CONTAINER, RECTANGULAR PHASE-CHANGING MATERIAL PLATE, CONTAINER ASSEMBLY KIT, AND INNER TANK

Abstract

The invention relates to a container, a rectangular phase-change material (PCM) plate, a container assembly, and an inner container. The invention relates to a temperature-controlled storage container comprising a first rectangular PCM plate with two opposing principal walls defining its height and width, a perimeter wall defining its thickness, and PCM arranged within the plate. A second rectangular PCM plate is arranged with the first plate to form a sealed loading chamber. The container may consist of an inner container and a lid to enclose the PCM plates, with insulation material, such as vacuum-insulated plates (VIPs), placed around the container. In some configurations, an outer container or outer box is made to enclose the inner container. The container may also include features such as beveled perimeters for plate alignment, anti-tampering mechanisms, and slots for PCM plates. The assembly kit includes the inner container, PCM panels, and VIPs are also depicted for building the container.

Description

PHASE CHANGE MATERIAL PANELS AND CONTAINER WITH PHASE CHANGE MATERIAL PANELSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 542191 entitled “PHASE CHANGE MATERIAL PANELS AND CONTAINER WITH PHASE CHANGE MATERIAL PANELS” filed October 3, 2023, and U.S. 63 / 663982 entitled “PHASE CHANGE MATERIAL PANELS AND CONTAINER WITH PHASE CHANGE MATERIAL PANELS” filed June 25, 2024.FIELD

[0002] This disclosure relates generally to containers for cold chain packaging, and specifically to containers using phase change material (PCM) panels for cold chain packaging.BACKGROUND

[0003] Phase Change Materials (PCM) are used in cold chain packaging to maintain consistent thermal conditions for sensitive products, such as pharmaceuticals, biological samples, and perishable foods. PCM is commonly provided in soft or hard-sided packs that are conditioned in a freezer before shipping and then inserted into shipping containers. However, these packs are known to shift during transport, which can compromise temperature stability and result in physical damage to the product.SUMMARY

[0004] There is a need for efficient and adaptable thermal management systems for transporting temperature-sensitive payloads. Shipping packages often fail to provide sufficient thermal insulation while maintaining ease of assembly and secure containment. The present specification addresses these issues by providing a container that combines PCM panels with structural features to enhance thermal performance and allow for straightforward construction.

[0005] An aspect of the specification provides a container including a first rectangular phase change material (PCM) panel. The first rectangular PCM panel includes two opposing main walls that define the height and width of the panel, with the two opposing main walls having beveled perimeters. A perimeter wall joins the two opposing main walls and defines the thickness of the first rectangular PCM panel. A PCM is disposed within the space between the two opposing main walls and the perimeter wall. The container further includes a second rectangular PCM panel with complementary beveled perimeters. The first and second rectangular PCM panels are arranged at a right angle to define a payload enclosure when either of the beveled perimeters abuts either of the complementary beveled perimeters.

[0006] In one example, the container further includes an inner tub with an interior configured to receive the PCM panels and an inner tub lid, wherein the inner tub and the inner tub lid are arranged to enclose the payload enclosure.

[0007] In one example, the inner tub interior has angled surfaces matching the beveled perimeters.

[0008] In one example, the inner tub has an outwardly extending flange to accommodate an insulation material positioned on the exterior of the inner tub.

[0009] In one example, the insulation material is a rectangular vacuum insulated panel (VIP).

[0010] In one example, the at least one rectangular vacuum insulated panel (VIP) is positioned in an exterior of the payload enclosure.

[0011] In another example, the container further includes an outer tub and an outer tub lid. The inner tub is disposed within the outer tub. The outer tub and the outer tub lid are arranged to enclose the inner tub and the inner tub lid.

[0012] In one example, the container further includes an outer box having a box base, four box walls, and a closure lid with a tuck flap, wherein the inner tub and the inner tub lid are disposed and enclosed within the outer box.

[0013] In one example, the container further includes an outer box having a box base, four box walls, and a closure lid with a tuck flap, wherein the outer tub and the outer tub lid are disposed and enclosed within the outer box.

[0014] In one example, two of the four box walls have a handle and a handle lip.

[0015] In one example, the handle lip has a handle lip hole, and the closure lid has a metal grommet at a location matching the handle lip hole to accommodate a cable tie for tamper-proofing the container.

[0016] In one example, the closure lid has a first notch and at least one of the four box walls has a second notch to accommodate a buckle closure arrangement formed by two buckle straps anchored to the outer box at the first and second notches.

[0017] In one example, the first rectangular PCM panel has a port disposed within a depression of the perimeter wall for filling the first rectangular PCM panel with the PCM, and a cap for closing the port.

[0018] In one example, the container includes four additional rectangular PCM panels further defining the payload enclosure.

[0019] A further aspect of the specification provides a rectangular phase change material (PCM) panel. The rectangular PCM panel includes two opposing main walls defining a height and a width of the rectangular PCM panel, the two opposing main walls including respective beveled perimeters; a perimeter wall joining the two opposing main walls and defining a thickness of the rectangular PCM panel; and a PCM within a space defined by the two opposing main walls and the perimeter wall.

[0020] In one example, the rectangular PCM panel further includes a port on a depression of the perimeter wall for filling the rectangular PCM panel with the PCM, and a cap for closing the port.

[0021] In one example, the rectangular PCM panel further includes at least one reinforcing feature connecting the two opposing main walls, the at least one reinforcing feature selected from the group consisting of: an indentation, a rib, a baffle, and a gusset.

[0022] In one example, the rectangular PCM panel further includes at least one grip disposed in one of the two opposing main walls, the at least one grip comprising an indentation sized to accommodate a finger.

