U.S. patent application number 14/427709 was filed with the patent office on 2015-08-27 for thermal stabilization shipping system and method.
The applicant listed for this patent is HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P.. Invention is credited to John R. Drake, Richard H. Hodge, David A. Moore, Stefan J. Wenner.
Application Number | 20150239639 14/427709 |
Document ID | / |
Family ID | 50627864 |
Filed Date | 2015-08-27 |
United States Patent
Application |
20150239639 |
Kind Code |
A1 |
Wenner; Stefan J. ; et
al. |
August 27, 2015 |
THERMAL STABILIZATION SHIPPING SYSTEM AND METHOD
Abstract
A thermal stabilization shipping system comprises a pallet (30,
130, 330) to underlie a palletized load (22) and a blanket (50, 250
150, 350) dimensioned to drape over a top of the palletized load
(22) and reach down to the pallet (30, 130, 330). The blanket (50,
250 150, 350) has compartments (54, 154, 454) containing a phase
change material (60).
Inventors: |
Wenner; Stefan J.;
(Boeblingen, DE) ; Hodge; Richard H.; (Houston,
TX) ; Moore; David A.; (Houston, TX) ; Drake;
John R.; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P. |
Houston |
TX |
US |
|
|
Family ID: |
50627864 |
Appl. No.: |
14/427709 |
Filed: |
October 31, 2012 |
PCT Filed: |
October 31, 2012 |
PCT NO: |
PCT/US2012/062789 |
371 Date: |
March 12, 2015 |
Current U.S.
Class: |
206/386 |
Current CPC
Class: |
C09K 5/063 20130101;
B65B 11/585 20130101; B65D 81/38 20130101; B65D 81/3816 20130101;
B65D 2519/0086 20130101; B65D 19/38 20130101 |
International
Class: |
B65D 81/38 20060101
B65D081/38; B65D 19/38 20060101 B65D019/38 |
Claims
1. A thermal stabilization shipping system comprising: a pallet
(30, 130, 330) to underlie a palletized load (22); a blanket (50,
250, 150, 350) dimensioned to be draped over a top of the
palletized load (22) and reach down to the pallet (30, 130, 330),
the blanket (50, 250 150, 350) having compartments (54, 154, 454)
containing a first phase change material (60).
2. The system of claim 1 further comprising: a second blanket (50,
150, 350) dimensioned so as to extend across the blanket (50, 250
150, 350) on top of the palletized load (22) and to reach down
along a second opposite side of the palletized load (22) to the
pallet (30, 130, 330), the blanket (50, 250, 150, 350) having
second compartments (54, 154, 454) containing a second phase change
material (60).
3. The system of claim 2, wherein the blanket (50, 150, 350) has a
top portion to overlie a top of the palletized load (22) and
wherein the second compartments (54, 154, 454) of the second
blanket (50, 150, 350) are arranged to overlie the top portion of
the blanket (50, 250 150, 350) when the first blanket (50, 250 150,
350) and the second blanket (50, 250 150, 350) are positioned about
the palletized load (22).
4. The system of claim 1, wherein the blanket (250) comprises: a
central portion (264) overlying the top of the palletized load
(22); and four panels for 266) extending from the central portion
to overlie four different sides of the palletized load (22).
5. The system of claim 1, wherein the pallet (30, 130, 330) has
cavities (136) and wherein the system further comprises a second
phase change material (134) within the cavities.
6. The system of claim 1, wherein the compartments (454) are
arranged to have vertically extending major dimension along sides
of the palletized load (22).
7. The system of claim 6, wherein the blanket (50, 250, 150, 350)
comprises segments, each of the segments including a plurality of
the compartments (54, 154, 454) and separated from an adjacent one
of the segments by a portion omitting a compartment, wherein the
segments have a vertical height corresponding to a vertical height
of an individual container of the palletized load (22).
8. The system of claim 1, wherein the pallet (30, 130, 330)
comprises a foam pallet (30, 130, 330).
9. The system of claim 1 further comprising a first layer (352) of
insulation on a first face of the blanket (50, 250, 150, 350).
10. The system of claim 1 further comprising: at least one first
layer (348) of insulation about the palletized load (22), wherein
the blanket (50, 250 150, 350) is draped over the at least one
first layer (348) of insulation; at least one second layer (role
352, 356) of insulation about the blanket (50, 250, 150, 350); and
a sheet (338) underlying the palletized load (22) and draped
upwardly about edges of the at least one first layer of insulation
(348), the blanket (50, 250 150, 350) and the at least one second
layer of insulation (352, 356).
11. The system of claim 1, wherein the first phase change material
(60) has a phase change temperature tuned based on a temperature
specification of the palletized load (22).
12. The system of claim 1, wherein the first phase change material
(60) has a phase change temperature based on a minimum temperature
specification of the palletized load (22), the phase change
temperature being at least the minimum temperature specification
and less than 5 degrees above the minimum temperature
specification.
13. The system of claim 1, wherein the blanket (50, 250, 150, 350)
has a woven layer (474) on at least one side to protect the blanket
(50, 250 150, 350).
14. A thermal stabilization shipping system comprising: a foam
pallet (130, 330) to underlie a palletized load (22), wherein the
pallet (30, 130, 330) has cavities (136, 336); a phase change
material (60) within the cavities (136, 336).
15. A thermal stabilization shipping method comprising: forming a
palletized load (22) upon a pallet (30, 130, 330); positioning a
blanket (50, 250, 150, 350) over the palletized load (22) upon the
pallet (30, 130, 330), the blanket (50, 250, 150, 350) being
dimensioned to extend over a top of the palletized load (22) and to
drape down to the pallet (30, 130, 330), the blanket (50, 250, 150,
350) having compartments (54, 154, 454) containing a phase change
material (60).
Description
BACKGROUND
[0001] Many products are susceptible to damage due to extreme
temperatures during shipping. Existing shipping methods are
complex, time-consuming to implement and costly. Such existing
shipping methods may not reliably protect the products during
shipping in extreme temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a sectional view of an example thermal
stabilization shipping system.
