Collapsible container with phase-change material

Abstract

A example container includes a front wall, a rear wall, a left wall extending between the front wall and the rear wall, and a right wall extending between the front wall and the rear wall. The left wall includes a predefined fold. The right wall includes a predefined fold. The container further includes a top wall hinged to the rear wall to open and close a top of the container and a bottom wall hinged to the front wall to open and close a bottom of the container. Phase-change material is disposed within the front wall, rear wall, left wall, right wall, top wall, and bottom wall to control the temperature of an object placed inside the container. The left wall and right wall are foldable along the predefined folds to collapse the container.

Description

Collapsible Container with Phase-Change MaterialCross-Reference to Related Applications

[0001] This application claims priority to and the benefit of US provisional patent application no. 63 / 462,692, filed Apr. 28, 2023, which is incorporated herein by reference.Background

[0002] Shipping is a worldwide industry. Shippers and their customers are typically concerned with delivery time and cost. However, many products require additional attention. Certain types of products, such as drugs, pharmaceutical products or components, food, lab samples, and medical supplies or materials, may require temperature control during shipping. Often such products need to be kept cool, at a stable temperature that is lower than the nominal temperature of the environment. Freezer ice packs, ice, dry ice, and other techniques have been used to solve this problem.Summary

[0003] According to an aspect of this disclosure, a container includes a front wall, a rear wall, a left wall extending between the front wall and the rear wall, and a right wall extending between the front wall and the rear wall. The left wall includes a predefined fold. The right wall includes a predefined fold. The container further includes a top wall hinged to the rear wall to open and close a top of the container and a bottom wall hinged to the front wall to open and close a bottom of the container. Phase-change material is disposed within the front wall, rear wall, left wall, right wall, top wall, and bottom wall to control the temperature of an object placed inside the container. The left wall and right wall are foldable along the predefined folds to collapse the container.

[0004] The top wall may be rotatable to a position that abuts an outside of the rear wall to collapse the container.

[0005] The bottom wall may be rotatable to a position that abuts an outside of the front wall to collapse the container.

[0006] The front wall, rear wall, left wall, right wall, top wall, and bottom wall may include flexible material.

[0007] The front wall, rear wall, left wall, right wall, top wall, and bottom wall may be made of fabric.

[0008] The phase-change material may be contained in panels that are disposed within the front wall, rear wall, left wall, right wall, top wall, and bottom wall.

[0009] The left wall may contain panels with phase change material on both sides of the predefined fold of the left wall.

[0010] The right wall may contain panels with phase change material on both sides of the predefined fold of the right wall.

[0011] The panels may be sewn into the front wall, rear wall, left wall, right wall, top wall, and bottom wall.

[0012] The container may further include a gap component configured to provide an air gap extending from the top to the bottom of the container when the container is collapsed to promote cooling air flow through the container.

[0013] According to another aspect of this disclosure, a container includes a plurality of walls, each wall defining a void therein. The container further includes phase-change material provided within the void in each wall. Each of at least two opposing walls include a predefined fold that promotes folding of the wall and collapse of the container. The phase-change material provided within each of at least two opposing walls is positioned on both sides of the predefined fold and away from the predefined fold.

[0014] Each of at least two other opposing walls that do not include a predefined fold may be hinged to open and close.

[0015] The container may further include a gap component to prevent complete collapse of the container and provide for air flow through the container when each of at least two other opposing walls are open.

[0016] According to another aspect of this disclosure, a kit for a container includes a container body and a plurality of phase-change material panels. The container body includes a plurality of walls, each wall defining a void therein. Each of at least two opposing walls include a predefined fold that promotes folding of the wall and collapse of the container body. The phase-change material panels are insertable within the void in each wall. Phase-change material panels insertable within each of at least two opposing walls are positionable on both sides of the predefined fold and away from the predefined fold.

[0017] Each of at least two other opposing walls that do not include a predefined fold may be hinged to open and close.

[0018] The container body may further include a gap component to prevent complete collapse of the container body and provide for air flow through the container body when each of at least two other opposing walls are open.Brief Description of the Figures

[0019] FIG. 1 is a perspective view of an example collapsible container according to the present invention.

[0020] FIG. 2 is perspective view of the example collapsible container of FIG. 1 when collapsed.

[0021] FIG. 3 is an end view of the example collapsible container of FIG. 1 with a gap component.

[0022] FIG. 4 is a perspective view of an example wall usable with the collapsible container of FIG. 1.

[0023] FIG. 5A is a schematic cross-sectional top view of the example collapsible container of FIG. 1 unfolded.

