Dual-Layer PCM Shipping Container to Prevent Product Cold Damage
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Solution Overview
Problem
Passive insulated shipping containers require double handling and lengthy chilling processes for cool packs, leading to inefficiencies and delayed availability for use, as they need to be chilled to low temperatures and then brought back up to the desired temperature for product transport, risking product damage from extreme cold.
Innovation Solution
A thermally insulated container design featuring a flexible barrier phase change material (PCM) layer between the main PCM layer and the product, allowing cool packs to be inserted at -18°C or lower without risking product temperature, with the barrier PCM layer maintaining even distribution and providing energy to the main PCM layer for temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cool packs are chilled to low temperatures (-18°C) to ensure adequate cooling capacity, then the cooling performance is improved, but the risk of product damage from extreme cold increases and double handling is required
Solution Approach 1:
A barrier layer containing phase change material is introduced between the main PCM layer and the product. This intermediary barrier absorbs excess cold energy when the main PCM layer is at -18°C, preventing direct contact with the product and thus avoiding product damage while maintaining adequate cooling capacity
Solution Approach 2:
The barrier PCM layer is pre-positioned in the container before the main PCM layer is inserted. This preliminary arrangement ensures that when chilled main PCM layers are added, the barrier is already in place to protect the product from extreme cold temperatures
2Quantity of substance
If cool packs are chilled to -18°C to reduce chilling time and storage space requirements, then the storage efficiency is improved, but double handling and lengthy preparation processes are required
Solution Approach 1:
The barrier PCM layer is pre-positioned in the container at room temperature before the main PCM layer is inserted. This allows the main PCM layers to be directly inserted at -18°C without requiring preliminary warming, eliminating double handling and reducing preparation time while maintaining storage efficiency
Solution Approach 2:
The PCM system is divided into two functional segments: the main PCM layer for bulk cooling capacity and the barrier PCM layer for temperature regulation. This segmentation allows each layer to perform its specific function independently, enabling the main layer to be stored efficiently at -18°C without requiring time-consuming temperature adjustments
3Object-affected harmful factors
If a thick barrier PCM layer is used to ensure adequate temperature protection, then the product protection is improved, but the quantity of PCM material required increases
Solution Approach 1:
The barrier PCM layer is applied locally at the interface between the main PCM layer and the product, rather than uniformly throughout the entire container. This localized application provides temperature protection exactly where needed (at the product contact interface) while minimizing the total quantity of PCM material required
Solution Approach 2:
The barrier PCM layer uses a different phase change temperature than the main PCM layer. The barrier layer is formulated to change phase at temperatures closer to the desired product storage temperature, allowing it to provide precise temperature protection with a thinner layer compared to using the same PCM material as the main layer
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
Enables immediate preparation and use of the container at short notice, avoiding double handling and potential product damage, while potentially reducing the quantity of PCM material needed and enhancing container performance by absorbing and transferring energy effectively.
Implementation Method 1
These may be cooled until a phase change occurs in the phase change material 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
a thermally insulating layer defining a first void
Data Source
Figure 1
Figure 2~3
AI summary
The present invention provides a thermally insulated shipping container (1) comprising a thermally insulating layer (5) defining a first void, a main layer (9, 10, 11) containing phase change material (main PCM layer) within the first void and defining a second void within the first void, a barrier layer (12) containing phase change material (barrier PCM layer) within the second void and distinct from the main PCM layer, the barrier PCM layer (12) defining a third void within the second void, the container being arranged to receive a product for transportation inside of the third void, wherein the main PCM layer (9, 10, 11) has an average thickness greater than the average thickness of the barrier PCM layer (12), the barrier PCM layer (12) comprises of an envelope in which the phase change material of the barrier PCM layer (12) is contained and the barrier PCM layer (12) is configured to maintain the phase change material with a relatively even distribution within the envelope.