A cold chain shipper and temperature control system

Abstract

The present invention relates to a transport container which gives mechanical and thermal stability to a load. The present invention also provides a temperature control system, which can be customized to suit the duration of an intended cold chain distribution, and which is manufactured while the container is loaded. In particular, the present invention relates to a temperature control system for a container which is stable and can be easily varied to suit the load. The cold chain shipper can be easily and simply flat-packed and can be manufactured substantially from sheet material such as cardboard and can therefore be easily and simply re-used or recycled - whilst other sheet material can be employed, if necessary.

Description

[0001] A COLD CHAIN SHIPPER AND TEMPERATURE CONTROL SYSTEM

[0002] Field of Invention

[0003]

[0001] The invention relates to a transport or shipping containers, and more particularly to insulated transport or shipping containers for transport of temperature-sensitive goods. The present invention also relates to a cold chain shipper and temperature control system for such shippers, such as unit load devices and pallet shippers transport containers. The present invention further relates to insulated shipping containers for holding temperature sensitive products and coolant in a predetermined relationship to maintain a refrigerated or frozen condition for an extended period of time and to a passive temperature control system for the same.

[0004] Background to the Invention

[0005]

[0002] Thermally insulated containers are in general use in cold chain logistics and typically comprise a pallet shipper, where the footprint of the container has the same dimensions as one of a number of standard pallets, which may be of industry or international standard sizes. Such containers find application in road cargo, maritime cargo and air cargo scenarios. Such pallet shippers may be arranged to be carried by a pallet, may be mounted to a pallet or may have a pallet formed integrally therein.

[0006]

[0003] With regard to shipping sensitive products, such as certain medical or pharmaceutical products, rigid polyurethane containers often are used because of the superior thermal properties. Conventional insulated shipping containers have many problems, particularly when shipping temperature sensitive products for extended periods of time, such as when products are shipped internationally. These containers, especially modular liner systems, often include a number of seams in the insulating material through which air can enter and heat or cool the cavity in the carton. In addition, the cavity often includes airspaces around the product and coolant which can facilitate but not control convection, especially if the insulating material includes leaking seams. Unfortunately, temperature gradients or zones can be created. These conditions may accelerate the melting of the coolant, consequently shortening the time that the container can maintain a refrigerated condition. In addition, the cover may be formed from different material, such as polyester foam which may have a thermal resistance substantially lower than the body itself and thus may compromise the performance of the container.

[0007]

[0004] Thermally insulated packages are widely used in the transportation of temperature sensitive goods, for example food, pharmaceuticals, biological

[0008] HEMA0124UK PCT for filing 12thAugust 2025 samples, vaccines and the like. Typically the product must be maintained within predetermined temperature ranges, for example 2° to 8°C , 15° to 25°C or less than -20°C, over relatively long time periods, for example 48 to 120 hours. It is important that some products, for example certain type of pharmaceuticals or biotech products, are maintained within a specified temperature range, to prevent the product from being damaged, or its shelf-life being reduced relative to the shelf-life stated on the product. The product may be a very high value medicine or the like, which will be worthless if its internal temperature is not correctly controlled. This may be problematic during shipment, particularly if the product is being shipped by air.

[0009]

[0005] One type of shipper is the active shipper. This generally comprises a thermally insulated container having a cooling device and / or heating element for controlling the interior temperature of the shipper and thus the product. Energy is provided, often from an external electrical supply or an internal battery. An advantage of an active shipper is that, in the case where it is connected to an external power supply, the temperature may be maintained within a desired range for a relatively long, or indefinite, period of time. However, a disadvantages of active shippers is that they can be less reliable than passive shippers. For example they can be subject to mechanical breakdown and may be reliant on being correctly connected to a reliable external power supply.

[0010]

[0006] Another type of shipper is the passive shipper, wherein temperature control packs - often referred to as cool-packs or heat-packs are provided to compensate for differences between an outside, ambient temperature and the desired temperature within. In the packaging of the temperature control packs, there must be provided sufficient capacity to provide continuing temperature control, despite, for example a delay in shipping, a change in temperature due to inaccurate weather forecasting upon which the provision of temperature control packs was made. Such temperature control is typically provided by way of a substance with a high thermal capacity and / or a phase change material, which can provide I absorb significant amounts of thermal energy due to melting from a solid to a liquid I cooling to a solid from a liquid or through sublimation.

[0011]

[0007] Known container systems can be fabricated from various types of panels. Polyurethane foam with or without facing materials have widespread use but suffer from not being particularly recyclable. Rigid polyurethane containers are also known as discussed above. Certain manufacturers provide cardboard walls which enclose or otherwise surround vacuum insulation panels typically comprising foamed silica, but this also suffers from recycling issues. Given that

[0012] 2

[0013] HEMA0124UK PCT for filing 12thAugust 2025 vacuum insulation panels are frangible, reuse options are limited and return to base swaps of vacuum insulation panels is typically practiced. Moreover in a bid to reduce greenhouse gases, governments are seeking to reduce use of plastics and increase use of cellulose, paper and card, where recycling and re-use is highly developed. Additionally, whilst international and national cold chain operations are highly regulated; containers and shippers need to be rugged to cope with drops and accidents arising from pallet handling equipment when transfers from road vehicle to port or airport handling equipment.

