Composite Container

Abstract

There is disclosed composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container. The thermally insulated inner container is configured to receive one or more phase change material (PCM) elements to define a payload enclosure. The one or more PCM elements are configured to maintain a payload disposed in the payload enclosure initially at -20.degree. C. between 8.degree. C. and -25.degree. C., such as between 2.degree. C. and 8.degree. C. or between -15.degree. C. and -25.degree. C., for a period of at least 48 hours in an ambient temperature of up to 35.degree. C. when tested pursuant to ISTA 7D Test Procedure. The composite container can be used to ship temperature-sensitive payloads such as perishable goods (e.g., a COVID-19 vaccine such as the Moderna COVID-19 vaccine).

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority of Canadian (CA) Patent Application No. 3,111,955, filed on Mar. 12, 2021, which are hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] The present invention relates to reusable composite containers. In particular, the present invention relates to reusable composite containers for cold chain packaging. Other aspects of the invention will become apparent to those of skill in the art upon reviewing the present specification.

Description of the Prior Art

[0003] Cold chain packaging allows temperature control of a payload (e.g., perishable goods) during shipping and distribution of a package. Containers used for cold chain packaging may be composed of a variety of materials including expanded polystyrene (EPS). EPS is thermally insulating and lightweight but easily damaged. Forces exerted upon an EPS container during shipping and handling can result in damage to the container as well as the payload housed inside. Further, when an EPS container harbouring a temperature-sensitive payload is damaged, the container must be opened and the payload transferred to a new container, which subjects the payload to potentially harmful temperature fluctuations. The relative fragility of EPS also leads many package recipients to consider EPS containers as single-use containers, resulting in their mass disposal and waste.

[0004] Senders and recipients of temperature-sensitive goods may desire improved thermal insulation over that provided by EPS alone. This is particularly important for perishable goods where even small temperature variations can impair the activity of the product (e.g., pharmaceuticals) or reduce its shelf-life (e.g., seafood).

[0005] In March 2020, a global pandemic was declared due to the now well-known outbreak of Covid-19. Later in 2020, both Pfizer-BioNTech and Moderna developed vaccines for Covid-19 and these vaccines began to receive regulatory approval by various countries toward the end of 2020.

[0006] These initially approved vaccines must be stored at very cold temperatures (e.g., -80.degree. C.) to maintain their viability and efficacy.

[0007] According to the Province of Ontario Ministry of Health guidelines, the recommended storage temperature of the Pfizer-BioNTech COVID-19 vaccine is -70.degree. C. while the recommended storage temperature of the Modern COVID-19 vaccine is -20.degree. C. (http://www.health.gov.on.ca/en/pro/programs/publichealth/coronavirus/doc- s/vaccine/vaccine_storage_handling_pfizer_moderna_pdf). These guidelines further state that, in the case of the Moderna vaccine, if placed in a portable freezer unit (-25.degree. C. to -15.degree. C.), the vaccines can go back into a freezer unit after they are received at their destination.

[0008] It would be desirable to a container capable of maintaining a payload disposed in the payload enclosure between -15.degree. C. and -25.degree. C. for a period of at least 48 hours in an ambient temperature of up to 35.degree. C. when tested pursuant to ISTA 7D Test Procedure.

SUMMARY OF THE INVENTION

[0009] It is an object of the present invention to obviate or mitigate at least one of the above-mentioned disadvantages of the prior art.

[0010] Accordingly, the present invention relates to a composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at -20.degree. C. between 8.degree. C. and -25.degree. C., such as between 2.degree. C. and 8.degree. C. or between -15.degree. C. and -25.degree. C., for a period of at least 48 hours in an ambient temperature of up to 35.degree. C. when tested pursuant to ISTA 7D Test Procedure.