[0024] FIG. 5B is a schematic cross-sectional top view of the example collapsible container of FIG. 1 partially folded.

[0025] FIG. 6 is a plan view of a sheet of phase-change material containers usable with the example collapsible container of FIG. 1.

[0026] FIG. 7 is a plot of results of a test conducted on a collapsible container consistent with this disclosure.

[0027] FIG. 8 is a plot of results of another test conducted on another collapsible container consistent with this disclosure.Detailed Description

[0028] A problem found in conventional shipping containers that provide temperature control is storage. Rigid containers take up the space when being stored as when being used. And while nesting containers of different sizes can reduce space required, many containers cannot be nested. Moreover, a container that is stored inside another might be forgotten. In the case of soft- walled containers, some of these may be collapsed for efficient storage. However, the cooling technology provided to such containers often has to be removed and stored separately to allow the container to collapse.

[0029] Disclosed herein are collapsible containers that include phase-change material to provide temperature control to products shipped within the containers. A container includes predefined folds to promote the folding of walls and thus the collapse of the container for storage in, for example, a freezer or cooler. A container may include features, such as openable tops and bottom and a standoff, to prevent the container from completely collapsing and thus allow air flow through the container to cool the phase-change material.

[0030] FIG. 1 shows an example collapsible container 100 according to the present invention. The container 100 may be used to transport objects that require a stable temperature, such as drugs, food, lab samples, medical supplies / materials, and similar.

[0031] The container 100 includes a front wall 102, a rear wall 104, a left wall 106, a right wall 108, a top wall 110, and a bottom wall 112. The terms “front,” “rear,” “left,” “right,” “top,” “bottom,” and similar terms are not intended to limit the invention and are used merely for sake of explanation.

[0032] The container 100 may be rectangular or cube-shaped and sized to fit an object to be transported.

[0033] The walls 102 - 112 may be made of flexible material, such as fabric. The walls 102 - 112 may be made with multiple layers of material, such as fabric, plastic film, foam, and similar. The walls 102 - 112 may be made from or may contain thermally insulative material. The walls 102 - 112 may have voids inside.

[0034] Phase-change material (PCM) is disposed within the front wall 102, rear wall 104, left wall 106, right wall 108, top wall 110, and bottom wall 112 to control the temperature of the object placed inside the container 100. Liquid / gel PCM may be provided within envelopes made of flexible film (e.g., plastic film) that are provided to the walls 102 - 112. An envelope of PCM may have one or more cells of PCM material. Alternatively or additionally, liquid / gel PCM may be provided within hard shells (e.g., rigid plastic shells) that are provided to the walls 102 - 112. Both flexible and hard PCM containers may be termed a “panel” or “mat.” Flat panels or mats that contain PCM may be sewn into double-layer walls 102 - 112.

[0035] Examples of suitable PCM include water-based gels (e.g., super- absorbent polymer or SAP, carboxymethyl cellulose or CMC, etc.) paraffins; hydrated salts or other binary eutectic mixtures; linear alcohols; organic compounds derived from animal fat or plant oil (sometimes referred to as biobased materials); materials based on palm oil, palm kernel oil, rapeseed oil, coconut oil, or soybean oil; and similar materials. A PCM may include a viscosity altering additive.

[0036] The top wall 110 is hinged to the rear wall 104 to open and close the top of the container 100. One edge of the top wall 110 may be hinge connected to the rear wall 104. The other edges of the top wall 110 may be free and may include a fastener, such as a zipper, that engages the top edges of the left wall 106, right wall 108, and front wall 102 to open and close the top of the container 100.

[0037] The bottom wall 112 is hinged to the front wall 102 to open and close the bottom of the container 100. One edge of the bottom wall 112 may be hinge connected to the front wall 102. The other edges of the bottom wall 112 may be free and include a fastener, such as a zipper, that engages the top edges of the left wall 106, right wall 108, and rear wall 104 to open and close the bottom of the container 100.

[0038] The left wall 106 extends between the front wall 102 and the rear wall 104 and includes a predefined fold 116. The fold 116 may extend from the top to the bottom of the container 100. The fold 116 may be positioned at the halfway point between the front wall 102 and the rear wall 104.

[0039] The right wall 108 extends between the front wall 102 and the rear wall 104 opposite the left wall 106 and includes a predefined fold 118. The fold 118 may extend from the top to the bottom of the container 100. The fold 118 may be positioned at the halfway point between the front wall 102 and the rear wall 104.