[0023] An aspect of the specification provides a kit for a container including an inner tub and six rectangular vacuum insulated panels (VIPs). The six rectangular VIPs are configured to be arranged on the exterior of the inner tub, and an outwardly extending flange of the inner tub is configured to accommodate at least one of the six rectangular VIPs on the exterior of the inner tub.

[0024] In one example, the kit further includes six rectangular phase change material (PCM) panels, wherein a first of the six rectangular PCM panels is configured to be arranged at the bottom of an interior of the inner tub, four of the six rectangular PCM panels are configured to be arranged in a direction orthogonal to the first PCM panel along the sidewalls of the interior of the inner tub, and a sixth of the six rectangular PCM panels is configured to be arranged on top of the interior of the inner tub, parallel to the first PCM panel.

[0025] In one example, the kit further includes an outer tub configured to receive the six rectangular PCM panels, the inner tub, and the six rectangular VIPs.

[0026] In one example, the kit further includes a box with a closure lid configured to receive and enclose the six rectangular PCM panels, the inner tub, and the six rectangular VIPs.

[0027] In one example, the inner tub includes a plurality of slots for receiving the four PCM panels that are orthogonal to the first PCM panel.

[0028] In one example, at least one of the slots is defined by at least one angled surface.

[0029] In one example, the PCM panels are square, and the plurality of slots are sized and shaped to receive the square PCM panels.

[0030] In one example, the inner tub is rectangular, having two shorter sides and two longer sides. The plurality of slots include a first and third slot defined along oppositeshorter sides of the inner tub, and a second and fourth slot defined along opposite longer sides of the inner tub, with the first and third slots spaced from the second and fourth slots.

[0031] An aspect of the specification provides an inner tub for a container, the inner tub comprising a plurality of slots disposed along sidewalls of the interior of the inner tub, the slots sized and shaped to receive a plurality of rectangular PCM panels.

[0032] In one example, the plurality of rectangular PCM panels includes a first PCM panel, four side PCM panels, and a sixth PCM panel. The first PCM panel is configured to be arranged at the bottom of an interior of the inner tub, the four side PCM panels are configured to be received by the plurality of slots in a direction orthogonal to the first PCM panel, and the sixth PCM panel is configured to be arranged on top of the interior of the inner tub, parallel to the first PCM panel.

[0033] In one example, each of the plurality of slots is defined by a retaining surface configured to retain one of the rectangular PCM panels against one of the sidewalls of the inner tub.

[0034] In one example, the retaining surface is angled to match a beveled perimeter of the plurality of rectangular PCM panels.

[0035] In one example, the bottom of the inner tub includes an angled surface to match the beveled perimeter of the first PCM panel.

[0036] In one example, the inner tub is rectangular, having two opposing shorter sides and two opposing longer sides. The plurality of slots include a first and third slot defined along each of the two opposing shorter sides, and a second and fourth slot defined along each of the two opposing longer sides of the inner tub, with the first and third slots spaced from the second and fourth slots.

[0037] In one example, the inner tub comprises a rigid polymer.BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Embodiments are described with reference to the following Figures.

[0039] Figures 1 A is a front view of an exemplary rectangular PCM panel.

[0040] Figure 1 B is a bottom view of an exemplary rectangular PCM panel.

[0041] Figure 1 C is a top view of an exemplary rectangular PCM panel.

[0042] Figure 2A is an exploded view of an exemplary payload enclosure formed with the PCM panels of Figure 1 A.

[0043] Figure 2B is a perspective view of the exemplary payload enclosure of Figure 2A.

[0044] Figure 3A is a front view of another exemplary rectangular PCM panel.

[0045] Figure 3B is a front view of another exemplary rectangular PCM panel.

[0046] Figure 4A is a front view of another exemplary rectangular PCM panel.

[0047] Figure 4B is a front view of another exemplary rectangular PCM panel.

[0048] Figure 5 is a perspective view of another exemplary payload enclosure.

[0049] Figure 6A is a front view of an exemplary elongated PCM panel.

[0050] Figure 6B is a front view of another exemplary elongated PCM panel.

[0051] Figure 7A is a perspective view of an inner tub for receiving the payload enclosure of Figure 2.

[0052] Figure 7B is a cross-sectional view of the inner tub of 7A containing the payload enclosure of Figure 2.

[0053] Figure 8A is a perspective view of another exemplary inner tub for receiving the payload enclosure of Figure 5.

[0054] Figure 8B is a perspective view of the inner tub of Figure 8A containing the payload enclosure of Figure 5.

[0055] Figure 9A is an exploded view of the inner tub of Figure 7A and VIPs.

[0056] Figure 9B is a partially exploded view of the inner tub of Figure 7A and VIPs.

[0057] Figure 10A is a perspective view of an exemplary outer container.

[0058] Figure 10B is a perspective view of a lid for the exemplary outer container ofFigure 9A.

[0059] Figure 11 A is a perspective view of an assembly comprising the exemplary payload enclosure of Figure 2A, the exemplary outer tub of Figures 10A and 10B, the exemplary inner tub of Figure 7A, a plurality of rectangular VIPs, and an exemplary outer box.

[0060] Figure 11 B is a partial perspective view of the outer box of Figure 11 A.

[0061] Figure 12 is an exploded view of the assembly of Figure 11 A.

[0062] Figure 13 is a cross-sectional view of the assembly of Figure 11 A.

[0063] Figure 14A is a perspective view of assembly including an inner tub tray.

[0064] Figure 14B is an exploded view of the exemplary inner tub tray of Figure 14A.

[0065] Figure 15A is a top perspective view of another inner tub.

[0066] Figure 15B is a top view of the inner tub of Figure 15A.

[0067] Figure 16A is a top perspective view of the inner tub of Figure 16A with the PCM panels of Figure 1 inserted therein.