[0011] As is known in the art, International Safe Transit Association (ISTA) 7D Test Procedure is a development test to evaluate the effects of external temperature exposures of individual packaged-products. The following are some features in overview of the ISTA 7D Test Procedure: [0012] it can be used for the development of temperature controlled transport packages made of any material; [0013] it can be used for individual or comparative performance analysis of standard or insulated transport packages against normally encountered conditions; [0014] it is designed to measure the relative ability of a package to protect a product when exposed to test cycles of temperature conditions; [0015] the product (payload) and package are considered together and not separately; and [0016] it is intended to evaluate the protection afforded packaged-products from shock, vibration and/or compression (see later--re. ISTA 3A Test Procedure). The details of conducting Test Procedure 7A are available from ISTA.

[0017] The composite container may be used to ship perishable goods, and during shipping, the perishable goods may be maintained at a nearly constant temperature below the ambient temperature using cooling means. The container may be shipped by a sending party and received by a receiving party, and the receiving party may return the container to the sending party after receiving the container. The sending party may then reuse the container to ship perishable goods.

[0018] The present composite container is well suited transport a COVID-19 vaccine such as the Moderna vaccine.

[0019] In a preferred embodiment the present composite container further comprises a Radio Frequency Identification (RFID) element (e.g., in the form of a tag, sticker, etc.) allowing the user to identify, authenticate, track, sense and engage with each item relatively seamlessly. Further details on suitable RFID elements can be found at https://rfid.averydennison.com/en/home/explore-rfid/for-brands-and-enterp- rise-customers.html.

[0020] If the RFID element is used with the present composite container, it may be preferably placed on one or two, more preferably, two interior surfaces of the inner container. Alternatively, the RFID element could be placed on one or two, more preferably, two exterior surfaces of the inner container. Alternatively, one RFID element could be placed on an interior surface of the inner container and one RFID element could be placed on an exterior surface of the inner container.

[0021] If the RFID element is used with the present composite container, it may be preferably placed on one or two, more preferably, two interior surfaces of the outer container. Alternatively, the RFID element could be placed on one or two, more preferably, two exterior surfaces of the outer container. Alternatively, one RFID element could be placed on an interior surface of the outer container and one RFID element could be placed on an exterior surface of the outer container.

[0022] If the RFID element is used with the present composite container, it is preferred to use two RFID elements, more preferably one RFID element on the container lid (inner container or outer container) and one RFID element on the container receptacle (inner container or outer container).

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:

[0024] FIG. 1 is a perspective exploded view of a preferred embodiment of the present composite container; and

[0025] FIGS. 2A-2B and 3A-3B illustrate the result of testing preferred versions of the composite container illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] The present invention relates to a composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at -20.degree. C. between 8.degree. C. and -25.degree. C., such as between 2.degree. C. and 8.degree. C. or between -15.degree. C. and -25.degree. C., for a period of at least 48 hours in an ambient temperature of up to 35.degree. C. when tested pursuant to ISTA 7D Test Procedure. Preferred embodiments of the present composite container may include any one or a combination of any two or more of any of the following: [0027] one or both of the thermally insulated inner container and the thermally insulated outer container are made from a foam material; [0028] the foam material is selected from the group consisting of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyethylene (EPE), porous EPP and expanded PS/PE; [0029] the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from a different foam; [0030] the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from EPP; [0031] the foam material has a density of at least about 1.5 pcf; [0032] the foam material has a density of at least about 1.6 pcf; [0033] the foam material has a density of at least about 1.7 pcf; [0034] the foam material has a density of at least about 1.75 pcf; [0035] the inner container is separable from the outer container; [0036] at least one of the inner container and the outer container is integral; [0037] the inner container comprises a an inner container lid element removably coupled to an inner container receptacle element. [0038] the inner container is shaped as a cube or rectangular cuboid; [0039] outer container comprises a an outer container lid element removably coupled to an container receptacle element; [0040] outer container is shaped as a cube or rectangular cuboid; [0041] the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about -25.degree. C.; [0042] the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about -30.degree. C.; [0043] the composite container comprising a plurality of phase change material (PCM) elements combining to define the payload enclosure; [0044] a first phase change material (PCM) element is configured to be in abutting relationship with a second phase change material (PCM); [0045] a first phase change material (PCM) element is configured to be in a detachably coupled relationship with a second phase change material (PCM); and/or [0046] the phase change material (PCM) element comprises a rigid container have disposed therein a gel material.