[0014]

[0008] Various forms of such packaging are known using a variety of temperature control media (for example phase change materials) and insulation. An example of such a product is described in US2017073147 (vac-U-tec) which discloses a carton provided with closely fitting phase change material containers having bevelled edges, which enable the PCM containers to abut together, as seen in Figure la. Each inner-wall element has predetermined dimensions matching those of the associated inner surface of the container. US5555980 (Johnson S Trading Post) provides a collapsible palletized container is provided including a base with individual sidewalls extending upward therefrom and a lid, shown in Figure lb. The base includes grooves thereon which receive tongues attached to lower edges of the sidewalls. The tongues are angled so that the sidewalls are pivoted into position adjacent the base. The tongues and grooves are configured to prevent vertical translation of the sidewalls away from the base. Each sidewall includes two side edges including joints thereon and ribs, whereby to, respectively, hold adjacent sidewalls together thereby obviating the need for girding straps to resist forces exerted horizontally by loads within the container and to reinforce the sidewalls. The lid connects to the sidewalls with clips connected therebetween.

[0015]

[0009] US2020108997 (Pelibiothermal) teaches of a thermal conditioning wall panel 10, 20 per Figures lc', lc" for use within a thermally insulating container and comprises a panel body having a channel formed therein along one face thereof for receiving and retaining thermal conditioning elements 16. At least one foot is formed at the lower end of the walls of a panel body for engagement within a plurality of socket elements provided within a complex, peripheral base of the container system. Thermal conditioning elements are inserted per Figure lc"' from above the top of the container which typically will be of the order of 1.8m - 2m in height, which can prove to be difficult for operatives when packing. European patent EP2876389 (va-Q-tec) teaches of a heat-insulated transport container having three side wall elements, a top element, a base element and at least one door element, pivotally mounted about a vertical axis. The container

[0016] 3

[0017] HEMA0124UK PCT for filing 12thAugust 2025 wall elements comprise a double-walled with a dimensionally stable inner and outer walls, with vacuum insulation elements placed therebetween, as shown in Figure Id. US7028504 (Derrifield) teaches of shipping containers for holding temperature sensitive products and coolant in a predetermined relationship to maintain a refrigerated or frozen condition for an extended period of time moulded from rigid polyurethane foam, as shown in Figure le. The external dimensions of typical transport containers such as pallet shippers would be: 1200 x 800 x 1080 mm (~47.2 x 31.5 x 42.5 in); 1200 x 1000 x 1260 mm (~47.2 x 39.4 x 49.6 in); smaller sizes and larger sizes exist.

[0018] Object of the Invention

[0019]

[0010] The present invention seeks to provide a solution to the problems addressed above. The present invention seeks to provide a temperature control system for a transport container which can be manufactured at low cost and can readily and easily be constructed from a flat-pack as is the case of a container within which it can be placed. Furthermore, the present invention seeks to provide a temperature control system for a transport container that when completed can maintain goods placed inside the container within a narrow temperature range.

[0020]

[0011] Additionally, the present invention seeks to provide a passive temperature control system that takes up little space and can be simply used with flat-pack storage containers. The present invention further seeks to provide a temperature control system for a transport container which is compatible with standard Unit Load Device specifications. The present invention further seeks to provide for a transport container with a temperature control system.

[0021] Statement of Invention

[0022]

[0012] According to the invention, there is provided a transport container having a temperature control system for use in cold chain transport, the transport container comprising a base panel, side wall panels and a cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, edge members in contact with adjacent panels and an inside face made from one or more insulating elements; wherein there is an inner coolant system operably arranged about a central rectangular load area, the coolant system comprising a support wall which comprises at least four upstanding wall elements which extend from a base edge in contact with the inside face of the base to a top edge which inter-engage with a cover element to operably enclose a load, wherein temperature control packages of a generally rectangular prism shape are associated with the wall, the number of temperature control packages being

[0023] 4

[0024] HEMA0124UK PCT for filing 12thAugust 2025 determined with reference to a cold chain event. The support walls and temperature control packages are provided with co-operating extending tabs and apertures whereby to provide at least lateral association of the temperature control packages and the capability to bear a weight associated with the temperature control packages or to permit the temperature control packages to be stacked and for the base panel to bear the weight.

[0025]

[0013] The walls of the temperature control systems can be manufactured from sheet material, conveniently card, cardboard, corrugated card and corrugated plastics. When the temperature control packages are used to maintain a temperature below atmospheric temperature, then the material needs to be capable of absorbing moisture, which will tend to accumulate about a reduced temperature body in any closed environment of a transport container. The temperature control system can be enclosed by external base, walls and cover elements, as is known.

[0026]

[0014] It will be appreciated that the temperature control packages can be fastened to the temperature control unit easily; operators will not desire personnel to be mounted on ladders or otherwise supported above the high walls of a container to ensure that the wall mounted elements are safely fastened, for health and safety reasons. The numbers of temperature control elements can be selected such that a minimum of temperature control packages are employed, which is of benefit when the weight of cargo is a significant determinant of cost of transportation, especially with regard to air freight. This may also provide an advantage in that the temperature control packages bear their weight upon a base or lower temperature control package, meaning that the support walls do not need to bear the weight and can be produced from a reduced weight / strength support material. The cooperating extending tabs and apertures can be defined from the sheet material products themselves, using known flat-bed cutting techniques such as laser cutting, water cutting, die board cutting etc. as are well known in the packaging industry.

[0027]

[0015] Conveniently, the base element comprises first, upper, and second, lower, parallel spaced apart sheet members with an insulating medium therebetween, the upper sheet member being arranged for placement of a load and comprises slots in correspondence with downwardly facing castellations of the wall elements, whereby the lowermost castellations abut against the lower, second sheet member. Conveniently, the base element comprises part of the transport container.

[0028] 5

[0029] HEMA0124UK PCT for filing 12thAugust 2025

[0016] Conveniently, the cover element extends beyond the extent of the upper edges of the upstanding walls; wherein the upper edges of the upstanding walls are provided with castellations; wherein the cover element comprises slots in correspondence with upwardly facing castellations of the wall elements, whereby the extending elements pass through the slots and troughs of the castellations abut against a lower face of the cover member.