[0003] FIG. 2 is a plan view of an example of a blanket arrangement
for the thermal stabilization shipping system of FIG. 1.
[0004] FIG. 3 is a plan view of an example blanket for the thermal
stabilization shipping system of FIG. 1.
[0005] FIG. 4 is a sectional view of an example pallet for the
thermal stabilization system of FIG. 1.
[0006] FIG. 5 is a top plan view of the pallet of FIG. 4.
[0007] FIG. 6 is a flow diagram of an example method that may be
carried out by the thermal stabilization system of FIG. 1.
[0008] FIG. 7 is an exploded perspective view of a portion of an
example implementation of the thermal stabilization shipping system
of FIG. 1.
[0009] FIG. 8 is a partially exploded perspective view of a portion
of the thermal stabilization shipping system of FIG. 1.
[0010] FIG. 9 is a partially exploded perspective view of a portion
of the thermal stabilization shipping system of FIG. 1.
[0011] FIG. 10 is a perspective view illustrating the application
of stretch wrap film to the palletized load when forming the
thermal stabilization shipping system of FIG. 7.
[0012] FIG. 11 is a perspective view illustrating the application
of a film top to the palletized load of FIG. 10 wrapped with the
stretch wrap film.
[0013] FIG. 12 is a perspective view illustrating the application
of insulation to the palletized load of FIG. 11.
[0014] FIG. 13 is a perspective view illustrating the securement of
the insulation about the palletized load of FIG. 12.
[0015] FIG. 14 is a perspective view illustrating the application
of blankets to the palletized load of FIG. 13.
[0016] FIG. 15 is a perspective view illustrating the further
securement of the blankets about the palletized load of FIG.
14.
[0017] FIG. 15A is an enlarged fragmentary view of a portion of the
blanketed palletized load of FIG. 15.
[0018] FIG. 16 is a perspective view illustrating the application
of insulation about the blanketed palletized load of FIG. 15.
[0019] FIG. 17 is a perspective view illustrating the application
of insulation and an insulated top panel to the palletized load of
FIG. 16.
[0020] FIG. 18 is a perspective view illustrating application of
insulation about the insulated palletized load of FIG. 17 and about
the insulated top panel.
[0021] FIG. 19 is a fragmentary sectional view illustrating the
palletized load of FIG. 18 in the up turning of a sheet.
[0022] FIG. 20 is a perspective view illustrating the application
of a stretch wrap film about the palletized load of FIG. 20.
[0023] FIG. 21 is a graph comparing temperatures of an example
palletized load with and without the thermal stabilization system
of FIG. 7.
DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS
[0024] FIG. 1 is a sectional view illustrating an example thermal
stabilization shipping system 20. Thermal stabilization shipping
system 20 protects palletized loads during shipping in extreme
temperatures. As will be described hereafter, thermal stabilization
shipping system 20 is relatively inexpensive and easily
implemented.
[0025] Thermal stabilization shipping system 20 is for shipping a
palletized load 22. Palletized load 22 comprises one or more
articles that have been palletized, arranged to rest upon pallet 30
for shipment. In one implementation, palletized load 22 may
comprise a three dimensional array of containers or boxes
containing the articles being shipped. Such articles being shipped
may be susceptible to damage when experiencing extreme
temperatures. For example, such articles may comprise electronic
devices, such as laptop computers, tablet computers, personal data
assistants and the like, which may have displays, such as liquid
crystal displays, that may become damaged if exposed to prolonged
temperatures below -30.degree. C. During shipping, such as during
shipping from China to Europe along the Trans-Siberian Railway, the
palletized load 22 may encounter prolonged periods of cold
temperatures that reach well below -30 degrees Celsius or even down
to -40 degrees Celsius. Thermal stabilization shipping system 20
protects or reduces the likelihood or extent of damage to the
articles of the palletized load 22 during shipping in such cold
temperatures. In other implementations, thermal stabilization
shipping system 20 may utilize other phase change materials (liquid
or solid) and be utilized to protect or reduce the likelihood or
extent of damage to articles of palletized load 22 during shipping
in extreme hot temperatures.
[0026] Thermal stabilization shipping system comprises pallet 30
and blanket 50. Pallet 30 comprises a platform supporting
palletized load 22 and upon which palletized load 22 rests. In one
implementation, pallet 30 has passages or openings to receive
pallet hooks or pallet jacks, allowing pallet 30 and the supported
palletized load 22 to be elevated and moved as a unit. In one
implementation, pallet 30 is formed from an arrangement of beams
and slats of wood or polymeric materials. In another
implementation, pallet 30 is molded from one or more polymeric
materials. In some implementations, pallet 30 may be formed from a
foam material.
[0027] Blanket 50 comprises a generally two-dimensional structure
providing compartments 54. Blanket 50 is sufficiently flexible so
as to bend at least 90 degrees, allowing blanket 50 to drape over
an underlying structure. Blanket 50 is dimensioned so as to extend
over a top of palletized load 22 and reach down along opposite
sides of palletized load 22 to pallet 30. In the example
illustrated, blanket 50 is dimensioned so as to extend across a
juncture of palletized load 22 and pallet 30, partially along sides
of pallet 30. By reaching at least partially alongside the pallet
30, blanket 50 more effectively thermally protects palletized load
22.
[0028] In one implementation, blanket 50 is formed from laminated
plastic sheeting. In one implementation, blanket 50 is formed from
polyethylene sheets sealed together to form compartments 54 and
further form filler tubes (fill passages) and valves. In one
implementation, additional layers of woven material are added to
one side of blanket 50 that is to face palletized load 22,
protecting blanket 50 and compartments 54 from puncturing. In one
implementation, additional layers of woven material are added to an
outer side of blanket 50 that faces away from palletized load 22 to
protect blanket 50 from external damage. In other implementations,
blanket 50 may be formed from other materials and formed in other
manners. In one implementation, blanket 50 may be part of a blanket
arrangement that includes multiple blankets which collectively
surround top and sides of palletized load 22. In another
implementation, blanket 50 may comprise a single blanket that is
configured to surround a top and sides of palletized load 22.