[0040] A hinge or predefined fold, as discussed herein, may include a crease, a thinned region of material, stitching, a seam, a region of material different from the material that makes up the bulk of the wall, a living hinge, or similar. A hinge or predefined fold promotes the folding of bulk wall material.

[0041] The container 100 may be provided as a kit to be assembled by the user. The walls 102 - 112 may be preassembled to form a container body. PCM panels may be provided separately for insertion into voids within the walls. In such examples, the walls 102 - 112 may be provided with a closure, such as hook-and-loop fasteners, that can be opened and closed to allow for insertion (and removal) of the PCM panels.

[0042] As shown in FIG. 2, each of the left wall 106 and right wall 108 is foldable along the respective predefined fold 116, 118 to collapse the container 100. The left wall 106 and right wall 108 may be foldable inwards, as depicted. Alternatively, the walls 106, 108 may be foldable outwards or foldable both inwards and outwards. The PCM does not have to be removed for the container to be collapsed.

[0043] The left wall 106 may contain separate panels of PCM on both sides of the predefined fold 116, so that the PCM does not significantly interfere with the foldability of the left wall 106. Likewise, the right wall 108 main contain separate panels of PCM on both sides of the predefined fold 118 for the same reason.

[0044] Also shown in FIG. 2, to facilitate collapse of the container 100, the top wall 110 is rotatable to a position that abuts (or nearly abuts) the outside of the rear wall 104. Similarly, thebottom wall 112 is rotatable to a position that abuts (or nearly abuts) the outside of the front wall 102. This provides the container 100 with a compact collapsed configuration.

[0045] The container 100 may, in its collapsed form, be placed within a freezer, refrigerator, or other cold / cool environment to bring the PCM to a desired state for transport of an object within the container 100. The PCM may be cooled until frozen.

[0046] The collapsible structure of the container 100 may be configured to provide an air flow channel 200 between the top and bottom of the container 100 to allow cooling air to flow through the container 100, while in collapsed form. Flow of cooling air may hasten the cooling of the PCM and allow the container 100 to be readied for use in a relatively short time.

[0047] As shown in FIG. 3, the container 100 may include a gap component 300 configured to provide an air gap 302 extending within the container 100 when the container 100 is collapsed to promote cooling air flow through the container 100. In this example, the gap component 300 includes a standoff or protrusion attached to the inside of the front wall 102 and positioned to abut the left wall 106 when the left wall 106 is folded inwards. Such a standoff or protrusion may be provided to any number of suitable walls to inhibit the complete collapse of the container. Note that in FIG. 3, the top wall 110 and bottom wall 112 are omitted for clarity.

[0048] FIG. 4 shows an example wall 400 that may be used with the collapsible container 100. The wall 400 is shown partially assembled. The wall 400 may be used as any of the walls 102 - 112 discussed herein.

[0049] The wall 400 includes a first sheet of material 402 and a second sheet of material 404 arranged to form an envelope. The sheets of material 402, 404 may be separate sheets or may be the same sheet that is folded over itself. A sheet of material 402, 404 may have a single- or multi-layer construction. For example, a sheet of material 402, 404 may include two opposing layers of fabric with insulating material therebetween.

[0050] Edges of the envelope formed by the sheets of material 402, 404 may be attached, such as by heat sealing, sewing, glue / adhesive, or similar technique. In the partially completed state shown, the envelope has an open end 406 through which PCM panels 408 may be inserted. Inthis example, the PCM panels 408 are in the form of multiple flexible packets of PCM. In other examples, other flexible or rigid PCM panels may be used.

[0051] The open end 406 is closed after insertion of the PCM panels 408. A permanent closure may be used, such as sewing, adhesive, heat sealing, etc. Alternatively, an openable closure may be used, such as a hook-and-loop fastener (e.g., Velcro™).

[0052] Also shown in FIG. 4 is an example location of a predefined fold line 410 if the wall 400 is to be used as a folding wall, such as the walls 106, 108 discussed above. As can be seen, the predefined fold line 410 is positioned away from, and in this example between, PCM panels 408 to avoid bending a PCM panel 408, which may cause a leak, or to avoid a PCM panel 408 resisting the bending of the wall 400. PCM is positioned on both sides of the predefined fold line 410, but not at the predefined fold line 410. In various examples, stitching, a seam, or a thinned region of materials 402, 404 is provided along the predefined fold line 410 to promote folding of the wall 400.

[0053] FIGs. 5A and 5B show the foldability of a collapsible container, such as the collapsible container 100 discussed above. FIGs. 5A and 5B show a container in cross-section from above, with top and bottom walls omitted for sake of clarity.