[0030]

[0017] The cover element is selected to be of sufficient thickness / strength to support the weight of temperature coolant packages placed thereon.

[0031]

[0018] It has been found to be convenient to have the upstanding walls comprised of two sheets defining a "C" in plan, with first and second hinge elements to define a middle wall; the middle walls oppose each other and the respective pairs of adjacent partly extending walls define third and fourth walls, to surround the load. Preferably, one pair of adjacent partly extending walls - i.e. both on one side of the container are not provided with castellations and are operable to act as doors, to enable access within the load enclosure. Conveniently, the cover element is reinforced by a lintel element on the side of the cover above the opening doors. The lintel component can comprise an "L"- shaped member, as are known from MDF edge protector members. The lintel component preferably comprises slots which engage with the upstanding castellations of an upstanding wall element at opposite ends of the lintel. Notwithstanding this a single wall element could also be provided, albeit larger elements can be more difficult to handle than smaller wall elements, due to weight and size considerations.

[0032]

[0019] In accordance with another aspect to the invention, there is provided a temperature control element combination for use with a cold chain transport container, the combination comprising a wall element that can be supported within a cold chain container, the wall element having one of a tab and an aperture, and a coolant package comprising a generally rectangular prismatic body and having a face with one of an aperture and a tab, whereby the two can become associated with each other.

[0033]

[0020] In one aspect of the invention, the tab and aperture elements of one or other of the wall and temperature control element combination cooperate to prevent lateral separation of the coolant package with respect to the wall. Conveniently, the wall element is supported upon a base surface of the container and the temperature control package is also supported upon the base floor of the container and wherein one or more vertically oriented temperature

[0034] 6

[0035] HEMA0124UK PCT for filing 12thAugust 2025 control packages aperture bear on lower temperature control packages, whereby the base surface takes the weight of the temperature control packages.

[0036]

[0021] In another aspect of the invention, the base comprises an upper sheet member spaced from a lower sheet member and the wall element is provided with castellations that extend downwardly and the castellations abut the lower sheet member. The slots of the temperature control members are supported by the tabs of the wall member, whereby the temperature control packages are supported by the wall and the wall is, in turn, supported by a secure, lower sheet member of the base member.

[0037]

[0022] In another aspect of the invention, the base comprises an upper sheet member spaced from a lower sheet member and the wall element is provided with castellations that extend downwardly; wherein the castellations abut the lower sheet member; wherein tabs of the temperature control members are supported by the slots of the wall member, whereby the temperature control packages are supported by the wall and the wall is, in turn, supported by a secure, lower sheet member of the base member.

[0038]

[0023] As will be familiar to the skilled man, the number and type of temperature control packages are determined with reference to at least one or more of the following factors: intended internal temperature range; heat capacity of load; expected external atmospheric conditions for the container; and an expected duration of a journey. It will also be appreciated that numerous cold chain transport operators have developed computer programmes which take into account these factors to provide recommended distribution of particular types of coolant packages, taking into account internal convection currents that will develop internally of a completed cold chain transport container

[0039]

[0024] The coolant package can be formed from sheet material, such as corrugated plastics or corrugated cardboard, configured to define an aperture for the placement of a standard shape coolant package. Known coolant packages can be manufactured from a plastics material and be filled with a gel material or can comprise one or more plastics bags containing a coolant material which are inserted into a cardboard box. For simplicity, the coolant package will define a body which has a high heat capacity and is operable to maintain a temperature - that is to say the coolant, by virtue of its high thermal capacity, can assist in maintaining a temperature above ambient, in a fashion similar to maintaining a temperature below ambient. Corrugated plastics or corrugated cardboard are materials that are commonly used in transport industries and is both relatively cheap and readily available.

[0040] 7

[0041] HEMA0124UK PCT for filing 12thAugust 2025

[0025] Conveniently, a container operably utilised with the invention comprises at least a base and upstanding wall panels with a cover and the temperature control element can be placed therein. Preferably, the outer container is of the type which is substantially air-tight, for example, where adjacent panels have cooperating tongue and groove edges, whereby the container, when closed, is substantially airtight, optionally or alternatively being provided with further sealant materials, such as rubber / polymeric strips. Of course, simple abutting joints can also provide substantially airtight enclosures for substantially flat / corresponding surfaces, especially if, in the case of resilient materials, pressure is applied to ensure contact is maintained. By having a container substantially air tight, when cool packs are employed is significant since, not only does an exchange of air with the atmosphere outside the container contribute to an increase in temperature within a container, the exchange of air with the atmosphere outside the container will also bring about condensation of the saturated air when cooled and possible frosting upon the cool packs. It will be realised that, subsequently, any temperature cycling, including frosting can affect the integrity of materials such as cardboard.

[0042]

[0026] It will be appreciated that the features of the present invention are realized by sheet material and when disassembled, the present invention provides a flat-pack transport container. The container can have a variety of forms, but a rectangular box is typically employed, even though it would be possible to have square section or cylindrical section boxes. Preferably, the container further comprises one or more insulating cover panels, which insulating cover panels correspond in type with either the first or second panel type, whereby the cover panel can be resiliently retained with respect to an upstanding wall panel.

[0043]

[0027] The insulating panels forming the walls of the container are preferably manufactured from cardboard, but can be fabricated from one or more types of panel including extruded polystyrene, polyurethane foam, expanded polystyrene, cardboard, laminated polyurethane foam, laminated expanded polystyrene. The laminate face can comprise one of card, plywood, polypropylene, aluminium or steel. Cardboard benefits from being substantially easily and widely recyclable and is in common use in the cold chain industry.