[0068] Figure 16B is a top perspective view of the inner tub of Figure 15A with the PCM panels of Figure 1 inserted therein.

[0069] Figure 17A is a top perspective view of another inner tub.

[0070] Figure 17B is a top perspective view of the inner tub of Figure 15A with singlebevelled PCM panels inserted therein.

[0071] Figure 18A is a top view of the inner tub of Figure 17A.

[0072] Figure 18B is a front view of the inner tub of Figure 17A.

[0073] Figure 19A is a bottom view of the inner tub of Figure 17A.

[0074] Figure 19B is a side view of the inner tub of Figure 17A.

[0075] Figure 20A is a top perspective view of another inner tub.

[0076] Figure 20B is a top perspective view of the inner tub of Figure 20A with unbevelled PCM panels inserted therein.

[0077] Figure 21 A is a top view of the inner tub of Figure 20A.

[0078] Figure 21 B is a front view of the inner tub of Figure 20A.

[0079] Figure 22A is a bottom view of the inner tub of Figure 20A.

[0080] Figure 22B is a side view of the inner tub of Figure 20A.DETAILED DESCRIPTION

[0081] Figures 1 A to 1C depict an example rectangular phase change material (PCM) panel 100 formed by two opposing rectangular main walls 104-1 , 104-2 (Herein referred to collectively as “main walls 104”, or generically as “main wall 104”. This terminology is used elsewhere herein.) defining a height H and a width W of the rectangular PCM panel 100, and a perimeter wall 108 joining the main walls 104-1 , 104-2 at their perimeters and defining a thickness T of the rectangular PCM panel 100. The perimeter wall 108 may be slightly rounded. The rectangular PCM panel 100 may be formed of, for example, a rigid polymer so that it may contain a PCM therein, for example, within a space defined by the main walls 104-1 , 104-2 and the perimeter wall 108.

[0082] Both of the main walls 104-1 and 104-2 have beveled perimeters 1 12-1 and 112-2, respectively, that meet at the perimeter wall 108. The beveled perimeters 112-1 , 112-2 are angled at about 45 degrees with respect to the main walls 104-1 , 104-2, respectively, so that the rectangular PCM panel 100 may be arranged at a right angle with respect to a second rectangular PCM panel 100 when either of the beveled perimeters 112-1 , 1 12-2 of the rectangular PCM panel 100 abuts a beveled perimeter of the second rectangular PCM panel. In a further alternative, only one of the main walls 104-1 or 104-2 may have a beveled perimeter 112-1 or 112-2. The beveled perimeter 112-1 or 112-2 may be angled, for example, at about 45 degrees with respect to the main wall 104-1 or 104-2 so that the rectangular PCM panel 100 may be arranged at a right angle with respect to a second rectangular PCM panel 100 when the beveled perimeter 112-1 or 112-2 abuts a beveled perimeter of the second rectangular PCM panel. The beveled perimeters 1 12-1 , 1 12-2 of a set of PCM panels 100 may have complementary shapes so as to fit together as closely as possible when arranging the PCM panels 100 in a box-like structure. This reduces or prevents air flow between the panels and prevents relative movement between panels.

[0083] The rectangular PCM panel 100 may further have a port 1 16 disposed within a depression 120 of the perimeter wall 108 for filling the rectangular PCM panel with the PCM and a cap 124 for closing the port 116. Disposing the port 116 within the depression 120 may facilitate arranging a plurality of rectangular PCM panels 100 together to define a payload enclosure as well as placing the payload enclosure within a cold chain container without the port 116 obstructing the arrangement of the PCM panels 100 or the placement of the payload enclosure within the cold chain container, as further explained below with reference to Figure 3B.

[0084] Because the height H and width W of the PCM panel 100 are substantially larger than the thickness T, the main walls 104 may tend to flex inwardly with pressure. To enhance the structural integrity of the PCM panel 100, one or more reinforcing features 128 may be included. In the example shown in Figure 1A, the reinforcing features 128 comprise a pair of opposing indentations which extend inwardly from the main walls 104- 1 , 104-2 of the PCM panel 100, meeting at a point between the main walls 104. The reinforcing feature 128 is not particularly limited to an indentation and in other examples, the reinforcing feature 128 comprises a rib, baffle, or gusset. In specific examples, the reinforcing feature 128 comprises a combination of indentations, ribs, baffles, and gussets. Generally, the reinforcing features 128 connect the two opposing main walls 104. The reinforcing features 128 may be evenly distributed across the main walls 104 of the PCM panel. The PCM panel 100 may further include one or more grips 130 comprising indentations that are sized to accommodate fingers and assist a user in handling the PCM panel 100. The grips 130 may be disposed in one or both of the main walls 104. In particular examples, the grips 130 are disposed in the main wall 104, proximal to the perimeter wall 108.

[0085] Figure 2A depicts an example of six rectangular PCM panels 100 (100-1 to 100-6) arranged at right angles with respect to each other and defining a payload enclosure 200 that hasa rectangular prism shape. In this example, both of the main walls 104-1 and 104-2 have beveled perimeters 112-1 and 112-2; this can improve assembly time as compared to PCM panels with a single beveled perimeter which must be correctly oriented with the beveled perimeter facing inwardly. As can be seen in Figure 2B, a port 116-6 disposed within a depression 120-6 of the rectangular PCM panel 100-6 does notobstruct the placement of the rectangular PCM panel 100-6 at a right angle with respect to the rectangular PCM panel 100-1 . A payload within the payload enclosure 200 may be maintained within a desired temperature range for a desired amount of time depending on the physical properties of a selected PCM contained within the rectangular PCM panels 100 forming the payload enclosure 200.

