Uniform temperature distribution system and tray

Abstract

Apparatus, systems, and methods are provided for uniformly cooling a tray of payload. The tray comprises a body. The body includes an inner wall, a plurality of side panels connected to the inner wall panel, and a plurality of dividers connected to the inner wall panel and one or more of the plurality of side panels. The plurality of partitions may define a plurality of chambers, each chamber of the plurality of chambers being at least partially defined by a partition of the plurality of partitions and / or (ii) an inner wall panel. Each of the plurality of chambers is configured to receive a portion of the coolant inserted into the body. A cover panel is attached to the body.

Description

Cross - Reference to Related Applications

[0001] This application claims priority to U.S. Non - Provisional Patent Application No. 18 / 080,593, filed on December 13, 2022, entitled "UNIFORM TEMPERATURE DISTRIBUTION SYSTEMS AND TRAYS", the entire content of which is incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Technology

[0003] This specification relates to temperature - regulating systems and devices, particularly systems and devices for uniform temperature regulation in modular shipping containers.

[0004] 2. Description of the Related Art

[0005] In the health, medical, pharmaceutical, and / or life sciences industries, it is important to safely store and rapidly transport payloads in a temperature - controlled and watertight environment. A rigid, reusable shipping container that maintains, regulates, or controls the temperature of the payload area is desirable for transporting temperature - sensitive payloads in such industries. The temperature of the payload area can be maintained by using phase - change materials (e.g., dry ice). Typically, trays containing dry ice are placed above, below, and / or to the sides of the payload. However, in such configurations, the temperature inside the payload area may not be uniform. Instead, as the dry ice sublimes and travels downward to the bottom of the payload area (where the payload is placed on the dry ice), the temperature above the payload may be warm while the temperature below the payload may be cold.

[0006] Accordingly, there is a need for systems and devices for providing a uniform temperature distribution inside the payload area and increasing the cooling capacity. SUMMARY OF THE INVENTION

[0007] Generally, one aspect of the subject matter described in this specification is implemented in a tray for uniformly cooling a payload. The tray may have a body. The body may have an inner wall panel, a plurality of side panels connected to the inner wall panel, and a plurality of dividers. The dividers may be connected to the inner wall panel and one or more of the plurality of side panels. The plurality of dividers may define a plurality of chambers, each of the plurality of chambers being at least partially defined by (i) at least one of the plurality of dividers and (ii) the inner wall panel. Each of the plurality of chambers may be configured to receive a portion of a coolant inserted into the body. A cover panel may be attached to the body.

[0008] This embodiment and other embodiments may optionally include the plurality of side panels, which include one or more protrusions. The cover panel may be configured to be attached to the body through one or more protrusions on the side panels. The inner wall panel may include a plurality of holes. Fasteners may be attached to the body to couple the tray to a second tray. The body of the tray may have a trapezoidal shape. The coolant may be dry ice or any other solid coolant, gel coolant, refrigerant, etc.

[0009] The separator may define four or more of the plurality of chambers in the body of the tray. The coolant may be disposed inside each of the plurality of chambers in the body of the tray.

[0010] In another aspect, the subject matter may be implemented by a tray system for uniformly cooling a payload. The tray system may include a plurality of trays. Each of the plurality of trays may include an inner wall panel, a plurality of side panels connected to the inner wall panel, a plurality of separators connected to the inner wall panel and one or more of the plurality of side panels, and a cover panel attached to the plurality of side panels. The separator may define two or more chambers configured to receive coolant inserted into each chamber.

[0011] In this embodiment and various embodiments, the plurality of trays may be configured to enclose the payload from six sides. The cover panel may be attached to the plurality of side panels through one or more protrusions. Each of the plurality of trays may have a trapezoidal shape so that the plurality of panels fit together to form a box. Each of the plurality of trays can be attached to each other by fasteners.

[0012] The plurality of trays may be stacked on top of each other for storage. The tray system may further include a strap configured to wrap around and bundle the plurality of trays.

