U.S. patent application number 14/100783 was filed with the patent office on 2017-04-20 for modular temperature controlled shipping container.
The applicant listed for this patent is Kenneth W. Broussard. Invention is credited to Kenneth W. Broussard.
Application Number | 20170108261 14/100783 |
Document ID | / |
Family ID | 58522972 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170108261 |
Kind Code |
A1 |
Broussard; Kenneth W. |
April 20, 2017 |
MODULAR TEMPERATURE CONTROLLED SHIPPING CONTAINER
Abstract
An active temperature controlled modular shipping container may
be in the active mode during flight. The container is also
desirable for use in overland shipping operations as it provides
accurate temperature control superior to known systems during
transportation. The container can maintain a fixed temperature
within 2.degree. C. in ambient temperatures ranging from
-20.degree. C. to 49.degree. C., using an integrated forced-air
convection system for heating and cooling the cargo space of the
container. The preferred embodiment of the container operates on
rechargeable batteries and can maintain the selected temperature
for at least 72 hours without recharging.
Inventors: |
Broussard; Kenneth W.;
(Bridge City, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Broussard; Kenneth W. |
Bridge City |
TX |
US |
|
|
Family ID: |
58522972 |
Appl. No.: |
14/100783 |
Filed: |
December 9, 2013 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25D 11/003 20130101;
F25D 2201/14 20130101; F25D 29/003 20130101; F25D 31/005 20130101;
F25D 2400/361 20130101 |
International
Class: |
F25D 11/00 20060101
F25D011/00; F25D 29/00 20060101 F25D029/00; F25D 16/00 20060101
F25D016/00; F25D 31/00 20060101 F25D031/00; F25D 17/04 20060101
F25D017/04; F25D 23/06 20060101 F25D023/06 |
Claims
1. A temperature controlled container for maintaining cargo in a
controlled temperature environment during shipping, the container
comprising: a. A cargo chamber having insulated side walls, ceiling
wall and floor; b. An insulated door providing access to the cargo
chamber; c. A powered temperature control system mounted in the
container and separate from the cargo chamber; d. Channels in the
walls of the chamber for providing air flow paths for communicating
the cargo chamber with the powered temperature control system.
2. The temperature controlled container of claim 1, further
comprising an evaporation chamber between the temperature
controlled system and the cargo chamber.
3. The temperature controlled container of claim 2, further
comprising an evaporation chamber between the temperature
controlled system and the cargo chamber, wherein the air flow paths
for introducing temperature controlled air into the cargo chamber
flows from the evaporation chamber and the air flow paths for
returning temperature controlled air return the air to the
evaporation chamber.
4. The temperature controlled container of claim 1, the floor
comprising: a. A structural layer; b. An insulating layer in
contact with the structural layer; c. A cargo support floor in
contact with the insulating layer.
5. The temperature controlled container of claim 4, wherein the
cargo support floor includes air flow paths.
6. The temperature controlled container of claim 1, further
comprising a control system for controlling the climate in the
cargo chamber.
7. The temperature controlled container of claim 6, wherein the
control system may be controlled from a remote location.
8. The temperature controlled container of claim 6, further
including location tracking while the container is enroute.
9. The temperature controlled container of claim 8, including GPS
global position monitoring.
10. The temperature controlled container of claim 8, including GSM
global position monitoring.
11. The temperature controlled container of claim 6, wherein the
control system includes data logging and reporting functions.
12. The temperature controlled container of claim 1, wherein the
outer wall of the container comprises a sandwich layered system
having an inner and outer skin and multiple layers of insulation
therebetween.
13. The temperature controlled container of claim 12, the outer
wall further comprising: a. A durable skin layer; b. A vacuum panel
mounted against the skin layer; c. A rigid insulation layer; and d.
A durable skin layer.
14. The temperature controlled container of claim 13, further
including multiple rigid insulation layers.
Description
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The subject invention is generally related to
refrigerated/heated climate control shipping containers and is
specifically directed to self-contained modular refrigerated/heated
shipping containers capable of maintaining closely controlled
temperatures for extended periods of time.
