdown passive thermally
regulated shipping containers in an effort to minimize the space
occupied by empty containers have meet with limited success as such
containers tend to provide limited thermal regulation, are labor
intensive and/or require trained technicians to assemble and
disassemble.
[0003] Accordingly, a substantial need continues to exist for
knockdown passive thermally regulated shipping container that
provides superior thermal regulation and is quick and easy to
assemble and disassemble without error.
SUMMARY OF THE INVENTION
[0004] A first aspect of the invention is a sidewall component
suitable for use in construction of a passive thermally regulated
knockdown shipping container. The sidewall component includes at
least two hingedly interconnected structural panels, each carrying
a detachable panel of fragile thermal insulation.
[0005] A second aspect of the invention is a passive thermally
regulated knockdown shipping container. The container includes (i)
a pair of separate and independent interchangeable end panels, each
carrying a detachable panel of fragile thermal insulation, (ii) a
plurality of separate and independent sidewall components in
accordance with the first aspect of the invention, (iii) a
plurality of primary connection mechanisms, each operable for
affecting border to border interconnection of a pair of sidewall
components pivoted into a use configuration to form an encircling
sidewall assembly, and (iv) a plurality of secondary connection
mechanisms, each operable for attaching one of the end panels to
the sidewall assembly over an open end of the assembly to form an
enclosure defining a thermally regulated payload retention
chamber.
[0006] A third aspect of the invention is a stackable panel. The
panel is configured and arranged with (i) a set of projections
extending longitudinally from a first major surface of the panel
operable for stably supporting the panel on a planar surface, and
(ii) a set of longitudinally inset depressions in the first major
surface. The depressions are configured and arranged on the panel
such that each projection on the panel, if inverted, would nest
within a corresponding depression in the panel upon rotation of the
inverted set of projections a defined angular distance about a
longitudinal axis of the panel relative to the set of
depressions.
[0007] A fourth aspect of the invention is a stackable container.
The container has one or more sidewalls longitudinally separating
identically configured and arranged top and bottom panels. The top
and bottom panels are each configured and arranged with (i) an
external set of projections operable for stably supporting the
container on a planar surface, and (ii) an external set of
depressions. The depressions are configured and arranged such that
each projection on the panel, if inverted, would nest within a
corresponding depression on the panel upon rotation of the inverted
set of projections a defined angular distance about a longitudinal
axis of the container relative to the set of depressions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an exploded isometric view of one embodiment of
the invention.
[0009] FIG. 2 is an isometric view of the container depicted in
FIG. 1 fully assembled.
[0010] FIG. 2A is a top view of the assembled container depicted in
FIG. 1.
[0011] FIG. 2B is a side view of the assembled container depicted
in FIG. 2A.
[0012] FIG. 3 is an isometric view of one of the sidewall
components depicted in FIG. 1 disposed in a planar storage
position.
[0013] FIG. 4 is a cross-sectional side view of the sidewall
component depicted in FIG. 3 taken along line 4-4.
[0014] FIG. 4A.sub.1 is a grossly enlarged portion of the
cross-sectional side view of the sidewall component depicted in
FIG. 4 for purposes of allowing depiction of one means for
detachably attaching the thermal insulation panel to the structural
sidewall panel.
[0015] FIG. 4A.sub.2 is a grossly enlarged portion of the
cross-sectional side view of the sidewall component depicted in
FIG. 4 for purposes of allowing depiction of another means for
detachably attaching the thermal insulation panel to the structural
sidewall panel.
[0016] FIGS. 5A-D depict various arrangements of variously shaped
projections and depressions on structural end panels of various
cross-sectional shapes that permit stable nestable stacking of
containers employing identical structural end panels as both the
top and bottom of the containers.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Definitions
[0017] As utilized herein, including the claims, the term
"detachable" means capable of being detached without application of
violent force and without damage to or destruction of either the
item being detached or the substrate from which the item is being
detached.