[0013] In another aspect, the subject matter may be a system for shipping a uniformly cooled payload. The system may include an outer enclosure and an inner enclosure. The outer enclosure may have a cavity. The inner enclosure may be positioned within the cavity of the outer enclosure and include a plurality of trays. The plurality of trays of the inner enclosure define a payload area. The plurality of trays may include a plurality of separators and coolant separated by the separators.

[0014] In this embodiment and in various embodiments, the plurality of trays may further include an inner wall panel connected to a separator, and a plurality of side panels connected to the inner wall panel. The plurality of side panels may be angled such that the plurality of trays are trapezoidal in shape, and each of the plurality of trays is configured to be connected to form a box. The plurality of trays may include a top tray, a plurality of side trays, and a bottom tray opposite the top tray. The plurality of side panels of the top tray may butt against the side panels of each of the plurality of side trays. The plurality of side panels of the bottom tray may butt against the side panels of each of the plurality of side trays. The side panels of the plurality of side trays may butt against each other. The outer enclosure may include a base and a lid, wherein the lid is removable to access the inner enclosure when the inner enclosure is within the cavity of the outer enclosure. Each of the plurality of trays may be attached to each other by fasteners.

[0015] A method is also disclosed. The method may be used to maintain the temperature of a payload area of a shipping container. The method may include inserting a coolant into the plurality of trays, wherein the trays include a separator to disperse the coolant. The method may include attaching a cover panel to each of the plurality of trays. The method may include connecting the plurality of trays to form an inner enclosure that defines a payload area.

[0016] In various embodiments, the method may include receiving a payload by the payload area of the inner enclosure. The method may include cooling the payload area by the coolant to maintain the payload area within a predetermined temperature range. The method may include placing the inner enclosure into a cavity of an outer enclosure, the outer enclosure having a plurality of side panels and a base that define the cavity in the outer enclosure. The method may include attaching a lid over the top of the outer enclosure to cover the cavity of the outer enclosure that contains the inner enclosure. The method may include stabilizing the payload by the plurality of trays of the inner enclosure. The predetermined temperature range may be between about 25 degrees Celsius and about -80 degrees Celsius. The method may include: wherein each of the plurality of trays is configured to be connected to each other by a plurality of side walls. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Upon review of the following drawings and detailed description, other systems, methods, features, and advantages of the present disclosure will be apparent to those of ordinary skill in the art. The components shown in the drawings are not necessarily drawn to scale and may be exaggerated to better illustrate the important features of the present disclosure.

[0018] Figure 1 An example of a tray for uniformly cooling a payload according to one aspect of the present invention is shown.

[0019] Figure 2 An example of a protrusion on a tray according to one aspect of the present invention is shown.

[0020] Figure 3 A view of a tray with an attached cover panel is shown according to one aspect of the present invention.

[0021] Figure 4A An example of a plurality of connected trays is shown according to one aspect of the present invention.

[0022] Figure 4B An example of a plurality of trays connected to form a box is shown according to one aspect of the present invention.

[0023] Figure 5 An example of a shipping container having a plurality of panels or trays is shown according to one aspect of the present invention.

[0024] Figure 6 An example of a stackable tray is shown according to one aspect of the present invention.

[0025] Figure 7 A method for maintaining the temperature of a payload area of a shipping container is shown according to one aspect of the present invention. DETAILED DESCRIPTION

[0026] Uniform temperature distribution systems and trays are disclosed herein. These systems and trays can be included in or used in combination with modular shipping containers that are configured to be temperature regulated with a coolant such as dry ice or another phase change material (PCM). The trays can be disposed around the payload of the shipping container, which is from within a payload area located in a base enclosure of the shipping container. The trays can enclose the payload from all six sides so as to form a box or box-like structure. The trays can each have a shell that is segmented internally. For example, the shell can be divided into chambers or cavities that are disposed one above the other. Each chamber can be filled with a coolant such as dry ice. The internally segmented arrangement of the chambers can prevent the dry ice from sinking to the bottom of the payload once it sublimes. Instead, the dry ice is trapped within the confinement of each chamber and can thus provide a uniform temperature distribution within the shipment and increase the cooling capacity of the shipment.

