Heat-insulating screw-on plate and heat-insulating shipping container that uses these

Abstract

Heat-insulating screw-on plate arrangement (100) with a thickness (100z) in the transverse direction, which has: (a) an integrated arrangement comprising at least: (i) a hermetically sealed solid vacuum insulation plate (110) with transversely spaced first and second main surfaces (1101, 1102), wherein the first main surface (1101) defines a perimeter (110 p ), and (ii) a rigid foam insulating layer (120) superimposed on the first main surface (1101) of the vacuum insulating plate (110), and (b) several mechanical fastening devices (130) which are joined with a transverse projection of the circumference (110 p ) of the vacuum insulation plate (110) are attached to the rigid foam insulation layer (120), each mechanical fastening device (130) being aligned with a transverse bore (129) in the rigid foam insulation layer (120).

Description

background

[0001] Goods such as medical supplies, blood, and vaccines are extremely temperature-sensitive and must be kept within a specific temperature range to prevent deterioration, denaturation, and spoilage. Maintaining thermal control during the transport of such thermally unstable goods presents a particular challenge.

[0002] The shipping of such thermally unstable goods is typically carried out using both actively controlled (i.e., powered) and passively controlled (i.e., without power supply, using thermal state phase-change plates) thermally insulated shipping containers. Vacuum insulated plates (VIPs) are generally the preferred form of thermal insulation in such shipping containers because they provide superior thermal insulation as long as the internal vacuum remains intact. However, once the vacuum is lost, the thermal performance of a VIP is greatly reduced.

[0003] While generally preferred, VIPs present some challenges. First, securing VIPs in place within a thermally insulated shipping container is difficult because the vacuum-sealed nature of VIPs precludes the use of conventional feedthrough fixings. JP2000248653 attempts to overcome this challenge by encapsulating a VIP within rigid foam insulation and mounting the resulting assembly with nails driven only through the foam edges. While effective in allowing VIPs to be mounted with conventional feedthrough fixings, the foam-only edges leave large gaps between the VIPs, reducing the thermal insulation value of the assembly.

[0004] US patent 8,202,599 offers a different solution by providing sealed through-holes in the VIP. While this is effective in facilitating the installation of the VIPs with conventional fastening devices, the design of the through-holes significantly increases both the cost of the VIPs and the likelihood of premature vacuum loss resulting from an imperfect seal in one of the through-holes.

[0005] Another challenge presented by the use of VIPs is their limited mean service life relative to other components of a typical insulated shipping container. This leads to a frequent need to replace worn VIPs and / or refurbish insulated shipping containers with a fresh set of VIPs. Consequently, it is desirable to insulate shipping containers with VIPs in such a way that the VIPs can be easily removed and replaced. Current efforts to facilitate VIP replacement in insulated shipping containers are complex and expensive and / or result in gaps between the VIPs, reducing their thermal insulation value.

[0006] Consequently, there remains a need for a cost-effective VIP arrangement that allows both a complete, undamaged lining of a thermally insulated shipping container with VIPs and quick and easy attachment and removal of the VIPs from the thermally insulated shipping container. Summary of the invention

[0007] A first aspect of the invention relates to a heat-insulating screw-on plate arrangement. The heat-insulating plate arrangement comprises an integrated superimposed arrangement of a hermetically sealed solid vacuum insulation plate and a rigid foam insulation layer with several mechanical fastening devices attached to the rigid foam insulation layer. The vacuum insulation plate has transversely spaced first and second main surfaces, the first main surface defining a perimeter. The rigid foam insulation layer is superimposed on the first main surface of the vacuum insulation plate. The several mechanical fastening devices are attached to the rigid foam insulation layer in a transverse projection of the perimeter of the vacuum insulation plate, each mechanical fastening device being aligned with a transverse bore in the rigid foam insulation layer.

[0008] In a preferred embodiment, the plate further comprises a housing that is constructed and configured to unite the vacuum insulation plate and the rigid foam layer.

[0009] A second aspect of the invention is a thermally insulated shipping container comprising a shell and at least one thermally insulating screw-on plate assembly of the first aspect of the invention. The shell has inner surfaces defining a storage chamber and several openings through it. The at least one thermally insulating screw-on plate assembly is screwed onto an inner surface of the shell via the multiple mechanical fastening devices on the thermally insulating screw-on plate assembly.