[0044]

[0028] In accordance with another aspect of the invention, there is provided a method of assembling a container temperature control pack system. Specifically, there is provided a method of erecting an inner coolant system of a transport container having a temperature control system for use in cold chain transport, wherein the transport container comprises a base panel, side wall panels and a

[0045] 8

[0046] HEMA0124UK PCT for filing 12thAugust 2025 cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, edge members in contact with adjacent panels and an inside face made from one or more insulating elements which cooperate to form a closed container; wherein there the inner coolant system, comprising single or multiple support walls, a cover element and a selected number of temperature control packages is operably arranged about a central load area defined with respect to an upper base panel of the transport container; the method comprising the steps of: arranging the single or multiple support walls with respect to the base by engaging any locating elements of the single or multiple support walls, so as to define an upstanding wall surround for the central load area; locating an upper panel about the upstanding wall and ensuring interlocking elements of the respective upper panel and wall elements engage; ensuring that the cooperating tabs and apertures of the fastening systems of the support walls and temperature control packages are opened / extended; attaching the temperature control packages to the walls in accordance with a desired temperature required with regard to the nature of the load and cold chain event; placing any temperature control packages upon the upper panel in accordance with a desired temperature required with regard to the nature of the load and cold chain event; completing the transport container by fastening the base panel with respect to the external side wall panels and the external cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, with edge members in contact with adjacent panels which cooperate to form a closed container.

[0047]

[0029] The skilled man will appreciate that the order of assembly may be varied to a degree. The temperature control elements may be hung upon the support walls; the temperature control elements may be placed upon each other with the cooperating tabs and apertures ensuring lateral placement thereof. A container temperature control pack in accordance with the present invention may be assembled in a rapid and expeditious manner. The parts making up the temperature control pack may be stacked for storage in a relatively small space, conveniently being prior attached to a panel for a container, and may be associated with a container also arranged in a flat-pack style. A distinct benefit of the present invention is that the construction permits the same size temperature control packs to be utilised in different containers; commonality of parts between ranges of product can provide more cost-effective construction and / or different functionality. Not all the spaces provided for temperature control element need be utilized, whether upon the top cover or upon the support walls.

[0048] Brief Description of the Figures

[0049] 9

[0050] HEMA0124UK PCT for filing 12thAugust 2025

[0030] For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein:-

[0051] Figures la - le illustrate various forms of cold chain transport containers;

[0052] Figure 2 illustrates an erected container made in accordance with the invention mounted upon a pallet base;

[0053] Figure 3a - 3b detail a first embodiment of one aspect of the invention;

[0054] Figure 4 shows an underside perspective view of a container in accordance with one aspect of the invention;

[0055] Figures 5a - 5c show aspects of the invention shown in Figure 4; a second embodiment of the invention in perspective view;

[0056] Figures 6a - 6d show further features of a container in accordance with the invention;

[0057] Figures 7a - 7h show an embodiment in various states of assembly indicating preferred and / or alternative features;

[0058] Figures 8a & 8b show a temperature control element in accordance with another aspect of the invention in plan and assembled forms;

[0059] Figures 9a - 9f detail attributes of a temperature control element in accordance with another aspect of the invention; and,

[0060] Figures 10a - 10b detail another temperature control carton.

[0061] Detailed description of the Preferred Embodiments

[0062]

[0031] There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

[0063]

[0032] Figure 2 shows an example of an erected container 20 made in accordance with the invention mounted upon a pallet base 22. The pallet base is provided with apertures (not shown) from at least one direction to permit the tines of a fork lift truck or a pallet trolley (also not shown) to be placed within; the tines are raised against an inside member of the base such that the pallet base and the container can be moved laterally and vertically. The container comprises a base element 24 and a lid 25, the lid being positioned about the upper edges of the four wall panels, noting that this container has first and second panels 26 of a first width and first and second panels 27 of a second width. It will be appreciated that the first and second sets of panels 26 and 27 may be of the

[0064] 10

[0065] HEMA0124UK PCT for filing 12thAugust 2025 same width. The panels are shown as being formed from cardboard, conveniently of a weight being 750 - lOOOgsm, being a five-wall aa flute, (although heavier weights and greater numbers of walls and differing flutes sizes are possible as will be known to the skilled man) but could be formed from a number of materials such as polyurethane foam and other plastics as known to the skilled man (as discussed in the background above). The wall panels could comprise two sets of materials, such as having vacuum insulation panels or other forms of insulation, including so-called bubble paper, foam plastics or other materials having different thermal conductivities to cardboard, polyurethane foam or other facing material.

[0066]

[0033] Figures 3a and 3b show first and second perspective views of one embodiment of the present invention. This embodiment features an enclosure 30 which, in use, surrounds a load, placed upon an inside of the embodiment, on an upper face of the base 22. The enclosure 30 is defined by two upstanding wall elements 31, 32, which support a lid or cover element 33. Each wall element is provided with castellations 34 which extend upwardly and through slots 35 defined in the lid element 33. It will be appreciated by the use of a cardboard of a weight being 750 - lOOOgsm, being a five-wall aa flute, (although heavier weights and greater numbers of walls and differing flutes sizes are possible as will be known to the skilled man) then the upstanding wall elements will remain in a secure lateral position. The lid 33 can also be employed to carry coolant elements (not shown).