[0029] Compartments 54 form enclosed cells or chambers that contain
phase change material 60. In one implementation, compartments 54
are provided with the phase change material 60 through fill
passages or fill ports which are subsequently closed or sealed
after compartments 54 are filled with the phase change material. In
some implementations, some of compartments 54 may remain unfilled
with phase change material to accommodate shorter stacks of boxes
upon pallet 30. Such unfilled portions of blanket 150 may be used
to seal gaps between corners of the pallet stack to improve
handling and storage. In other implementations, unused unfilled
portions of blanket 150 may be cropped. In other implementations,
both blankets 50 may also also be filled 100%, creating a double
layer of PCM coverage at the top. Although FIG. 1 illustrates
blanket 50 being draped over a single square or rectangular
palletized load 22, in other implementations, blanket 50 may be
provided with other dimensions and may be draped over a block of
multiple adjacent or side-by-side palletized loads 22. For example,
a block may comprise a pair of adjacent rows of palletized load 22
and underlying pallet 30, a 2.times.2 or 3.times.3 collection of
palletized loads 22 and their underlying pallet 30. In other
implementations, the block may comprise other Rangers of individual
pallets 30 and their palletized loads 22.
[0030] Phase change material 60 has a composition such that it
releases heat reductions in external air temperature in response to
extreme cold temperatures. In particular, phase change material 60
undergoes a phase change from a liquid to a solid when the phase
change material is exposed to a temperature at or below the melting
point temperature of the phase change material 60. While undergoing
the phase change, material 60 releases stored heat, known as the
"latent heat of fusion." The heat stored in phase change material
60 is substantially retained until material 60 is exposed to a
temperature at or closely approaching the melting point
temperature. This has the effect of "pausing" the temperature
decline of the phase change material at the melting point
temperature. As a result, the specific melting point temperature of
the phase change material 60 serves as a predetermined trigger
point for the release of heat to protect palletized load 22 in
extremely cold temperatures. Materials encased within a shell of
the phase change material are therefore isolated from the decline
in external temperature until the phase change material has
completely "frozen" into a solid state. This effect can
significantly extend the "survivable exposure time" of the enclosed
materials, by delaying exposure to extreme low temperature
conditions.
[0031] In one implementation, the composition of phase change
material 60 is adjusted or modified so as to specifically tune the
phase change temperature of material 60 (the trigger point at which
the greatest amount of heat is released) based upon a minimum
temperature specification of the articles forming palletized load
22. The minimum temperature specification of the articles is the
minimum environmental temperature for the articles below which the
articles may be susceptible to unacceptable levels of risk of
damage. By tuning the composition of the phase change material
based upon the minimum temperature specification of the articles,
the stored heat within the phase change material is preserved until
the release of such heat is most beneficial. For example, during
shipping, the environmental temperature may greatly fluctuate
day-to-day and daytime to nighttime. Such fluctuations may
undesirably result in the phase change material freezing, resulting
in the stored heat being released and exhausted at inopportune
times such that is no longer available when the palletized load 22
encounters environmental temperatures below the minimum temperature
specification for prolonged periods of time. Because the
composition of material 60 is fine tuned, system 20 protects
palletized load 22 in spite of such fluctuations and at a lower
cost for material 60. This fine tuning can be accomplished by
varying the chemical composition of the phase change material, for
instance by adjusting the percentage of a salt water solution to
achieve the desired melting point.
[0032] In one implementation, the phase change material 60 has a
phase change temperature based on a minimum temperature
specification of the palletized load, wherein the phase change
temperature is at least the minimum temperature specification and
less than 5 degrees above the minimum temperature specification. In
one implementation, phase change material 60 comprises a brine
having a phase change temperature of -17.degree. C. In one example
implementation, system 20 utilizes blanket 50 to uniformly
distribute 160 liters of the -17.degree. C. tuned brine above and
over sides of a palletized load 22 having a length of 1.2 m, a
width of 1 m and a height of 2 m. With such an architecture, system
20 may protect palletized load 22 from temperatures at negative
40.degree. C. for up to five days. In other implementations, phase
change material 60 may be provided with other phase change
temperatures and may be provided about a palletized load in other
surface area concentrations. In other implementations, blanket 50
and phase change material 60 may be combined with other heat
releasing mechanisms and with others structures providing
insulation and/or liquid barrier protection.
[0033] In other implementations, the composition of phase change
material 60 may be altered when system 20 is to protect articles or
products in extremely hot temperatures. In such an alternative
implementation, the phase change material may have a composition so
as to absorb heat rather than release heat at a predefined trigger
temperature. In some implementation's, liquid phase change material
60 may transition from a solid to a liquid when absorbing such
heat.
[0034] FIG. 2 is a top view schematically illustrating blanket
arrangement 100 for surrounding a top and sides of palletized load
22. Blanket arrangement 100 extends over a top of palletized load
22 and reaches down along opposite sides of palletized load 22 to
pallet 30 (shown in FIG. 1). In the example illustrated, blanket
arrangement 100 is dimensioned so as to extend across a juncture of
palletized load 22 and pallet 30, partially along sides of pallet
30 (shown in FIG. 1). Blanket arrangement 100 comprises blanket
150A and blanket 150B (collectively referred to as blankets 150).
As with blanket 50, blankets 150 are formed from polyethylene
sheets sealed together to form compartments 154 and further form
filler tubes and valves. In one implementation, additional layers
of woven material are added to one or both side(s) of blankets 150
load 22, protecting blankets 150 and compartments 154 from
puncturing. In other implementations, blankets 150 may be formed
from other materials and formed in other manners.
[0035] Blankets 150 overlap one another to extend along all four
sides of palletized load 22. Blanket 150A underlies blanket 150B,
extending more closely to palletized load 22 along a top of
palletized load 22. Blanket 150A comprises a rectangular blanket
having a major length and a minor width, wherein the major length
has a first side portion 162, a top portion 164 and a second side
portion 166. Side portions 162 and 166 extend along opposite sides
of palletized load 22 while top portion 164 extends across the top
of palletized load 22. Top portion 164 underlies the corresponding
top portion of blanket 150B. In the example illustrated, side
portions 162 and 166 include compartments 154 containing phase
change material 60 while top portion 164 omits compartments. In
other implementations, top portion 164 may alternatively include
compartments 154, wherein such compartments 154 contain a lesser
amount of phase change material 60 or wherein such compartments 154
are empty and substantially flat. As a result, the compartments and
phase change material of blanket 150B that overlies top portion 164
remain closer to palletized load 22, wherein top portion 164
protects blanket 150A from being punctured along its top side. In
addition, phase change material 60 more uniformly extends about the
top and sides of palletized load 22.