[0047] The present composite may be used to transport payload disposed in the payload enclosure from a shipping location to a destination location. The payload maybe a perishable product, preferably a pharmaceutical product, preferably a vaccine product such as product such as COVID-19 vaccine product (e.g., the Moderna vaccine described above).

[0048] The present composite container comprises a thermally insulated inner container disposed within a thermally insulated outer container. Preferably, one or both, more preferably both, of the thermally insulated inner container disposed and the thermally insulated outer container are made of foam.

[0049] Some details of preferred embodiments of the present composite container may be found in International Publication Number WO2016/008057A1.

[0050] In a preferred embodiment, the present composite container is configured to comply with ISTA 3A Test Procedure.

[0051] As is known in the art, Test Procedure 3A is a general simulation test for individual packaged-products shipped through a parcel delivery system. The test is appropriate for four different package types commonly distributed as individual packages, either by air or ground. The types include standard, small, flat and elongated packages. Basic Requirements: atmospheric pre-conditioning, random vibration with and without top load, and shock testing. The details of conducting Test Procedure 3A are available from ISTA.

[0052] The phase change material (PCM) element is generally known. A PCM will maintain the temperature of the payload at its stated phase change temperature while undergoing its solid/liquid phase transitions. A PCM will respond to the outside environmental temperature by absorbing or releasing heat as it changes state from solid to liquid and back. The process is reversible and repeatable while always maintaining the same temperature.

[0053] Preferably, the phase change material (PCM) element useful in the present composite container is in the form of a rigid container comprising a cooling gel. In a preferred embodiment, the rigid high-density polyethylene (HDPE) plastic container is sealed to prevent leakage and offers excellent resistance to compression and breakage. Durability also means the product is capable of being cleaned and refrozen for repeated use. It does not change shape when thawed or frozen, helping to prevent contents from shifting.

[0054] A preferred phase change material (PCM) element useful in the present composite container is commercially available from Rapid Aid under the tradename Temp Aid.TM..

[0055] With reference to FIG. 1, there a perspective exploded view of a preferred embodiment of the present composite container. In a first more preferred embodiment, the phase change material (PCM) elements are specified at -20.degree. C. In a first more preferred embodiment, the phase change material (PCM) elements are specified at 5.degree. C.

[0056] The product changes phase at the specified temperature to provide optimal thermal protection. When the adjacent temperature dips below the phase change temperature, the gel will solidify and release its stored energy. If the surrounding temperature goes above the phase change temperature, it will liquefy and absorb the excess energy.

[0057] The a composite container in accordance with the first more preferred embodiment was tested with a simulated payload (a compartmentalized water blanket modified to include three (3) thermocouples to measure the temperature at the top, middle and bottom of the simulated payload), together with a temperature probe in the product itself. This composite container was subjected to the ISTA 7D Test Procedure.

[0058] The results of the ISTA 7D Test Procedure are illustrated in FIG. 2a (ambient conditions) and FIG. 2b (payload temperature). As shown in the combination of FIGS. 2a and 2b, the composite container in accordance with the first more preferred embodiment was able to maintain the temperature of the top, middle and bottom of the payload deposited at -20.degree. C. between -15.degree. C. and -25.degree. C. for least 48 hours when the composite container was placed in ambient conditions ranging from 22.degree. C. to 35.degree. C.

[0059] The a composite container in accordance with the second more preferred embodiment was tested with a simulated payload (a compartmentalized water blanket modified to include three (3) thermocouples to measure the temperature at the top, middle and bottom of the simulated payload), together with a temperature probe in the product itself. This composite container was subjected to the ISTA 7D Test Procedure.