[0027] Other benefits and advantages include that the trays can be attached to one another or are foldable or stackable. For example, the trays can each have a trapezoidal shape that enables easy connection of the trays. The trays can also be stacked one above the other for storage when not in use.

[0028] In various aspects of the present invention, Figure 1Shown is a tray 100 for uniformly cooling a payload. The tray 100 may include a body 110. In various embodiments, the body 110 may include an inner wall panel 112, a plurality of side panels 114, and a plurality of dividers 116. The plurality of side panels 114 may be connected to the inner wall panel 112. In various embodiments, the inner wall panel 112 may be shaped like a square, and four side panels 114 extend from each side of the inner wall panel 112. In various embodiments, the body 110 may have a trapezoidal shape. For example, the side panels 114 may extend from the inner wall panel 112 at an angle to form a trapezoidal prism shape.

[0029] In various embodiments, the dividers 116 may be connected to the inner wall panel 112. In various embodiments, the dividers 116 may be connected to one or more of the side panels 114. In various embodiments, the dividers 116 may define a plurality of chambers 120.

[0030] In various embodiments, the plurality of chambers 120 may be partially defined by at least one divider 116 and the inner wall panel 112. In various embodiments, each of the plurality of chambers 120 may be configured to receive a coolant. In various embodiments, there may be four or more chambers 120. The chambers 120 may be arranged such that they divide the body 110 into four quadrants. The plurality of chambers 120 may be provided within the body 110 to receive a portion of the coolant.

[0031] In various embodiments, the inner wall panel 112 may include a plurality of holes 130. The plurality of holes 130 may cover a part or all of the inner wall panel 112. The plurality of holes 130 may be arranged to allow the coolant to release cooling gas or vapor from the base of the body 110 through the inner wall panel 112.

[0032] In various embodiments, the tray 100 is configured to receive a coolant. The coolant may be dry ice or dry ice pieces. The coolant may be inserted into each of the plurality of chambers 120. For example, the coolant may be filled into the plurality of chambers 120. The tray 100 may be configured to provide temperature dispersion.

[0033] In various embodiments, the tray 100 may include a cover panel 150. The cover panel 150 may be attached to the body 110. The cover panel 150 may enclose the body 110 when attached to the body 110. For example, the cover panel 150 may close the body 110 to prevent the coolant from being released from the tray 100.

[0034] In various embodiments, the body 110 may include one or more protrusions 140. In various embodiments, the plurality of side panels 114 may include the protrusions 140. The body 110 may also be configured to receive a cover panel 150. In various embodiments, the protrusions 140 may be configured to latch onto or connect to the cover panel 150. The protrusions 140 may hold the cover panel 150 in place. The cover panel 150 may be removed from the body 110 by pressing one or more of the protrusions 140.

[0035] In various embodiments, as Figure 2 shown and continuing to refer to Figure 1 , the protrusions 140 may attach the cover panel 150 to the body 110. The protrusions 140 may have protrusion projections 142. The protrusion projections 142 may attach to the cover panel 150 to hold the cover panel 150 to the body 110.

[0036] In various embodiments, as Figure 3 shown, the tray 300 may include a cover panel 160. In various embodiments, the cover panel 160 may be slidably attached to the tray 100. For example, the tray 100 may slide into a channel portion 302 of the cover panel 160 to attach the tray 100 to the cover panel 160.

[0037] In various embodiments, the cover panel 160 may enclose the body 110 by being slidably connected to the body 110. For example, an edge of the body 110 may slide into the channel 302 to position the body 110 within the channel 302, thereby enclosing the body 110.

