Convection Packaging Layout Without Side Refrigerants
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Solution Overview
Problem
Current pallet shippers for temperature-sensitive products require side refrigerant components, which are inefficient, prone to displacement, increase shipping weight and cost, and may result in products overheating, making their elimination unacceptable for maintaining temperatures below 15°C.
Innovation Solution
A packaging system utilizing convection-based cooling with hollow vertical posts and strategically placed refrigerant layers to eliminate the need for side refrigerants, enhancing thermal performance and efficiency by facilitating air circulation and maintaining product temperature through cooled air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If side refrigerant components are used, then product temperature control is improved, but packaging efficiency and weight are worsened
Solution Approach 1:
The invention removes side refrigerant components from the packaging system, extracting only the essential top and bottom refrigerant layers while eliminating redundant side elements. This extraction reduces packaging weight and complexity while maintaining temperature control through the remaining strategic refrigerant placement combined with convective air flow mechanisms.
Solution Approach 2:
The invention replaces the mechanical refrigerant system on all six sides with a convective cooling mechanism that uses air flow patterns. Instead of relying solely on physical contact with refrigerants on every surface, the system uses natural convection currents to distribute cooling throughout the product space, reducing the need for extensive mechanical refrigerant structures.
2Temperature
If side refrigerant components are used, then temperature coverage is improved, but packing efficiency is worsened
Solution Approach 1:
The invention extracts side refrigerant components from the packaging configuration, removing obstacles that interfere with efficient product arrangement. This allows for better utilization of packing space while maintaining temperature control through the simplified top-and-bottom refrigerant layer configuration enhanced by convective air flow.
Solution Approach 2:
The invention transitions from a three-dimensional surround refrigerant approach to a two-dimensional top-and-bottom layer configuration. By changing the dimensional arrangement of refrigerants and utilizing vertical air convection currents, the system maintains temperature coverage while improving packing efficiency and space utilization.
3Productivity
If side refrigerant components are eliminated, then packaging efficiency is improved, but temperature control is worsened
Solution Approach 1:
The invention introduces air as an intermediary medium to transfer cooling from the top and bottom refrigerant layers to the product surfaces that would previously contact side refrigerants. The convective air currents act as mediators, distributing thermal energy throughout the packaging cavity and maintaining temperature control without requiring direct physical contact with side refrigerant components.
Solution Approach 2:
The invention replaces the mechanical side refrigerant contact system with a fluid dynamics-based convective cooling system. Natural convection currents carry cooled air from the top and bottom refrigerant layers throughout the packaging space, providing temperature control through fluid motion rather than direct mechanical contact with refrigerants on all surfaces.
4Temperature
If side refrigerant components are used, then cooling coverage is improved, but shipping cost is worsened
Solution Approach 1:
The invention extracts unnecessary side refrigerant components, reducing overall shipping weight while maintaining adequate cooling coverage through the optimized top-and-bottom layer configuration. The removed weight directly translates to reduced shipping costs while the convective air flow ensures cooling is distributed throughout the entire product space.
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 system effectively maintains temperature-sensitive products within a desired range without side refrigerants, reducing weight and shipping costs while ensuring efficient cooling through convective air movement, even in varying ambient conditions.
Implementation Method 1
Each vertical post has an open top end and an open bottom end and defines a vertical inner space within the post. Adjacent vertical posts define a vertically oriented channel between the vertical posts. It is believed that warm air rises through the inner spaces in the vertical posts until the air exits the posts and is cooled by the top cooling layers. The relatively denser cooled air then falls through the channels between the posts, contacting and cooling the payload.
Implementation Method 2
the air exits the posts and is cooled by the top cooling layers
Implementation Method 3
The relatively denser cooled air then falls through the channels between the posts, contacting and cooling the payload
Data Source
AI summary
A packaging system for a temperature sensitive payload is provided. The system includes insulative panels, including side panels and end panels, forming a product compartment. Cooling layers within the product compartment are located below and above the payload. Vertical posts disposed between the side panels and the payload and between the end panels and the payload create spaces and channels for convective air movement.