[0060] The results of the ISTA 7D Test Procedure are illustrated in FIG. 3a (ambient conditions) and FIG. 3b (payload temperature). As shown in the combination of FIGS. 3a and 3b, the composite container in accordance with the second more preferred embodiment was able to maintain the temperature of the top, middle and bottom of the payload deposited at 5.degree. C. between 2.degree. C. and 8.degree. C. for least 48 hours when the composite container was placed in ambient conditions ranging from 22.degree. C. to 35.degree. C.

[0061] The a composite container in accordance with the preferred embodiment illustrated in FIG. 1 was tested for ruggedness with a simulated payload (3.5 kg of sand split between two plastic bags). This composite container was subjected to the ISTA 3A Test Procedure. More specifically, the packaged-product was subjected to each of the following:

[0062] Atmospheric Pre-Conditioning 12 hrs Room Condition.

[0063] First Sequence Shock Test. Results: no puncture of package box (including inside the packaging) greater than 9 square inches or 10% of the damaged box surface, no failure of the tape or seal (include inside the packaging) and no any parts escape the package box.

[0064] Random Vibration with Dynamic Load--Over the Road Trailer Simulation. Results: No abnormality was observed externally on the packaged-product and inside containers of EPP and EPS after completion.

[0065] Random Vibration without Load--Pick-up and Delivery Vehicle Simulation. Results: No abnormality was observed externally on the packaged-product and inside containers of EPP and EPS after completion

[0066] Second Sequence Shock Test. Results: no puncture of package box (including inside the packaging) greater than 9 square inches or 10% of the damaged box surface, no failure of the tape or seal (include inside the packaging) and no any parts escape the package box.

[0067] In summary, the composite container in accordance with the preferred embodiment illustrated in FIG. 1 meet the requirements of the ISTA 3A Test Procedure.

[0068] While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.

[0069] All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.

Claims

1. A composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at -20.degree. C. between 8.degree. C. and -25.degree. C., such as between 2.degree. C. and 8.degree. C. or between -15.degree. C. and -25.degree. C., for a period of at least 48 hours in an ambient temperature of up to 35.degree. C. when tested pursuant to ISTA 7D Test Procedure.

2. The container of claim 1, wherein one or both of the thermally insulated inner container and the thermally insulated outer container are made from a foam material.

3. The container of claim 2, wherein the foam material is selected from the group consisting of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyethylene (EPE), porous EPP and expanded PS/PE.

4. The container of claim 2, wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from a different foam.

5. The container of claim 2, wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from EPP.

6. The container of claim 2, wherein the foam material has a density of at least about 1.5 pcf.

7. The container of claim 1, wherein the inner container is separable from the outer container.

8. The container of claim 1, wherein at least one of the inner container and the outer container is integral.

9. The container of claim 1, wherein the inner container comprises an inner container lid element removably coupled to an inner container receptacle element.

10. The container of claim 1, wherein the inner container is shaped as a cube or rectangular cuboid.

11. The container of claim 1, wherein the outer container comprises a an outer container lid element removably coupled to an container receptacle element

12. The container of claim 1, wherein the outer container is shaped as a cube or rectangular cuboid.

13. The container of claim 1, wherein the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about -25.degree. C.

14. The container of claim 1, wherein one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about -30.degree. C.

15. The container of claim 1, comprising a plurality of phase change material (PCM) elements combining to define the payload enclosure.

16. The container of claim 15, wherein a first phase change material (PCM) element is configured to be in abutting relationship with a second phase change material (PCM).

17. The container of claim 15, wherein a first phase change material (PCM) element is configured to be in a detachably coupled relationship with a second phase change material (PCM).

18. The container of claim 1, wherein the phase change material (PCM) element comprises a rigid container have disposed therein a gel material.

19. The container of claim 1, wherein the container is configured to comply with ISTA 3A Test Procedure.

20. The container of claim 1 wherein the container is used to transport payload disposed in the payload enclosure from a shipping location to a destination location.