Temperature control transport container with durable polymer coating

Abstract

A temperature control transport container (10) includes a first sensor (20) and a plurality of panel assemblies (12, 14, 16, 18) that collectively define a volume configured to receive a temperature sensitive product (32). The first panel assembly (12) includes a panel core (40) and a first data logger (62). The panel core (40) includes inner and outer surfaces (48, 50). At least a portion of the outer surface (50) of the panel core (40) includes a durable polymer coating (36). The first data logger (62) is positioned either: at least within a recessed portion (60) of the outer surface (50), wherein the durable polymer coating (36) is positioned between the panel core (40) and the first data logger (62), or at least partially between the inner and outer surfaces (48, 50), wherein the durable polymer coating (36) extends beyond an outer surface (176) of the first data logger (62).

Description

TEMPERATURE CONTROL TRANSPORT CONTAINER WITH DURABLE POLYMER COATINGAPPLICATION FIELD

[0001] This application relates generally to cold chain or temperature-controlled shipping, and more specifically to cold chain shipping.BACKGROUND

[0002] Various high value items are required to be shipped (preferably by air freight or container for both ocean and land transportation) within a temperature-controlled container. These high value items may include medicines (e.g., vaccines, organic compositions, individually developed treatments, and / or perishable medical material), food & beverage (e.g., seafood, spices, meat, yeast, and / or easily perishable edibles, diary, alcohol, etc.), and / or plants (e.g., flowers and / or seeds). For bulk loads, pallet sized loads, and other similarly sized loads, larger insulated shipping containers may include insulating features to minimize loss due to ambient conditions.

[0003] Generally, there are two types of containers: active containers and passive containers. Active containers actively control a shipping container’s cargo temperature, and include an electronic means to sense the temperature of the cargo bay. Autonomous control system directs heating and cooling actuators and associated systems maintain and correct for temperature deviations. Passive systems generally incorporate pre-conditioned material for thermal capacitance. These pre-conditioned materials may include phase change materials (PCM) for latent capacity of non PCM materials for sensible capacity, PCM mediums can also include dry ice (DI). The efficacy is related to performance, duration, and weight. Performance attributes include proper regulation of the cargo temperature over various shapes and sizes of cargo, overcoming loss due ambient exposure of the container (both environmental and radiated), and uniformity of thermal regulation over the volume and geometry of the load. Adequate duration is desirable based on the anticipated period of transportation. Weight contributes significantly to freight costs.

[0004] Collapsible insulative shipping systems have a limited lifecycle due to properties of the insulative materials the outer panel assemblies are made from. Rigid container insulative shipping systems are far more durable with outer skins constructed of materials such as aluminum. While rigid container insulative shipping systems offer repeated reusability, they are heavy and costly to ship and reposition after use. Additionally, damage is costly and time consuming to repair putting the whole system out of service until complete. Challenges include a robust and straightforward method of assembly and adhesion, accuracy and repeatability, weight, durability, material cost and supply, manufacturing time, and recyclability.

[0005] As a result, it is desirable to produce a durable collapsible container that is capable of being repeatedly reused.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate examples of the invention, and, together with the general description of the invention given above, and the detailed description of the examples given below, serve to explain the principles of the present invention.

[0007] FIG. 1 depicts a front perspective view of an example of a temperature control transport container, where the container includes a data logger assembly;

[0008] FIG. 2 depicts an exploded perspective view of the container of FIG. 1 but prior to the application of the durable polymer coating, where the container includes end panel assemblies, side panel assemblies, a top panel assembly, a bottom panel assembly, edge protectors, corner protectors, a sensor, and the data logger assembly;

[0009] FIG. 3 depicts an enlarged exploded perspective view of the end panel assembly and the data logger assembly of FIG. 2;

[0010] FIG. 4 depicts an enlarged exploded perspective view of the side panel assembly, corner protectors, and edge protectors of FIG. 2;

[0011] FIG. 5 depicts an enlarged exploded perspective view of the top panel assembly, corner protectors, and edge protectors of FIG. 2;

[0012] FIG. 6 depicts an enlarged perspective view of the bottom panel assembly and pallet of FIG. 2;

[0013] FIG. 7A depicts a schematic sectional view of an example of a durable polymer coating applied to the end panel assembly of FIG. 4, where the durable polymer coating has a first thickness for an outer surface of the end panel assembly and a second thickness on the inner surface of the end panel assembly;

[0014] FIG. 7B depicts a schematic sectional view of another example of a durable polymer coating applied to the end panel assembly of FIG. 4, where the durable polymer coating includes two layers on an outer surface of the end panel assembly and a single layer on an inner surface of the end panel assembly;

[0015] FIG. 8 depicts an enlarged perspective view of a detailed portion of FIG. 1 that includes the end panel assembly and the data logger assembly of FIG. 1, where the data logger assembly is positioned within a recessed portion of an outer surface of the end panel core;

[0016] FIG. 9 depicts a perspective sectional view of the end panel assembly and the data logger assembly of FIG. 4;

[0017] FIG. 10 depicts an enlarged exploded perspective view of the data logger assembly of FIG. 8;

[0018] FIG. 11 depicts a wire extending from the data logger to the sensor positioned within a temperature sensitive product;

[0019] FIG. 12 depicts a perspective view of the data logger being positioned completely within an internal cavity disposed between inner and outer surfaces of the end panel assembly of FIG. 4 that includes the durable polymer coating;

[0020] FIG. 13 depicts a sectional view of the data logger of FIG. 12 and a sensor positioned within the durable polymer coating taken along line 13-13 of FIG. 12;

[0021] FIG. 14 depicts an exploded perspective view of the sensor and a portion of the end panel core of FIG. 12;

[0022] FIG. 15 depicts the container of FIG. 1 in a non-assembled configuration;

[0023] FIG. 16 depicts an enlarged perspective view of an edge of a side panel core of FIG.2 including the durable polymer coating on select portions of the edge;

[0024] FIG. 17 depicts a portion of a side panel assembly of FIG. 4 in abutting contact with an end panel assembly of FIG. 5;

[0025] FIG. 18A depicts another example of a corner protector for use with the container of FIG. 1;

[0026] FIG. 18B depicts another example of an edge protector for use with the container of FIG. 1;

[0027] FIG. 19 depicts a perspective view of the container of FIG. 1 in a partially assembled configuration;

[0028] FIG. 20 depicts an enlarged perspective view of a handle and a tensioning strap extending through a loop of the handle of the container of FIG. 1;

[0029] FIG. 21 depicts a first example of a method of manufacturing the container of FIG. 1; and

[0030] FIG. 22 depicts a second example of a method of manufacturing the container of FIG. 1.

[0031] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.DETAILED DESCRIPTION

[0032] The following description of certain examples of the technology should not be used to limit its scope. Other examples, features, aspects, embodiments, and advantages of the technology will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the technology. As will be realized, the technology described herein is capable of other different and obvious aspects, all without departing from the technology. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

[0033] I. Example of Temperature Control Transport Container

[0034] A. Overview

[0035] FIGS. 1-2 show an example of a temperature control transport container (10). Container (10) includes a plurality of panel assemblies, which are shown as two end panel assemblies (12), two side panel assemblies (14), a top panel assembly (16), and a bottom panel assembly (18). However, more or fewer panel assemblies (12, 14, 16, 18) are envisioned. Panel assemblies (12, 14, 16, 18) are configured to be converted by a user between an assembled configuration (see FIG. 1) and a non-assembled configuration (see FIG. 15). In the assembled configuration, end panel assemblies (12) are disposed opposite each other. Similarly, side panel assemblies (14) are disposed opposite each other and extend between end panel assemblies (12). End and side panel assemblies (12, 14) are disposed between top panel assembly (16) and bottom panel assembly (18) to collectively enclose container (10) in the assembled configuration. Container (10) may be repeatedly reused (e.g., about 2-10 times), and may optionally include minor refurbishment between successive uses.