Nomenclature
[0018] 10 Passive Thermally Regulated Shipping Container [0019] 19
Payload Retention Chamber [0020] 20 Outer Structural Shell [0021]
21 Structural End Panel [0022] 21.sub.1 Upper Structural End Panel
[0023] 21.sub.2 Lower Structural End Panel [0024] 21i Interior
Major Surface of Structural End Panel [0025] 21j Exterior Major
Surface of Structural End Panel [0026] 21p Projections Extending
from the Exterior Major Surface of Structural End Panel [0027] 21d
Depressions in the Exterior Major Surface of Structural End Panel
[0028] 22 Structural Sidewall Component [0029] 22i Interior Major
Surface of Structural Sidewall Component [0030] 22j Exterior Major
Surface of Structural Sidewall Component [0031] 23 Sidewall Panel
on Structural Sidewall Component [0032] 23i Interior Major Surface
of Structural Sidewall Panel [0033] 24 Live Hinge Interconnecting
First and Second Structural Sidewall Panels on Structural Sidewall
Component [0034] 30 Thermal Insulation Panel [0035] 30b Border Area
of Thermal Insulation Panel [0036] 40 Phase Change Material Panels
(PCM Panel) [0037] 50 Means for Detachably Attaching Thermal
Insulation Panel to a Structural Panel [0038] 50.sub.1 Hook and
Loop Tape [0039] 50.sub.2 Pressure Sensitive Adhesive [0040] 60
Connection Mechanism for Attaching Structural Sidewall Components
[0041] 70 Connection Mechanism for Attaching Structural End Panel
to Erected Structural Sidewall Assembly [0042] x10 Longitudinal
Axis of Shipping Container [0043] x21 Longitudinal Axis of
Structural End Panel
Construction
[0044] Referring generally to FIG. 1, the present invention is
directed to various components of a modular kit operable for
assembly into a passive thermally regulated stackable shipping
container 10, and a shipping container 10 assembled therefrom.
[0045] When assembled, the shipping container 10 includes an outer
structural shell 20, a layer of thermal insulation 30, and
optionally a layer of phase change material (not shown) retained
within PCM panels 40, defining a passive thermally regulated
payload retention chamber 19.
[0046] The outer structural shell 20 may be solid or hollow and may
be made from any material possessing sufficient structural
integrity, including specifically but not exclusively, cellulosic
materials such as paperboard and cardboard, engineered wood
products such as laminated and unlaminated fiberboard and plywood,
wood, plastics such as polyethylene, polypropylene, polyethylene
terephthalate, nylon polycarbonates and phenolic resins,
wood-plastic composites, metals such as aluminum, copper, brass and
steel, glass, ceramics, combinations thereof, and the like.
[0047] The outer structural shell 20 is divided into separate and
independent structural end panels 21 and at least one structural
sidewall component 22. These units are capable of being repeatedly
attached to and detached from one another.
[0048] Assembly of a shipping container 10 requires two structural
end panels 21--one to cover the top 21.sub.1 and another to cover
the bottom 21.sub.2. The top 21.sub.1 and bottom 21.sub.2
structural end panels are preferably interchangeable with one
another so that only a single style end panel 21 need be
manufactured and stocked. Use of interchangeable top 21.sub.1 and
bottom 21.sub.2 structural end panels also simplifies assembly of
the shipping container 10 as there is no need to obtain and
identify separate top 21.sub.1 and bottom 21.sub.2 structural end
panels. A technician assembling a shipping container 10 need only
obtain two structural end panels 21.
[0049] The exterior major surface 21j of the structural end panels
21 may be contoured with a set of rotationally spaced longitudinal
projections 21p and rotationally displaced "matching" set of
longitudinal depressions 21d whereby (i) the projections 21p
terminate along a single horizontal plane such that the structural
end panel 21 can rest stably upon the projections 21p when placed
upon a flat horizontal surface, and (ii) the projections 21p on
both structural end panels 21, disposed with their exterior major
surfaces 21j facing one another, will nest within corresponding
depressions 21d on the other facing structural end panel 21 when
one of the facing panels 21 is rotated a defined angular distance
about the longitudinal axis x21 of the panel 21. This permits
interchangeable top 21.sub.1 and bottom 21.sub.2 structural end
panels to be used in assembling a shipping container 10 while still
allowing such assembled shipping containers 10 to be stably and
nestably stacked upon one another by simply rotating an overlying
shipping container 10 a defined angular distance about the
longitudinal axis x10 of the shipping container 10 relative to the
immediately underlying shipping container 10.
[0050] Exemplary operable arrangements of variously shaped
projections 21p and depressions 21d on structural end panels 21
having various cross-sectional shapes are depicted in FIGS. 5A-D,
wherein depressions 21d are shaded and projections 21p are
unshaded. Each is described in further detail in TABLE ONE.
TABLE-US-00001 TABLE ONE NECESSARY PROJECTIONS ANGULAR CROSS-
ROTATION SECTIONAL SHAPE OF TO ACHIEVE FIG. # # SHAPE PANEL NESTING
5A 4 Square Rectangle 180.degree. 5B 4 Triangle Square 90.degree.