[0067]

[0034] In this embodiment, the two wall elements 31, 32 are arranged in a general "C" plan, providing first 36i,ii, second 37i,ii, and third 38i,ii wall elements respectively. Upon the sides of the enclosure, it can be seen that there are a number of flap or flap-like elements 39 which extend upwardly and outwardly and are arranged to engage with temperature control elements as shall be discussed below. These flap-like elements, conveniently have a shape that is at least one of a trapezoid or rectangular, preferably having a trapezoidal isosceles shape with a base side being hingedly retained with respect to the wall elements 31, 32, with the side and length opposite the base being press-cut from the wall elements 31, 32, thereby providing an aperture when the flap is arranged at an acute angle to the support wall elements 31, 32. Conveniently, the press-cut features are defined by a die-board or laser-cut manufacturing process. In use, these upwardly directed flaps 39 are used to engage or otherwise associate with a slotlike aperture defined within a temperature control package 50 (with reference to Figure 5a, b & c (at least)). It will be appreciated, however, that the flap elements may have rounded edges and / or comprise ellipse or oval sections

[0068] 11

[0069] HEMA0124UK PCT for filing 12thAugust 2025

[0035] Turning now to Figure 4, there is shown a perspective view of the enclosure 30 from below. In correspondence with Figures 3a and 3b, there are downwardly depending castellations 41 which depend through slots 35 in an upper base panel member 42. In this embodiment, the base comprises an upper cardboard member spaced from a lower cardboard member, with the castellations extending downwardly to enable the castellations to bear weight against the lower cardboard member 43. That is to say, the weight of the walls and cover, together with any temperature control elements are borne through the castellation to a secure, base panel. This feature may be extended to the provision of a coolant system comprising a base element, a support wall, an upper lid or cover element 33 and temperature control packages, wherein the base element is dimensioned to be placed in known transport containers, to thereby update a temperature control system thereof.

[0070]

[0036] It will be appreciated that there can be many forms of insulation members such as vacuum insulation panels, foam, other forms of insulation positioned between the two, upper and lower cardboard panels. As discussed above, the cardboard can be of various grades, such as 750 - lOOOgsm weight, with the fluting of a three wall cardboard being fabricated from be flute tri-walls, albeit, as above, various grades of cardboard can be employed to ensure that the selection of the cardboard is sufficient for the intended load. In another alternative, the base may comprise multiple layers of cardboard and the upper surface could assist in bearing weight, as well as the lowest cardboard layer or an intermediate layer, noting that the use of castellations present in orthogonal associated panels may assist in maintaining lateral positioning of the wall panel members.

[0071]

[0037] It can be seen from the underside of the base and the topside of the cover 33 from Figures 3a, 3b and 4 that the castellations are arranged in a general "U" shape: i.e. the two short sides and one long side of the bases and cover are provided with castellations. This permits two of the upstanding wall members 36i and 36ii to hinge about corners 44, 44', the two wall members being provided handle elements 45. Note also that this cover is not formed as a rectangular sheet as such; the edge of the door edge of the cover having an overall shall "V" shape whereby to enable the handles to upstand and the doors to be flush about any enclosed load. Note also that on each of the door walls 36i, 36ii, there is a single array of flap or flap-like elements 39 which extend outwardly to engage with temperature control elements. Whilst a lintel element is conveniently provided to enable the door elements to operate, a detent arrangement may be provided by tabs 45 acting against a part of the cover panel 33 to offset weight

[0072] 12

[0073] HEMA0124UK PCT for filing 12thAugust 2025 due to temperature control packages acting on the hinges 43, causing a doordrop effect, although tab 71 (with reference to Figure 7a) provides an alternative or additional solution to this weight distribution issue.

[0074]

[0038] Referring now to Figures 5a - 5d, there is shown the enclosure of Figure 4 provided with temperature control packages 50, in accordance with another aspect of the invention. Whilst Figure 5a only has temperature control packages about the walls of the enclosure, Figure 5b also has temperature control packages placed upon the cover 33. Whilst the cover could be provided with one or more arrays of flap or flap like elements 39 to enable the horizontally laid thermal control packages to locate therewith, this would not necessarily be required if the cover 33 was covered with thermal control packages. Notwithstanding this, it will be known that the use of thermal control packages with be determined upon the nature of the intended cold chain journey, with regard to the desired internal temperature, duration of the journey and the likely ambient temperatures. Accordingly, if only a reduced number of temperature control elements are required then positive location features may well be useful, noting that the packages or containers for the temperature control elements could be neutral or not be filled with a temperature control element. Apertures may be provided in the sidewall of the containers to indicate the type on temperature control retained therein, if any. Figure 5c is similar to Figure 5b save that the temperature control elements are spaced from the walls and cover of the enclosure, whilst Figure 5d shows one set of thermal control packages 51 from their mating side with respect to the enclosure 30.

[0075]

[0039] Figure 6a shows a further feature in relation to supporting a weight associated with any coolant packages 51 that are placed upon the cover element 33 of the enclosure, wherein a lintel or lintel-like element 61 is placed below the cover element. This lintel could be formed from "L"-section mdf / paperboard elements that are widely used as edge protection elements for the transport of new white goods, for example. It will be appreciated that the "L"-section board will assist in maintaining the distance between two opposite short sides of the enclosure 30. Figure 6a shows the lintel 61 in an exaggerated form; the extension is not so great as shown, noting that the outer walls of the container would not otherwise be capable of being employed. In Figure 6b, the orientation of the "L" member is distinct to that of the one shown in Figure 6a. With reference to Figure 6c, the orientation and placement of the temperature control packs 51 are shown as abutting the upstanding castellations 34. This Figure also shows a correctly truncated length of lintel 61 "L"-section material. It will be

[0076] 13

[0077] HEMA0124UK PCT for filing 12thAugust 2025 noted that the inside top edge 65 of the lintel abuts upstanding castellation member 34 indicated. It would also be possible to have the "L"-section member have a slot through which an upstanding castellation could pass through, to make the arrangement even more secure, dispensing with any need for adhesive, which could also be utilised if deemed necessary - albeit there is a growing desire to dispense with the need for adhesives to be employed from a recycling point of view and an extra process step in manufacture. Figure 6d shows an example of how the door elements 36i & 36ii can be restrained during packaging: the handles 45 are restrained with respect a lintel 61, by way of an elasticated tie 64. Whilst the support walls are shown as being perpendicular from the base in the figures, it may be desirous that the support walls are inclined so that, the shape can provide greater stability, for example, the four walls, inwardly towards the top of the coolant support structure.