[0086] The dimensions of the rectangular PCM panels 100 may be selected to form payload enclosures 200 of different volume capacities. Example PCM panels are shown in Figures 3A, 3B, 4A, 4B, 6A, and 6B. Six PCM panels 300 of W = 15 cm (about 6”), L = 15 cm (about 6”), and T = 2.1 cm (about 1.06”) may be assembled into a payload enclosure having an interior volume of about 3 L; six PCM panels 304 of W = 23.5 cm (about 9.25”), L = 23.5 cm (about 9.25”), and T = 2.7 cm (about 1 .06”) may be assembled into a payload enclosure having an interior volume of about 10 L; six PCM panels 400 of W = 28 cm (about 11 ”), L = 28 cm (about 11 ’)’, and T = 2.7 cm (about 1.06”) may be assembled into a payload enclosure having an interior volume of about 16 L; and six PCM panels 404 of W = 33 cm (about 13”), L = 33 cm (about 13”), and T = 2.7 cm (about 1 .06”) may be assembled into a payload enclosure having an interior volume of about 28 L. In these examples, the PCM panels are square (W = L) which assemble into a cubic payload enclosure, however in other examples, PCM panels with an elongated shape (W + L) may be additionally used to assemble a non-cubic payload enclosure, as shown in Figure 5. In Figure 5, an example payload enclosure 500 is shown which comprises four elongated panels 504 and two square panels 508 assembled into an elongated payload enclosure 500. Examples of elongated rectangular panels are shown in Figures 6A and 6B. Four PCM panels 600 of W = 20.5 cm (about 8.1 ”), L = 32.6 cm (about 12.8”), and T = 2.7 cm (about 1.1 ”) and two PCM panels (not shown) of W = 20.5 cm (about 8.1 ”), L = 20.5 cm (about 8.1 ”), and T = 2.7 cm (about 1.1 ”) may be assembled into a payload enclosure having an interior volume of about 8 L. Four PCM panels 604 of W = 35.5 cm (about 14.0”), L = 45.7 cm (about 18.0”), and T = 2.7 cm (about 1.1 ”) and two PCM panels (not shown) of W = 35.5 cm (about 14.0”, L = 35.5 cm (about 14.0”), and T = 2.7 cm (about 1.1 ”) may be assembled into a payload enclosure having an interior volume of about 37 L. As exemplified in Figures 3A, 3B,4 A, 4B, 6A and 6B, the number and size of reinforcing features 128 in the PCM panel may depend on the shape and dimensions of the PCMpanel. The cold chain container will be explained herein with reference to the PCM panel 100, however it should be understood that any description of the PCM panel 100 similarly applies to the PCM panels 300, 304, 400, 404, 600, and 604.

[0087] While the example payload enclosures 200, 500 depicted in Figures 2 and 5 are defined by six rectangular PCM panels arranged in a box-like structure, an alternative payload enclosure may be defined by a larger number (n>6) of PCM panels, for example ten, fourteen, or twenty-four rectangular PCM panels arranged in a larger box-like structure. Optionally, additional rectangular PCM panels may be further included to subdivide the alternative payload enclosure. Alternatively, a partial box-like payload enclosure, not fully enclosing the payload, may be defined by a smaller number (n<6) of PCM panels, for example, five or four rectangular PCM panels. In a further alternative, a partial non-box-like payload enclosure may be defined by a smaller number (n<6) of PCM panels placed opposing each other, for example, by two rectangular PCM panels placed at opposing ends of the payload.

[0088] Figure 7A depicts an example rectangular prism shaped inner tub 700 configured to receive a payload enclosure formed of rectangular PCM panels 100 such as the example payload enclosure 200. The inner tub 700 may be formed of a rigid polymer so that it may provide payload protection. Additionally, as it will be further explained below, the inner tub 700 may provide protection of vacuum insulated panels (VIPs) arranged exterior to the inner tub 700, maintain the rectangular PCM panels 100 assembled into the payload enclosure 200, ease the assembly of the payload enclosure 200, and eliminate any gaps due to dimensional tolerances of the VIPs. The inner tub 700 may be manufactured, for example, by injection molding, rotational molding or 3D printing. The inner tub 700 has an interior 704 of dimensions matching outer dimensions of the payload enclosure 200. Additionally, the interior 704 has angled surfaces 706, 708 matching the beveled perimeters 112 of the rectangular PCM panels 100 forming the payload enclosure 200. The dimensions of the interior 704 and the angled surfaces 706, 708 may facilitate ease of assembly of the payload enclosure within the inner tub 700 as well as a tight-fit placement of the payload enclosure 200 within the inner tub 700 to maintain the rectangular PCM panels 100 in an assembled configuration, as further explained below with reference to Figure 7B.

[0089] Figure 7B depicts the example payload enclosure 200 arranged within the example inner tub 700. As can be seen in Figure 7B, the port 116-1 disposed within the depression 120-1 does not obstruct a tight-fit placement of the payload enclosure 200 within interior walls of the inner tub 700. As further shown in Figure 7B, the outer dimensions of the payload enclosure 200 closely match the dimensions of the interior 704, the interior 704 maintaining the rectangular PCM panels 100 in the assembled configuration that forms the payload enclosure 200. To assemble the payload enclosure 200 within the inner tub 700, a first rectangular PCM panel 100-1 may be arranged in a bottom of the interior 704, where bottom angled surfaces 708 may help seating the first rectangular PCM panel 100-1 in a centered position. This may facilitate arranging four side rectangular PCM panels 100-2, 100-3, 100-4, 100-5 along sidewalls of the interior 704, where the bottom angled surfaces 708, the first rectangular PCM panel 100-1 , and side angled surfaces 706 may help placing the four, side rectangular PCM panels 100-2, 100-3, 100-4, 100-5 in a direction orthogonal to the first bottom rectangular PCM panel 100-1. This, in turn, may facilitate arranging a sixth rectangular PCM panel 100-6 on a top of the interior 704, where the four, side rectangular PCM panels 100-2, 100-3, 100-4, 100-5 may help seating the sixth rectangular PCM panel 100-6 in a centered position parallel to the first rectangular PCM panel 100-1 . Additionally, the interior 704 may provide a cleanable surface for easy reuse of the inner tub 700 and of the payload enclosure 200.