[0003] Discussion of the Prior Art
[0004] There is a compelling public interest in transportation of
biomedical materials and other temperature sensitive materials both
overland and by air. Typically, one of the drawbacks to these types
of shipments is the inability to assure proper climate control
during an extended period of time during transit and warehousing. A
system having the ability to control the climate, particularly
temperature, is essential in order to assure proper maintenance and
viability of the materials.
[0005] Temperature controlled shipping containers are part of a
comprehensive cold chain which controls and documents the
temperature of a product through its entire distribution cycle.
When selecting a temperature controlled shipping container for a
specific cargo, several factors need to be considered: the
sensitivity of the product to temperatures (high and low) and to
time at temperature, the specific distribution system being used,
the expected (and worst case) time and temperatures, regulatory
requirements, and the specific combination of packaging components
and materials being used.
[0006] Typically, a temperature controlled shipping container is an
intermodal container used in freight transport for the
transportation of temperature sensitive cargo. It is
distinguishable from a refrigerated trailer (reefer) in that the
container is self-contained with the cooling source carried in the
container, whereas the reefer has an integral refrigeration unit
for cooling all contents of the trailer and is typically powered by
the diesel generator (or similar power supply) carried by the
truck.
[0007] Historically, temperature controlled containers fall into
two categories, passive and active. An example of a passive
container is the cryogenic cooling system, often referred to as
total loss refrigeration, in which a source of cold air is provided
by an element such as, by way of example, frozen carbon dioxide or
liquid nitrogen. The cryogenically frozen gas slowly evaporates,
and thus cools the container and is vented from it. The container
is cooled for as long as there is frozen gas available in the
system. The temperature is regulated by a thermostatically
controlled electric fan.
[0008] Active refrigerated containers utilize powered cooling
systems. The level of reliability for valuable,
temperature-sensitive, or hazardous cargo typically can only be
achieved using containers with active cooling systems. There are
numerous commercially available battery-powered systems in use
today. However, in most cases the systems do not have the
capability of assuring temperature control over an extended period,
typically up to 72 hours, which is required to permit long distance
shipping, particularly by air transit. This is particularly true
for systems used in air transit.
[0009] To date there are not any active systems meeting FAA
approval unless the power system is shut down during flight.
Specifically, prior art active systems must operate in a passive
mode during flight.
SUMMARY OF THE INVENTION
[0010] The subject invention is directed to an active temperature
controlled modular shipping container that meets FAA standards and
may be in the active mode during flight. The system has a
self-contained power supply which does not interfere with FAA
communication regulations. The container is also desirable for use
in overland shipping operations as it provides accurate temperature
control superior to known systems during transportation, and can be
shipped in a non-temperature controlled cargo space.
[0011] The self-powered, palletized shipping container of the
preferred embodiment utilizes a high-efficiency compression cooling
system when the ambient temperature is warmer than the desired
temperature for the payload and an electric heating element to
maintain temperature when the ambient temperature is below the
desired temperature of the payload. High performance insulation in
the sidewall panels, door and ceiling are of a thin wall
construction, maximizing the cargo space inside the container.
[0012] The container heating and cooling system operates
autonomously on rechargeable batteries which are rechargeable at a
standard 115/230 VAC outlet or a 24 VDC supply.
[0013] The container may include as an option GPS and GSM global
tracking. The temperature history of the container is collected,
monitored and logged, with reporting function. The data may be
downloaded on a standard flash drive, or directly to an off board
computer system. Where desired, internet communication gateways are
provided, permitting wireless communication with the container for
both programming and monitoring the climate control. Smart phones
and tablets and similar PDA's are also supported.
[0014] When connected directly to an external power supply, the
container will run indefinitely, without requiring recharging. In
the event of power loss, the internal, rechargeable system will be
automatically activated.
[0015] The containers are stackable, and are palletized.
[0016] In the preferred embodiment of the invention the container
can maintain a fixed temperature within 2.degree. C. in ambient
temperatures ranging from -20.degree. C. to 49.degree. C., using an
integrated forced-air convection system for heating and cooling the
cargo space of the container. The preferred embodiment of the
container operates on rechargeable batteries and can maintain the
selected temperature for up to 72 hours without recharging.