[0036] Blanket 150B comprises a rectangular blanket extending
perpendicular to blanket 150A while overlapping top portion 164 of
blanket 150A. As with blanket 150A, blanket 150B includes side
portion 172 top or central portion 174 and side portion 176. Side
portions 172 and 176 extend along opposite sides of palletized load
22 down to pallet 30 does a partially overlap pallet 30. Top
portion 174 extends over a top of palletized load 22 on top of top
portion 164. Unlike top portion 164, top portion 174, like side
portions 172 174, comprises compartments 154 containing phase
change material 60. As a result, palletized load 20 is uniformly
surrounded by compartments 154 containing phase change material
60.
[0037] In the example illustrated, compartments 154 of side
portions 162 and 166 comprise elongated tubular compartments
extending along major axes that are perpendicular to the
longitudinal major dimension of blanket 150A. Compartments 154 of
portions 172, 174 176 comprise elongated tubular compartments
extending along major axes that are also perpendicular to the
longitudinal major dimension of blanket 150B. As a result, the
elongated tubular compartments 154 of top portion 174 extend along
axes that are perpendicular to the axis along which compartments
154 of side portions 162, 166 extend. When deployed over palletized
load 22, each of compartments 154 extends along a substantially
horizontal axis. As a result, the height of each of side portions
162, 166, 172 and 176 may be easily adjusted to accommodate
different heights of palletized load 22 by simply trimming blankets
150 to remove one or more rows of horizontally extending
compartments 154. In one implementation, one of blankets 150 is
1200 mm wide while the other of blankets 150 is 1000 mm wide with
one blanket covering palletized load 22 in the length direction and
the other blanket covering palletized load 22 in a cross direction.
In other implementations, blankets 150 may have other widths and
other dimensions.
[0038] Although compartments 154 are illustrated as comprising
elongated tubular compartments having horizontal orientations, in
other implementations, such compartments 154 may alternatively have
vertical orientations or diagonal, slanted orientations. In other
implementations, such compartments 154 may have other shapes, such
as spheres, semi-spheres and bubble-wrap film shapes. Although
blanket 150B is illustrated as overlapping blanket 150A, in other
implementations, this relationship may be reversed. In still other
implementations, both of top portions 164 and 174 may include
compartments 154 containing phase change material 60. Although
blankets 150 are illustrated as having compartments 154 having a
single consistent shape and size, in other implementations,
blankets 150 may have different portions with differently sized
and/or differently shaped compartments 154. For example, different
portions of a single blanket may have different sized or different
shaped compartments as compared to one another.
[0039] FIG. 3 is a top view of blanket 250, another example
implementation of blanket 50. Blanket 250 comprises a single
blanket that covers the top and all four sides of palletized load
22. Blanket 250 comprises a central portion 264 and four panels or
side portions 266 which integrally extend as a single unitary body
from center portion 264 so as to overlie four different sides of
palletized load 22. In the example illustrated, compartments 154 in
central portion 264 extend parallel to those compartments 154 in
two of side portions 266 and parallel to those compartments 154 in
the other two side portion 266. In other implementations, the
central portion 264 may have compartments having a distinct size or
shape as compared to those compartments of side portion 266. As
with compartments 154 in blankets 150, compartments 154 in blanket
250 may have other orientations. For example, compartments 154 may
alternatively be oriented so as to extend vertically when hanging
down over the sides of the palletized load 22.
[0040] FIGS. 4 and 5 schematically illustrate pallet 130, an
example implementation of pallet 30. As with pallet 30, pallet 130
is configured to underlie and support palletized load 22 (shown in
FIG. 1) with blanket 50 (or blank arrangement 100 or blanket 250)
overlying the palletized load 22 and extending at least partially
along sides of pallet 130. Pallet 130 provides additional
insulation and heat storage/release capability. Pallet 130
comprises body 132 and phase change material 134. Body 132
comprises a platform upon which palletized load 22 extends. In the
example illustrated, body 132 is formed from foam, such as expanded
polystyrene (EPS) so as to serve as a layer of insulation for the
bottom of the cargo or palletized load 22. In one implementation,
body 132 may include a bottom surface having nine blocks to
facilitate material handling with forklifts and pallet jacks from
all four sides. At the same time, the top side of body 132
facilitates stacking of containers or boxes to form palletized load
22.
[0041] As shown by FIGS. 4 and 5, body 132 includes cavities 136.
Cavities 136 comprise depressions formed into body 132 below the
upper surface of body 132 with support palletized load 22. Cavities
136 each contain phase change material 134. In one implementation,
cavities 136 contain cartridges, liquid bottles, liquid bags or
other liquid containers that contains a phase change material 134.
In yet other implementations, cavities 136 may themselves form
closable compartments that are fillable with phase change material
134 through fill passages integrated into body 132. Although body
132 is illustrated as including four symmetrically located and
spaced cavities 136, in other implementations, body 132 may include
a greater or fewer of such cavities 136.