[0090] Figure 7B additionally shows that the inner tub 700 additionally has an outwardly extending flange 712 that extends radially outwardly with respect to a direction of insertion of the payload enclosure 200 into the inner tub 700 and that further extends along the direction of insertion so that the flange 712 may protect the upper surface of the VIPs, as further explained below with reference to Figures 9A and 9B. The flange 712 may further include a lip 716 for retaining the VIPs against the inner tub 700.

[0091] The exemplary inner tub 700 of Figures 7A and 7B is sized and dimensioned to receive a cubic payload enclosure, however other configurations are contemplated. Elongated payload enclosures, such as the exemplary elongate payload enclosure 500, may be received by an inner tub with corresponding interior dimensions. Figures 8A and 8B show an exemplary inner tub 800 for receiving the exemplary elongate payload enclosure 500. The cold chain container will be explained herein with reference to theexemplary inner tub 700 and exemplary payload enclosure 200, however it should be understood that any description of the inner tub 700 similarly applies to the inner tub 800, and any description of the elongate payload enclosure 200 similarly applies to the payload enclosure 500.

[0092] Figure 9A is an exploded view of an example assembly 900 including the inner tub 700 with the payload enclosure 200 inserted therein, an inner tub lid 912, and a plurality of rectangular vacuum insulated panels (VIPs) 904-1 , 904-2, 904-3, 904-4, 904- 5, 904-6. The VIPs may be thermally insulating and may include, for example, a panel of a rigid, highly porous material such as Expanded Polystyrene (EPS), fumed silica, an aerogel, perlite, glass fiber, etc. and membrane walls preventing air from entering the highly porous material, so that the VIPs may aid the payload enclosure 200 in maintaining the payload at the desired temperature range when arranged in the assembly 900. The VIPs 904-1 to 904-4 may be maintained assembled in an exterior of the inner tub 700 by the flange 712 and the lip 716. When arranged in the assembly 900, the inner tub 700 may protect the VIPs 904-1 to 904-6, which may sharply lose thermal insulation capacity if damaged; additionally, the inner tub 700 may eliminate gaps due to dimensional tolerances of the VIPs 904. The VIPs 904-1 to 904-6 may additionally have a plurality of linings 908-1 to 908-6 that may provide cushioning, and a clean end to the VIPs 904. The linings 908 are foam, or any suitable cushioning material, and in particular examples, the linings 908 are ethyl vinyl acetate (EVA) foam. The linings 908-2 to 908-5 may comprise strips placed between the VIPs 904-2 to 904-5 and an underside of the flange 712, the lining 908-1 may be placed between the VIP 904-1 and the bottom of the inner tub 700, and the lining 908-6 may be placed between the VIP 904-6 and the inner tub lid 912. Although not shown in Figure 7B, VIPs 904-1 to 905-4 may further include linings 908 on the respective sides facing the inner tub 700. Alternatively, instead of five separate VIPs 904-1 to 904-5, a box-shaped cooler with an open end comprised of a highly porous material and membrane walls preventing air from entering the highly porous material could be arranged exterior to the inner tub 700, and a cooler lid conformed to match with the open end of the box-shaped cooler could be provided instead of the VIP 904-6. As a further alternative, instead of the VIPs, any other insulation means, for example urethane,cotton, cellulose, fiberglass, cork, wool, polystyrene foam, etc. in non-panel form could be arranged exterior to the inner tub 700.

[0093] Figure 9B depicts the assembly 900 in an assembled configuration. As shown in Figure 9B, the inner tub lid 912 may be provided between the VIP 904-6 and the payload enclosure 200, to protect the uppermost VIP 904-6 and prevent movement of the payload enclosure 200 within the inner tub 700. . In particular embodiments, the inner tub lid 912 comprises a rigid polymer, although any suitable material may be used. While the inner tub 700 and inner tub lid 912 may facilitate assembling the payload enclosure 200, arranging the VIPs 904-1 to 904-4, and protect the assembly 900, as explained above, an alternative assembly may only comprise the payload enclosure 200 and the VIPs 904- 1 to 904-5, omitting the inner tub 700.

[0094] In some embodiments, the inner tub 700 and VIPs 904 are sized and dimensioned to fit within an outer tub 1000, such as the outer tub 1000 shown in Figure 10A. As shown in Figure 10B, an outer tub lid 1004 may be configured to enclose the inner tub 700 within the outer tub 1000. The outer tub lid 1004 may include a lip 1006 for aligning the outer tub lid 1004 within the opening of the outer tub 1000. To reduce the weight of the outer tub 1000 and the outer tub lid 1004, one or both of the outer tub 1000 and the outer tub lid 1004 may include at least one cut-out 1002. Generally, the outer tub 1000 and the outer tub lid 1004 comprise an open-cell foam or closed-cell foam for insulating the payload and protecting exterior surfaces of the VIPs, and in particular examples, the outer tub 1000 and outer tub lid 1004 comprise expanded polypropylene (EPP), expanded polystyrene (EPS), open cell polyurethane, or closed cell polyurethane, however the outer tub 1000 and outer tub lid 1004 are not particularly limited. Generally, the materials comprising the outer tub 1000 and outer tub lid 1004 are suitable to provide cushioning to the assembly 900 (comprising the VIPs 904, optionally the inner tub 700, the payload enclosure 200, and the payload) and the inner tub lid 912, when the assembly 900 is disposed within the outer tub 1000 and when the outer tub 1000 and the outer tub lid 1004 are arranged in the assembled configuration to enclose the inner tub 700 and the VIPs 904.