[0010] A third aspect of the invention is a method for assembling a thermally insulated shipping container according to the second aspect of the invention. The assembly method comprises the steps (i) obtaining a shell with inner surfaces defining a storage chamber and having multiple openings through it, (ii) obtaining at least one thermally insulating screw-on plate assembly according to the first aspect of the invention, (iii) arranging the at least one thermally insulating screw-on plate assembly against an inner surface of the shell, wherein the exposed main surface of the rigid foam insulation layer faces the inner surface of the shell and at least two of the transverse bores in the rigid foam insulation layer are aligned with a corresponding opening through the shell, and (iv) screwing the thermally insulating screw-on plate assembly to the shell.by rotating matching mechanical fastening devices from outside the storage chamber into a threaded engagement with a mechanical fastening device on the heat-insulating screw-on plate assembly.

[0011] A fourth aspect of the invention is a method for shipping thermally unstable goods using a thermally insulated shipping container according to the second aspect of the invention. The shipping method comprises the steps (i) obtaining a thermally insulated shipping container according to the second aspect of the invention, (ii) arranging a cargo of thermally unstable goods in the storage compartment of the thermally insulated shipping container to form a loaded shipping container, (iii) sealing the storage compartment of the loaded shipping container to form a sealed shipping container, and (iv) preparing the sealed shipping container for transport to another location. Brief description of the drawings Fig. Figure 1 is an isometric view of an embodiment of a heat insulation panel according to the invention. Fig. 2 is a top view of the thermal insulation panel of Fig.1, where a section of the casing has been removed to show an inner layer. Fig. 3 is a side view of the thermal insulation panel of Fig. 2, where a section of the casing has been removed to show the inner layers. Fig. 4 is a view from below of the thermal insulation panel of Fig. 2, where a section of the casing has been removed to show an inner layer. Fig. Figure 5 is an enlarged cross-sectional view of the thermal insulation panel taken along line 5-5. Fig. 1. Fig. Figure 6 is an enlarged cross-sectional side view of an alternative thermal insulation panel according to the invention. Fig. Figure 7 is an isometric view of an embodiment of a heat-insulated shipping container according to the invention. Fig. Figure 8 is a front view of the thermally insulated shipping container from Fig.7, with the flap open to facilitate viewing of the thermally insulated storage compartment and the cargo. Detailed description of a preferred embodiment Definitions

[0012] As used here, including in the claims, the term "solid" means having no gaps, breaks, holes, cracks, discontinuities or interruptions. terminology 100 heat-insulating panel arrangement 100x length of the heat-insulating panel arrangement 100y width of the heat-insulating panel arrangement 100z height (thickness) of the heat-insulating plate arrangement 110 vacuum insulation plate 1101 first main surface of the vacuum insulation plate 1102 second main surface of the vacuum insulation plate 110 p Scope of the vacuum insulation plate 120 rigid foam insulation layer 120 ininner main surface of the rigid foam insulation layer 120 out outer main surface of the rigid foam insulation layer 120 p Extent of the rigid foam insulation layer 129 Drill hole in the rigid foam insulation layer 130 mechanical fastening device attached to the rigid foam insulation 130a Nut attached to the rigid foam insulation 130b screw that is attached to the rigid foam insulation 140 socket 150 cases 200 thermally insulated shipping containers 202 flap 203 Flap lock 209 Cargo storage compartment of the thermally insulated shipping container 210 case 210 in Inner surfaces of the casing 219 openings through the shell 230 suitable mechanical fastening devices 230b Screw that engages in a screwing manner with the nut that is attached to the rigid foam insulation. P Cargo Construction: Heat-insulating screw-on plate arrangement

[0013] Referring to the explanatory drawings and in particular to Fig. 1-6 describes a first aspect of the invention directed to a heat-insulating screw-on plate arrangement 100. In particular, with reference to Fig. 2 - 6 The heat-insulating panel assembly 100 comprises a superimposed arrangement of a hermetically sealed solid vacuum insulation panel 110 and a rigid foam insulation layer 120. Several mechanical fastening devices 130 (e.g. nuts 130a or screws 130b) are attached to the rigid foam insulation layer 120 for use in the removable mounting of the heat-insulating panel assembly 100 to a shipping container, in order to form a lined, heat-insulated shipping container 200.