[0038] In various embodiments, as Figure 4A and Figure 4B shown, and continuing to refer to Figures 1 to 3 , the tray system 400 may include a plurality of trays 100. In various embodiments, each of the plurality of trays 100 may be assembled together to form a box. In various embodiments, the side panels 114 of each of the plurality of trays 100 may be configured to be assembled together and form a box. In various embodiments, each of the plurality of trays 100 may have a trapezoidal shape such that the plurality of panels are assembled together to form a box. For example, the side panels 114 may extend at a 45-degree angle with respect to the transverse axis of the inner wall panel 112. Thus, the side panels 114 of each tray 100 are complementary to each other to form a box. In various embodiments, the plurality of trays 100 may be configured to enclose a payload from six sides. For example, in various embodiments, the plurality of trays 100 may define a payload area 410. The payload area 410 may be configured to receive a payload. In various embodiments, the trays 100 may be connected to each other by fasteners. The fasteners may be used to couple a tray 100 to a second tray 100.

[0039] In various embodiments, with reference to Figure 4A and Figure 4B , the pallet system 400 can include a plurality of pallets 100, including a top pallet, a plurality of side pallets, and a bottom pallet opposite the top pallet. A plurality of side panels 114 of the top pallet can dock with side panels 114 of each of the plurality of side pallets. A plurality of side panels 114 of the bottom pallet can dock with side panels 114 of each of the plurality of side pallets. The side panels 114 of the plurality of side pallets dock with each other.

[0040] Figure 5 An exploded view of a shipment 500 is shown. The shipment 500 maintains a temperature-controlled environment for the payload within a payload area 512. The shipment 500 can include an outer enclosure 502 and an inner enclosure 504. The outer enclosure 502 can have a cavity 510. The outer enclosure 502 can be trapezoidal. For example, the outer enclosure 502 can be rectangular. In other instances, the outer enclosure 502 can be cubic. The outer enclosure 502 can be a cube that includes a base 514, a removable lid 516, and a plurality of side walls 518. The lid 516 can be removable to access the inner enclosure 504 when the inner enclosure 504 is within the cavity 510 of the outer enclosure 502. Additionally, the outer enclosure 502 can be made of an insulating material, a metallic material, or a non-metallic material, such as made of polycarbonate or other polymers. The outer enclosure 502 can be designed to withstand shock and vibration at low temperatures that occur during transportation and / or storage.

[0041] In various embodiments, the base 514, the lid 516, and / or the plurality of side walls 518 can form or define a cavity 510 that receives the inner enclosure 504 within the cavity 510. The lid 516 can be removable to allow access to the inner enclosure 504. The lid 516 can be coupled to the plurality of side walls 518 via one or more hinges, latches, and / or connectors, and / or the size and formation of the lid can be set to fit and rest on the plurality of side walls 518 to enclose and / or surround the cavity 510. This allows the lid 516 to be removable and / or movable between an open position and a closed position to provide access to the cavity 510 and the contents within the cavity 510.

[0042] The inner enclosure 504 and the payload can be placed within the cavity 510. The lid 516 can be placed over the inner enclosure 504 to prevent access to the inner enclosure 504 and / or the payload within the cavity 510, and to seal or partially seal the payload within the inner enclosure and / or the cavity. Thus, the outer enclosure 502 can protect the inner enclosure 504 and the payload placed within the cavity 510 from shock and / or vibration during storage and transportation.

[0043] In various embodiments, the shipping piece 500 includes an inner enclosure 504. The inner enclosure 504 can be positioned within the cavity 510 of the outer enclosure 502. The inner enclosure 504 can include a plurality of trays 100. The inner enclosure 504 can be configured to provide temperature dispersion. The plurality of trays 100 can be positioned within the cavity 510 along and / or adjacent to the inner surfaces of the base 514, the plurality of sidewalls 518, and / or the lid 516. The plurality of trays 100 can define a payload area 512 that can receive and enclose a payload placed within the payload area 512. In various embodiments, the inner enclosure 504 can include a plurality of trays 100 including a top tray, a plurality of side trays, and a bottom tray opposite the top tray.