[0036] As shown in the exploded perspective view of FIG. 2, container (10) includes sensors (20), temperature stabilization modules (22), load spreaders (24), load separators (26), corner protectors (28), edge protectors (30), and temperature sensitive product (32) arranged on a product pallet (34). In the assembled configuration of FIG. 1, panel assemblies (12, 14, 16, 18) collectively define a volume configured to receive temperature sensitive product (32). Temperature stabilization modules (22) may include aqueous-based petrochemical, organic and inorganic PCM mediums. Temperature stabilization modulesachieve absorb and / or release energy by changing states or phases, most commonly from a solid to a liquid, although sublimation can effectively mean a medium skips a phase change stage. Temperature stabilization modules (22) may be used to maintain a product temperature range of about -90°C to about -60°C (ultra low), about -60°C to about -40°C (deep frozen), about -20°C to about -30°C (frozen), about 2°C to about 8°C (chilled), or about 15°C to about 25°C (control room temperature). Temperature stabilization modules (22) may provide other temperature levels and ranges if desired. Water goes through the liquification / solidification phase change at 0°C which is a few degrees colder than one exemplary temperature for shipping temperature sensitive goods with a temperature range of about 2°C to about 8°C, to counteract the cooling effect, sensible heat is added to the latent heat. Non-aqueous based temperature stabilization modules have an engineered phase change point at the desired product temperature (i.e., about 5°C for chilled shipments).

[0037] Container (10) transports product pallet (34) of temperature sensitive product (32) and maintains a desired product temperature for a duration of up to 120 hours. Temperature sensitive product (32) may include pharmaceutical, food, beverage and / or chemical products. The desired temperature may vary depending on the temperature sensitive product (32) contained within container (10). While container (10) is sized and configured to protect a pallet side load of temperature sensitive product (32), container (10) may have other sizes suitable for smaller loads or larger loads and / or for various other durations of time. Load spreaders (24) and load separators (26), are shown as extruded polypropylene and polycarbonate sheets; however, other materials for load spreaders (24) are also envisioned. Nine temperature stabilization modules (22), arranged in three rows of three, are disposed between bottom panel assembly (18) and lower load spreader (24), and eighteen temperature stabilization modules (22) are disposed between upper load spreader (24) and top panel assembly (16) arranged in two layers with each layer being three rows of three. However, more or fewer temperature stabilization modules (22) are envisioned. Load separators (26) separate the three rows. As shown in FIG. 2, panel assemblies (12, 14, 16, 18) may include an optional vacuum insulated panels (VIPs) (38). While each panel assembly (12, 14, 16, 18) is shown as including VIP (38), VIPs (38) may be included in some or none of panel assemblies (12, 14, 16, 18).

[0038] As will be described in greater detail, a durable polymer coating (36, 36a) may be applied to select portions of panel assemblies (12, 14, 16, 18) or an entirety of individual panel assemblies (12, 14, 16, 18). Panel assemblies (12, 14, 16, 18) with durable polymer coating (36, 36a) are intended to be scratch, scuff, impact, and chemical resistant. For example, panel assemblies (12, 14, 16, 18) are sufficiently durable to be repeatedly reused. Panel assemblies (12, 14, 16, 18) are configured to be easily inspected, repaired if needed, or discarded if desired. Durable polymer coating (36, 36a) may increase the durability of panel assemblies (12, 14, 16, 18) during shipping, usage and return of container (10) to maintain the thermal and mechanical properties of panel assemblies (12, 14, 16, 18).

[0039] As shown, each panel assembly (12, 14, 16, 18) includes a unique electronic identifier (39) that is different for each panel assembly (12, 14, 16, 18). For example, a first end panel assembly (12) includes a first unique electronic identifier (39), and second end panel assembly (12) includes a second unique electronic identifier (39). Likewise, a first side panel assembly (14) includes a third unique electronic identifier (39), and a second side panel assembly (14) includes a fourth unique electronic identifier (39). Top panel assembly (16) includes a fifth unique electronic identifier, and bottom panel assembly (18) includes a sixth unique electronic identifier (39). Unique electronic identifier (39) may include a Radio Frequency Identification (RFID) tag. Alternatively, unique electronic identifier (39) may include a Near Field Communication (NFC) tag, a low energy device such as a Bluetooth Low Energy (BLE) device, or a cellular device. RFID and NFC rely on radio frequency for communication purposes, whereas BLE utilizes the 2.4 GHz ISM band for field communication. RFID may be used for long-range applications, whereas NFC may be used for short-range applications. Each RFID tag, NFC tag, and / or BLE device may be positioned entirely within one of panel cores (40, 78, 106, 120) that includes durable polymer coating (36, 36a) as shown and described below. Unique electronic identifier (39) allows for tracking on a panel assembly by panel assembly basis.

[0040] B. Example of End Panel Assembly

[0041] As shown in FIGS. 2-3, each end panel assembly (12) includes an end panel core (40), a flexible holder (42), a liner member (44), and a data logger assembly (46). End panel core (40) includes an inner surface (48), an outer surface (50), and an edge (52)extending between inner and outer surfaces (48, 50). Edge (52) includes an outer portion (53) and an inner portion (55). Outer portion (53) is perpendicular inner and outer surfaces (48, 50), and inner portion (55) is mitred and may function as a sealing surface. At least outer surface (50) of end panel core (40) includes durable polymer coating (36). Outer surface (50) extends outwardly away from temperature sensitive product (32), and inner surface (48) extends inwardly toward temperature sensitive product (32). While first panel assembly is shown and described as end panel assembly (12), it is envisioned that first panel assembly may alternatively be one of side panel assemblies (14), top panel assembly (16), or bottom panel assembly (18). As will be described in greater detail with reference to FIG. 8-11, end panel core (40) includes a recessed portion (60) configured to receive data logger assembly (46). Data logger assembly (46) includes a data logger (62), a flexible insert (64), and an exterior data logger cover (66). Data logger (62) is positioned within recessed portion (60) of end panel core (40) includes durable polymer coating (36) and is protected by exterior data logger cover (66). Data logger (62) is in communication with sensor (20) and may be in communication with optional unique electronic identifier (39).

[0042] End panel core (40) is in direct contact with durable polymer coating (36). As shown, durable polymer coating (36) is in direct contact with and covers an entirety of end panel core (40). In other words, inner surface (48), outer surface (50), and edge (52) are each covered with durable polymer coating (36). End panel core (40) includes at least one of expanded polystyrene, extruded polystyrene, expanded polypropylene, or polyurethane. For example, end panel core (40) may include expanded polystyrene with a graphite additive. At least one optional VIP (38) may be embedded within end panel core (40), or alternatively may be inserted into or operatively coupled with end panel assembly (12). For example, VIP (38) may be positioned on inner surface (48) of end panel core (40). A portion of surface area of VIP (38) may include durable polymer coating (36). In some versions, an entirety of the outer surface area of VIP (38) includes durable polymer coating (36).

[0043] Flexible holder (42) includes a cavity (54) is configured to retain at least one temperature stabilization module (22) therein. As shown, cavity (54) of flexible holder (42) receives two rows of four temperature stabilization modules (22) within each row.Flexible holder (42) is removably coupled with end panel core (40) and is detachable for refurbishment or replacement. Flexible holder (42) is removably coupled with end panel core (40) using hook and loop fasteners; however, other coupling methods are also envisioned including adhesive and / or fasteners. Hook and loop fasteners are commercially available from Velcro IP Holdings LLC. For example, end panel core (40) may include a first portion (70) of hook and loop fasteners, and flexible holder (42) may include a second portion (72) of hook and loop fasteners. For example, first portion (70) may be the hook portion, and second portion (72) may be the loop portion. In some versions, flexible holder (42) may be formed from corrugated plastic (e.g., corrugated polypropylene). Liner member (44) may include an optional cover (56). In some versions, optional cover (56) is formed from molded acrylonitrile butadiene styrene (ABS). Liner member (44) includes a sensor holder (58) configured to fix the position of sensor (20) to ensure consistent measurements of sensor (20), which may be a temperature sensor configured to measure the temperature of the internal volume of container (10).

[0044] C. Example of Side Panel Assembly

[0045] FIG. 4 shows an enlarged exploded perspective view of side panel assembly (14), corner protectors (28), and edge protectors (30) of FIG. 2. As shown, each side panel assembly (14) includes a side panel core (78), a flexible holder (80), a liner member (82), and handles (84) (see FIG. 1). Flexible handles (84) are shown as being positioned adjacent edges of side panel assemblies (14). While six handles (84) are shown in FIG. 1, more or fewer handles (84) are envisioned. For example, FIG. 2 shows top panel core (106) and side panel cores (78) each including handles (84).

[0046] Side panel core (78) includes an inner surface (86), an outer surface (88), and an edge (90) extending between inner and outer surfaces (86, 88). At least outer surface (88) of side panel core (78) includes durable polymer coating (36). Outer surface (88) extends outwardly away from temperature sensitive product (32), and inner surface (86) extends inwardly toward temperature sensitive product (32). Edge (90) includes an inner portion (92) and an outer portion (94). Outer portion (94) includes first and second lateral rebate portions (96, 98) configured to abut edges (52) of adjacent end panel cores (40) of end panel assemblies (12) in the assembled configuration. End panel cores (40) do not includefirst and second lateral rebate portions (96, 98). However, end panel cores (40) may include first and second lateral rebate portions (96, 98) instead of side panel core (78). Inner portion (94) is mitred and may function as a sealing surface.