[0017] The container is defined by a rectangular box having a door
at one end and the cooling system mounted in the opposite end and
accessible from outside the cargo chamber. The cooling system is a
condenser controlled evaporator system powered by rechargeable
batteries. In the preferred embodiment the battery power supply
comprises a number of 12 volt deep-cycle lead-acid batteries
connected to provide 24 volt operating power of not less than 250
ampere-hours total capacity. The temperature sensors are calibrated
to 0.1.degree. C. Heaters consist of waterproof resistance heaters
mounted under the evaporator coil. In the preferred embodiment the
heaters have a total capacity of 150 watts at 24.1 volts and do not
draw more than 8 amps peak current under full battery charge
conditions. Internal fans are provided to assure air circulation in
the cargo chamber.
[0018] The cargo chamber is constructed to minimize heat flux
between the interior of the chamber and the environment. This is
achieved by utilizing a sandwich type, layered side-wall and roof
construction comprising a multi-layer insulation system with
minimum flow paths for transfer. A mechanical tie-through is
achieved without introducing significant heat loss. Vacuum
insulation panels compensate for limited wall thickness and are
stacked or in multiple layers to provide redundancy and minimize
thermal consequences from failure of any single panel.
[0019] The floor, door and back wall insulation structures of the
cargo chamber utilize dedicated heat or cooling paths for creating
mechanical ties between the inner and outer structure without
introducing significant heat loss. They are positioned to surround
the cargo with airflow, assuring that the entire cargo area is of a
common temperature.
[0020] The container floor structure is adapted for permitting use
of a forklift to load and unload cargo directly from the floor of
the container, with the structure forming an integral component of
the external air flow system. This permits stacking of the
containers on all sides without restricting condenser air flow.
[0021] The general air flow design of the cargo chamber
incorporates fan control and thermostat control. Air flow is
primarily distributed from the chamber ceiling and slots provided
in the side walls and door. Return air flow is through the floor.
The back wall of the cargo chamber forms the return air plenum. The
evaporator coil can direct excess condensate to an integral drain
or to an evaporating wick when it is essential to maintain
humidity.
[0022] Precision temperature control is provided by microprocessor
controlled gates and valves. Integral data logging is also
provided. The logging data may be accessed via wireless
connectivity to cell phone, interne and satellite
communication.
[0023] A sealed sump is provided to permit condensation to be
collected during transit and discharged at the destination.
[0024] The temperature control system includes a monitor which can
be read on-sight, or remotely via the Internet. The temperature can
be programmed and adjusted while in transit by using the remote
communications link. Continuous monitoring and logging of the
climate data inside the box, including both temperature and
humidity, is provided and may be downloaded either on-sight or
remotely.
[0025] The box may be reinforced for additional strength where
desired.
[0026] Typically, the box is designed to receive a cargo box which
can slide into and out of the box and is of sufficient dimensions
to sit tightly in the box without additional securing
components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of the preferred embodiment of
the container of the subject invention looking from the door end
toward the back.
[0028] FIGS. 2a, 2b and 2c illustrate various stacking and loading
configurations of the container of FIG. 1.
[0029] FIG. 3 is a cutaway perspective view of the container of
FIG. 1, showing the back chamber with the power supply, condenser
cooling system, heating coils, and moisture collection sump.
[0030] FIG. 4 is a cutaway perspective view showing the structural
features of the inner and outer box of the container.
[0031] FIG. 5 is a side view, with outer skin removed, showing the
structure of the inner and outer box of the container.
[0032] FIG. 6 is a rear view of the container, with the door
removed, showing the heating/cooling/sump and power supply
chamber.
[0033] FIG. 7 is an enlarged fragmentary view showing the
sandwiched insulation configuration.
[0034] FIG. 8 is an illustration of the home screen of the control
panel.
[0035] FIG. 9 is an illustration of the log-in screen.
[0036] FIG. 10 is an illustration of the home/default screen as it
appears after log-in by an authorized user or administrator.
[0037] FIG. 11 is an illustration of the alert and alarm
screen.
[0038] FIG. 12 is an illustration of an example of the
informational screens available.