[0095] The outer tub 1000 may be further inserted into an outer box to improve handling and protection. Figure 11 A depicts an assembly comprising the payload enclosure, the outer tub, the inner tub, and a plurality of rectangular VIPs, inserted into an outer box 1100 to form a cold chain container. In embodiments that do not include the outer tub 1000, the VIPs, inner tub 700, and payload enclosure 200 may be inserted directly into the outer box 1100.

[0096] The outer box 1100 comprises a box base 1 104, four box walls 1108-1 , 1108- 2, and a closure lid 1112 with a tuck flap 1116. A handle 1120 and a handle lip 1124 may be provided in two of the box walls 608 (for example, 1008-2 and 1008-4).

[0097] The outer box 1100 may additionally comprise a handle lip hole 1128 on the handle lip 1124. Additionally, a grommet 1132, for example a metal grommet, may be provided in the closure lid 1112 at a location matching the handle lip hole 1128 to accommodate a cable tie for tamper-proofing the cold chain container. As shown in Figure 11 B, the outer box 1100 may further include a first notch 1134 on the closure lid 1112 and a second notch 1135 on the box wall 1 108-1 . The first and second notches may accommodate a buckle closure arrangement 1136 formed by two buckle straps anchored to the outer box 1100 at the first and second notches 1134, 1135, for example, by thin metal or plastic rods or plates to which the buckle straps may be sown. The rods or plates sown to the buckle straps may be inserted into the notches 1134, 1135 and attached to an interior of the closure lid 1 112 and the box wall 1108-1 , for example, by riveting, taping or gluing.

[0098] Figure 12 depicts an exploded view of an example assembly 1200 comprising the outer box 1100, the outer tub 1000 and the outer tub lid 1004, and the assembly 900 (including the payload enclosure 200, inner tub 700, and VIPs 904). In this example, the payload enclosure 200 is inserted into the inner tub 700, the VIPs 904 are disposed around the inner tub 700, the assembly 900 is inserted into the outer tub 1000, and the outer tub 1000 is inserted into the outer box 1100.

[0099] Figure 13 depicts a cross-section of the assembly 1200 comprising the outer box 1100, outer tub 1000, VIPs 904, inner tub 700, and payload enclosure 200. In this example, the components of the assembly 1200 are sized and shaped such that thereare substantially no gaps therebetween. While tolerances may vary, it is generally preferred to have little or no gaps in order to avoid relative movement and reduce gaps that may compromise the temperature control function of the cold chain container.

[0100] In some examples, the outer tub 1000 may be omitted. Figure 14A shows an assembly 1400 that includes the payload enclosure 200, the inner tub 700, and the outer box 1100, but does not include the outer tub 1000 or the outer tub lid 1004. An inner tub lid 1402 may be attached to an inner surface of the closure lid 1 112, such that the inner tub lid 1402 is received by the outer vox 1100 when the closure lid 11 12 is in the closed configuration. The inner tub lid 1402 may be attached to the closure lid 1112 with an adhesive, a fastener, or any suitable attachment means. As shown in Figure 14B, the inner tub lid 1402 is sized and dimensioned to receive the VIP 904-6. The inner tub lid 1402 may comprise a rigid polymer material for protecting the VIP 904-6 and attaching the VIP 904-6 to the outer tub lid 1004. The inner tray 1402 may further receive the lining 908-6 for cushioning the VIP 904-6.

[0101] Different configurations of the elements disclosed above may be provided as a kit for assembly of a cold chain container. For example, six rectangular PCM panels 100, an inner tub 700, an inner tub lid 912, six rectangular VIPs 904, and an outer box 1100 may be provided in the kit. Additionally, the kit may further comprise an outer tub 1000 and an outer tub lid 1004. An alternative kit may only comprise the inner tub 700, the inner tub lid 912, the six rectangular VIPs 904, optionally the outer tub 1000 and the outer tub lid 1004, and the outer box 1100, omitting the six rectangular PCM panels 100.

[0102] In various examples, color-coding may be used to communicate different temperature services for particular implementations of containers discussed herein. PCM panels, VIPs, tubs, boxes, etc. may be produced in different colors to describe the temperature service thereof, so as to simplify usage and assembly. The material forming the walls of the PCM panels may be transparent or translucent (e.g., semi-transparent plastic) and the PCM contained therein may be dyed to indicate its useful temperature service.

[0103] As described above, inner tub 800 can house an elongate payload enclosure, such as the payload enclosure 500, using a combination of square (W = L) and elongatePCM panels (W + L). However this can increase the manufacturing costs as compared with a cuboid payload enclosure, such as the payload enclosure 200, which only requires panels of a single size. Furthermore, the assembly time and cost are elevated when assembling elongate panels (W + L), since each panel must be correctly positioned and oriented before insertion into the tub. Accordingly, an elongate assembly formed from only square-shaped panels (W = L) is provided herein.

[0104] Figure 15A illustrates an example of an inner tub 1500 which has two shorter sides 1501 and two longer sides 1502 which are longer than the shorter sides 1501. Despite the non-cuboid shape, the inner tub 1500 can be configured to receive a plurality of PCM panels 100 that are square (W = L). Thus, the arrangement and orientation of the PCM panels 100 are not particularly limiting, and a single set of PCM panels 100 may be compatible with both rectangular tubs and cuboid tubs. In a non-limiting example, PCM panel 100 may be sized and shaped to fit in both inner tub 700 and inner tub 1500. This can simplify the manufacturing and assembly process, particularly in facilities where both elongate and cuboid shipping containers are produced or deployed.

