Temperature control for actively cooled totes used in last-mile food delivery

Abstract

Systems and methods for temperature management are provided. In some embodiments, a vehicle for transporting one or more actively cooled totes includes a central heat rejection subsystem operable to reject heat from the one or more actively cooled totes, and an attachment mechanism for transferring heat from the one or more actively cooled totes to the central heat rejection subsystem.

Description

Detailed Description of the Invention

[0001] Related Applications This application claims the benefit of Provisional Patent Application No. 63 / 402,862, filed August 31, 2022, Provisional Patent Application No. 63 / 429,764, filed December 2, 2022, and Provisional Patent Application No. 63 / 443,160, filed February 3, 2023, the disclosures of which are hereby incorporated by reference in their entireties. [Technical Field]

[0002] TECHNICAL FIELD This disclosure relates generally to temperature controlled environments. [Background technology]

[0003] Cold chain transportation of food, medicine, or any product requiring temperature control for distribution is currently carried out using three-temperature or refrigerated trucks and vans, which are augmented by compressor-based systems that cool or freeze the entire truck compartment. This system must run continuously to maintain the temperature inside the truck, regardless of whether the truck contains a gallon of mickey mouse or a pint of ice cream, necessitating the cooling or freezing of the entire space. Compressor-based refrigerated and three-temperature trucks or vans require external access to the compressor-based system's cooling platform inside the truck or van, voiding the van or truck's warranty. Furthermore, to operate a three-temperature truck, a partition must be used between the temperature zones to maintain temperature. Separating the spaces requires separating orders with items in more than two zones. Compressor-based systems consume too much power to be installed in or on fully electric vehicles without significantly reducing the vehicle's range.

[0004] Improved systems and methods for temperature management are needed. Summary of the Invention

[0005] Systems and methods for temperature management are provided. In some embodiments, a vehicle for transporting one or more actively cooled totes includes a central heat rejection subsystem operable to reject heat from the one or more actively cooled totes, and an attachment mechanism for transferring heat from the one or more actively cooled totes to the central heat rejection subsystem.

[0006] Those skilled in the art will appreciate the scope of the present disclosure and realize additional aspects thereof after reading the following detailed description of the preferred embodiments in conjunction with the accompanying drawing figures.

[0007] The accompanying drawing figures, which are incorporated in and form a part of this specification, illustrate several aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure. [Brief explanation of the drawings]

[0008] [Figure 1] A-D show the use of a portable, self-contained refrigeration or freezing system combined with integrated, automated control and monitoring. [Figure 2] 1 illustrates an exemplary embodiment of an active cooler, according to an embodiment of the present disclosure. [Figure 3] 1A and 1B show an exemplary embodiment of an active cooler according to an embodiment of the present disclosure. [Figure 4] 1 illustrates a system including an active cooler, according to some embodiments of the present disclosure. [Figure 5] 1 illustrates an example of a tote as described herein. [Figure 6] Showing that different versions of the tote are available in refrigerated or frozen versions. [Figure 7] 1 shows an exploded view of a tote including a thermoelectric unit as described herein. [Figure 8] A typical three-temperature truck used for delivery is shown. [Figure 9] Indicates a delivery truck that does not require a refrigeration system or has low refrigeration requirements. [Figure 10] 1 illustrates various ways in which ventilation ducts can be integrated into a tote rack. [Figure 11] 1 illustrates various ways in which ventilation ducts can be integrated into a tote rack. [Figure 12] 1 illustrates a circuit wiring diagram of some embodiments. [Figure 13] Contains logic tables for controlling various totes. [Figure 14] 1 illustrates a racking system and tote arrangement according to some embodiments. [Figure 15] Shown is a single truck and two zones created using a conventional compressor cooling and transport process. [Figure 16] 1 illustrates an exemplary use of the disclosed tote for multi-temperature cold chain shipping. [Figure 17] It shows how using "on-demand" cooling can save energy and extend a vehicle's range. [Figure 18] Demonstrates the ability to place all customer orders at all temperatures on one shelf or section of a truck. [Figure 19] In addition to the ability to move totes in and out of the van per order, it is shown that tote liners can be placed inside the totes to aid in transporting items in and out of the van. [Figure 20] An example is shown in which an existing refrigerated truck is expanded to a truck capable of handling three temperature zones or multiple temperature zones. DETAILED DESCRIPTION OF THE INVENTION