[0054] Outer and inner walls 500, 502 are arranged to create a double- walled envelope. Each wall 500, 502 may be formed of one or multiple layers of material, which may include any suitable combination of fabric, film, foam, insulation, etc., as discussed elsewhere herein.

[0055] Within the void between the outer and inner walls 500, 502, PCM panels 504 are positioned. The PCM panels 504 are positioned away from the corners 506 to avoid restricting bending of the wall 500, 502 material at the corners 506. The PCM panels 504 are also positioned away from predefined fold lines 508 (illustrated schematically) to avoid restricting bending of the wall 500, 502 material at these fold-promoting locations 510.

[0056] As can be seen, normal force 520 is applied to opposing walls with the predefined fold lines 508 to cause these walls fold inwards, so that the entire container may be collapsed, which may be aided by additional normal force 522 applied to opposing non-folding walls.

[0057] As discussed above with regard to FIG. 4, individual PCM panels may be inserted into a void within a wall. Alternatively, as shown in FIG. 6, multiple PCM panels may be provided together, such as being formed by sheets of material 600 that are overlaid and selectively bonded to form individual PCM panels 602. Regions where the sheets are bonded, such as along line 604, allow for bending that is compatible with a folding wall of a collapsible container.

[0058] A collapsible container may use the techniques discussed above to increase efficiency, reduce complexity (and cost), promote reuse, and offer convenience to users. The container may be collapsed to save space when being stored or being cooled.

[0059] It should be recognized that features and aspects of the various examples provided above can be combined into further examples that also fall within the scope of the present disclosure. In addition, the figures are not to scale and may have size and shape exaggerated for illustrative purposes.

Claims

Claims1. A container comprising: a front wall; a rear wall; a left wall extending between the front wall and the rear wall, the left wall including a predefined fold; a right wall extending between the front wall and the rear wall, the right wall including a predefined fold; a top wall hinged to the rear wall to open and close a top of the container; a bottom wall hinged to the front wall to open and close a bottom of the container; and phase-change material disposed within the front wall, rear wall, left wall, right wall, top wall, and bottom wall to control the temperature of an object placed inside the container; wherein the left wall and right wall are foldable along the predefined folds to collapse the container.

2. The container of claim 1 , wherein the top wall is rotatable to a position that abuts an outside of the rear wall to collapse the container.

3. The container of claim 1, wherein the bottom wall is rotatable to a position that abuts an outside of the front wall to collapse the container.

4. The container of claim 1, wherein the front wall, rear wall, left wall, right wall, top wall, and bottom wall comprise flexible material.

5. The container of claim 4, wherein the front wall, rear wall, left wall, right wall, top wall, and bottom wall are made of fabric.

6. The container of claim 1 , wherein the phase-change material is contained in panels that are disposed within the front wall, rear wall, left wall, right wall, top wall, and bottom wall.

7. The container of claim 6, wherein the left wall contains panels with phase change material on both sides of the predefined fold of the left wall.

8. The container of claim 6, wherein the right wall contains panels with phase change material on both sides of the predefined fold of the right wall.

9. The container of claim 6, wherein the panels are sewn into the front wall, rear wall, left wall, right wall, top wall, and bottom wall.

10. The container of claim 1, further comprising a gap component configured to provide an air gap extending from the top to the bottom of the container when the container is collapsed to promote cooling air flow through the container.

11. A container comprising: a plurality of walls, each wall defining a void therein; and phase-change material provided within the void in each wall; wherein each of at least two opposing walls include a predefined fold that promotes folding of the wall and collapse of the container; wherein the phase-change material provided within each of at least two opposing walls is positioned on both sides of the predefined fold and away from the predefined fold.

12. The container of claim 11, wherein each of at least two other opposing walls that do not include a predefined fold are hinged to open and close.

13. The container of claim 12, further comprising a gap component to prevent complete collapse of the container and provide for air flow through the container when each of at least two other opposing walls are open.

14. A kit for a container comprising:a container body including a plurality of walls, each wall defining a void therein, wherein each of at least two opposing walls include a predefined fold that promotes folding of the wall and collapse of the container body; a plurality of phase-change material panels insertable within the void in each wall, wherein the phase-change material panels insertable within each of at least two opposing walls are positionable on both sides of the predefined fold and away from the predefined fold.

15. The kit for the container of claim 14, wherein each of at least two other opposing walls that do not include a predefined fold are hinged to open and close.

16. The kit for the container of claim 15, wherein the container body further comprises a gap component to prevent complete collapse of the container body and provide for air flow through the container body when each of at least two other opposing walls are open.

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