[0078]

[0040] Figure 7a shows further aspects of construction of the enclosure 30, with a door element 36ii of side wall component 32 being placed during construction. This particular door is provided with an additional castellation member 71 to enable the door element 36ii to locate securely with a corresponding aperture associated with the base 42. Figure 7b shows a wall element 31 (32) upstanding during fabrication of the enclosure. Figure 7c shows a wall element 31 (32) with the locating tabs 39 for the coolant element pressed from the cardboard wall during fabrication. Figure 7d shows an example of the enclosure fitted with temperature control packs 51 arranged about the side elements 31, 32 and cover 33. It can be seen that the lowest temperature control packs 51i, mid-level temperature control packs 51ii and uppermost temperature control packs 51iii are dimensioned such that, the base of the respective lowest control pack is placed upon the base or the Figure 7e is similar to Figure 7d except that the door on the right is partially ajar; Figure 7f show the same enclosure with the left hand door 36i wide open, with no coolant packages on the door, clearly showing the locating tabs 39. Figure 7f also shows an aperture 72 to enable an operator to insert, for example a tool such a hook or a finger to pull out the flap 39. Figures 7g and 7h show the same enclosure complete, with 27 vertical and 12 horizontal coolant packages in place, from first and second perspective viewpoints.

[0079]

[0041] Turning now to another aspect of the invention, there is shown in Figure 8a, a first coolant package which is arranged as a die-cut sheet material element 80, to be manufactured from suitable sheet material such as card, cardboard (preferably), plastics sheet or extruded (corrugated) plastics sheet. In practice a three wall 400gsm cardboard having b flutes will provide sufficient strength. An

[0080] 14

[0081] HEMA0124UK PCT for filing 12thAugust 2025 aperture 86 is defined within a rectangular main face 81: fold lines 88 depending therefrom and subsequent fold lines 89 create first and second generally rectangular tabs 82, 82i; 83, 83i, 84, 84i; and 85, 85i, which are folded to create a generally rectangular prism-shaped container. Aperture 86 is used to create a tab receiving element 39 of the wall elements of the enclosure, whereby in one sense a completed coolant package - with coolant placed therein, as shall be discussed below - can be used to retain the coolant package to the enclosure wall. Conveniently, the generally rectangular prism can engage with a tab receiving element 39 to provide lateral positioning of a coolant package with respect to a wall of the enclosure. Figure 8b shows a completed coolant package, without surface detail. It will be appreciated that other forms of location are possible. For example, the wall structure could be delimited outwardly by a further piece of rectangular cardboard with an aperture in the form of a rectangle within, akin to a picture frame, with the inside edge of the picture frame preventing outward movement at the base.

[0082]

[0042] It will be appreciated that the coolant packages will be of a size that is easily handled by personnel and provide sufficient volumetric latent heat for a cold chain supply. Table 1 provides a comparison of a number of categories of phase change materials, their densities, latent heat per Kilogramme and their volumetric latent heat. When a choice of phase change material is made, then the period of cold chain delivery needs to be taken into account together with the latent heat of the produce to be transported. The weight of a coolant package can therefore amount to several of Kilogrammes, which need to be securely maintained in place in a pallet shipper or similar container.

[0083] Table 1

[0084]

[0043] PCM gel packs are typically supplied with respect to common temperature ranges (e.g., 2-8 °C, 0-5 °C, frozen ranges) and are provided in packs of a

[0085] 15

[0086] HEMA0124UK PCT for filing 12thAugust 2025 specific masses like 1 kg, 2 kg or custom sizes; flexible gel packs aim to be lighter / less bulky than ice for the same thermal hold time because they match temperature more tightly. PCM gels and encapsulated PCMs can reduce leakage risk and are often formulated to be non-toxic and reusable. Volumetric energy density matters when there is limited payload volume: salt-hydrates often give the highest kJ / L, ice is excellent by absolute latent heat but provides a fixed 0°C plateau, and paraffins / organic PCMs give stable, safe performance across many set-points but lower kJ / L than many salt-hydrates. Accordingly, a PCM is selected in view of a required hold temperature first (melting / freezing point), then by volumetric / mass constraints. A PCM with the "right" phase-change temperature but lower volumetric density may still be preferable if it avoids overcooling sensitive payloads.

[0087]

[0044] In more detail and with refence to Figures 9a - 9d, a coolant package 80 is shown attached to a wall of an enclosure. Specifically, with reference to Figure 9a, walls 81, 82 and 83 of the package are shown once the laser-cut I die-cut element 80 has been folded into rectangular prism. Whilst not shown, slit elements and tabs could cooperate to enable an adhesive-free assembly of the prism. With reference to Figure 9b, the aperture defined by a trapezoidal / rectangular shaped aperture 86 is reinforced by having the tab 99 being folded back against an inside face of wall 81. Figure 9c shows a cross-sectional view of the package 80 about the support wall 31, 32. Wall 81 of the coolant package abuts a wall of the upstanding walls 31, 32. Tab 39 of the enclosure element extends within the aperture 86.