[0014] In particular with reference to Fig. The heat-insulating plate arrangement 100 has a length of 100 x , a width of 100 y and a height or thickness of 100 z Preferred dimensions of the heat-insulating plate arrangement 100 and each of its component layers, when intended for use in the construction of the heat-insulated shipping containers 200, are set out below in Table 1. Table 1 Length (cm) Width (cm) Height (cm) heat-insulating panel arrangement 100 Generally 10 to 200 10 to 200 1 to 20 Preferred 20 to 100 20 to 100 2 to 10 Preferably 20 to 50 20 to 30 2 to 5 Vacuum insulation panel 110 Generally 10 to 200 10 to 200 1 to 10 Preferred 20 to 100 20 to 100 1 to 5 Preferably 20 to 50 20 to 30 1 to 3 Rigid foam insulation 120 Generally 10 to 200 10 to 200 1 to 10 Preferred 20 to 100 20 to 100 1 to 5 Preferably 20 to 50 20 to 30 1 to 3

[0015] Referring to Fig. 5 and Fig.6. A vacuum insulation panel 110 is a technologically advanced insulating product consisting of a (non-separately numbered) cellular foam core material to which a vacuum is applied, surrounded by a (non-separately numbered) gas-tight thin outer layer. A vacuum insulation panel 110 is a highly effective insulator as long as the integrity of the vacuum is not compromised. Once the vacuum is lost, the panel 110 provides only a modest insulation value and should be replaced. With particular reference to Fig. 3, Fig. 4 and Fig. 5 The vacuum insulation plate 110, which is used in the heat-insulating plate arrangement 100, has transversely spaced first and second main surfaces (1101 and 1102 respectively), wherein the first main surface 1101 has a perimeter 110 p defined.

[0016] In particular with regard to Fig. 1, Fig. 3, Fig. 5 and Fig.6. Taking up, the rigid foam insulating layer 120, which is used in the heat-insulating panel arrangement 100, has transversely spaced inwardly facing and outwardly facing main surfaces (each 120). in and 120 out ), wherein the inward-facing main surface is 120 in a scope of 120 p defined. The rigid foam insulating layer 120 is superimposed on the vacuum insulating panel 110, with the main surface 120 facing inwards. in the rigid foam insulating layer 120 faces the first main surface 1101 of the vacuum insulating plate 110.

[0017] The rigid foam insulation layer 120 can be selected from any suitable heat-insulating foam material with the necessary structural integrity, which includes in particular, but not exclusively, materials such as polystyrene, polyisocyanurate and polyurethane.

[0018] Referring to Fig. 1, Fig. 2, Fig. 5 and Fig. 6 the several mechanical fastening devices 130 (in Fig. 5 as T-nuts with closed ends and in Fig. 6 as screws 130b shown) in the circumferential limit 110 p The mechanical fastening devices 130 are positioned on the vacuum insulation panel 110, but are attached to the rigid foam insulation layer 120 and only pass through it in order not to compromise the sealed integrity of the vacuum insulation panel 110. The mechanical fastening devices 130 can be removed from the inner main surface 120 before the rigid foam insulation layer 120 is placed on the vacuum insulation panel 110. in pressed into the rigid foam insulation layer 120, so that the mechanical fastening device 130, as in Fig. 5 shown, rests against the first main surface 1101 of the vacuum insulation plate 110, or they can be molded into the rigid foam insulation layer 120, so that the mechanical fastening device 130, as shown in Fig.6 shown, may be offset perpendicular to the vacuum insulation plate 110.

[0019] The mechanical fastening devices 130 are positioned in corresponding transverse bores 129 in the rigid foam insulation 120. The heat-insulating panel arrangement 100 should comprise at least three and preferably at least four mechanical fastening devices 130. Additional mechanical fastening devices 130 can be used as needed and to the extent required.

[0020] The mechanical fastening devices 130 are attached to the rigid foam insulation layer 120 to withstand the axial rotation of the mechanical fastening devices 130, which is inherent during the screw engagement of the mechanical fastening devices 130 by a suitable mechanical fastening device 230. Such resistance to axial rotation can be provided by any number of devices, including, but not limited to, square or rectangular T-nuts or carriage bolts with a torque washer.