[0009] The embodiments described below present the information necessary to enable one skilled in the art to practice the embodiments and illustrate the best mode for practicing the embodiments. Upon reading the following description in light of the accompanying drawings, one skilled in the art will recognize the concepts of the present disclosure and will understand applications of these concepts not specifically addressed herein. It is understood that these concepts and applications are within the scope of the present disclosure and the appended claims.

[0010] Cold chain transportation of food, medicine, or any product requiring temperature control for distribution is currently carried out using three-temperature or refrigerated trucks and vans, which are augmented by compressor-based systems that cool or freeze the entire truck compartment. This system must run continuously to maintain the temperature inside the truck, regardless of whether the truck contains a gallon of mickey mouse or a pint of ice cream, necessitating the cooling or freezing of the entire space. Compressor-based refrigerated and three-temperature trucks or vans require external access to the compressor-based system's cooling platform inside the truck or van, voiding the van or truck's warranty. Furthermore, to operate a three-temperature truck, a partition must be used between the temperature zones to maintain temperature. Separating the spaces requires separating orders with items in more than two zones. Compressor-based systems consume too much power to be installed in or on fully electric vehicles without significantly reducing the vehicle's range.

[0011] An alternative to compressor-based refrigeration is to use passive cooling products such as gel packs or dry ice to cool the packaged product inside a box or tote, which is a very costly process in both labor and materials. The use of both compressors and passive cooling and freezing has a significant negative impact on the environment due to the continuous operation of trucks and compressors to maintain the refrigerant, materials, or temperature.

[0012] Augmenting the transportation fleet with thermoelectric active cooling and freezing totes with on-demand cooling and sustainable refrigerants, which eliminates the need for van / truck break-ins and minimizes impact on electric vehicle range.

[0013] The ability to use mobile and portable containers using thermoelectric cooling installed in transportation vehicles (e.g., vans, box trucks, cars, trains, planes, boats) also includes the ability to use the same container for transportation from physical centers such as MFCs, stores, and mobile vehicles to homes, apartments, or businesses. This capability also includes full IoT functionality for commanding, controlling, and monitoring the temperature of each container during transportation. In some embodiments, this capability is used in EV or combustion engine vehicles, powering the totes using the vehicle's power source and / or a battery pack that is recharged by the vehicle.

[0014] Last-mile food delivery requires temperature-controlled transportation of perishable foods using shipping vans or similar vehicles. For temperature control, refrigerated or frozen totes mounted in vans (e.g., cargo vans) or box trucks may be used.

[0015] These totes use an active heat pump to draw heat from an enclosed chamber and expel it into the surrounding ambient environment. When this heat is in an enclosed location, such as a delivery van, the hot air can be removed from the van to improve the operating performance of the tote.

[0016] These totes require power during transport to maintain food safety requirements for perishable goods. The electrical systems required to reach (and / or maintain) the proper temperature must meet certain expectations for tote operation.

[0017] 1A-1D illustrate the use of a portable, self-contained refrigeration or freezing system combined with integrated, automated control and monitoring.

[0018] 2, 3A, and 3B illustrate an exemplary embodiment of an active cooler according to an embodiment of the present disclosure.

[0019] FIG. 4 illustrates a system including an active cooler, according to some embodiments of the present disclosure.