[0042] Phase change material 134 is similar to phase change
material 60. As with phase change material 60, phase change
material 134 has a composition such that it releases heat upon
reductions in external air temperature. In particular, phase change
material 134 undergoes a phase change from a liquid to a solid when
the phase change material is exposed to a temperature at the phase
change temperature of the phase change material 134. While
undergoing the phase change, material 134 releases stored heat. In
one implementation, the composition of phase change material 134 is
adjusted or modified so as to specifically tune the phase change
temperature of material 134 (the trigger point at which the
greatest amount of heat is released) based upon a minimum
temperature specification of the articles forming palletized load
22. By tuning the composition of the phase change material 134
based upon the minimum temperature specification of the articles,
the stored heat within the phase change material is preserved until
the release of such heat is most beneficial. In one implementation,
the phase change material 134 has a phase change temperature based
on a minimum temperature specification of the palletized load,
wherein the phase change temperature is at least the minimum
temperature specification and less than 5 degrees above the minimum
temperature specification. In one implementation, phase change
material 134 comprises a brine having a phase change temperature of
-17.degree. C. In other implementations, phase change material 134
may be provided with other phase change temperatures. In other
implementations, phase change material 134 may be utilized in
combination with other heat emitting materials or mechanisms
carried within body 132. Although pallet 130 is described as being
used with blanket 50 (or blanket arrangement 100, blanket 250), in
other implementations, pallet 130 may be utilized independent of
such blankets.
[0043] FIG. 6 is a flow diagram illustrating a method 300 for
thermally stabilizing a palletized load during shipping using
system 20 shown in FIG. 1, using the variations shown in FIG. 2-5
or using the other variations described hereafter. As indicated by
step 302, a palletized load 22 is formed upon a pallet 30. As noted
above, pallet 30 may comprise the example pallet 130 shown and
described with respect to FIG. 4. As indicated by step 304, blanket
50 (or blankets 150 or blanket 250) containing phase change
material 60 are positioned about palletized load 22. In particular,
the blanket or blanket arrangement 50, 100, 250 extends and wraps
over a top of palletized load 22 and down along all sides of
palletized load 22 to a point where the blanket or blankets extend
across a juncture of palletized load 22 so as to overlap at least a
portion of sides of pallet 30, 130. With the method 130, a
palletized load 22 resting upon a pallet 30 may be economically,
reliably and easily protected against drops in temperature by
utilizing existing material handling equipment, such as forklifts,
to lift and position the blanket or blanket arrangement 50, 100,
250 over palletized load 22 already upon pallet 30, 130. The
underside of palletized load 22 does not need to be wrapped with a
blanket where the blanket may be more susceptible to puncturing or
damage due to the weight and interaction between palletized load 22
and the pallet 30, 130. Moreover, the thermally protected
palletized load 22 may continue to be handled with the blanket or
blanket arrangement in place. Once a shipment has been completed,
the blanket may be easily removed and reused if desired. In
addition to being cost-effective and easy to implement, method 300
and system 20 may be easily adapted to accommodate different sizes
of pallet 30 and palletized loads 22 in a fast and cost-efficient
manner.
[0044] FIG. 7 is an exploded perspective view illustrating thermal
stabilization shipping system 320, an example implementation of
thermal stabilization shipping system 20. Thermal stabilization
shipping system 320 comprises base pallet 322, slip sheet 324,
pallet 330, bottom sheet 338, bottom tray 340, supplemental heat
supplies 342, corner or edge protectors 343, top tray 344, stretch
wrap film 346 (shown in FIG. 9), film top 347 (shown FIG. 11),
insulation 348, blankets 350A, 350B (shown FIG. 8), insulation 352
(shown in FIG. 16), top panel 354 (shown the FIG. 7) insulation 356
(shown in FIG. 18) and stretch wrap film 358 (shown in FIG.
20).
[0045] Base pallet 322 comprises a pallet to underlie pallet 330
and the palletized load 22 (shown in FIG. 10). The example
illustrated, pallet 322 comprises a slatted pallet for being
engaged by material handling equipment such as forklifts and pallet
jacks. Slip sheet 324 comprises a sheet of material such as
plastic, laminated kraft paperboard or corrugated fiberboard to
facilitate handling of pallet 330 and palletized load 22. Such a
slip sheet 324 may be additionally used below a bottom tray 340
when multiple sub stacks of containers or boxes are being assembled
into a single stack upon pallet 330. In some implementations,
pallet 322 and slip sheet 324 may be omitted. Slip-sheet might be
used where the placement of the load onto the PCM-pallet should
happen at a different time or location as when the products get
palletized, e.g. when you do not want salt-water filled pallets in
the production building of the products. The slip-sheets might also
be used to generate a taller load out of multiple less tall
segments.
[0046] Pallet 330 is similar to pallet 130. Pallet 330 underlies
the palletized load 22 that serves as a platform for moving the
palletized load 22. Pallet 330 comprises body 332 and phase change
material 334. Body 332 is formed from foam, such as expanded
polystyrene (EPS) so as to serve as a layer of insulation for the
bottom of the cargo or palletized load 22. In the example
illustrated, body 332 comprises a bottom surface having a
two-dimensional array or grid of nine blocks 335 to facilitate
material handling with forklifts and pallet jacks from all four
sides. At the same time, the top side of body 332 facilitates
stacking of containers or boxes to form palletized load 22.
[0047] Body 332 includes cavities 336. Cavities 336 comprise
depressions formed into body 332 below the upper surface of body
332 with support palletized load 22. Cavities 336 each contain
phase change material 134. In the example illustrated, cavities 336
contain cartridges, liquid bottles, liquid bags or other liquid
containers 337 that contain phase change material 334. In one
implementation, the containers 337 containing the phase change
material 334 may comprise cut or separated portions or segments of
blanket 350. In other implementations, cavities 336 may themselves
comprise enclosed compartments that are fillable with phase change
material 334 through fill passages integrated into body 332.
Although body 332 is illustrated as including six symmetrically
located in spaced cavities 336, in other implementations, body 332
may include a greater or fewer of such cavities 336.
[0048] Phase change material 334 is similar to phase change
material 60. As with phase change material 60, phase change
material 334 has a composition such that it releases heat upon
reductions in external air temperature. In particular, phase change
material 334 undergoes a phase change from a liquid to a solid when
the phase change material is exposed to a temperature at the phase
change temperature of the phase change material 334. While
undergoing the phase change, material 334 releases stored heat. In
one implementation, the composition of phase change material 334 is
adjusted or modified so as to specifically tune the phase change
temperature of material 334 (the trigger point at which the
greatest amount of heat is released) based upon a minimum
temperature specification of the articles forming palletized load
22. By tuning the composition of the phase change material 334
based upon the minimum temperature specification of the articles,
the stored heat within the phase change material is preserved until
the release of such heat is most beneficial. In one implementation,
the phase change material 334 has a phase change temperature based
on a minimum temperature specification of the palletized load,
wherein the phase change temperature is at least the minimum
temperature specification and less than 5 degrees above the minimum
temperature specification. In one implementation, phase change
material 334 comprises a brine having a phase change temperature of
-17.degree. C. In other implementations, phase change material 334
may be provided with other phase change temperatures. In other
implementations, phase change material 334 may be utilized in
combination with other heat emitting materials or mechanisms
carried within body 332. Although pallet 330 is described as being
used with blankets 350, in other implementations, pallet 330 may be
utilized independent of such blankets.