[0088]

[0045] With reference to Figure 9d, three coolant package 80, 80i & 80ii are show one atop another: The coolant package on the base, since it is engaged with the tab 39, cannot be pulled away from the plane of the enclosure wall. Nonetheless, the base walls 84 of the coolant element 80 rest upon the base 42, meaning that distorting forces do not necessarily act through the walls 31, 32 of the enclosure. That is to say the system, in one embodiment, can be adapted such that the support walls 31, 32 provide lateral positioning alignment but bear little or no weight. Subsequent packages 80i and 80ii locate upon the top surface of the packages below them, spreading their weight through such packages to the base. Figure 9d also indicates the width of the aperture 86 as "W" and the width of the tab 39 as "w" - it will be appreciated that to simplify placement, the width of the tab 39 is not as great as the width of the aperture "W", noting that if they were the same, they could attach with a sliding tolerance fit, which may suit certain types of materials of the wall element and the coolant package container.

[0089] 16

[0090] HEMA0124UK PCT for filing 12thAugust 2025

[0046] Figure 9e is a cross-sectional view through a wall member associated with the container supporting temperature control packages in another alternative. In this arrangement the tabs 39 are, with respect to this embodiment, associated with the temperature control packages 80, 80i & 80ii, and are directed downwardly, with the tabs being located within apertures 86 - shown in Figure 9f, below - defined within the upright wall member. It will be noted that temperature control package 80 rests upon the upper surface 42 of the base; that temperature control package 80i rests upon the upper surface of temperature control package 80; and that that temperature control package 80ii rests upon the upper surface of the temperature control member 80i. The tabs 39 and apertures 86 ensure lateral stability of the temperature control packs; moreover, they are supported by the base member. With reference to Figure 9f, a wall member 31, 32, 95 is shown with apertures 86. It will also be appreciated that a wall member 95, with either apertures or engagement tabs 39 could be placed adjacent an inside surface of a pre-existing external wall member of another type of container so as to provide a retro-fit facility. Whilst it will be appreciated that the internal enclosure as shown and discussed with respect to Figures 3 - 7 can be substantially independent from the construction of the external walls - per walls 26, 27 and cover 25, per Figure 2. Accordingly, optional downwardly depending castellations 96 can be provided to engage with slots in a base. Alternatively an additional base layer may be provided. It is important to note that since the wall does not bear the weight of the coolant media within the coolant packages, the stability of the wall itself is not as critical as is often found in prior systems - confirming the retro-fit attributes of the present invention.

[0091]

[0047] Referring now to Figures 10 and 10b, there is shown, respectively a simple temperature control package carton blank 100 and a temperature control package 108 formed therefrom. The rectangular blank has an aperture 86 defined therein in a first rectangular area 101 which faces an internal wall of an associated container with respect to which it is associated by means of a tab 39, which is hingedly connected to a short top section 102, which in turn is hingedly connected to a single rear face section 103. The rear face section is, similarly, hingedly attached to a complementary section 104, which faces top section 102, which in turn terminates in section 105 which then is attached to the first rectangular area 101 by means of co-operating tab 107 and slit 108, although adhesive could be used as a first alternative. In use a coolant bag or receptacle is placed in the cavity 109 defined by the blank 100. The depth of the slits used in development were of between 5 and 10cm, and the width was up to 70% of

[0092] 17

[0093] HEMA0124UK PCT for filing 12thAugust 2025 the width of the package, but variations will arise, dependent upon the weights of the coolant, size of the coolant package, inherent strength of the sheet material.

[0094]

[0048] The skilled man will appreciate that various strengths and thicknesses of board for the provision of the support walls and the coolant packages can be created dependent upon the weight per square of the sheet material, the size of flutings and number of walls of material and the type of material employed, taking into account the function of the materials. Equally, the skilled man will realize that whilst corrugated sheet materials are preferred, non-corrugated sheet materials could also be employed, noting that corrugated sheet materials will have a substantially higher bending stiffness, edgewise compression strength (resistance to crushing under vertical load) and cushioning ability in comparison to non-corrugated sheet materials of the same weight.

[0095]

[0049] The present invention provides several benefits: The thermal control packages can be simply and easily placed upon or against the support walls of this system so that they remain in place, using lateral engagement therewith together with the weight of the package to stay in place upon the support wall or upon a base floor of the transport container; In the event that the weight of the thermal control packages is employed to maintain position in use, then the position of the thermal control package upon the wall - as in a mid or upper position is possible without the necessity of a lower thermal control package being present, albeit to mitigate this a thermal control package box which does not retain any temperature stabilizing material could instead be utilized; The thermal control packages can be easily manufacture from readily available materials; The cost of the construction and the recyclability of paper based systems make single use followed by recycling an economically viable; The cost of the construction and the recyclability of polypropylenes also permit plastics corrugated materials to be economically viable; with the variability of the actual temperature control medium and the variable numbers of the temperature control packages mean that a wide variety of configurations can be provided for most particular cold chain events. That is to say, depending upon the nature of the goods, the nature of the cold chain event, as in: "anticipated transport duration" and "anticipated variations in external atmospheric temperature and pressure", noting that in the transportation of a package from one country to another in an aeroplane, then the pressures and the temperatures will differ, from storage depot, to runway, flight time and onward transfer etc.. In view of such variations, then a selection of the correct temperature control package will be made, with an appropriate safety margin.

[0096] 18

[0097] HEMA0124UK PCT for filing 12thAugust 2025

Claims

CLAIMS:

1. A transport container having a temperature control system for use in cold chain transport, the transport container comprising a base panel, side wall panels and a cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, edge members in contact with adjacent panels and an inside face made from one or more insulating elements; wherein there is an inner coolant system operably arranged about a central rectangular load area the coolant system comprising a support wall which comprises at least four upstanding wall elements which extend from a base edge in contact with the inside face of the base to a top edge which inter-engage with a cover element to operably enclose a load, wherein temperature control packages of a generally rectangular prism shape are associated with the wall, the number of and type of temperature control packages being determined with reference to a cold chain event.