[0020] For further details, the interested reader is directed to U.S. Provisional Patent Application No. 62 / 953,771, entitled "THERMOELECTRIC REFRIGERATED / FROZEN PRODUCT STORAGE AND TRANSPORTATION COOLER," U.S. Patent Application No. 17 / 135,420 (now U.S. Patent Application Publication No. 2021 / 0199353A1), entitled "THERMOELECTRIC REFRIGERATED / FROZEN PRODUCT STORAGE AND TRANSPORTATION COOLER," and International Patent Application No. PCT / US2020 / 067172 (now International Patent Publication No. WO2021 / 134068), entitled "THERMOELECTRIC REFRIGERATED / FROZEN PRODUCT STORAGE AND TRANSPORTATION COOLER," which are hereby incorporated by reference in their entireties.

[0021] Figure 5 shows an example of a tote as described herein. Figure 6 shows that different versions of the tote can be used in refrigerated or frozen versions. Figure 7 shows an exploded view of a tote including a thermoelectric unit as described herein.

[0022] Figure 8 shows a typical tri-temperature truck used for deliveries, which may contain several different refrigeration systems that need to be carried, whether or not they are currently needed.

[0023] FIG. 9 shows a delivery truck that does not require a refrigeration system or has reduced refrigeration requirements. In this embodiment, totes provide the appropriate temperature for various items. This can make the truck more efficient in many ways. This also adds flexibility in configuration. If the entire truck needs to be kept at a specific temperature, this can be easily achieved as opposed to a standard truck. These trucks may include charging capabilities or other amenities.

[0024] Figures 10 and 11 show various ways in which ventilation ducts can be integrated into tote trucks. Additional heat from the totes can be removed by actively passing hot exhaust air through ducts to the outside environment. A central exhaust fan provides airflow to the outside. Flexible ducts can be used to connect individual totes. The connection can include a spring-loaded mechanism to press the tote against a compressible gasket and seal the duct to the tote's exhaust port. Dampers can be used to reduce air backflow into the van when the tote location is unoccupied.

[0025] Ducting can also be integrated into the support structure of the racking, reducing the space it takes up. The support beams for the racking can be hollow, and the ducting can be installed through these hollow channels.

[0026] To further improve air exchange from the outside, vents are included on the sides of the van to improve air intake from the outside. These vents are angled to increase the amount of air entering as the van's speed increases. Additional vents are included at the rear to enhance turbulence and air mixing inside the van.

[0027] Another method of removing heat from the tote is to use a liquid cooling loop. The tote exhaust heat exchanger can be made of a flat plate attached to a liquid cooling plate that remains fixed inside the van. The liquid can be cooled using a radiator or a refrigerant cooling loop.

[0028] Figure 12 shows a circuit wiring diagram of some embodiments. Multiple batteries are shown connected in parallel with connectors (e.g., Anderson connectors) to the rest of the circuit. Between the batteries and the distribution block are current shunts connected to a current / voltage monitoring system. The system also includes multiple relays and a battery charger.

[0029] Figure 13 contains logic tables for controlling various totes. An example of eight totes is shown. The first row shows the case where all totes are brought down to the target temperature. This is required at start-up. The next row shows turning off power to all totes once the target temperature is reached and the lids are closed. The third row shows turning on the selected tote(s) if their lids are open and the temperature is below the threshold temperature. The time to bring down to the threshold temperature is calculated and power is applied until the threshold temperature is reached.

[0030] FIG. 14 illustrates a racking system and tote arrangement, according to some embodiments.

[0031] In some embodiments, the power distribution includes multiple rechargeable lithium ion batteries sized to meet the power requirements of multiple thermoelectric totes, power cables sized to power ratings, power connectors, shunts, power distribution blocks with connection point polarity, current and voltage monitoring systems, relay polarity, and / or active thermoelectric totes.

[0032] In some embodiments, the power distribution includes a heating system that monitors battery temperature and provides heat to the battery to improve its suitability for use in cold environments.

[0033] In some embodiments, the power distribution includes insulating materials that trap heat during use and allow for higher ambient temperature differentials within selected areas for placing the battery when not in use.