[0044] In various embodiments, as Figure 6 shown, the stackable tray system 600 can include a plurality of trays 100. The plurality of trays 100 can be configured to be stacked on top of each other for storage. The stackable tray system 600 can be strapped together with a strap or other device to connect the plurality of trays 100.

[0045] Now referring Figure 7 , a method 700 is provided. The method 700 can be used to maintain the temperature of the payload area of a shipping container. The method 700 can include inserting a coolant into the plurality of trays (block 702). The trays can include dividers to disperse the coolant. The method 700 can include attaching a cover panel to each of the plurality of trays (block 704). The method 700 can include connecting the plurality of trays to form an inner enclosure (block 706). In various cases, the inner enclosure can define a payload area.

[0046] The method 700 can include receiving a payload by the payload area of the inner enclosure (block 708). The method 700 can include cooling the payload area with the coolant to maintain the payload area within a predetermined temperature range (block 710). The method 700 can include placing the inner enclosure into the cavity of the outer enclosure (block 712). In various embodiments, the outer enclosure can have a plurality of side panels and a base that define a cavity in the outer enclosure. The method 700 can include attaching a lid to the top of the outer enclosure (block 714). In various embodiments, attaching the lid to the top of the outer enclosure can cover the cavity of the outer enclosure that contains the inner enclosure. The method 700 can include stabilizing the payload through the plurality of trays of the inner enclosure (block 716).

[0047] In connection with method 700, various aspects and different embodiments can be combined. For example, the predetermined temperature range can be below 0 degrees Celsius. The predetermined temperature range can be below approximately 0 degrees Celsius. The predetermined temperature range can be between 25 degrees Celsius and -80 degrees Celsius. The predetermined temperature range can be between approximately 25 degrees Celsius and approximately -80 degrees Celsius. The predetermined temperature range can be between -150 degrees Celsius and -190 degrees Celsius. The predetermined temperature range can be between approximately -150 degrees Celsius and approximately -190 degrees Celsius. The predetermined temperature range can be below approximately -150 degrees Celsius. The predetermined temperature range can be below -150 degrees Celsius. The inner enclosure can have a plurality of trays that define a payload area. A payload can be inserted into the payload area, where the payload is stabilized by the plurality of trays of the inner enclosure. Each of the plurality of trays is configured to be connected to each other by a plurality of sidewalls.

[0048] Exemplary embodiments of the method / system have been disclosed in an illustrative manner. Accordingly, the terms used throughout should be construed in a non-limiting manner. Although those skilled in the art will make minor modifications to the teachings herein, it should be understood that all such embodiments that reasonably fall within the scope of the advancement of the art contributed hereby are intended to be limited only by the scope of the patent warranted herein, and that scope should not be limited except in view of the appended claims and their equivalents.

Claims

1. A tray for uniformly cooling a payload, the tray comprising: A body, the body comprising: An inner wall panel; A plurality of side panels connected to the inner wall panel; and A plurality of partitions connected to one or more of the inner wall panel and the plurality of side panels, Wherein the plurality of partitions define a plurality of chambers, each of the plurality of chambers being at least partially defined by at least one of the plurality of partitions and the inner wall panel, Wherein each of the plurality of chambers is configured to receive a portion of a coolant inserted into the body, and Wherein the body is configured to be attached to a cover panel to at least partially cover each of the plurality of chambers.

2. The tray according to claim 1, further comprising a cover panel attached to the body.

3. The tray according to claim 2, wherein, The plurality of side panels include one or more protrusions, wherein the cover panel is configured to be attached to the body by the one or more protrusions on the side panels.

4. The tray according to claim 1, wherein, The inner wall panel includes a plurality of holes defined therethrough.

5. The tray according to claim 1, further comprising a fastener attached to the body to couple the tray to a second tray.

6. The tray according to claim 1, wherein, The body of the tray has a trapezoidal shape.

7. The tray according to claim 1, wherein, The coolant is dry ice.

8. The tray according to claim 1, wherein The plurality of partitions define four or more of the plurality of chambers in the body of the tray.