[0105] The inner tub 1500 has an interior 1504 that includes at least one slot 1508-1 , 1508-2, 1508-3, 1508-4 (referred to herein collectively as “slots 1508” or generally as “slot 1408”) for receiving a PCM panel. In this example, the slots 1508 are positioned along the two longer sides 1502 and the two shorter sides 1501 such that the slots 1508-1 , 1508-3 are spaced from the slots 1508-2, 1508-4, however other arrangements are possible. Figure 15B is a top elevation view of the inner tub 1500 showing that the slots 1508 are defined by a pair of retaining walls 1512-1 , 1512-2, 1512-3, 1512-4 which are positioned to retain the PCM panel 100 against a sidewall 1516 of the interior of the inner tub 1500. The retaining walls 1512 are angled to match the beveled perimeters 112 of the rectangular PCM panels 100. The dimensions of the interior 1504 and the retaining walls 1512 may facilitate ease of assembly as well as a tight-fit placement of the PCM panels 100 within the inner tub 1500 to maintain the rectangular PCM panels 100 in an assembled configuration. Furthermore, the tub bottom 1520 may be sized and shaped to accommodate a PCM panel 100. In particular examples, the tub bottom 1520 includes at least one angled surface 1528 for aligning the first PCM panel 100. The tub bottom 1520 may be shaped such that the PCM panel 100-1 positioned along the tub bottom 1520interlocks with the two PCM panels 100-3, 100-5 positioned along the longer sides 1502 of the inner tub 1500 via respective beveled perimeters 112. Similarly, the top PCM panel 100-6 may be positioned across the tub opening such that the top PCM panel 100-6 interlocks with the panels 100-3, 100-5 positioned along the elongate sides via respective beveled perimeters 112.

[0106] Figure 16A is a perspective view of an assembly 1600 including the inner tub 1500 and PCM panels 100. PCM panel 100-2 is inserted into slot 1508-1 , and PCM panel 100-3 is inserted into slot 1508-2.

[0107] Figure 16B is a perspective view of an assembly 1610 including the inner tub 1500 and PCM panels 100. PCM panel 100-6 is disposed on top of PCM panel 100-3 and panel 100-5 (not shown) in order to provide cooling above the payload.

[0108] While inner tub 1500 is adapted for the PCM panels 100 having a double bevelled perimeter 1 12, other embodiments are contemplated.

[0109] Figure 17A shows an inner tub 1700 having slots 1708-1 , 1708-2, 1708-3, 1708-4 configured to receive PCM panels having a single bevelled edge. Figure 17B shows an assembly 1610 which includes the inner tub 1700 with PCM panels 1704-2, 1704-3, 1704-6 inserted therein. The PCM panels 1704 have a bevelled perimeter 1706 on one side, such that the cross-section of the PCM panel 1704 is trapezoidal. The slots 1708 are shaped accordingly to receive the PCM panels 1704 therein, with a pair of retaining walls 1712 that are angled to match the bevelled perimeter 1706. It should be understood that the slots 1708 may receive both single bevel PCM panels (such as PCM panel 1704) and double bevel panels (such as PCM panels 100). Figure 18A shows a top view of the inner tub 1700. Figure 18B shows a front view of the inner tub 1700. Figure 19A shows a bottom view of the inner tub 1700. Figure 19B shows a side view of the inner tub 1700.

[0110] Another exemplary inner tub 2000 is shown in Figure 20A. Inner tub 2000 includes slots 2008-1 , 2008-2, 2008-3, 2008-4 for receiving PCM panels that do not include a bevelled perimeter. Figure 20B shows an assembly 2010 that includes the inner tub 2000 with PCM panels 2004-2, 2004-3, 2004-6 inserted therein. The PCM panels 2004 are unbevelled. Since the PCM panels 2004 are substantially shaped as rectangularprisms, the slots 2008 are shaped accordingly to receive the PCM panels 2004 therein. The slots 2008 include a pair of retaining walls 2012 that are substantially parallel to an inner surface 2016. Figure 21 A shows a top view of the inner tub 1900. Figure 21 B shows a front view of the inner tub 1900. Figure 22A shows a bottom view of the inner tub 1900. Figure 22B shows a side view of the inner tub 2000.

[0111] While the embodiments have been described above with respect to PCM, other embodiments are contemplated. In some embodiments, the panels comprise gel, supersaturated salt solutions, refrigerant, ice, dry ice, or other thermal management materials.

[0112] The scope of the claims should not be limited by the embodiments set forth in the above examples but should be given the broadest interpretation consistent with the description as a whole.

Claims

CLAIMSWhat is claimed is:1 . A container comprising: a first rectangular phase change material (PCM) panel including: two opposing main walls defining a height and a width of the first rectangular PCM panel, the two opposing main walls including beveled perimeters; a perimeter wall joining the two opposing main walls and defining a thickness of the first rectangular PCM panel; and a PCM disposed within a space between the two opposing main walls and the perimeter wall; and a second rectangular PCM panel including complementary beveled perimeters, wherein the first and second rectangular PCM panels are arranged at a right angle to define a payload enclosure when either of the beveled perimeters abuts either of the complementary beveled perimeters.

2. The container of claim 1 further comprising: an inner tub with an interior configured to receive the PCM panels therein; and an inner tub lid; wherein the inner tub and the inner tub lid are arranged to enclose the payload enclosure.

3. The container of claim 2 wherein the inner tub interior has angled surfaces matching the beveled perimeters.

4. The container of claim 2 wherein the inner tub has an outwardly extending flange to accommodate an insulation material positioned in an exterior of the inner tub.