[0034] In some embodiments, the power distribution includes a heating element and / or fan appropriately positioned relative to the battery system, with current being fed through the heating element to maintain circulating air at higher ambient temperature differentials.

[0035] In some embodiments, the power distribution includes a processor and regulated logic used to optimize charging times and power distribution during regulation of the tote by reducing the temperature of the active tote to a desired target temperature, maintaining the temperature during idle states, and maintaining a threshold temperature during active use.

[0036] In some embodiments, the racking system includes tote docking connectors, power distribution cables, and expandable racking for improved access to the totes.

[0037] In some embodiments, the power distribution includes rechargeable lithium ion battery polarity sized to meet the power requirements of the thermoelectric tote polarity, power cables sized to the power ratings, power connectors, shunts, power distribution blocks with connection point polarity, current and voltage monitoring systems, relay polarity, and active thermoelectric totes.

[0038] In some embodiments, the system also includes a heating system that monitors battery temperature and provides heat to the battery to improve its suitability for use in cold environments.

[0039] In some embodiments, the system also includes insulating materials that trap heat during use and allow for higher ambient temperature differentials within selected areas for placing the battery when not in use.

[0040] In some embodiments, the system also includes a heating element and fan appropriately positioned relative to the battery system, with current supplied through the heating element to maintain circulating air at higher ambient temperature differentials.

[0041] In some embodiments, the system also includes a processor and regulated logic used to optimize charging times and power distribution during regulating the tote by reducing the temperature of the active tote to a desired target temperature, maintaining the temperature during idle states, and maintaining a threshold temperature during active use.

[0042] In some embodiments, the racking system includes tote docking connectors, power distribution cables, and / or expandable racking for improved access to the totes.

[0043] In some embodiments, it may be necessary to insulate the truck, penetrate the exterior, operate multiple compressor systems inside and outside the truck, provide support structures to support the weight of the refrigeration systems, and provide bulkhead dividers to separate the zones. Figure 15 shows a single truck and two zones created using a conventional compressor refrigeration and transport process.

[0044] Figure 16 shows an exemplary use of the disclosed totes. The use of these totes enables multi-temperature cold chain transportation and expansion of electric or gas vehicles.

[0045] In some embodiments, an "on-demand" system allows for cooling only what needs to be cooled, when it needs to be, at the temperature it needs to be, all staying within the confines of the actively cooled tote. By using "on-demand" cooling, cooling for each tote or order can be stopped at each stop, saving energy and extending the vehicle's range. An example of this is shown in Figure 17. In this example, SS Power (W) per tote = 85W (low power operation, maintain <10°F), per tote at full power = 135W, Total Energy Usage (kW-hrs) = 3.9kW, EV Truck kWh / mile * = 2.0, estimated total realized range reduction (miles) = 2.0, etc. assumptions are used.

[0046] The ability to carry a customer's entire order at any temperature on one shelf or section of a truck by using temperature-controlled totes mounted on extended shelving with a contact power source that powers the totes during transit or at rest. This is shown in Figure 18. The contact power can be supplied from a separate rechargeable battery system or from the vehicle battery system.

[0047] In addition to the ability to move totes in and out of the van per order, tote liners can be placed within the tote to aid in transporting items in and out of the van, such as when multiple totes of orders need to be delivered by dolly or cart to areas such as office buildings or apartment buildings, or when the distance from the delivery vehicle to the delivery point is long. An example of this is shown in FIG.

[0048] Refrigerated (cold) trucks have been converted to tri- or multi-temperature trucks. With totes, there is the ability to expand an existing refrigerated truck to tri- or multi-temperature capability by placing a power contact. With refrigerated totes, a refrigerated truck can run refrigerated totes without adding a compressor system or separating the truck with bulkheads or partitions, leaving the truck open for customers to use their existing assets. An example of this is shown in Figure 20.