[0047] Side panel core (78) may be coupled with corner protectors (28) and / or edge protectors (30) prior to or after the application of durable polymer coating (36) to side panel core (78). In some versions, side panel core (78) is coupled with comer protectors (28) prior to the application of durable polymer coating (36) and side panel core (78) is coupled with edge protectors (30) after the application of durable polymer coating (36) to side panel core (78). Corner protector (28) may be included at comers of adjacent panel assemblies (12, 14, 16, 18). Comer protectors (28) and / or edge protectors (30) may be adhered to or within durable polymer coating (36) to offer increased strength at predetermined locations of container (10). Comer protectors (28) and / or edge protectors (30) protect container (10) from potential damage associated with users dragging and / or pivoting container (10) on corners. Coating a specific panel core (40, 78, 106, 120) together with corner protector (28) and / or edge protector (30) further increases the protection provided and reduces the likelihood that comer protector (28) and / or edge protector (30) are inadvertently broken off. Durable polymer coating (36) may permanently couple one or more corner protectors (28) and / or one or more edge protectors (30) with specific panel cores (40, 78, 106, 120).

[0048] Corner protectors (28) may be formed from plastic, paperboard, and / or metal. Edge protectors (30) may be formed form plastic, paperboard, and / or metal. For example, edge protectors (30) may consist of extruded plastic, which may be rigid or flexible. Edge protector (30) may be coupled (e.g., adhered using adhesive) with two adjoining panel assemblies, edge protector (30) is configured to protect lateral edges of panel assemblies (12, 14, 16, 18).

[0049] Durable polymer coating (36) may bond variations of insulative materials together to form a robust panel assembly (12, 14, 16, 18). Components added to the coated panel assembly (12, 14, 16, 18) to be easily detachable whether permanently or temporarily to aid the speed of refurbishment of panel assembly (12, 14, 16, 18) or to increase the lifecycle of panel assembly (12, 14, 16, 18) by replacement of less durable components, which may only be used once (i.e., single use components). Flexible holder (80) is removably coupledwith side panel core (78). For example, inner surface (86) of side panel core (78) may include a first portion (100) of hook and loop fasteners, and flexible holder (80) may include a second portion (102) of hook and loop fasteners; however, this may vary. Flexible holder (80) includes a cavity (104) configured to retain at least one temperature stabilization modules (22) therein.

[0050] D. Example of Top Panel Assembly

[0051] FIG. 5 shows an enlarged exploded perspective view of top panel assembly (16), corner protectors (28), and edge protectors (30) of FIG. 2. Top panel assembly (16) includes a top panel core (106) that may be coupled with corner protectors (28) and / or edge protectors (30) prior to the application of durable polymer coating (36). Top panel core (106) includes an inner surface (108), an outer surface (110), and an edge (112) extending between inner and outer surfaces (108, 110). At least outer surface (110) of top panel core (106) includes durable polymer coating (36). Outer surface (110) extends outwardly away from temperature sensitive product (32), and inner surface (108) extends inwardly toward temperature sensitive product (32). Edge (112) includes an outer portion (114), an intermediate portion (116), and an inner portion (118). Outer portion (114) is perpendicular to inner and outer surfaces (108, 110). Intermediate portion (116) extends parallel to inner and outer surfaces (108, 110) and is positioned between outer and inner portions (114, 118). Inner portion (118) is mitred and may function as a sealing surface.

[0052] E. Example of Bottom Panel Assembly

[0053] FIG. 6 shows an enlarged perspective view of bottom panel assembly (18) including a pallet (122). Top panel assembly (16) includes a bottom panel core (120) that may be operatively coupled with pallet (122) prior to the application of durable polymer coating (36). Similar to top panel core (106), bottom panel core (120) includes an inner surface (124), an outer surface (126), and an edge (128) extending between inner and outer surfaces (124, 126). At least outer surface (126) of bottom panel core (120) includes durable polymer coating (36). Outer surface (126) extends outwardly away from temperature sensitive product (32), and inner surface (124) extends inwardly toward temperature sensitive product (32). Edge (128) includes an outer portion (130), an intermediate portion(132), and an inner portion (134). Outer portion (130) is perpendicular to inner and outer surfaces (124, 126). Intermediate portion (132) extends parallel to inner and outer surfaces (124, 126) and is positioned between outer and inner portions (130, 134). Inner portion (134) is mitred and may function as a sealing surface.

[0054] Pallet (122) includes a raised outer lip (136) configured to receive end panel cores (40) and side panel cores (78). Raised outer lip (136) of pallet (122) together with intermediate portion (132) and inner portion (134) of bottom panel assembly (18) collectively define a rebate channel (138) see FIG. 19) configured to receive edge (52) of end panel assemblies (12) and edge (90) of side panel assemblies (14) in the assembled configuration. In some versions, pallet (122) may have a thickness of about 6 mm.

[0055] F. Examples of Durable Polymer Coatings

[0056] FIG. 7A shows a schematic sectional view of durable polymer coating (36) applied to end panel core (40) of end panel assembly (12) of FIG. 4. Durable polymer coating (36) is applied to inner surface (48), outer surface (50) and edge (52) of end panel core (40) as a single layer. In some versions, a portion of each panel assembly (12, 14, 16, 18) includes durable polymer coating (36). In some versions, the thickness of durable polymer coating (36) varies depending on the risk of potential damage to that particular surface. Single layer (140) of durable polymer coating (36) has a first maximum thickness (Tl) on outer surface (50) of end panel core (40) and a second maximum thickness (T2) on inner surface (48) of end panel core (40). Second maximum thickness (T2) is less than first maximum thickness (Tl). As shown moving inwardly toward temperature sensitive product (32), end panel assembly (12) includes durable polymer coating (36) with first maximum thickness (Tl), end panel core (40), durable polymer coating (36) with second maximum thickness (T2), first portion (70) of hook and loop fasteners, second portion (72) of hook and loop fasteners, an outer wall of flexible holder (42), cavity (54) receiving temperature stabilization modules (22), an inner wall of flexible holder (42), liner member (44), and sensor holder (58) coupled with sensor (20). Durable polymer coating (36) may include a polyurea coating having a thickness of about 0.5 millimeter to about 3.0 mm. However, other durable polymer coatings (36) are also envisioned including polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, and acrylic.

[0057] FIG. 7B shows a schematic sectional view of another example where multiple layers of durable polymer coating (36a) are applied to end panel core (40a) of end panel assembly (12a) of FIG. 3. Durable polymer coating (36a) includes first and second layers (142, 144) on outer surface (50) of end panel core (40). Data logger (62) is configured to communicate with sensor (20). Each sensor (20) is configured to sense at least one condition of temperature control transport container (10). It is beneficial to know the position and / or condition of container (10), including at an individual panel assembly level (RFID and / or GPS). As shown moving inwardly toward temperature sensitive product (32), second layer (144) of durable polymer coating (36a) with a third thickness (T3), first layer (142) of durable polymer coating (36a) with second thickness (T2), end panel core (40) including sensor (20) and unique electronic identifier (39), first layer (142) of durable polymer coating (36a) with a first thickness (T2), first portion (70) of hook and loop fasteners, second portion (72) of hook and loop fasteners, an outer wall of flexible holder (80), cavity (104) receiving temperature stabilization modules (22), an inner wall of flexible holder (80), liner member (44), and sensor holder (58) coupled with sensor (20).