9. The tray according to claim 8, further comprising a coolant disposed inside each of the plurality of chambers of the body of the tray.

10. A tray system for uniformly cooling a payload, the tray system comprising: A plurality of trays, each of the plurality of trays comprising: A body, the body comprising: An inner wall panel; A plurality of side panels connected to the inner wall panel; and A plurality of partitions connected to one or more of the inner wall panel and the plurality of side panels, wherein the plurality of partitions define two or more chambers configured to receive a coolant inserted into each of the chambers.

11. The tray system according to claim 10, wherein, Each of the plurality of trays further comprises a cover panel attached to the plurality of side panels.

12. The pallet system according to claim 10, wherein, The plurality of trays are arranged to enclose the payload from six sides.

13. The tray system according to claim 11, wherein, At least one of the plurality of side panels includes one or more protrusions, wherein the cover panel is configured to be attached to the body by the one or more protrusions on the side panels.

14. The tray system according to claim 10, wherein, Each of the plurality of trays has a trapezoidal shape such that the plurality of trays fit together to form a box.

15. The tray system according to claim 10, wherein, Each of the plurality of trays can be attached to each other by one or more fasteners.

16. The pallet system according to claim 10, wherein, The plurality of trays can be stacked on top of each other for storage.

17. The tray system according to claim 16, further comprising a strap configured to wrap around and bind the plurality of trays.

18. The tray system according to claim 10, wherein, The coolant is dry ice.

19. A system for shipping a uniformly cooled payload, the system comprising: An outer enclosure having a cavity; An inner enclosure positioned within the cavity of the outer enclosure, the inner enclosure including a plurality of trays, Wherein, a plurality of trays of the inner enclosure define a payload area, and wherein, each of the plurality of trays includes a plurality of partitions that define compartments separated by the plurality of partitions to receive coolant.

20. The system according to claim 19, wherein, Each of the plurality of trays further includes: an inner wall panel that is connected to the plurality of partitions; and a plurality of side panels that are connected to the inner wall panel, wherein the plurality of side panels are angled such that the plurality of trays are trapezoidal in shape, and each of the plurality of trays is configured to be connected to form a box.

21. The system according to claim 20, wherein, The plurality of trays further includes: a top tray; a plurality of side trays; and a bottom tray that is opposite the top tray, wherein, a plurality of side panels of the top tray are docked with side panels of each of the plurality of side trays, wherein, a plurality of side panels of the bottom tray are docked with side panels of each of the plurality of side trays, and wherein, side panels of the plurality of side trays are docked with each other.

22. The system according to claim 19, wherein, The outer enclosure includes a base and a lid, wherein the lid is removable to access the inner enclosure when the inner enclosure is within a cavity of the outer enclosure.

23. The system according to claim 19, wherein, Each of the plurality of trays is capable of being attached to each other by fasteners.

24. A method for maintaining the temperature of a payload area of a shipping container, the method comprising: inserting coolant into a plurality of trays, wherein each of the plurality of trays includes partitions to disperse the coolant; attaching a cover panel to each of the plurality of trays; and connecting the plurality of trays to form an inner enclosure, wherein the inner enclosure defines the payload area.

25. The method of claim 24, further comprising: receiving a payload by the payload area of the inner enclosure.

26. The method of claim 25, further comprising: cooling the payload area by the coolant to maintain the payload area within a predetermined temperature range.

27. The method of claim 26, further comprising: placing the inner enclosure into a cavity of an outer enclosure, the outer enclosure having a plurality of side panels and a base that define the cavity in the outer enclosure.

28. The method of claim 27, further comprising: attaching a lid on top of the outer enclosure to cover the cavity of the outer enclosure containing the inner enclosure.

29. The method of claim 28, further comprising: stabilizing the payload by the plurality of trays of the inner enclosure.

30. The method according to claim 26, wherein The predetermined temperature range is between about 25 degrees Celsius and about -80 degrees Celsius.

31. The method according to claim 24, wherein, Each of the plurality of trays is configured to be connected to each other by a plurality of side walls.

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