DETAILED DESCRIPTION
[0039] As shown in FIG. 1, the container 10 of the subject
invention is a box having sidewalls 11 (and an opposite wall 26,
see FIG. 3) a top 12 and a bottom structure 13. The front end 14
includes and access door 16 mounted on hinges 17 and including a
locking and latching system 18. As will be further described herein
the back end 19 of the box includes an accessible chamber housing
the on-board power supply, heating and cooling system and sealed
sump. As shown in FIGS. 1 and 3, the bottom structure 13 includes a
raised floor, mounted on or near the top of the bottom rails 21,
22, 23 and 24. This permits a forklift or similar machine to lift
and move the box by inserting the forks into the rail slots 25
provided in the rails 21-24. Where desired, reinforcing bands 26
may be mounted on the outer structure for increasing the strength
and rigidity of the box.
[0040] FIGS. 2a, 2b and 2c are illustrations of exemplary, but not
exhaustive, configurations for stacking, loading and preparing the
container 10. As shown in FIG. 2a, the containers are stackable,
and may be positioned using a forklift (not shown) and engaging the
loading slots 25 in the bottom rails. 21-24. As shown in FIG. 2b,
the container may be loaded in a typical trailer by using a
forklift (not shown) and engaging the loading slots. Other loading
arrangements may be used as well, such as the end-to-end
configuration of FIG. 2c since the loading slots 25 are on all
sides and ends of the container.
[0041] The basic container structure is illustrated in FIGS. 3-6.
FIG. 3 shows the container 10 is perspective, looking from back to
front, with the outer walls removed and exposing the operating
chamber 30. Integral racks are provided by mounting rails 32 on the
outer skeleton of the container 10. A cooling condenser 32, and
electric heating coils 34 are mounted on the lowest rack, as well
as compressor 35. A sealed sump system 37 is also located on the
lowest rack. The upper two sets of racks provide support for the
rechargeable battery array comprising batteries 36a-n. A number of
batteries have been removed for clarity. In the preferred
embodiment the battery power supply comprises a number of 12 volt
deep-cycle lead-acid batteries connected to provide 24 volt
operating power of not less than 250 ampere-hours total capacity.
The temperature sensors are calibrated to 0.1.degree. C. Heaters
shall consist of waterproof resistance heaters mounted under the
evaporator coil. In the preferred embodiment the heaters have a
total capacity of 150 watts at 24.1 volts and do not draw more than
8 amps peak current under full battery charge conditions.
[0042] In the preferred embodiment of the invention, the container
can maintain a fixed temperature within 2.degree. C. in ambient
temperatures ranging from -20.degree. C. to 49.degree. C., using an
integrated forced-air convection system for heating and cooling the
cargo space of the container. The preferred embodiment of the
container operates on rechargeable batteries and can maintain the
selected temperature for up to 72 hours without recharging.
[0043] As best seen in FIGS. 5 and 6, the container comprises and
inner box forming the cargo chamber 50 an outer box 52 spaced apart
from the inner box. This provides a gap 54 between the inner box
and the outer box, providing for the sandwiched insulation system
between the inner and outer boxes. Air is drawn from the cargo
compartment 50 of the container into the operating chamber 30 using
the floor slats to provide additional air passageway, and into the
condenser/heater plenum 38, The treated air then flows back into
the cargo chamber 50 under pressure via one or more fan blowers 49
(see FIGS. 5-6) which distributes the air around the sidewalls and
ceiling structure of the container. An isolation wall 60 separates
the operating chamber 30 from the boxes 50 and 52. An access door
(not shown) is provided in the back wall 19 of the container to
close the operating chamber 30 and to provide access to the chamber
30 for maintenance.
[0044] The battery power supply may be connected to external power
via a typical charger system 40 mounted in a sidewall of the box.
In the preferred embodiment the rechargeable battery array may be
charged using any external 115/130 VAC or 24 VDC source.
[0045] The sump 37 collects condensate and retains it in a closed
system, to be drained once the container reaches the destination
where it is to be unloaded from the transport.
[0046] A control panel 40 is located in a sidewall of the container
and is connected to a typical electrical/electronic control module
42 for managing and controlling the system to maintain temperature
inside the container at desired ranges.