[0058] It is desirable to minimize damage (e.g., cracks and / or holes) to panel assemblies that may affect insulative qualities of container (10). Outer surfaces (50, 88, 110, 126) of panel assemblies (12, 14, 16, 18) are protected during use to resist shipping damages. Outer surfaces (50, 88, 110, 126) of panel assemblies (12, 14, 16, 18) generally encounter the most wear and potential damage during use. Multiple mechanical handling points, including road transport, air transport, and / or mechanical handling machinery such as forklift trucks during loading and unloading may cause damage. Inner surfaces (48, 86, 108, 124) face experience wear and tear during assembly, disassembly, and flat packing. Container (10) may be manually handled during assembly and disassembly. Durable polymer coating (36, 36a) ensures that panel assemblies (12, 14, 16, 18) do not sustain damage when being stacked flat after use and returned for reuse. Durable polymer coating (36) protects panel assemblies (12, 14, 16, 18) during the process of stacking and storing panel assemblies (12, 14, 16, 18) during disassembly and preserves the integrity of panel assemblies (12, 14, 16, 18) during return to a service center to be prepared for reuse. After disassembly, each panel assembly (12, 14, 16, 18) is separate, and therefore, vulnerable to damage on inner surfaces (48, 86, 108, 124), outer surfaces (50, 88, 110, 126), internal andedge seals. Durable polymer coating (36, 36a) protects edges (52, 90, 112, 128) of panel assemblies (12, 14, 16, 18) from sustaining damage (including cracks, dents or pieces to be broken away). Protecting edges (52, 90, 112, 128) of panel assemblies (12, 14, 16, 18) maintains thermal performance and sealing of container (10).

[0059] As a result, it may be desirable to coat one or more panel assemblies (12, 14, 16, 18) in a non-uniform manner, which allows durable polymer coating (36, 36a) to provide adequate durability while minimizing the additional weight due to the durable polymer coating (36). Different surfaces may have differing layers and / or different thicknesses to provide the desired level of protection. For example, outer surfaces (50, 88, 110, 126) may have about a 2 millimeter thickness to withstand external impacts, whereas inner surfaces (48, 86, 108, 124) may have about a 1 millimeter thickness due to the likelihood of fewer impacts. Edges (52, 90, 112, 128) may have a durable polymer coating thickness of about 0.5 millimeters.

[0060] Durable polymer coating (36) allows for data logging, tracking, and data storage devices to be embedded within panel assemblies (12, 14, 16, 18) for effective management of panel assemblies (12, 14, 16, 18) for reuse and support ofin use shipments. For example, durable polymer coating (36, 36a) may encapsulate individual panel assemblies (12, 14, 16, 18) including sensor (20) and / or data logger (62). This allows tracking and identification during assembly, transit, use, and return to global service centers.

[0061] Container (10) provides reusability like a completely rigid shipping system without the increased shipping and repositioning costs or time-consuming repairs where the entire rigid container is out of commission for the duration oof the repair. Should a specific panel assembly (12, 14, 16, 18) sustain damage, repairs may be performed to that specific panel assembly (12, 14, 16, 18), while the remaining panel assemblies (12, 14, 16, 18) are returned to stock and reused. The collapsibility of panel assemblies (12, 14, 16, 18) provides reduced space requirements and ability to stack for efficient return, repositioning and reuse of container (10), while durable polymer coating (36, 36a) ensures this may be achieved with limited damage. Durable polymer coating (36, 36a) allows panel assemblies (12, 14, 16, 18) to provide superior performance during use and of reuse and managementby the customer and / or manufacturer. Container (10) ensures that the lifecycle of materials is maximized prior to being disposed.

[0062] G. Example of Sensor and / or Data Logger Positioned Within RecessedPortion

[0063] At least one of sensor (20) or data logger (62) is positioned within a recessed portion(60) of outer surface (50) of end panel core (40) that includes durable polymer coating (36). FIGS. 8-9 show data logger (62) positioned within recessed portion (60) of outer surface (50) of end panel core (40). Particularly, FIG. 8 shows an enlarged perspective view of a detailed portion of FIG. 1 that includes end panel assembly (12) and data logger assembly (46) of FIG. 1, and FIG. 9 shows a perspective sectional view of end panel core (40) and data logger assembly (46) of FIG. 4. Data logger assembly (46) includes a data logger (62), a flexible insert (64), and an exterior data logger cover (66). Depth (D) of recessed portion (60) depends on the thickness of data logger assembly (46).

[0064] FIG. 10 shows an enlarged exploded perspective view of data logger assembly (46) of FIG. 1. Data logger (62) includes a screen (146), buttons (148), a communication antenna (150), a memory (152) and a processor (154). Data logger (62) is configured to communicate with one or more sensors (20), with two shown in FIG. 2. Data logger (62) is also configured to communicate with one or more user devices using communication antenna (150), so that the user can track the conditions tracked by data logger in real time at any location. One such suitable data logger (62) is commercially available from Frigga of Shanghai, China. Other suitable data loggers (62) are also envisioned. Flexible insert (64) is generally U-shaped and secures data logger (62) in position. Exterior data logger cover (66) includes apertures (156) configured to allow for air and / or moisture transfer. Durable polymer coating (36) may be sprayed over exterior data logger cover (66) to embed data logger (62) within end panel core (40). Data logger (62) may determine ambient temperature through apertures (156). Regarding routing and management of wire(s) (166), wire(s) (166) are routed through container (10).

[0065] Data logger (62) is positioned entirely within recessed portion (60) of outer surface(50) of end panel core (40) that includes durable polymer coating (36) so as not to extendoutwardly from end panel core (40). As shown in FIG. 10, recessed portion (60) includes first side wall (158), second side wall (160), inner wall (162), and bottom wall (164). Recessed portion (60) opens up to edge (52) on top of end panel core (40). Each end panel assembly (12) is shown as including durable polymer coating (36) and a data logger (62). In some versions, opposing end panel assembly (12) includes a second sensor (20), which may measure the same or a different measurement compared to first sensor (20). At least one of sensor (20) or data logger (62) is positioned within recessed portion (60) formed in outer surface (50) of end panel core (40).

[0066] FIG. 11 shows a wire (166) extending from data logger (62) to sensor (20) positioned within a temperature sensitive product (32). Sensor (20) includes a temperature probe (174) that is shown in contact with product but which may alternatively be fixably secured with an inner surface of liner member (44) to ensure consistent temperature measurement.

[0067] Sensors (20) may include one or more of a temperature sensor, a global positioning sensor, an accelerometer, a light detector, a pressure sensor, or a hygrometer. For example, the accelerometer may measure G-force, shock, and / or orientation of end panel core (40) to determine whether end panel core (40) is right side up as shown in in FIG. 1, on its side, or upside down. The pressure sensor may measure pressure (e.g., internal and / or external conditions of container (10) such as the pressure of a plane hold). The hygrometer may measure moisture content within container (10). Sensor (20) may include a tracking device, such as GPS, RFID, NFC, BLE, cellular components, embedded within panel assembly (12, 14, 16, 18) to allow for tracking, data logging, monitoring, and management services to increase reuse efficiency. Embedded tracking and logging capabilities for data collection provides efficient positioning and traceability of panel assemblies (12, 14, 16, 18) during transit to customer, usage by customer, or transit from customer (return logistics).

[0068] One of sensors (20), in the form of a fixed position integration temperature probe, together with data logger (62) provides consistent internal and external temperature monitoring for container (10). Sensor (20) may communicate wirelessly with data logger (62). Multiple embedded sensors (20) for internal and external temperature monitoringcommunicating wirelessly to a data logger (62). Sensors (20) may each communicate with a single data logger (62) or multiple data loggers (if desired). Apertures (156) allow for ambient temperature tracking. Wireless charging may provide power to data logger (62). Inner surfaces (48, 86, 108, 124) of panel assemblies (12, 14, 16, 18) may experience a low temperature of about -20°C and a high temperature of about +20°C. Outer surfaces (50, 88, 110, 126) of panel assemblies (12, 14, 16, 18) may experience low temperatures of about -20°C and high temperatures of about +50°C.

[0069] H. Example of Sensor and / or Data Logger Positioned Within InternalCavity

[0070] FIGS. 12-14 show sensor (20) and data logger (62) positioned at least partially between inner and outer surfaces (48, 50) of end panel core (40). Durable polymer coating (36) extends at least partially over an outer surface (176) of data logger (62). FIG. 12 shows a perspective view of data logger (62) positioned completely within an internal cavity (168) disposed between inner and outer surfaces (48, 50) of end panel core (40) of FIG. 4 that includes durable polymer coating (36). Another sensor (20) is shown partially between the inner and outer surfaces (48, 50) of end panel core (40). Durable polymer coating (36) extends outwardly away from a center of container (10) at least partially beyond outer surface (176) of data logger (62).

[0071] FIG. 13 shows a sectional view of FIG. 12 taken along line 13-13 where sensor (20) is positioned within durable polymer coating (36). FIG. 14 shows an exploded perspective view of sensor (20) of FIG. 11 and a portion of end panel core (40). Sensor (20) may sense an ambient temperature and may be positioned entirely within inner and outer surfaces (48, 50) where a small aperture extends through durable polymer coating (36). Data logger (62) is positioned adjacent sensor (20). Sensor (20) has an outer surface (180) that is in direct contact with durable polymer coating (36). Data logger (62) is completely within an internal cavity (168) of end panel core (40) that includes durable polymer coating (36). Sensors (20) may communicate wirelessly with data logger (62). For example, sensor (20) and second sensor may communicate wirelessly with data logger (62) using Bluetooth. Data logger (62) may be charged wirelessly.