[0049] Bottom sheet 338 comprises a sheet of liquid impermeable
material extending between a top of pallet 330 and palletized load
22. Bottom sheet 338 provides a liquid barrier to prevent
palletized load 22 from experiencing condensation resulting from
rising water vapor. N. Bottom sheet 338 extends across an entire
upper surface of pallet 330 and drapes down along side of pallet
330. As will be described hereafter with respect to FIGS. 18 and
19, during assembly of system 320, those downward extending
portions of sheet 338 are subsequently secured in an upwardly
extending position to wrap about a lower portion of palletized load
22. As a result, bottom sheet 338 provides a convection barrier,
inhibiting cold air coming from below and in between different
layers of insulation and blankets 350 along a perimeter of the
palletized load. In one implementation, bottom sheet 338 comprises
a sheet of polyethylene having dimensions of 1800.times.1600 mm,
wherein pallet 330 has dimensions of 1200.times.1000 mm. In other
implementations, bottom sheet 338 may be formed from other liquid
impermeable materials and may have other dimensions.
[0050] Bottom tray 340 comprises a tray facing upwardly and located
above sheet 338 and below palletized load 22. Bottom tray 340
cooperates with top tray 344 to facilitate and retain boxes or
containers in a stacked arrangement. In some implementations,
bottom tray 340 may be omitted.
[0051] Supplemental heat supplies 342 (one of which is shown)
comprise units to be arranged as part of the stack of boxes or
containers forming palletized load 22 to fill voids in the
three-dimensional stack of containers such that the stack of
containers forming palletized load 22 has uniform dimensions across
its width and length. In other words, supplies 342 complete the
rectangular or square shape of palletized load 22. Each heat supply
342 comprises box 370, bag 372 and container 374 containing phase
change material 375. Box 370 comprises a cellulose-based box or
container. In the example illustrated, each box 370 has dimensions
corresponding to the boxes containing articles or products being
shipped. In some circumstances, such voids within the rectangular
stack may have dimensions different than that of the boxes
containing articles. In such circumstances, boxes 370 may have
different dimensions corresponding to the different voids in the
rectangular stack. Each box 370 contains bag 372 and container 374
containing phase change material 375.
[0052] Bag 372 comprises a water impermeable bag containing
container 374. Bag 372 provide a secondary layer of protection
should container 374 become punctured to inhibit leakage of the
phase change material 375 to box 370 and to those other boxes
containing the articles or products being shipped. In some
implementations, bag 372 may be omitted. In other implementations,
bag 372 may be omitted, where box 370 has an internal water
impermeable lining or wherein box 370 is itself formed from a water
impermeable material and forms a water impermeable enclosure.
[0053] Container 374 contains a phase change material 375. Phase
change material 374 may be similar to phase change material 334 or
the phase change material contained within blankets 350. In other
implementations, phase change material 375 may have different phase
change temperatures as compared to the phase change temperatures of
phase change materials within container 337 or blankets 350. In one
implementation, container 374 comprises a cut out segment or
portion of an overall sheet from which blankets 350 are provided.
In some implementations, supplemental heat sources 342 may be
omitted.
[0054] Top tray 344 (shown in FIG. 10) comprises a downwardly
facing tray on a top of palletized load 22. As noted above, top
tray 344 cooperates with bottom tray 340 to align and retain the
stack of containers forming palletized load 22 as well as boxes 370
in a rectangular configuration. In some implementations, corner or
edge protectors 343 may additionally be provided. Protectors 343
extend along the corners of the rectangular stack of containers
forming palletized load 22 to protect such corners from impact and
provide alignment.
[0055] Stretch wrap film 346 (shown in FIG. 10) comprises one or
more layers of Stretch wrap film extending about and along sides of
pallet 330 and palletized load 22. Stretch wrap film 346 provides a
water impermeable barrier between palletized load 22 and blankets
350. As a result, upon accidental puncturing of blankets 350, such
liquids may not infiltrate palletized load 22 where such liquid may
damage the products or articles being shipped. Stretch wrap film
346 further stabilizes the palletized load or cargo. As shown by
FIG. 11, in some implementations, film top 347 may be provided over
and above top tray 344. In one implementation, the top 347 provides
a water impermeable barrier above palletized load 22 to further 22
from liquid infiltration should those portions ablaze 350 above
load 22 become punctured. In some implementations, stretch wrap
film 346 and/or film top 347 may be omitted.
[0056] Insulation 348 comprises one or more layers of thermally
insulative material configured to be wrapped about palletized load
22. As shown by FIG. 8, insulation 348 comprises roll stock
insulation which, in some implementations, is wrapped twice about
pallet 330, about palletized load 22, about the stretch wrap film
346 and over a top of palletized load 22. In one implementation,
insulation 348 comprises expanded polyethylene (EPE) roll stock. In
one implementation, installation 34A comprises closed cell
polyethylene foam insulation having a thickness of 5 mm. In other
implementations, insulation 348 may comprise other panels or sheets
of thermally insulative material.
[0057] Blankets 350 form an arrangement of blankets similar to
arrangement 100. Blankets 350A and 350B are similar to blankets
150A and 150B, respectively, except that blankets 350 comprise
compartments 454 in place of compartments 154. FIG. 15A illustrates
compartments 454 in detail. FIG. 15A further illustrates fill
passages 456, fill valves 458 and seals 460. As shown by FIG. 15A,
compartments 454 each comprise an elongate tubular chamber having a
major dimension that extends along a vertical axis. In the example
illustrated, compartments 454 form a row of vertically extending
compartments. Because compartments 454 extend in a vertical
direction (as compared to the horizontal direction of compartments
154, if a compartment 444 is punctured, only liquid above the
puncture leaks. For example, if a puncture forms such as puncture
465, only phase change material 60 above the puncture hole (above
line 466) will leak.