5. The container of claim 4 wherein the insulation material is a rectangular vacuum insulated panel (VIP).

6. The container of claim 1 wherein at least one rectangular vacuum insulated panel (VIP) is positioned in an exterior of the payload enclosure.

7. The container of claim 2 further comprising: an outer tub; and an outer tub lid; wherein the inner tub is disposed within the outer tub and wherein the outer tub and the outer tub lid are arranged to enclose the inner tub and the inner tub lid.

8. The container of claim 2 further comprising an outer box having: a box base; four box walls; and a closure lid with a tuck flap; wherein the inner tub and the inner tub lid are disposed and enclosed within the outer box.

9. The container of claim 7 further comprising an outer box having: a box base; four box walls; and a closure lid with a tuck flap; wherein the outer tub and the outer tub lid are disposed and enclosed within the outer box.

10. The container of claim 8 wherein two of the four box walls have a handle and a handle lip.

11. The container of claim 10 wherein the handle lip has a handle lip hole and wherein the closure lid has a metal grommet at a location matching the handle lip hole to accommodate a cable tie for tamper-proofing the container.

12. The container of claim 8 wherein the closure lid has a first notch and wherein at least one of the four box walls has a second notch to accommodate a buckle closure arrangement formed by two buckle straps anchored to the outer box at the first and second notches.

13. The container of claim 1 wherein the first rectangular PCM panel has: a port disposed within a depression of the perimeter wall for filling the first rectangular PCM panel with the PCM; and a cap for closing the port.

14. The container of claim 1 further comprising: four additional rectangular PCM panels further defining the payload enclosure.

15. A rectangular phase change material (PCM) panel comprising: two opposing main walls defining a height and a width of the rectangular PCM panel, the two opposing main walls including respective beveled perimeters; a perimeter wall joining the two opposing main walls and defining a thickness of the rectangular PCM panel; and a PCM within a space defined by the two opposing main walls and the perimeter wall.

16. The rectangular PCM panel of claim 15 further comprising:a port on a depression of the perimeter wall for filling the rectangular PCM panel with the PCM; and a cap for closing the port.

17. The rectangular PCM panel of claim 15 further comprising at least one reinforcing feature connecting the two opposing main walls, the at least one reinforcing feature selected from the group consisting of: an indentation, a rib, a baffle, and a gusset.

18. The rectangular PCM panel of claim 15 further comprising at least one grip disposed in one of the two opposing main walls, the at least one grip comprising an indentation that sized to accommodate a finger.

19. A kit for a container, the kit comprising: an inner tub; and six rectangular vacuum insulated panels (VIPs); wherein the six rectangular VIPs are configured to be arranged in an exterior of the inner tub; and wherein an outwardly extending flange of the inner tub is configured to accommodate at least one of the six rectangular VIPs in the exterior of the inner tub.

20. The kit of claim 19 further comprising six rectangular phase change material (PCM) panels; wherein a first of the six rectangular PCM panels is configured to be arranged in a bottom of an interior of the inner tub, four of the six rectangular PCM panels are configured to be arranged in a direction orthogonal to the first of the six rectangular PCM panels along sidewalls of the interior of the inner tub, and a sixth of the six rectangular PCM panels is configured to be arranged on a top of the interior of the inner tub parallel to the first of the six rectangular PCM panels.21 . The kit of claim 20 further comprisingan outer tub configured to receive the six rectangular PCM panels, the inner tub, and the six rectangular VIPs.

22. The kit of claim 20 further comprising a box with a closure lid configured to receive and enclose the six rectangular PCM panels, the inner tub, and the six rectangular VIPs.

23. The kit of claim 22 wherein the inner tub includes a plurality of slots for receiving the four PCM panels that are orthogonal to the first PCM panel.

24. The kit of claim 23 wherein at least one of the slots is defined by at least one angled surface.

25. The kit of claim 24 wherein the PCM panels are square, and wherein the plurality of slots are sized and shaped to receive the square PCM panels.

26. The kit of claim 25 wherein the inner tub is rectangular having two shorter sides and two longer sides; wherein the plurality of slots include: a first and third slots defined along opposite shorter sides of the inner tub; and a second and fourth slots defined along opposite longer sides of the inner tub; and wherein the first and third slots are spaced from the second and fourth slots.

27. An inner tub for a container, the inner tub comprising a plurality of slots disposed along sidewalls of the interior of the inner tub, the slots sized and shaped to receive a plurality of rectangular PCM panels.

28. The inner tub of claim 27wherein the plurality of rectangular PCM panels includes a first PCM panel, four side PCM panels, and a sixth PCM panel; and wherein the first PCM panel is configured to be arranged in a bottom of an interior of the inner tub, the four side PCM panels are configured to be received by the plurality of slots in a direction orthogonal to the first PCM panel, and the sixth PCM panel is configured to be arranged on a top of the interior of the inner tub, parallel to the first PCM panel.

28. The inner tub of claim 27 wherein each of the plurality of slots are defined by a retaining surface configured to retain one of the rectangular PCM panels against one of the sidewalls of the inner tub.

29. The inner tub of claim 28 wherein the retaining surface is angled to match a beveled perimeter of the plurality of rectangular PCM panels.

30. The inner tub of claim 29 wherein the bottom of the inner tub bottom includes an angled surface to match the beveled perimeter of the first PCM panel.31 . The inner tub of claim 27 wherein the inner tub is rectangular having two opposing shorter sides and two opposing longer sides; wherein the plurality of slots include: a first and third slot defined along each of the two opposing shorter sides; and a second and fourth slot defined along each of the two opposing longer sides of the inner tub; and wherein the first and third slots are spaced from the second and fourth slots.

32. The inner tub of claim 27 comprising a rigid polymer.

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