[0021] If the mechanical fastening devices 130 refer to Fig.If there are 5 nuts 130a, it is generally desirable to insert a protective guide bushing 140 into the bore 129 to prevent suitable screws 230b, which are inserted into the bores 129 and in a screw engagement with the corresponding nut 130a, from damaging the rather fragile rigid foam insulation 120 during assembly and subsequent use.

[0022] If the mechanical fastening devices 130 refer to Fig. If 6 screws 130b are used, it is generally desirable to use round flat head screws to reduce the likelihood of the screw head puncturing the vacuum insulation plate 110.

[0023] The vacuum insulation panel 110 and the rigid foam insulation layer 120 can be joined together by any suitable means to form an integrated assembly 100, provided that the sealed integrity of the vacuum insulation panel 110 is not compromised. Suitable integration methods include, but are not limited to, lamination with adhesive, double-sided adhesive tape positioned between the layers, packing tape wrapped around both layers, shrink wrapping around both layers, etc. Fig. 1 - 6 is a preferred way of joining the vacuum insulation panel 110 and the rigid foam insulation layer 120 in an integrated arrangement 100, a housing 150 which protectively covers all exposed surfaces of the vacuum insulation panel 110 and the circumferential edges of the outer main surface 120 outthe rigid foam insulating layer 120 comprises, without covering the mechanical fastening devices 130 or the bores 129 in the rigid foam insulating layer 120. An effective plastic housing 150 can be constructed from a wide variety of materials, with plastic generally being preferred. A suitable material for use as the housing 150 is polycarbonate. Thermally insulated shipping container

[0024] With reference to the explanatory drawings and in particular Fig. 7 and Fig. 8 is a second aspect of the invention directed to a thermally insulated shipping container 200 which uses a thermally insulated screw-on plate arrangement 100 of the first aspect of the invention. In particular with regard to Fig. 7 and Fig.8. Taking up, the thermally insulated shipping container 200 defines a cargo storage chamber 209 and comprises a structural shell 210 with at least one thermally insulating screw-on plate arrangement 100, which is attached to the inner surface 210. in the shell 210 is mounted to form a thermally insulated cargo storage chamber 209.

[0025] The structural shell 210 can be constructed from any material that possesses the necessary structural integrity, including, but not limited to, corrugated cardboard, wood (including natural and manufactured wood panels), plastics, and metals. The structural shell 210 can form the outer shell of a conventional shipping container, such as those used in... Fig. 7 and Fig. 8 shown, exhibit or can form a framework intended to be used as an inner lining in such an outer shell.

[0026] Referring to Fig.7 Several openings 219 are provided by a shell 210, which are designed and configured to align with the mechanical fastening devices 130 and corresponding bores 129 in the thermally insulating panel assemblies 100, thereby allowing matching mechanical fastening devices 230 to pass through each aligned opening 219 (i.e., a threaded nut (not shown) on a screw 130b extending from the associated thermally insulating panel assembly 100 through an aligned opening 219 in the shell 210, or passing a screw 230b through an aligned opening 219 in the shell 210 and into a threaded engagement with a nut 130a of the associated thermally insulating panel assembly 100) into corresponding mechanical fastening devices 130 on the thermally insulating panel assemblies 100, thereby fastening the thermally insulating panel assemblies 100 to the inner surface 210in the shell 210 is attached and a heat-insulating inner lining is formed.

[0027] Referring to Fig. 8 of the scope 110 p the vacuum insulation plate 110 and the circumference 120 p The shell 210 can be lined with a solid layer of vacuum insulation panels 110 where the rigid foam insulation 120 is adjacent to each heat-insulating panel arrangement 100.