[0058] As shown by FIG. 15, in the example illustrated, each
compartment 454 has a vertical height less than a height of an
individual container or box of the stack of boxes that form
palletized load 22. Each of the compartments 454 are further
arranged in an aligned row also having a height less than the
height of an individual container or box of the stack of boxes that
form palletized load 22. Adjacent rows of compartments 454 are
vertically separated from one another by a horizontally extending
portion 470 that omits or does not contain a compartment. As a
result, each of blankets 350 comprises multiple horizontally
extending, vertically spaced rows of compartments 454, allowing
blanket 350 to be segmented into a plurality of segments without
the edges of such segments extending through the interior of a
compartment 454. Thus, the vertical length or height of blankets
350 along a side of the palletized load may be easily trimmed or
cropped based upon the number of boxes stacked to form palletized
load 22. Alternatively, the compartments 454 of particular segments
may be left empty.
[0059] In the example illustrated in FIG. 15, the palletized load
22 has a height formed from six stacked containers or boxes (shown
in FIG. 10). Likewise, blankets 350 each have a height form from
six segments or six horizontally extending rows of compartments
454. To accommodate an alternative palletized load having a height
of only four stacked containers or boxes, each of blankets 350 may
be modified by easily removing the lowermost two segments are rows
of horizontally extending compartments 454. In other
implementations, compartments 454 may be provided with a vertical
height such that a plurality of consecutive vertical compartments
454, collectively, have a height that is slightly less than the
height of an individual container or box forming the stack of
palletized load 22. In such an implementation, the horizontal
portions 470, extending between the vertically extending
compartments 454 and omitting such compartments 454, will still
align with the horizontal edges of the individual boxes forming the
stack of palletized load 22. In other words, portions 470 align
with the horizontal boundaries between adjacent containers or
boxes. Consequently, blankets 350 may be easily trimmed to
accommodate and substantially match different numbers of boxes or
containers stacked upon one another to form palletized load 22.
Alternatively, those compartments 454 which do not extend adjacent
to a box containing articles being shipped may be left unfilled
with phase change material 60 and may be simply folded and taped or
otherwise secured over adjacent compartments 454 that are filled
with phase change material 60. In other implementations,
compartments 454 may have other heights such that compartments 454
overlapping the boundaries between adjacent containers or boxes of
the stack of palletized load 22.
[0060] As further shown by FIG. 15A, fill passages 456 comprise
passages within, through or along blankets 350 by which phase
change material 60 may be supplied to compartments 454. In the
example illustrated, fill passages 456 extend along an upper end of
each row of compartments 454 to service all of the compartments 454
of the row. In one implementation, fill passages 456 are formed by
the lamination of the sheets forming blanket 350. In other
implementations, separate tubular members may be inserted, attached
are molded into blankets 350.
[0061] Valves 458 are located at a top of each of compartments 454
between the passage 456 and compartment 454. In the example
illustrated, valves 458 comprise one-way valves which open to allow
phase change material 60 to flow into compartments 454 from fill
passages 456 but closed to inhibit reverse flow of phase change
material 60 out of compartments 454 back into fill passage 456.
Because valves 458 are located at the top of each compartment 454,
the leaking of phase change material 60 back into fill passage 456
is reduced even upon failure of valves 458. In other
implementations, other forms of valves may be employed. In still
other implementations, valves 458 may be omitted, such as where
inlet openings of compartments 454 are closed, such as through heat
sealing, after being sufficiently filled with phase change material
60. In still other implementations, valves and fill passages may be
omitted where the phase change material (such as a liquid brine) is
deposited or is used to fill compartments 454 at the formation of
blanket 350 such as when the compartments 454 (formed as bubbles)
are being formed and sealed.
[0062] In example illustrated, once each compartment 454 has been
filled with phase change material 60, seals 460 are further formed.
Seals 460 seal off or close the ends of fill passages 456. As a
result, leakage of liquid remaining in fill passage 456 is further
inhibited. In one implementation, seals 460 comprise a thermal heat
seal, such as a heat seal formed with the heat clamp. In other
implementations, seals 460 may be omitted.
[0063] As further shown by FIG. 15, in one implementation, each of
blankets 350 further comprises a fabric or woven layer 474 on a
face of each of blankets 350 that is to face palletized load 22.
Layer 474 may be wrapped, bonded, welded, fastened or laminated to
the polymeric sheets forming the rest of blankets 350. Layer 474
protects blankets 350 from abrasion, damage and puncturing when
placed against palletized load 22. In other implementations, layer
474 may be omitted.
[0064] Insulation 352 (shown in FIGS. 16 and 17) comprises one or
more layers of insulation formed about blankets 350. In the example
illustrated, insulation 352 comprises two layers of roll stock
insulation wrapped about blankets 350. In the example illustrated,
insulation 352 comprises the same insulation material as insulation
348. Insulation 352 assists in retaining heat about palletized load
22.
[0065] Top panel 354 (shown the FIG. 7) comprises a panel of thick
thermally insulative material. Panel 354 is placed over blankets
350. In one implementation panel 354 comprises expanded
polyethylene (EPE). In other implementations, top panel 354 may
comprise other thermally insulation materials or may be
omitted.
[0066] Insulation 356 (shown in FIG. 18) comprises one or more
layers of insulation material formed about insulation 352 and
further formed over top panel 354. In the example illustrated,
insulation 356 comprises two layers of roll stock insulation. In
the example illustrated, insulation 356 comprises the same
thermally insulating material as insulation 348 and 352. Insulation
356 assists in retaining heat about palletized load 22. In one
implementation, insulation 352 and 356 comprise closed cell
polyethylene foam and provide a total insulation thickness of
approximately 15 mm. Insulation 352 and insulation 356 retard heat
transfer between the good phase change material 60 and the outside
environment. Stretch wrap film 358 (shown in FIG. 20) extends about
insulation 356 to form a final cargo stabilizing water impermeable
barrier about palletized load 22. Stretch wrap film 358 further
provides an airtight seal, inhibiting convective heat transfer to
the cargo.