[0049] In some embodiments, the system uses water and CO2 cooled and frozen totes. In some embodiments, portable active cooling totes can be used for picking, staging, loading into vehicles, and delivery to customer homes. In some embodiments, contact or wireless charging locations for totes in racks and shelves. In some embodiments, no penetration of the vehicle exterior is required. In some embodiments, IoT is used to maintain cold chain documentation. In some embodiments, IoT is used to turn totes on and off as orders are delivered, reducing power for "on-demand cooling." In some embodiments, the ability to store any temperature required for food safety of an entire order in one section of the vehicle without separation or partitions.

[0050] In some embodiments, the integrated contacts can allow for direct connection and / or stand-alone battery modules to be securely docked / attached to the container for self-powered applications.

[0051] These embodiments may be used in, but are not limited to, robotic warehousing / racking systems where manual plugging / unplugging of containers is not possible and / or undesirable, manual systems where employee interaction time must be minimized, mobile delivery platforms to extend safe delivery ranges, and remote deployment docks / racks. These typical automated warehousing / racking locations may be kept at room temperature according to some embodiments of the present disclosure.

[0052] Some embodiments include optional security features that allow for remote, unattended drop-off and / or pickup. Secure local / remote docks, according to some embodiments of the present disclosure, may provide access control to the tote itself, as opposed to, or in addition to, access control of the tote's contents. In some embodiments, implementations of racks with docking / locking rails, according to some embodiments of the present disclosure, are used. More details can be found in patent application PCT / US2021 / 054515, filed October 12, 2021, the disclosure of which is hereby incorporated by reference in its entirety.

[0053] Those skilled in the art will recognize improvements and modifications to the preferred embodiments of the present disclosure, and all such improvements and modifications are considered to be within the scope of the concepts disclosed herein and the following claims.

Claims

1. 1. A vehicle for transporting one or more actively cooled totes, comprising: a central heat rejection subsystem operable to reject heat from the one or more actively cooled totes; an attachment mechanism for transferring heat from the one or more actively cooled totes to the central heat rejection subsystem; The vehicle.

2. the central heat rejection subsystem: a central ventilation fan capable of providing airflow to the exterior of the vehicle; a liquid cooling loop; The vehicle of claim 1 , comprising one or more of:

3. The vehicle of any preceding claim, wherein the attachment mechanism for transferring heat comprises a flexible duct.

4. 4. The vehicle of claim 1, wherein the attachment mechanism for transferring the heat includes one or more compressible gaskets capable of sealing a duct to the exhaust heat of one of the one or more actively cooled totes.

5. 5. The vehicle of claim 1, wherein the attachment mechanism for transferring heat includes one or more spring-loaded mechanisms that assist in the attachment of the one or more actively cooled totes.

6. 6. The vehicle of any preceding claim, further comprising one or more dampers capable of reducing air return into the vehicle when a tote location is unoccupied.

7. a support structure operable to hold the one or more actively cooled totes; The vehicle of any preceding claim, wherein the attachment mechanism for transferring heat from the one or more actively cooled totes to the central heat rejection subsystem is integrated into the support structure.

8. 8. The vehicle of claim 7, wherein the support structure includes hollow channels through which ducts can be attached.

9. 9. The vehicle of any preceding claim, further comprising one or more dampers capable of reducing air return into the vehicle when a tote location is unoccupied.

10. A vehicle according to any preceding claim, further comprising one or more vents for improving intake of air from the outside.

11. 11. The vehicle of claim 10, wherein the one or more vents are angled to increase the amount of air entering as the vehicle travels faster.

12. A vehicle according to any preceding claim, further comprising one or more additional vents at the rear of the vehicle to enhance turbulence and / or air mixing within the vehicle.

13. The vehicle of any of claims 2 to 12, wherein the liquid cooling loop comprises a liquid cold plate that remains stationary within the vehicle and is operable to couple to the one or more actively cooled totes.

14. A vehicle according to any one of claims 2 to 13, wherein the liquid cooling loop is cooled using a radiator and / or a refrigerant cooling loop.

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