Fillable PCM Bladder Packaging to Reduce Cold-Chain Storage Costs
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Solution Overview
Problem
Current temperature-controlled product shippers require pre-conditioning and storage of large volumes of phase change material (PCM) gel packs, which is expensive and inefficient, especially in cold-chain applications.
Innovation Solution
A novel phase change material (PCM) bladder designed to receive and hold flowable PCM at the point of packaging, eliminating the need for pre-conditioned gel packs, with various embodiments featuring single or dual chambers, filling ports, and shapes to accommodate different product boxes, including asymmetrical and dual-chamber configurations with flutes for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pre-conditioned gel packs are used to maintain temperature in product shippers, then temperature control is achieved, but the cost of pre-conditioning and storage increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-freezing the PCM in a compact, concentrated form within the bladder at the manufacturing stage. This allows the bladder to be stored in a small volume and then deployed at the point of use, eliminating the need for large-volume pre-conditioned gel packs while maintaining temperature control functionality.
Solution Approach 2:
The patent utilizes the hydraulic principle by employing a flowable PCM that can be pumped or flowed into the bladder container at the point of packaging. This fluid-based approach allows for on-demand filling of the bladder, replacing the need for pre-stored solid gel packs and significantly reducing storage requirements.
2Reliability
If large volumes of pre-conditioned gel packs are stored, then temperature control capability is ensured, but the expense of pre-conditioning and maintenance increases
Solution Approach 1:
The patent performs the energy-intensive pre-conditioning action during manufacturing when the PCM is frozen into the bladder in a concentrated form. This one-time pre-conditioning replaces ongoing pre-conditioning expenses, ensuring temperature control capability is maintained without continuous energy input or large-volume storage requirements.
Solution Approach 2:
The patent changes the physical state and concentration parameters of the PCM by using a highly concentrated flowable formulation that can be stored in a compact, pre-frozen state. This parameter change allows the system to maintain reliable temperature control while dramatically reducing the volume and energy required for storage and pre-conditioning operations.
3Temperature
If conventional gel packs are used, then temperature control is provided, but the complexity of pre-conditioning and storage logistics increases
Solution Approach 1:
The patent segments the temperature control system into two independent components: a compact, pre-prepared PCM bladder container and a separate filling mechanism. This segmentation allows the bladder to be manufactured and stored in a simple, compact form, while the filling operation is performed locally at the point of use, eliminating complex pre-conditioning and storage logistics.
Solution Approach 2:
The patent introduces a flowable PCM as an intermediary substance that bridges the manufacturing stage and the final application. This intermediary material can be easily transported in a compact, pre-frozen state and then conveniently filled into the bladder at the point of use, simplifying the entire logistics chain from manufacturing to deployment.
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 PCM bladder system reduces the need for pre-conditioning and storage of gel packs, providing a uniform thermal profile and efficient temperature control by allowing on-site filling and use of flowable PCM, thereby minimizing costs and enhancing packaging efficiency.
Implementation Method 1
phase change material (PCM) bladder which is designed and configured to receive and hold a flowable PCM
Implementation Method 2
The bladder chamber is configured so that it has a substantially uniform thickness when filled with the flowable PCM whereby the bladder provides a substantially uniform thermal profile around all sides of the product box
Data Source
AI summary
A method of packing a temperature sensitive product utilizes a temperature controlled product shipper that includes a phase change material bladder which can be filled at the point of packaging. The temperature sensitive product is contained within an product box or master case, which is in turn packed inside an insulated liner and an outer box. The PCM bladder fits between the master case and the insulated liner and is filled with a preconditioned flowable PCM at the point of packing just before closing the box for shipment.