[0028] General reference to Fig. 7 and Fig. 8. Taking up, the thermally insulated shipping container 200 includes an access opening, such as a removable or hinged top, a lid, cover or flap 202 with or without a locking mechanism 203, through which a load P can be inserted into the load storage chamber 209. Assembly process

[0029] A third aspect of the invention is a method for assembling a thermally insulated shipping container 200, which uses the thermally insulating screw-on plate assemblies 100. The assembly method comprises the steps (i) obtaining a shell 210 with internal surfaces 210 in (ii) defining a storage chamber 209 and having multiple openings 219 through it, (iii) having at least one heat-insulating screw-on plate arrangement 100, (iii) arranging the at least one heat-insulating screw-on plate arrangement 100 against an inner surface of the casing 210, wherein the outwardly facing exposed main surface 120 out the rigid foam insulation layer 120 of the inner surface 210 in(iv) facing the shell 210 and at least two and preferably all of the transverse bores 129 in the rigid foam insulating layer 120 are aligned with a corresponding opening 219 through the shell 210, and (iv) screwing the heat-insulating screw-on plate assembly 100 to the shell 210 by turning matching mechanical fastening devices (i.e. a nut (not shown) if the mechanical fastening device 130 on the heat-insulating plate assembly 100 is a screw 130b, or a screw 230b if the mechanical fastening device on the heat-insulating plate assembly 100 is a nut 130a) from outside the storage chamber 209 into a threaded engagement with a mechanical fastening device 130 on the heat-insulating screw-on plate assembly 100.Steps (iii) and (iv) are preferably repeated until the entire inner surface of the shell 210 is lined with heat-insulating plate arrangements 100. Shipping procedure

[0030] A fourth aspect of the invention is a method for shipping thermally unstable goods P using a thermally insulated shipping container 200 according to the second aspect of the invention. The shipping method comprises the steps (i) obtaining a thermally insulated shipping container 200, (ii) arranging a cargo of thermally unstable goods P in the storage compartment 209 of the thermally insulated shipping container 209 to form a loaded shipping container 200, (iii) sealing the storage compartment 209 of the loaded shipping container 200 to form a sealed shipping container 200, and (iv) preparing the sealed shipping container 200 for transport to another location, typically via a courier delivery service such as USPS, UPS, FedEx, etc.