[0072] FIG. 15 shows container (10) of FIG. 1 in the non-assembled configuration. In the non-assembled configuration, panel assemblies (12, 14, 16, 18) are stacked for storage or shipment and do not define the volume. The non-assembled, flat pack, configuration, allows container (10) to be returned efficiently for refurbishment / cleansing and reuse efficiently at lower cost. This non-assembled configuration may reduce the volume by about 2 / 3. Applying the durable polymer coating (36) to panel assemblies (12, 14, 16, 18) and not the entire container (10) as a single unitary component allows for additional flexibility. In some versions, two panel assemblies (12, 14, 16, 18) may be coupled and then collectively coated with durable polymer coating (36).

[0073] FIGS. 16 and 17 show select portions of another side panel core (78a) not including durable polymer coating (36). FIG. 16 shows select mating surfaces of side panel core (78a). As shown, inner surface (86), outer surface (88), and a select portion of edge (90) including durable polymer coating (36). Regarding edge (90a), inner portions (92a) do not include durable polymer coating (36) unlike inner portions (92) of FIG. 4. Similar to FIG. 4, outer portion (94), first lateral rebate portion (96), and second lateral rebate portion (98) each include durable polymer coating (36).

[0074] FIG. 17 shows a portion of end panel assembly of FIG. 4 in abutting contact with a side panel assembly of FIG. 5. Panel assemblies (12, 14, 16, 18) have mating surfaces configured to be in abutting contact. At least some of mating surfaces of panel assemblies (12, 14, 16, 18) do not include durable polymer coating (36) to minimize thermal bridging. As shown, mating surfaces include a mitred edge. A portion of each panel assembly (12, 14, 16, 18) includes durable polymer coating. Selective application of durable polymer coating (36) may keep thermal bridges between adjacent panel assembly (12, 14, 16, 18) to a minimum. A thermal bridge may be considered a “path” of energy transport. By making this “path” longer and creating a tortuous path, energy loss is increased on the path which improves the insulative R-value.

[0075] FIG 18A shows side panel core (78) coupled with corner protector (28a) prior to the application of durable polymer coating (36). As a result, durable polymer coating (36) covers both side panel core (78) and corner protector (28a) to bond side panel core (78) and comer protector (28a) together.

[0076] FIG. 18B shows an example of another edge protector (30a) that may be used instead of edge protector (30). Edge protector (30a) is flexible and is generally L shaped to protect generally perpendicular surfaces. In some versions, edge protector (30a) may be formed using about 3 -millimeter-thick extruded polyvinyl chloride (PVC). Edge protector (30a) may be applied to panel cores (40, 78, 106, 120) using adhesive and / or fasteners.

[0077] FIG. 19 shows a perspective view of container (10) of FIG. 1 in a partially assembled configuration. Panel assemblies (12, 14, 16, 18) fit together using rebate channel (138) and raised outer lip (136) of pallet (122). Durable polymer coating (36) preserves the integrity of rebate channel (138) to ensure appropriate assembly and sealing of container (10).

[0078] FIG. 20 shows an enlarged perspective view of handle (84) and tensioning strap (170) extending through loop (172) of handle (84). Handles (84) positioned on side panel core (78) of side panel assemblies (14). Handles (84) include respective loops (172) sized and configured to receive tensioning strap (170) therethrough. Loops (172) aid with the installation process and correct spacing of tensioning strap (170). Loops (172) assist with horizontal positioning of tensioning strap (170) during the strapping process.

[0079] I. First Exemplary Method of Manufacture

[0080] FIG. 21 shows a first example of a method (210) of manufacturing a temperature control transport container (10). At step (212), method (210) includes applying a first layer (142) of a durable polymer coating to at least inner surface (48) and outer surfaces (50) of end panel assembly (12). First layer (142) may be spray applied, brush applied, roller applied, or dipped. A reactive, two-part, liquid material may be sprayed, painted, or otherwise applied to outer surfaces (50, 88, 110, 126) of panel cores (40, 78, 106, 120). Durable polymer coating (36) may be applied as a secondary process offline process. In some versions, durable polymer coating (36) is a two-part polyurea (PU) spray coating. One suitable polyurea (PU) spray coating is commercially available from BASF SE. Durable polymer coating (36) may include non -polyurea layer(s) such as a polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic layers. In one version, durable polymer coating includes a first amine input component and a second isocyanateinput component. In other versions, the durable polymer coating includes a first polyol input component and a second isocyanate input component. In some versions, durable polymer coating (36) may be applied as a uniform thickness of about 0.5 millimeter or above covering each surface of panel cores (40, 78, 106, 120) to encapsulate each individual panel core (40, 78, 106, 120). Durable polymer coating (36) applied via spraying or painting on and may be used to combine and robustly join different insulative materials to provide a durable composite panel assembly (12, 14, 16, 18). Prior to step (212), it may be beneficial to reduce the moisture content of panel assemblies (12, 14, 16, 18), including panel assembly (12, 14, 16, 18).

[0081] At step (214), method (210) includes applying a second layer (144) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating to at least outer surface of panel cores (40, 78, 106, 120). First layer (142) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating and second layer of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating have different thermal emissivities. The polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating may have a color configured to minimize thermal emissivity, to only outer surfaces (50, 88, 110, 126) of first panel assembly. In some versions, a durable sheet material (not shown) may be applied to panel assembly (12, 14, 16, 18) instead or in additional to the spray applied, brush applied, or roller applied coating. For example, a polystyrene sheet may be heat applied (e.g., in mold or post mold) to panel cores (40, 78, 106, 120). Second layer (144) may have a different color such as a white low thermal emissivity (“low e”). For example, second layer (144) may include titanium oxide or another whitening agent to reduce thermal emissivity.

[0082] As step (216), method (210) optionally includes inserting data logger (62) at least partially within a recessed portion of outer surface of first panel core after applying first layer of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating.

[0083] J. Second Exemplary Method of Manufacture

[0084] FIG. 22 shows a second example of a method (310) of manufacturing temperature control transport container (10). At step (312), method (310) includes inserting sensor (20) and / or data logger (62) completely within internal cavity (168) disposed between inner and outer surfaces (48, 50) of end panel core (40) of end panel assembly (12) prior to applying first layer of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating.

[0085] At step (314), method (310) includes applying first layer (142) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating. At step (316), method (310) includes optionally applying second layer (144) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating on top of first layer (142).

[0086] II. Exemplary Combinations

[0087] The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to restrict the coverage of any claims that may be presented at any time in this application or in subsequent filings of this application. No disclaimer is intended. The following examples are being provided for nothing more than merely illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in numerous other ways. It is also contemplated that some variations may omit certain features referred to in the below examples. Therefore, none of the aspects or features referred to below should be deemed critical unless otherwise explicitly indicated as such at a later date by the inventors or by a successor in interest to the inventors. If any claims are presented in this application or in subsequent filings related to this application that include additional features beyond those referred to below, those additional features shall not be presumed to have been added for any reason relating to patentability.

[0088] Example 1

[0089] A temperature control transport container (10) comprising: (a) a first sensor (20) configured to sense at least one condition of the temperature control transport container (10); (b) a plurality of panel assemblies (12, 14, 16, 18) that collectively define a volumeconfigured to receive a temperature sensitive product (32), wherein the plurality of panel assemblies includes first and second panel assemblies, the first panel assembly (12) comprising: (i) a first panel core (40) that includes inner and outer surfaces (48, 50), wherein at least a portion of the outer surface (50) of the panel core (40) includes a durable polymer coating (36); (ii) a first data logger (62) configured to communicate with the first sensor (20), wherein the first data logger (62) is positioned either: (1) at least partially within a recessed portion (60) of the outer surface (50) of the first panel core (40), wherein the durable polymer coating (36) is positioned between the first panel core (40) and the first data logger (62), or (2) at least partially between the inner and outer surfaces (48, 50) of the first panel core (40), wherein the durable polymer coating (36) extends beyond an outer surface (176) of the first data logger (62).

[0090] Example 2

[0091] The temperature control transport container (10) of Example 1, wherein the first panel core (40) is in direct contact with the durable polymer coating (36).

