Cool pack arrangement for thermally insulated container assembly
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Solution Overview
Problem
Existing thermally insulated containers for passive shippers require complex assembly of multiple cool packs, which can lead to inefficiencies in thermal insulation due to convection currents and increased handling burdens, especially when a large number of shippers need to be prepared simultaneously.
Innovation Solution
A cool pack arrangement featuring rigid compartments joined by living hinges, allowing for folding and interlocking to form a continuous layer within the container, which reduces the number of components and simplifies assembly, while also enhancing thermal efficiency by minimizing convection through stepped profiles and chamfered edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple separate cool packs are used to line the container, then thermal coverage is improved, but assembly complexity and handling burden increase
Solution Approach 1:
The patent combines multiple separate cool packs into a single integrated cool pack assembly that lines the entire inner surface of the container. This single assembly comprises multiple cool pack segments joined together, eliminating the need to handle and assemble multiple separate cool packs while maintaining complete thermal coverage of the container interior.
Solution Approach 2:
The integrated cool pack assembly is divided into multiple segments or modules that can be separately manufactured and then joined together. Each segment can be independently cooled and stored, but when assembled forms a continuous thermal barrier lining the container, thus reducing handling complexity while maintaining thermal effectiveness.
2Temperature
If cool packs are positioned with edges abutting each other, then thermal continuity is improved, but convection currents increase between adjacent edges
Solution Approach 1:
The patent applies different geometric profiles to different edges of the cool pack segments. Specifically, alternating edges are provided with different profiles (e.g., convex vs concave, or different chamfer angles) so that when segments are abutted together, the unique local geometries interlock to block convection currents while maintaining thermal continuity. This local differentiation of edge qualities prevents harmful convection without compromising thermal performance.
3Productivity
If a large number of shippers are prepared simultaneously, then productivity is improved, but handling and assembly time increase
Solution Approach 1:
The cool pack segments are pre-assembled into complete integrated assemblies during manufacturing, ready for direct installation into containers. This preliminary assembly eliminates the need for on-site assembly of multiple separate cool packs when preparing shippers for shipment, thus maintaining high productivity while minimizing assembly time at the point of use.
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 cool pack arrangement significantly simplifies assembly, improves thermal efficiency by reducing convection, and maintains consistent temperature through a minimized number of cool pack types, ensuring effective temperature control for products during transportation.
Implementation Method 1
These may be cooled until a phase change occurs in the refrigerant in the cool packs from a liquid to a solid, so that the subsequent phase change back from a solid to a liquid acts to maintain the contents of the container at a constant temperature.
Implementation Method 2
This prevent adjacent edges of cool packs being closely abutted and thus would make it difficult to restrict convection currents between adjacent cool packs
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A thermally insulated container 1 comprising an expanded foam layer 2, a further layer 3, internal of the expanded foam layer 2, formed of a plurality of cool packs 29, 30, 32-35 or insulation panels 4a to 4f, and a locking lid 13. The cool packs consist of a combination of cool packs with stepped edges (29, 30) and individual side wall cool packs side wall cool packs, wherein the cool packs 29-30 consist of a protruding fill point on one edge and blanking protrusions on the remaining three edges, and the cool packs 32-35 comprise recesses 46 and 47 on the top and bottom edges to accommodate either the fill point or the blanking protrusion of each adjacent cool pack 29 and 30 .