5C 3 Circle Square 180.degree. 5D 3 Hexagon Hexagon 60.degree.
[0051] Assembly of a shipping container 10 also requires at least
three structural sidewall panels 23.
[0052] Structural sidewall panels 23 are grouped together on
structural sidewall components 22, with the structural sidewall
panels 23 on each structural sidewall component 22 interconnected
by a hinge 24, such as a live hinge.
[0053] The structural sidewall components 22 can be constructed
with any number of hingedly interconnected structural sidewall
panels 23 on each structural sidewall component 22. However, as the
number of panels 23 on each component 22 increases, so too does the
difficulty and complexity of storing and handling the structural
sidewall component 22. A nonexhaustive listing of various geometric
and configurational options for the structural sidewall components
22 and shipping containers 10 constructed therefrom is provided
below in table TWO.
TABLE-US-00002 TABLE TWO SIDEWALL COMPONENT SHIPPING CONTAINER # of
Panels # of Sidewall Cross-Sectional on Each Components Shape 2 2
Square 2 3 Hexagon 2 4 Octagon 2 5 Decagon 3 1 Triangle 3 2 Hexagon
3 3 Nonagon 4 1 Square 4 2 Octagon 5 1 Pentagon 5 2 Decagon
[0054] When the shipping container 10 is constructed from two or
more structural sidewall components 22 the structural sidewall
components 22, as with the end panels 21, are preferably
interchangeable with one another so that only a single style
structural sidewall component 22 need be manufactured and
stocked.
[0055] The structural sidewall panels 23 on each structural
sidewall component 22 are configured and arranged such that the
structural sidewall panels 23 can be pivoted relative to one
another as between a planar storage configuration in which the
structural sidewall panels 23 do not contact one another, and a
three-dimensional use configuration in which the and structural
sidewall panels 23 abut one another along a length of a border area
thereof.
[0056] A panel of thermal insulation 30 is detachably attached to
the interior major surface 21i of each structural end panel 21 and
the interior major surface 23i of each structural sidewall panel 23
on each structural sidewall component 22. The panels of thermal
insulation 30 may be constructed of any material having good
thermal insulating qualities, (i.e., having a high thermal
resistance "R"), such as Styrofoam, vacuum insulated panels, or the
like.
[0057] The panels of thermal insulation 30 are aligned on the
structural sidewall panels 23 so that the panels of thermal
insulation 30 do not contact one another when the structural
sidewall panels 23 are disposed in the planar storage
configuration, but abut one another along a length of a border area
30b thereof when the structural sidewall panels 23 are disposed in
the three-dimensional use configuration.
[0058] In a similar fashion, the panels of thermal insulation 30
are aligned on the structural end panels 21 so that the panels of
thermal insulation 30 on the end panels 21 abut the panels of
thermal insulation 30 attached to the structural sidewall panels 23
along a length of a border area thereof when the structural end
panel 21 is attached to the assembled structural sidewall panels
23.
[0059] Preferred materials for use as the thermal insulating panels
30 tend to be fragile and/or frangible (e.g., panels of Styrofoam
or vacuum insulated panels). This results in all too frequent
damaging of the thermal insulating panels 30 and resultant loss of
insulating value. In order to facilitate replacement of damaged
and/or failing thermal insulating panels 30 without requiring
replacement of an entire structural end panel 21 or structural
sidewall panel 23, the thermal insulating panels 30 are detachably
attached to the structural end panels 21 and structural sidewall
panels 23.
[0060] A wide variety of options are available for detachably
attaching the thermal insulating panels 30 to the interior major
surface 21i of each structural end panel 21 and the interior major
surface 23i of each structural sidewall panel 23. A preferred
option is hook and loop tape 50.sub.1 such as shown in FIG.
4A.sub.1. Another preferred option is double-sided pressure
sensitive adhesive tape 50.sub.2 such as shown in FIG. 4A.sub.2.
Yet another preferred attachment means is a layer of pressure
sensitive adhesive coated directly upon the structural end panel
21, structural sidewall panel 23, and/or thermal insulating panel
30. Mechanical fasteners may also be used, such as elastic straps,
reversible snap fit, reversible press-fit, etc. However, such
mechanical fasteners should generally be avoided as they tend to
prevent direct contact between the thermal insulating panels 30
when the container 10 is fully assembled, leaving a gap in the
layer of thermal insulation through which significant heat loss can
occur.
