Insulated Shipping Container Door Plug Assembly
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Solution Overview
Problem
Existing shipping systems for temperature-sensitive materials face challenges in maintaining consistent temperatures over extended periods without the high costs associated with active temperature-control systems, and passive systems often lack effective insulation at the door opening, leading to thermal inefficiencies.
Innovation Solution
A novel shipping system featuring an insulated container with a thermally insulating door plug assembly, comprising flexible foam insulation and backing sheets, which provides additional insulation at the door opening and includes data logger holders to monitor temperature, thereby enhancing thermal efficiency and maintaining temperature stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If passive temperature-control devices are used, then transportation costs are reduced, but thermal insulation efficiency at the door opening deteriorates
Solution Approach 1:
The patent applies local quality by placing a specific thermal insulation component (door plug assembly) at the door opening location where thermal loss is most critical. This localized approach addresses the specific weakness at the door without requiring complete system redesign, providing enhanced insulation precisely where needed while maintaining cost-effectiveness of passive cooling.
Solution Approach 2:
The door plug assembly utilizes composite materials combining rigid foam insulation with a fabric cover. This composite structure provides both thermal insulation properties from the foam and protective/durable characteristics from the fabric covering, creating an effective solution for the door opening insulation problem.
2Reliability
If active temperature-control devices are used, then temperature maintenance reliability is improved, but transportation costs increase
Solution Approach 1:
The door plug assembly is designed as a self-service component that can be easily installed and removed by users without requiring technical expertise or additional equipment. The assembly uses simple elastic retention mechanisms that automatically hold the plug in place, enabling end-users to maintain temperature effectiveness without requiring active control systems or specialized installation procedures.
3Ease of operation
If the door remains open for loading/unloading, then ease of operation is improved, but thermal loss increases
Solution Approach 1:
The door plug assembly enables preliminary action by allowing users to close and insulate the door opening immediately after loading or unloading operations are completed. The elastic retention mechanism ensures the plug is quickly secured in place, minimizing the time the opening remains exposed and reducing overall thermal loss from necessary door accesses during the shipping process.
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 materials within a desired range for extended periods by minimizing thermal loss through the door opening and allowing for precise temperature monitoring, reducing costs and improving insulation efficiency.
Implementation Method 1
the plug being thermally insulating and dimensioned to substantially close the payload space when the door is open
Data Source
AI summary
Shipping system for temperature-sensitive materials. In one embodiment, the shipping system may include an insulated container. The insulated container may include a frame surrounding a payload space, the frame including a door providing access to the payload space. The shipping system may additionally include a door brace assembly. The door brace assembly may be mounted within the payload space just inside the door and may include a door plug configured to substantially close the payload space. The door brace assembly may additionally include a door brace mounted within the door plug. The door brace may be transformable between a retracted state and an expanded state. When in its retracted state, the door brace assembly may be loaded into or removed from the insulated container. When in its expanded state, the door brace assembly engages the four corners of the frame just inside the door to keep the frame square.