[0092] Example 3

[0093] The temperature control transport container (10) of any preceding Example, wherein the durable polymer coating (36) is in direct contact with an entirety of the first panel core (40).

[0094] Example 4

[0095] The temperature control transport container (10) of any preceding Example, wherein the first panel core (40) includes at least one of expanded polystyrene, extruded polystyrene, expanded polypropylene, or polyurethane.

[0096] Example 5

[0097] The temperature control transport container (10) of any preceding Example, wherein the first data logger (62) is positioned entirely between the inner and outer surfaces (48, 50) of the first panel core (40).

[0098] Example 6

[0099] The temperature control transport container (10) of any preceding Example, wherein the first data logger (62) is completely embedded within an internal cavity (168) disposed between the inner and outer surfaces (48, 50) of the first panel core (40).

[0100] Example 7

[0101] The temperature control transport container (10) of any preceding Example, the first panel assembly (12) further comprising a flexible holder (42) configured to retain at least one temperature stabilization modules (22) therein, wherein the flexible holder (42) is removably coupled with the first panel core (40).

[0102] Example 8

[0103] The temperature control transport container (10) of Example 7, further comprising a plurality of the temperature stabilization modules (22) positioned within the flexible holder (42).

[0104] Example 9

[0105] The temperature control transport container (10) of any one of Examples 7 or 8, wherein the flexible holder (42) is removably coupled with the first panel core (40) using first and second portions (70, 72) of hook and loop fasteners.

[0106] Example 10

[0107] The temperature control transport container (10) of any preceding Example, wherein the plurality of panel assemblies (12, 14, 16, 18) are configured to be converted between assembled and non-assembled configurations, wherein the plurality of panel assemblies (12, 14, 16, 18) collectively define the volume in the assembled configuration, wherein the plurality of panel assemblies (12, 14, 16, 18) are arranged for storage or shipment and do not define the volume in the non-assembled configuration.

[0108] Example 11

[0109] The temperature control transport container (10) of any preceding Example, wherein the first panel assembly comprises a vacuum insulated panel assembly (VIP) (38),wherein the VIP (38) has a surface area, wherein at least a portion of the surface area of the VIP (38) includes the durable polymer coating (36).

[0110] Example 12[OHl] The temperature control transport container (10) of any preceding Example, further comprising at least one Radio Frequency Identification (RFID) tag (39), wherein the inner surface (48) of the first panel core (40) includes the durable polymer coating (36), wherein the RFID tag (39) is positioned completely within the internal cavity (168) of the first panel core (40) between the inner and outer surfaces (48, 50) of the first panel core (40).

[0112] Example 13

[0113] The temperature control transport container (10) of any preceding Example, wherein the first sensor (20) has an outer surface (180) that is in direct contact with the durable polymer coating (36).

[0114] Example 14

[0115] The temperature control transport container of any preceding Example, wherein the first sensor (20) includes at least one of a temperature sensor, a global positioning sensor, an accelerometer, a light detector, a pressure sensor, or a hygrometer.

[0116] Example 15

[0117] The temperature control transport container (10) of any preceding Example, wherein the first sensor (20) includes a temperature sensor that is fixably secured with a sensor holder (58) of the first panel assembly to ensure consistent temperature measurement.

[0118] Example 16

[0119] The temperature control transport container of any preceding Example, wherein the first sensor (20) communicates wirelessly with the first data logger (62).

[0120] Example 17

[0121] The temperature control transport container (10) of any preceding Example, wherein the first data logger (62) is positioned entirely within the recessed portion (60) of the outer surface of the first panel core (40) that includes the durable polymer coating (36) so as not to extend outwardly from the first panel core (40).

[0122] Example 18

[0123] The temperature control transport container (10) of any preceding Example, further comprising an exterior data logger cover (66), wherein the first data logger (62) is positioned within the recessed portion (60) of the first panel assembly (12) that includes the durable polymer coating (36) and is protected by the exterior data logger cover (66).

[0124] Example 19

[0125] The temperature control transport container (10) of any preceding Example, wherein the first data logger (62) is positioned completely within the internal cavity (168) of the first core panel (40) that includes the durable polymer coating (36).

[0126] Example 20

[0127] The temperature control transport container (10) of any preceding Example, further comprising a second sensor (20) configured to sense an ambient temperature, wherein the second sensor (20) includes an outer surface (180) in contact with the durable polymer coating (36).

[0128] Example 21

[0129] The temperature control transport container (10) of any preceding Example, wherein the first sensor (20) communicates wirelessly with the first data logger (62).

[0130] Example 22

[0131] The temperature control transport container (10) of any preceding Example, wherein the second panel assembly (12) includes the durable polymer coating (36), the temperature control transport container further comprising a second sensor (20) or a second data logger (62), wherein at least one of the second sensor (20) or the second data logger (62) is positioned: (a) within a recessed portion (60) formed in an outer surface (50) of thesecond panel core (40) that includes the durable polymer coating (36), or (b) completely within an internal cavity (168) of the second panel core (40) that includes the durable polymer coating (36).

[0132] Example 23

[0133] The temperature control transport container (10) of any preceding Example, the plurality of panel assemblies comprising: (a) end panel assemblies (12) that include the first panel assembly, (b) side panel assemblies (14) extending between the end panel assemblies (12), (c) a top panel assembly (16) configured to contact an upper edge of end and side panel assemblies (12, 14), and (d) a bottom panel assembly (18) that together with the end panel assemblies (12), side panel assemblies (14), and top panel assembly (16) collectively define the volume.

[0134] Example 24

[0135] The temperature control transport container (10) of Example 23, wherein at least one of the side panel assemblies (14) includes first and second lateral rebate portions (96, 98) configured to abut an edge of adjacent panel assemblies (12) of the plurality of side panel assemblies in an assembled configuration.

[0136] Example 25

[0137] The temperature control transport container (10) of Example 24, further comprising a pallet (122) operatively coupled with the bottom panel assembly (18), wherein the pallet (122) and the bottom panel assembly (18) collectively define a rebate channel (138) configured to receive bottom surfaces of the first side panel assembly (12), the second side panel assembly (12), the first end panel assembly (14), and the second end panel assembly (14) in an assembled configuration.

[0138] Example 26

[0139] The temperature control transport container (10) of any preceding Example, wherein the plurality of panel assemblies have mating surfaces configured to be in abutting contact, wherein at least some of the mating surfaces (92a) of the plurality of panelassemblies (12, 14, 16, 18) do not include the durable polymer coating (36) to minimize thermal bridging.

[0140] Example 27

[0141] The temperature control transport container (10) of Example 26, wherein the mating surfaces include a mitred edge (55, 94, 118, 134).

[0142] Example 28

[0143] The temperature control transport container of any preceding Example, wherein a portion of each panel assembly (12, 14, 16, 18) of the plurality of panel assemblies includes the durable polymer coating (36).

[0144] Example 29

[0145] The temperature control transport container (10) of any preceding Example, wherein the outer surface (50) of the first panel core (40) has a first maximum thickness (Tl) of the durable polymer coating (36), wherein the inner surface of the first panel assembly has a second maximum thickness (T2) of the durable polymer coating (36), wherein the second maximum thickness (T2) is less than the first maximum thickness (Tl).

[0146] Example 30

[0147] The temperature control transport container (10) of any preceding Example, wherein at least one of the panel assemblies (12, 14, 16, 18) include unique electronic identifiers (39).

[0148] Example 31

[0149] The temperature control transport container (10) of Example 30, wherein the unique electronic identifiers (39) include at least one of a Radio Frequency Identification (RFID) tag, a Near Field Communication (NFC) tag, or a Bluetooth Low Energy (BLE) device positioned entirely within the panel core (40) that includes the durable polymer coating (36).

[0150] Example 32

[0151] The temperature control transport container (10) of any preceding Example, further comprising at least one corner protector (28a), wherein the durable polymer coating (36) permanently couples the corner protector (28a) and the first panel assembly (12) together.

[0152] Example 33

[0153] The temperature control transport container (10) of any preceding Example, further comprising a flexible edge protector (30a) coupled with two adjoining panel assemblies of the plurality of panel assemblies, wherein the flexible edge protector (30a) is configured to protect edges of panel assemblies.

[0154] Example 34

[0155] The temperature control transport container (10) of any preceding Example, further comprising handles (84) positioned on one of the plurality of panel assemblies (14), wherein the handles (84) include a loop (172) sized and configured to receive a tensioning strap (170) therethrough.

[0156] Example 35

[0157] The temperature control transport container (10) of Example 1, wherein the durable polymer coating includes a first polyol input component and a second amine input component.