[0061] Referring to FIG. 1, the payload retention chamber 19 can be
lined with panels of phase change material (PCM panels) 40. The PCM
panels 40 can be filled with any suitable phase change material,
such as water or various hydrocarbons.
[0062] Either of the structural end panels 21 on the shipping
container 10 can be selectively removable from the sidewall
assembly for allowing insertion and removal of goods from the
payload retention chamber 19. PCM panels 40 deployed within the
payload retention chamber 19 may similarly be removed for thermal
conditioning.
[0063] A primary connection mechanism 60 releasably attaches
structural sidewall components 22 to one another. A secondary
connection mechanism 70 releasably attaches structural end panels
21 to the longitudinal ends of a fully assembled sidewall assembly.
Both the primary 60 and secondary 70 connection mechanisms can be
selected from the wide variety of known mechanical type fasteners
capable of repetitive attachment and detachment of components. A
nonexhaustive list of such fasteners includes bolts, buckles,
catches, clamps, clasps, hasps, latches, hook and loop tape, and
the like.
Assembly and Use
[0064] For simplification purposes only, assembly, use and
disassembly of a shipping container 10 in accordance with this
invention shall be based upon the shipping container 10 depicted in
FIGS. 1, 2, 2A and 2B.
[0065] The shipping container 10 depicted in FIGS. 1, 2, 2A and 2B
can be rapidly assembled by (i) obtaining a pair of structural end
panels 21 and a pair of structural sidewall components 22, (ii)
placing one of the structural end panels 21 onto a planar
horizontal surface (not shown) with the interior major surface 21i
of the selected end panel 21 facing upward to establish a bottom
structural end panel 21.sub.2, (iii) placing both structural
sidewall components 22--pivoted into the three-dimensional use
position--into orthogonal fitted engagement with the periphery of
the interior major surface 21i of the bottom structural end panel
21.sub.2 and into orthogonal fitted engagement with one another to
define a payload retention chamber 19, (iv) securing the structural
sidewall components 22 together with the primary connection
mechanisms 60 to form an encircling structural sidewall assembly,
(v) securing the structural sidewall assembly to the bottom
structural end panel 21.sub.2 with the lower sets of secondary
connection mechanisms 70, (vi) placing the other structural end
panel 21 over the open longitudinal end of the structural sidewall
assembly in orthogonal fitted engagement with the structural
sidewall components 22 to establish a top structural end panel
21.sub.1, and (vii) securing the top structural end panel 21.sub.1
to the structural sidewall assembly with the upper sets of
secondary connection mechanisms 70.
[0066] Loading thermally labile goods (not shown) into an assembled
shipping container 10 for transport includes the steps of: (a)
detaching the top structural end panel 21.sub.1 from the structural
sidewall assembly by disengaging the upper sets of secondary
connection mechanisms 70, (b) removing the detached top structural
end panel 21.sub.1 from the structural sidewall assembly for
providing access to the payload retention chamber 19, (c)
optionally lining the payload retention chamber 19 with thermally
conditioned PCM panels 40, (d) placing the payload of thermally
labile goods (not shown) into the lined or unlined payload
retention chamber 19, (e) optionally covering the open top of the
loaded payload retention chamber 19 with a thermally conditioned
PCM panel 40, (f) placing the top structural end panel 21.sub.1
back over the open longitudinal end of the structural sidewall
assembly, and (g) securing the top structural end panel 21.sub.1 to
the structural sidewall assembly with the upper sets of secondary
connection mechanisms 70.
[0067] Unloading thermally labile goods (not shown) from a shipping
container 10 includes the steps of: (A) detaching the top
structural end panel 21.sub.1 from the structural sidewall assembly
by disengaging the upper sets of secondary connection mechanisms
70, (B) removing the detached top structural end panel 21.sub.1
from the structural sidewall assembly, (C) removing any underlying
PCM panel 40 for providing access to the payload retention chamber
19, and (D) removing the payload of thermally labile goods (not
shown) from the payload retention chamber 19.
[0068] Knocking down an unloaded shipping container 10 for return
transport includes the steps of (1) removing any PCM panels 40
still in the payload retention chamber 19, (2) detaching the
structural sidewall components 22 from one another by disengaging
the primary connection mechanisms 60, (3) detaching the structural
sidewall components 22 from the bottom structural end panel
21.sub.2 by disengaging the lower sets of secondary connection
mechanisms 70, and (4) removing the structural sidewall components
22 from the bottom structural end panel 21.sub.2.
* * * * *