[0067] FIGS. 10-20 illustrate one example method for forming
thermal stabilization shipping system 320. As shown by FIG. 10,
boxes or containers 341 containing articles to be shipped and
supplemental heat sources 342 are stacked upon bottom tray 342 form
palletized load 22. Palletized load 22 rests upon sheet 338 that
overlies pallet 330 containing containers 337 of phase change
material 334 (shown in FIG. 7). In some implementations, pallet 330
and the above contents are loaded upon slip sheet 324 and pallet
322. In the example shown in FIG. 10, multiple sub stacks of boxes
341, each supported by a tray 340, and supplemental heat sources
342 are stacked upon one another upon pallet 330. Once a stacks are
arranged, edge protectors 343 are secured in place and top tray 344
is placed upon a top of the stack. Once the assembly is completed,
stretch wrap film 346 is wrapped about palletized load 22, along
the side of pallet 330 and around edge protectors 343. As shown by
FIG. 11, once the sides of palletized load 22 have been surrounded
by stretch wrap film 346, film top 347 is placed over the uppermost
top tray 344. The stretch wrap film as well the corners are taped
for integrity.
[0068] As shown by FIGS. 12 and 13, insulation 348 is formed about
the stretch wrapped palletized load 22. In the example illustrated,
insulation 348 comprises two layers of insulation roll stock. In
other implementations, insulation 348 may form a single layer or
greater than two layers of such insulation. In some
implementations, insulation 348 may be omitted. As shown by FIG.
13, insulation 348 is taped and extends completely about sides of
the stretch wrapped palletized load 22.
[0069] As shown by FIGS. 14, 15 and 15A, blankets 350 are overlaid
across and over palletized load 22 outside of insulation 348. Each
of blankets 350 hang in an inverted U-shape over palletized load
22, wherein blankets 350 are sandwiched between insulation 348 and
insulation 352 to release heat and block thermal leakage. In the
example shown in FIG. 14, the underlying blanket 350A includes a
central portion 374 which also includes compartments 454 containing
phase change material 60. As a result, palletized load 22 is
covered by two layers of blanket having phase change material 60.
In other implementations, center portion 374 may omit such
compartments 454 or may include compartments 454 which are empty
and do not contain phase change material 60 (such as shown FIG. 8).
As shown by FIG. 15, blankets 350 are secured by taping 480.
[0070] As shown by FIGS. 16 and 17, insulation 352 is formed or
wrapped about blankets 350 surrounding palletized load 22. In the
example illustrated, insulation 352 comprises two layers of such
insulation. In other implementations, insulation 352 may comprise a
single layer or more than two of such layers. As shown by FIG. 17,
insulation 352 is secured by taping. As further shown by FIG. 17,
insulation panel 354 is subsequently placed on top of blankets 350
and on top of the inwardly folded and taped insulation 352.
[0071] As shown by FIG. 18, insulation 356 is formed about
insulation 352 and over panel 354. Insulation 356 is also secured
by taping. As shown by FIG. 19, each of insulation 348, blankets
350, insulation 354 and insulation 356 extend along outer sides of
palletized load 22 across a junction of palletized load 22 and
pallet 330, and along sides of pallet 330. The ends of insulation
348, blankets 350, insulation 354 and insulation 356 terminate
above the bottom 382 of the top deck of pallet 330. In the example
illustrated, such ends terminate a minimum distance D of, for
example, at least 10 mm above bottom 382 and, for example, no
greater than 100 mm above bottom 382. As a result, reliable thermal
seals formed at the junction of palletized load 22 and pallet 330.
At the same time, the insulation and blankets along the sides of
pallet 330 do not interfere with the use of material handling
equipment such as forklifts and pallet jacks. As further shown by
FIG. 19, sheet 338 is wrapped up across the lower ends of
insulation 348, blankets 350, insulation 354 and insulation 356,
and up alongside of insulation 356 where it is secured by taping
386. As a result, sheet 338 further protects the ends of the
insulation layers and blanket 350 from fraying, abrasion and
damage.
[0072] As shown by FIG. 20, the entire arrangement of FIG. 18 is
surrounded with stretch wrap film 358 to further protect against
moisture. In addition, any leakage from blank 350 is contained
within film 358 so as to not contaminate other adjacent enclosed
palletized loads 22.
[0073] FIG. 21 is a graph illustrating a comparison of temperatures
at a corner and center of a palletized load 22 without insulation
348, 352, 356, 354 and blankets 350 (unprotected) with temperatures
at the corner and at the center of palletized load 22 protected by
the above described system 320 (PCM). As shown by FIG. 21, thermal
stabilization shipping system 320 greatly prolongs the time until
the corner and the center of the palletized load reach the ambient
temperature of -15.degree. C. in the example. As a result,
palletized load 22 may survive those periods during shipping in
which the load 22 is subjected to extremely cold temperatures,
protecting the article being shipped as part of palletized load 22.
As noted above, the composition of the phase change material 60 may
be fine tuned based upon the minimum temperature specifications for
the products being shipped to conserve the energy stored by phase
change material 60 until the environmental temperatures reach or
proximate the minimum temperature specifications when the release
of heat is most beneficial. The phase change material used for the
FIG. 21 data had a melting point of 0.degree. C.
[0074] Although the present disclosure has been described with
reference to example embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the claimed subject matter.
For example, although different example embodiments may have been
described as including one or more features providing one or more
benefits, it is contemplated that the described features may be
interchanged with one another or alternatively be combined with one
another in the described example embodiments or in other
alternative embodiments. Because the technology of the present
disclosure is relatively complex, not all changes in the technology
are foreseeable. The present disclosure described with reference to
the example embodiments and set forth in the following claims is
manifestly intended to be as broad as possible. For example, unless
specifically otherwise noted, the claims reciting a single
particular element also encompass a plurality of such particular
elements.
* * * * *