Composite Container with Nested Insulation for Cold Chain Durability
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Solution Overview
Problem
Existing cold chain packaging materials, such as expanded polystyrene, are fragile and prone to damage during shipping, leading to temperature fluctuations that can compromise the integrity of temperature-sensitive goods, and are often considered single-use, resulting in waste.
Innovation Solution
A composite container with a thermally insulated inner and outer container, incorporating phase change materials to maintain a payload temperature between −15° C. and −25° C. for at least 48 hours in ISTA 7D Test conditions, and optionally equipped with RFID elements for tracking and authentication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If EPS container is used for cold chain packaging, then thermal insulation is provided and lightweight structure is achieved, but the container is easily damaged during shipping and handling
Solution Approach 1:
The patent uses a composite structure combining EPS inner container with an outer protective container. The EPS provides thermal insulation while the outer container provides mechanical strength and damage resistance, resolving the contradiction between thermal insulation and durability.
Solution Approach 2:
The EPS inner container is nested within an outer protective container. This nested structure allows the EPS to provide thermal insulation while being protected by the outer container from mechanical damage during shipping and handling.
2Strength
If EPS container is damaged during shipping, then the container must be opened and payload transferred, but this subjects the payload to temperature fluctuations
Solution Approach 1:
The outer protective container is designed to absorb and withstand shipping forces before they can reach the EPS inner container. This beforehand protection prevents damage to the thermal insulation layer, thereby maintaining temperature stability and avoiding the need to open the container during transit.
3Ease of operation
If EPS containers are considered single-use due to fragility, then disposal is simplified, but mass disposal results in waste
Solution Approach 1:
The outer protective container is designed to be reusable and durable, capable of withstanding multiple shipping cycles. This multi-use design reduces waste generation while the EPS inner container can be replaced or refrozen, making the overall system both environmentally friendly and operationally efficient.
4Temperature
If improved thermal insulation is desired over EPS alone, then temperature control is enhanced, but container complexity increases
Solution Approach 1:
The nested structure of an inner EPS container within an outer protective container provides improved thermal insulation without excessive complexity. The simple nested design allows each layer to perform its specific function while maintaining overall structural efficiency.
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
The composite container effectively maintains temperature stability and durability, allowing for the reuse of the container and reducing waste by ensuring the integrity of perishable goods, such as vaccines, during transportation.
Implementation Method 1
one or more phase change material (PCM) elements configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours
Implementation Method 2
a thermally insulated inner container disposed within a thermally insulated outer container
Data Source
AI summary
There is disclosed composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container. The thermally insulated inner container is configured to receive one or more phase change material (PCM) elements to define a payload enclosure. The one or more PCM elements are configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. The composite container can be used to ship temperature-sensitive payloads such as perishable goods (e.g., a COVID-19 vaccine such as the Moderna COVID-19 vaccine).