[0047] A skeletal frame 66 forms the outer box 52. Inwardly of the
frame 66 is a second skeletal frame 68 for forming the inner box,
or cargo chamber 50. The frames are typically constructed of rigid
struts and beams, such as, by way of example, aluminum. The
specific configuration and material is a matter of choice. However,
in the preferred embodiment weight is taken into consideration,
particularly when the containers are to be used for air
transit.
[0048] An enlarged, fragmentary cross-section of the insulation
system in the gap between the inner box 50 and the outer box 52 is
shown in FIG. 7. This is taken at an upper corner at the junction
of top 12 and side wall. Starting at the outside and working in, a
side or edge brace 70 of the sidewall 27 is secured to a top brace
to a bracket 74. In the preferred embodiment the skin 76, such as a
thin walled dibond, is secured to the braces in standard manner and
comprises an outer wall for the container. A VIP (vacuum) panel 78
is mounted in contact with the skin. A first layer of rigid
insulation 80 is then mounted in contact with the VIP panel 78.
Multiple layers of rigid insulation 80 may be employed, as
indicated at 82. An inner skin 84 (usually of the same material as
the outer skin 76) is then mounted against the final layer of rigid
insulation. The skeletal supports 86 for the inner box are then
mounted against the inner skin 84 and the cargo chamber walls are
then formed with a final skin layer 88, also typically of the same
material as the other skin layers. This sandwiched insulation
system provides a high degree of insulation, typically in excess of
R______, in a minimum of space.
[0049] FIGS. 8-12 are examples of the information and control
screens for the control module 40. In the preferred embodiment the
control panel is a touch screen. However, this should be considered
as only an example. For example, a keypad input device could be
used, as well as a remote input device. In additions, the system is
may be controlled by any input device such as a PDA, tablet, smart
phone, remote computer or similar device wirelessly via the
internet. Further, as previously mentioned, GPS and GSM global
positioning is available so the location of the container may be
readily determined.
[0050] The screen of FIG. 8 is the home screen and is visible and
access upon powering up of the system. The control module is for
use at two levels of access. The first level can be accessed by any
user, without password security. This will permit any user to
determine the current conditions of the container, specifically
temperature and or humidity, and battery life, for example. The
unsecure user may also review alarms and will have access to the
signal status.
[0051] The second level of access is for an authorized operator
with password access. This person will log in by pressing the
log-in block on the screen of FIG. 8 and progress to the log-in
screen shown in FIG. 9. The authorized operator can then read the
history, set or reset temperature parameters, turn the system on or
off, as well as specific components and functions such as cooling,
defrosting, and heating.
[0052] As shown in FIG. 10, the authorized operator will be able to
set temperature parameters, monitor the current cargo chamber
temperature, stat and stop the system, turn on and off specific
components and determine the status of the battery power system,
among other functions.
[0053] As shown in FIG. 11, when the alarm summary of the home
screen of FIG. 8 is depressed, the alarm summary screen appears,
giving both access to current alarm status, and history of alarms,
where desired. In the embodiment shown, to levels of alarms are
incorporated in the system. On the right are alarms that will shut
down the system and, therefore, place the cargo in jeopardy. On the
left are operational alarms that indicate system issues which must
be dealt with in order to keep the system running properly. Where
desired the operational alarms may be made available to personnel
not having password clearance. That is, they can determine the
alarm condition, but then may have to contact authorized personnel
to correct.
[0054] The screen of FIG. 12 is an informational screen showing
current status. A log is also maintained of the system from power
up to final power down, showing the temperature log for the entire
operation, as well as other important data, including battery
level, location of the container, time stamps and other desired
information. This is essential when handling cargo that is
temperature sensitive throughout its life.
[0055] The data log may be read on screen, down loaded on a flash
drive or the like, or downloaded via a plug-in hardwire connection
to a laptop, PDA or the like. It may also be transmitted via the
Internet to a remote location, both while in transit and when
docked.
[0056] While certain features and embodiments have been described
in detail herein, it should be understood that the invention
encompasses all modifications and enhancements within the scope and
spirit of the following claims.
* * * * *