Cold-Chain Packaging Configuration for Route Temperature Excursions
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Solution Overview
Problem
Current cold-chain shipment packaging methods do not account for temperature fluctuations along transit routes, leading to inefficient use of phase change materials and potential temperature excursions, resulting in increased costs and reduced product integrity.
Innovation Solution
A system that calculates a temperature profile for each stage of a transit route by correlating origin, destination, and intermediate locations with weather and transit data, then performs thermodynamic calculations to determine the optimal packaging configuration, considering phase change materials, container size, and insulation, to ensure products remain within a specified temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the same size shipping container and layout of phase change materials are used for each cold-chain shipment, then packaging simplicity is maintained, but temperature excursions occur during hot or cold transit routes
Solution Approach 1:
The patent implements dynamic packaging configuration by calculating optimal container size, phase change material quantity, and dunnage placement based on specific transit route weather conditions. The system transitions from static, standardized packaging to dynamic, customized packaging that adapts to environmental variables such as temperature, humidity, and transit duration for each shipment route.
Solution Approach 2:
The patent changes key packaging parameters (container size, phase change material amount, insulation thickness) based on calculated temperature profiles of specific transit routes. By adjusting these parameters according to predicted weather conditions and route characteristics, the system optimizes temperature control while minimizing packaging material usage.
2Reliability
If excessive phase change materials are used in cold-chain packaging, then temperature control reliability is improved, but cost increases due to waste
Solution Approach 1:
The patent applies partial action by calculating and using only the necessary amount of phase change materials required to maintain temperature control for each specific shipment scenario. Instead of universally over-packaging, the system determines the precise quantity of phase change materials needed based on transit route conditions, product thermal properties, and container insulation characteristics.
Solution Approach 2:
The system dynamically adjusts the quantity of phase change materials as a variable parameter based on calculated temperature excursions and transit duration. By changing this parameter according to specific route conditions, the patent eliminates material waste while ensuring adequate temperature control protection.
3Manufacturing precision
If weather and transit route conditions are considered in packaging calculations, then temperature control precision is improved, but system complexity increases
Solution Approach 1:
The patent performs preliminary calculations of temperature profiles and optimal packaging configurations before actual shipment preparation. By pre-calculating the thermal behavior of products during transit based on forecasted weather conditions and route characteristics, the system determines optimal packaging parameters in advance, simplifying the actual packaging process while maintaining high precision.
Solution Approach 2:
The patent replaces complex manual packaging decision-making with an automated computational system that uses thermodynamic models and weather data. This substitution of mechanical/judgment-based processes with algorithmic calculations achieves high precision in packaging optimization while managing system complexity through software automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces waste by optimizing the use of phase change materials and minimizes temperature excursions, thereby enhancing the reliability and efficiency of cold-chain shipments while maintaining product integrity and reducing costs.
Implementation Method 1
Specialized packaging may include, for example, phase change materials such as frozen ice packs, gel packs, dry ice, etc.
Implementation Method 2
phase change materials such as frozen ice packs, gel packs, dry ice
Implementation Method 3
cold-chain shipments may also utilize insulated shipping containers and/or specialized packaging
Data Source
AI summary
Various techniques are described to compensate for weather and other extraneous temperature conditions along a transit route when preparing a product for cold-chain shipment packaging. The origin and destination of the shipment may be determined to calculate one or more transit routes, which may include each stage along each transit route. Weather data may be received from one or more sources to build a weather database for one or more locations, which may be used to generate a temperature profile indicating the expected temperature and duration at each stage of transit to which the cold-chain shipment will be exposed. Thermodynamic calculations may then be performed in accordance with the temperature profile to determine the best available packaging option to prevent the product's temperature from falling outside of a desired or mandatory cold-chain temperature range.