[0158] Example 36

[0159] The temperature control transport container (10) of Example 1, wherein the durable polymer coating includes a first polyol input component and a second isocyanate input component.

[0160] Example 37

[0161] The temperature control transport container (10) of any preceding Example, wherein the durable polymer coating (36) includes a polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating.

[0162] Example 38

[0163] The temperature control transport container (10) of any preceding Example, wherein the durable polymer coating (36) includes a first layer of a polyurea coating having a thickness (Tl, T2, T3) of about 0.5mm to about 2.0 mm.

[0164] Example 39

[0165] A temperature control transport container (10) comprising: (a) a plurality of panel assemblies (12, 14, 16, 18, 20) that collectively define a volume configured to receive a temperature sensitive product (32), wherein at least an outer surface (50) of a first panel assembly of the plurality of panel assemblies includes a polyurea coating (36); (b) at least one of a first sensor (20) or a first data logger (62) positioned: (i) within a recessed portion (60) of an outer surface of the panel assembly (12) that includes the polyurea coating (36), or (ii) completely within an internal cavity (168) of the panel assembly (12) that includes the polyurea coating (36).

[0166] Example 40

[0167] A method of manufacturing a temperature control transport container (10), wherein the temperature control transport container (10) includes a plurality of panel assemblies (12, 14, 16, 18), wherein the plurality of panel assemblies (12, 14, 16, 18) includes first and second panel assemblies, the method comprising: (a) applying a first layer (142) of a polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating to at least inner and outer surfaces (48, 50) of a panel core (40) of the first panel assembly (12); and (b) applying a second layer (144) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating to at least the outer surface (50) of the panel core (40), the first and second layers (142, 144) having different thermal emissivities.

[0168] Example 41

[0169] The method of Example 40, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises mixing a first polyol input component with a second input component.

[0170] Example 42

[0171] The method of Example 40, wherein applying the first or second layers of the polyurea coatings (1 2, 144) further comprises mixing a first polyol input component with a second isocyanate input component.

[0172] Example 43

[0173] The method of Example 40, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises mixing a first amine input component with a second isocyanate input component.

[0174] Example 44

[0175] The method of any one of Examples 40 through 43, further comprising inserting a data logger completely within an internal cavity (168) disposed between inner and outer surfaces (48, 50) of the panel core (40) prior to applying the first layer (142) of the polyurea coating.

[0176] Example 45

[0177] The method of any one of Examples 40 through 43, further comprising inserting a data logger (62) within a recessed portion (60) of the outer surface (50) of the panel core (40) after applying the first layer of the polyurea coating (142).

[0178] Example 46

[0179] The method of any one of Examples 40 through 45, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises spray applying at least one of the first or second layers (142, 144) of the polyurea coatings.

[0180] Example 47

[0181] The method of any one of Examples 40 through 45, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises brush applying or roller applying at least one of the first or second layers of polyurea coatings using a brush or roller.

[0182] Example 48

[0183] A method of manufacturing a temperature control transport container, wherein the temperature control transport container includes a plurality of panel assemblies (12, 14, 16, 18) that collectively define a volume configured to receive a temperature sensitive product (32), wherein the plurality of panel assemblies (12, 14, 16, 18) includes first and second panel assemblies, the method comprising: (a) inserting a data logger (62) at least partially between the inner and outer surfaces (48, 50) of a panel core (40) of the first panel assembly (12); (b) applying a polyurea, polycarbonate, polyurethane, poly ether, polyester, epoxy resin, nylon, or acrylic coating so that the polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating extends beyond an outer surface (176) of the data logger (62).

[0184] Example 49

[0185] The method of Example 48, wherein inserting the data logger (62) further comprises inserting the data logger (62) completely within an internal cavity (168) disposed between inner and outer surfaces (48, 50) of the panel core (40).

[0186] Example 50

[0187] The method of any of Example 40 - 49, further comprising assembling the plurality of panel assemblies (12, 14, 16, 18) together to define the volume configured to receive the temperature sensitive product (32) in an assembled configuration.

[0188] Example 51

[0189] The method of any of Examples 40 through 49, further comprising assembling the plurality of panel assemblies (12, 14, 16, 18) together to define the volume configured to receive the temperature sensitive product (32) in an assembled configuration.

[0190] It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The above-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in theart in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

[0191] It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0192] Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometries, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

Claims

I / We Claim:

1. A temperature control transport container (10) comprising:(a) a first sensor (20) configured to sense at least one condition of the temperature control transport container (10); and(b) a plurality of panel assemblies (12, 14, 16, 18) that collectively define a volume configured to receive a temperature sensitive product (32), wherein the plurality of panel assemblies includes first and second panel assemblies, the first panel assembly (12) comprising:(i) a first panel core (40) that includes inner and outer surfaces (48, 50), wherein at least a portion of the outer surface (50) of the panel core (40) includes a durable polymer coating (36); and(ii) a first data logger (62) configured to communicate with the first sensor (20), wherein the first data logger (62) is positioned either:(1) at least partially within a recessed portion (60) of the outer surface (50) of the first panel core (40), wherein the durable polymer coating (36) is positioned between the first panel core (40) and the first data logger (62), or(2) at least partially between the inner and outer surfaces (48, 50) of the first panel core (40), wherein the durable polymer coating (36) extends beyond an outer surface (176) of the first data logger (62).

2. The temperature control transport container (10) of claim 1, wherein the first panel core (40) is in direct contact with the durable polymer coating (36).

3. The temperature control transport container (10) of any preceding claim, wherein the durable polymer coating (36) is in direct contact with an entirety of the first panel core (40).

4. The temperature control transport container (10) of any preceding claim, wherein the first panel core (40) includes at least one of expanded polystyrene, extruded polystyrene, expanded polypropylene, or polyurethane.

5. The temperature control transport container (10) of any preceding claim, wherein the first data logger (62) is positioned entirely between the inner and outer surfaces (48, 50) of the first panel core (40).

6. The temperature control transport container (10) of any preceding claim, wherein the first data logger (62) is completely embedded within an internal cavity (168) disposed between the inner and outer surfaces (48, 50) of the first panel core (40).

7. The temperature control transport container (10) of any preceding claim, the first panel assembly (12) further comprising a flexible holder (42) configured to retain at least one temperature stabilization modules (22) therein, wherein the flexible holder (42) is removably coupled with the first panel core (40).

8. The temperature control transport container (10) of claim 7, further comprising a plurality of the temperature stabilization modules (22) positioned within the flexible holder (42).

9. The temperature control transport container (10) of any one of claims 7 or 8, wherein the flexible holder (42) is removably coupled with the first panel core (40) using first and second portions (70, 72) of hook and loop fasteners.

10. The temperature control transport container (10) of any preceding claim, wherein the plurality of panel assemblies (12, 14, 16, 18) are configured to be converted between assembled and non-assembled configurations, wherein the plurality of panel assemblies (12, 14, 16, 18) collectively define the volume in the assembled configuration, wherein the plurality of panel assemblies (12, 14, 16, 18) are arranged for storage or shipment and do not define the volume in the non-assembled configuration.

11. The temperature control transport container (10) of any preceding claim, wherein the first panel assembly comprises a vacuum insulated panel assembly (VIP) (38), wherein the VIP(38) has a surface area, wherein at least a portion of the surface area of the VIP (38) includes the durable polymer coating (36).

12. The temperature control transport container (10) of any preceding claim, further comprising at least one Radio Frequency Identification (RFID) tag (39), wherein the inner surface (48) of the first panel core (40) includes the durable polymer coating (36), wherein the RFID tag(39) is positioned completely within the internal cavity (168) of the first panel core (40) between the inner and outer surfaces (48, 50) of the first panel core (40).

13. The temperature control transport container (10) of any preceding claim, wherein the first sensor (20) has an outer surface (180) that is in direct contact with the durable polymer coating (36).

14. The temperature control transport container (10) of any preceding claim, wherein the first sensor (20) includes at least one of a temperature sensor, a global positioning sensor, an accelerometer, a light detector, a pressure sensor, or a hygrometer.

15. The temperature control transport container (10) of any preceding claim, wherein the first sensor (20) includes a temperature sensor that is fixably secured with a sensor holder (58) of the first panel assembly to ensure consistent temperature measurement.

16. The temperature control transport container of any preceding claim, wherein the first sensor (20) communicates wirelessly with the first data logger (62).