Claims

[1] Heat-insulating screw-on plate arrangement (100) with a thickness (100z) in the transverse direction, which has: (a) an integrated arrangement comprising at least: (i) a hermetically sealed solid vacuum insulation plate (110) with transversely spaced first and second main surfaces (1101, 1102), wherein the first main surface (1101) defines a perimeter (110 p ), and (ii) a rigid foam insulating layer (120) superimposed on the first main surface (1101) of the vacuum insulating plate (110), and (b) several mechanical fastening devices (130) which are joined with a transverse projection of the circumference (110 p ) of the vacuum insulation plate (110) are attached to the rigid foam insulation layer (120), each mechanical fastening device (130) being aligned with a transverse bore (129) in the rigid foam insulation layer (120). [2] Heat-insulating screw-on plate arrangement according to claim 1, wherein the plate further comprises at least one housing (150) which is constructed and configured to unite the vacuum insulation plate (110) and the rigid foam layer (120). [3] Heat-insulating screw-on plate arrangement according to claim 1, wherein the heat-insulating plate has a thickness (100z) between 2 and 10 cm. [4] Heat-insulating screw-on plate arrangement according to claim 1, wherein the heat-insulating plate has a length (100x) between 20 and 200 cm and a width (100y) between 20 and 200 cm. [5] Heat-insulating screw-on plate arrangement according to claim 1, wherein (i) the rigid foam insulating layer (120) has transversely spaced inwardly and outwardly facing main surfaces (120 in 120 out ) has, (ii) the inward-facing main surface (120 in ) defines a perimeter (120p), and (iii) the perimeter (120 1p ) of the rigid foam insulation to the perimeter (110p ) adjacent to the vacuum insulation plate (110). [6] Heat-insulating screw-on plate arrangement according to claim 1, comprising at least three mechanical fastening devices (130) which are attached to the rigid foam insulating layer (120). [7] Heat-insulating screw-on plate arrangement according to claim 1, comprising at least four uniformly distributed mechanical fastening devices (130) which are attached to the rigid foam insulating layer (120). [8] Heat-insulating screw-on plate arrangement according to claim 1, comprising at least six mechanical fastening devices (130) which are attached to the rigid foam insulating layer (120). [9] Heat-insulating screw-on plate arrangement according to claim 1, wherein the mechanical fastening devices (130) are T-nuts (130a) (120) . [10] Heat-insulating screw-on plate arrangement according to claim 7, wherein the mechanical fastening devices (130) are T-nuts (130a) with closed ends. [11] Heat-insulating screw-on plate arrangement according to claim 9, wherein the T-nuts (130a) are attached to the rigid foam insulating layer (120) to resist rotation during screwing engagement with a screw (130b). [12] Heat-insulating screw-on plate arrangement according to claim 1, wherein (i) the rigid foam insulating layer (120) has transversely spaced inwardly and outwardly facing main surfaces (120 in 120 out ) has, and (ii) the mechanical fastening devices (130) are screws (130b) which are attached to the outwardly facing main surface (120 out ) protrude outwards. [13] Heat-insulating screw-on plate arrangement according to claim 12, wherein the screws (130b) are flat head screws. [14] Heat-insulating screw-on plate arrangement according to claim 12, wherein the screws (130b) are attached to the rigid foam insulating layer (120) to resist rotation during screwing engagement with a nut. [15] Heat-insulating screw-on plate arrangement according to claim 1, wherein (i) the rigid foam insulating layer (120) has transversely spaced inwardly and outwardly facing main surfaces (120 in , 120 out ) has, (ii) the bores (129) in the rigid foam insulation layer (120) are through holes, and (iii) the mechanical fastening devices (130) are located away from the inwardly facing main surface (120) in ) extend into the through holes. [16] Heat-insulating screw-on plate arrangement according to claim 1, wherein the mechanical fastening devices (130) are embedded in the rigid foam insulating layer (120), wherein the mechanical fastening devices (130) are spaced transversely from the first main surface (1101) of the vacuum insulating plate (110). [17] Thermally insulated shipping container (200) which features: (a) a shell (210) with interior surfaces (210 in ), which define a storage chamber (209) and have several openings (219) through it, and (b) at least one heat-insulating screw-on plate arrangement (100) according to claim 1, which, via the multiple mechanical fastening devices (130) on the heat-insulating screw-on plate arrangement (100), connects to an inner surface (210) in ) the casing (210) is screwed on. [18] Thermally insulated shipping container (200) which features: (a) a shell (210) with interior surfaces (210 in), which define a storage chamber (209) and have several openings (219) through it, and (b) at least two adjacent heat-insulating screw-on plate arrangements (100) according to claim 5, which are connected via the multiple mechanical fastening devices (130) on the heat-insulating screw-on plate arrangement (100) to an inner surface (210 in ) the casing (210) are screwed on. [19] Thermally insulated shipping container (200) which features: (a) a shell (210) with interior surfaces (210 in ), which define a storage chamber (209) and have several openings (219) through it, and (b) at least four heat-insulating screw-on plate assemblies (100) according to claim 11, which are fastened to an inner surface (210) via screws (230b) extending through the openings (219) in the casing (210) and into a threaded engagement with the T-nuts (130a) on the heat-insulating screw-on plate assembly (100). in) the casing (210) are screwed on. [20] Method for assembling a thermally insulated shipping container (200) comprising the following steps: (a) Obtaining a shell (210) with interior surfaces (210 in ), which define a storage chamber (209) and which have several openings (219) through it, (b) Gaining at least one heat-insulating screw-on plate arrangement (100) according to claim 1, (c) Arranging the at least one heat-insulating screw-on plate arrangement (100) against an inner surface (210) in ) of the shell (210), wherein the exposed main surface (120 in , 120 out ) the rigid foam insulating layer (120) of the inner surface (210 in ) is facing the shell (210) and at least two of the transverse bores (129) in the rigid foam insulation layer (120) are aligned with a corresponding opening (219) through the shell (210), and (d) Screwing the heat-insulating mounting plate assembly (100) to the casing (210) by screwing matching mechanical fastening devices (230) from outside the storage chamber (209) into a threaded engagement with a mechanical fastening device (130) on the heat-insulating mounting plate assembly (100). [21] A method for shipping thermally unstable goods comprising the following steps: (a) Obtaining a heat-insulated shipping container (200) according to claim 17, (b) Arranging a load (P) of heat-conditioned thermally unstable goods in the storage compartment (209) of the heat-insulated shipping container (200) to form a loaded shipping container, (c) Sealing the storage chamber (209) of the loaded shipping container (200) to form a sealed shipping container, and (d) Setting up the sealed shipping container for transport to another location.

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