2. A transport container according to claim 1, wherein the co-operating extending tabs and apertures of the support walls and temperature control packages provide lateral association of the temperature control packages with the support walls and the support walls bear a weight associated with the temperature control packages.

3. A transport container according to claim 1, wherein the co-operating extending tabs and apertures of the support walls and temperature control packages provide lateral association of the temperature control packages with the support walls, the temperature control packages are stacked and the base panel bears a weight associated with said temperature control packages.

4. A transport container according to any one of claims 1 - 3, wherein the base element comprises first upper and second, lower parallel spaced apart sheet members with an insulating medium therebetween, the upper sheet member being arranged for placement of a load and comprising slots in correspondence with downwardly facing castellations of the wall elements, whereby the lowermost castellations abut against the lower, second sheet member.

5. A transport container according to any one of claims 1 - 4, wherein the cover element extends beyond the extent of the upper edges of the upstanding walls; wherein the upper edges of the upstanding walls are provided with castellations;19HEMA0124UK PCT for filing 12thAugust 2025wherein the cover element comprises slots in correspondence with upwardly facing castellations of the wall elements, whereby the extending elements pass through the slots and troughs of the castellations abut against a lower face of the cover member.

6. A transport container according to any one of claims 1 to 5, wherein the cover element supports the weight of temperature coolant packages placed thereon.

7. A transport container according to any one of claims 1 to 6, wherein the upstanding walls comprise two sheets defining a "C" in plan, with first and second hinge elements to define a middle wall; the middle walls oppose each other and the respective pairs of adjacent partly extending walls define third and fourth walls, to surround the load.

8. A transport container according to claim 7, wherein one pair of adjacent partly extending walls are not provided with castellations and are operable to act as doors, to enable access within the load enclosure.

9. A transport container according to claim 8, wherein there is provided a lintel element to support the cover one pair of adjacent partly extending walls are not provided with castellations and are operable to act as doors, to enable access within the load enclosure.

10. A transport container according to claim 9, wherein the lintel component comprise an "L"-shaped member.

11. A transport container according to claim 9 or 10, wherein the lintel component comprises slots which engage with the upstanding castellations of an upstanding wall element at opposite ends of the lintel.

12. A temperature control element combination for use with a cold chain transport container, the combination comprising a wall element that can be supported within a cold chain container, the wall element having one of a tab and an aperture, and a coolant package comprising a generally rectangular prismatic body and having a face with one of an aperture and a tab, whereby the two can become associated with each other.

13. A temperature control element combination according to claim 12, wherein the tab and aperture cooperate to prevent lateral separation of the coolant package with respect to the wall.

14. A temperature control element combination according to claim 13, wherein the wall element is supported upon a base surface of the container and the20HEMA0124UK PCT for filing 12thAugust 2025temperature control package is also supported upon the base floor of the container and wherein one or more vertically oriented temperature control packages aperture bear on lower temperature control packages, whereby the base surface takes the weight of the temperature control packages.

15. A temperature control element combination according to claim 12, wherein the base comprises an upper sheet member spaced from a lower sheet member; wherein the wall element is provided with castellations that extend downwardly; wherein the castellations abut the lower sheet member; wherein the slots of the temperature control members are supported by the tabs of the wall member, whereby the temperature control packages are supported by the wall and the wall is, in turn, supported by a secure, lower sheet member of the base member.

16. A temperature control element combination according to claim 12, wherein the base comprises an upper sheet member spaced from a lower sheet member; wherein the wall element is provided with castellations that extend downwardly; wherein the castellations abut the lower sheet member; wherein tabs of the temperature control members are supported by the slots of the wall member, whereby the temperature control packages are supported by the wall and the wall is, in turn, supported by a secure, lower sheet member of the base member.

17. A transport container according to any one of claims 1 - 12, wherein the number of temperature control packages are determined with reference to one or more of the following factors: intended internal temperature range; heat capacity of load; expected external atmospheric conditions for the container; duration of the journey.

18. An inner coolant system for a cold chain container, wherein the inner coolant system is operably arranged about a central rectangular load area the coolant system comprising a support wall which comprises at least four upstanding wall elements which extend from a base edge in contact with the inside face of the base to a top edge which inter-engage with a cover element to operably enclose a load, wherein temperature control packages of a generally rectangular prism shape are associated with the wall, the number of temperature control packages being determined with reference to a cold chain event.21HEMA0124UK PCT for filing 12thAugust 202519. A method of erecting an inner coolant system of a transport container having a temperature control system for use in cold chain transport, in accordance with any one of claims 1 - 18, wherein the transport container comprises a base panel, side wall panels and a cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, edge members in contact with adjacent panels and an inside face made from one or more insulating elements which cooperate to form a closed container; wherein there the inner coolant system, comprising single or multiple support walls, a cover element and a selected number of temperature control packages is operably arranged about a central load area defined with respect to an upper base panel of the transport container; the method comprising the steps of: arranging the single or multiple support walls with respect to the base by engaging any locating elements of the single or multiple support walls, so as to define an upstanding wall surround for the central load area; locating an upper panel about the upstanding wall and ensuring interlocking elements of the respective upper panel and wall elements engage; ensuring that the cooperating tabs and apertures of the fastening systems of the support walls and temperature control packages are opened / extended; attaching the temperature control packages to the walls in accordance with a desired temperature required with regard to the nature of the load and cold chain event; placing any temperature control packages upon the upper panel in accordance with a desired temperature required with regard to the nature of the load and cold chain event; completing the transport container by fastening the base panel with respect to the external side wall panels and the external cover panel arranged in a general rectangular prism; wherein each of the panels has an outside face, with edge members in contact with adjacent panels which cooperate to form a closed container.22HEMA0124UK PCT for filing 12thAugust 2025

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