17. The temperature control transport container (10) of any preceding claim, wherein the first data logger (62) is positioned entirely within the recessed portion (60) of the outer surface of the first panel core (40) that includes the durable polymer coating (36) so as not to extend outwardly from the first panel core (40).

18. The temperature control transport container (10) of any preceding claim, further comprising an exterior data logger cover (66), wherein the first data logger (62) is positioned within the recessed portion (60) of the first panel assembly (12) that includes the durable polymer coating (36) and is protected by the exterior data logger cover (66).

19. The temperature control transport container (10) of any preceding claim, wherein the first data logger (62) is positioned completely within the internal cavity (168) of the first core panel (40) that includes the durable polymer coating (36).

20. The temperature control transport container (10) of any preceding claim, further comprising a second sensor (20) configured to sense an ambient temperature, wherein the second sensor (20) includes an outer surface (180) in contact with the durable polymer coating (36).

21. The temperature control transport container (10) of any preceding claim, wherein the first sensor (20) communicates wirelessly with the first data logger (62).

22. The temperature control transport container (10) of any preceding claim, wherein the second panel assembly (12) includes the durable polymer coating (36), the temperature control transport container further comprising a second sensor (20) or a second data logger (62), wherein at least one of the second sensor (20) or the second data logger (62) is positioned:(a) within a recessed portion (60) formed in an outer surface (50) of the second panel core (40) that includes the durable polymer coating (36), or(b) completely within an internal cavity (168) of the second panel core (40) that includes the durable polymer coating (36).

23. The temperature control transport container (10) of any preceding claim, the plurality of panel assemblies comprising:(a) end panel assemblies (12) that include the first panel assembly,(b) side panel assemblies (14) extending between the end panel assemblies (12),(c) a top panel assembly (16) configured to contact an upper edge of end and side panel assemblies (12, 14), and(d) a bottom panel assembly (18) that together with the end panel assemblies (12), side panel assemblies (14), and top panel assembly (16) collectively define the volume.

24. The temperature control transport container (10) of claim 23, wherein at least one of the side panel assemblies (14) includes first and second lateral rebate portions (96, 98) configured to abut an edge of adjacent panel assemblies (12) of the plurality of side panel assemblies in an assembled configuration.

25. The temperature control transport container (10) of claim 24, further comprising a pallet (122) operatively coupled with the bottom panel assembly (18), wherein the pallet (122) and the bottom panel assembly (18) collectively define a rebate channel (138) configured to receive bottom surfaces of the first side panel assembly (12), the second side panel assembly (12), the first end panel assembly (14), and the second end panel assembly (14) in an assembled configuration.

26. The temperature control transport container (10) of any preceding claim, wherein the plurality of panel assemblies have mating surfaces configured to be in abutting contact, wherein at least some of the mating surfaces (92a) of the plurality of panel assemblies (12, 14, 16, 18) do not include the durable polymer coating (36) to minimize thermal bridging.

27. The temperature control transport container (10) of claim 26, wherein the mating surfaces include a mitred edge (55, 94, 118, 134).

28. The temperature control transport container of any preceding claim, wherein a portion of each panel assembly (12, 14, 16, 18) of the plurality of panel assemblies includes the durable polymer coating (36).

29. The temperature control transport container (10) of any preceding claim, wherein the outer surface (50) of the first panel core (40) has a first maximum thickness (Tl) of the durablepolymer coating (36), wherein the inner surface of the first panel assembly has a second maximum thickness (T2) of the durable polymer coating (36), wherein the second maximum thickness (T2) is less than the first maximum thickness (Tl).

30. The temperature control transport container (10) of any preceding claim, wherein at least one of the panel assemblies (12, 14, 16, 18) include unique electronic identifiers (39).

31. The temperature control transport container (10) of claim 30, wherein the unique electronic identifiers (39) include at least one of a Radio Frequency Identification (RFID) tag, a Near Field Communication (NFC) tag, or a Bluetooth Low Energy (BLE) device positioned entirely within the panel core (40) that includes the durable polymer coating (36).

32. The temperature control transport container (10) of any preceding claim, further comprising at least one comer protector (28a), wherein the durable polymer coating (36) permanently couples the corner protector (28a) and the first panel assembly (12) together.

33. The temperature control transport container (10) of any preceding claim, further comprising a flexible edge protector (30a) coupled with two adjoining panel assemblies of the plurality of panel assemblies, wherein the flexible edge protector (30a) is configured to protect edges of panel assemblies.

34. The temperature control transport container (10) of any preceding claim, further comprising flexible handles (84) positioned on one of the plurality of panel assemblies (14), wherein the flexible handles (84) include a loop (172) sized and configured to receive a tensioning strap (170) therethrough.

35. The temperature control transport container (10) of claim 1, wherein the durable polymer coating includes a first polyol input component and a second amine input component.

36. The temperature control transport container (10) of claim 1, wherein the durable polymer coating includes a first polyol input component and a second isocyanate input component.

37. The temperature control transport container (10) of any preceding claim, wherein the durable polymer coating (36) includes a polyurea, polycarbonate, polyurethane, poly ether, polyester, epoxy resin, nylon, or acrylic coating.

38. The temperature control transport container (10) of any preceding claim, wherein the durable polymer coating (36) includes a first layer of a polyurea coating having a thickness (Tl, T2, T3) of about 0.5mm to about 2.0 mm.

39. A temperature control transport container (10) comprising:(a) a plurality of panel assemblies (12, 14 ,16, 18, 20) that collectively define a volume configured to receive a temperature sensitive product (32), wherein at least an outer surface (50) of a first panel assembly of the plurality of panel assemblies includes a polyurea coating (36); and(b) at least one of a first sensor (20) or a first data logger (62) positioned:(i) within a recessed portion (60) of an outer surface of the panel assembly (12) that includes the polyurea coating (36), or(ii) completely within an internal cavity (168) of the panel assembly (12) that includes the polyurea coating (36).

40. A method of manufacturing a temperature control transport container (10), wherein the temperature control transport container (10) includes a plurality of panel assemblies (12, 14, 16, 18), wherein the plurality of panel assemblies (12, 14, 16, 18) includes first and second panel assemblies, the method comprising:(a) applying a first layer (142) of a polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating to at least inner and outer surfaces (48, 50) of a panel core (40) of the first panel assembly (12); and(b) applying a second layer (144) of polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating to at least theouter surface (50) of the panel core (40), the first and second layers (142, 144) having different thermal emissivities.

41. The method of claim 40, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises mixing a first polyol input component with a second input component.

42. The method of claim 40, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises mixing a first polyol input component with a second isocyanate input component.

43. The method of claim 40, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises mixing a first amine input component with a second isocyanate input component.

44. The method of any one of claims 40 - 43, further comprising inserting a data logger completely within an internal cavity (168) disposed between inner and outer surfaces (48, 50) of the panel core (40) prior to applying the first layer (142) of the polyurea coating.

45. The method of any one of claims 40 - 43, further comprising inserting a data logger (62) within a recessed portion (60) of the outer surface (50) of the panel core (40) after applying the first layer of the polyurea coating (142).

46. The method of any one of claims 40 - 45, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises spray applying at least one of the first or second layers (142, 144) of the polyurea coatings.

47. The method of any one of claims 40 - 45, wherein applying the first or second layers of the polyurea coatings (142, 144) further comprises brush applying or roller applying at least one of the first or second layers of polyurea coatings using a brush or roller.

48. A method of manufacturing a temperature control transport container, wherein the temperature control transport container includes a plurality of panel assemblies (12, 14, 16, 18) that collectively define a volume configured to receive a temperature sensitive product (32), wherein the plurality of panel assemblies (12, 14, 16, 18) includes first and second panel assemblies, the method comprising:(a) inserting a data logger (62) at least partially between the inner and outer surfaces (48, 50) of a panel core (40) of the first panel assembly (12); and(b) applying a polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating so that the polyurea, polycarbonate, polyurethane, polyether, polyester, epoxy resin, nylon, or acrylic coating extends beyond an outer surface (176) of the data logger (62).

49. The method of claim 48, wherein inserting the data logger (62) further comprises inserting the data logger (62) completely within an internal cavity (168) disposed between inner and outer surfaces (48, 50) of the panel core (40).

50. The method of any of claims 40 - 49, further comprising assembling the plurality of panel assemblies (12, 14, 16, 18) together to define the volume configured to receive the temperature sensitive product (32) in an assembled configuration.

51. The method of claim 50, further comprising disassembling the plurality of panel assemblies (12, 14, 16, 18) to transition the container (10) from the assembled configuration to a disassembled configuration.