Flat Cold Pack Rapid Freezing Using Multi-Plate Refrigerant Contact
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Solution Overview
Problem
Traditional methods for freezing water-based cold packs are energy-intensive and time-consuming, leading to inefficiencies in aligning supply with demand and resulting in irregularly shaped packs that do not fit well in tight packaging spaces.
Innovation Solution
A system using hollow plates with low-temperature refrigerant and a mechanical refrigeration system to rapidly freeze cold packs between two plates, creating a flat, block-like shape with distinct ice layers for efficient heat transfer and consistent dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional refrigeration is used to freeze water-based cold packs, then the cold packs will eventually freeze, but the process takes a long time (several weeks at large scale) and is energy intensive
Solution Approach 1:
The cold pack is divided into multiple segments or zones that can be frozen simultaneously from different directions using multiple plates, dramatically reducing the overall freezing time compared to traditional single-direction freezing
Solution Approach 2:
The invention transitions from traditional single-sided or top-down freezing to multi-sided simultaneous freezing by placing the cold pack between multiple plates that contact different faces, adding spatial dimensions to the heat transfer process and exponentially increasing freezing efficiency
2Manufacturing precision
If traditional refrigeration is used, then the cold packs will freeze, but they develop irregular shapes due to shifting or lumping during transit
Solution Approach 1:
The cold packs are frozen in their final desired shape and size before shipping using molds or forms during the freezing process, eliminating the need for subsequent handling that could cause shifting or lumping. The freezing process itself creates the final dimensions and flat faces required for tight packing
Solution Approach 2:
The cold packs utilize flexible outer layers or films that maintain their shape during freezing and transit, preventing lumping while allowing the internal gel to freeze uniformly. These flexible shells provide structural integrity throughout the supply chain
3Productivity
If traditional refrigeration is used, then freezing can be performed, but it is difficult to align cold pack supply with shipment demand due to long lead times
Solution Approach 1:
The system enables cold packs to be pre-frozen in advance and stored in an unfrozen or partially frozen state near point-of-use locations, allowing rapid deployment when shipment demand arises. The multi-plate freezing technology creates inventory that can be quickly activated without requiring weeks of lead time
Solution Approach 2:
The invention dramatically compresses the freezing timeline from weeks to hours or minutes by using multiple plates with refrigerant systems that simultaneously extract heat from all faces of the cold pack, enabling the freezing process to be completed and skipped to the storage/distribution stage much faster than traditional methods
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 achieves rapid freezing with high energy efficiency, producing flat, dimensionally consistent cold packs suitable for packaging, reducing energy consumption and ensuring uniform cooling effects.
Implementation Method 1
a mechanical refrigeration system that works to compress the refrigerant gas
Implementation Method 2
cool the gas and allow it to condense into a liquid refrigerant
Implementation Method 3
allow the liquid refrigerant to expand as it enters the plates, thereby converting back to a gas refrigerant and absorbing heat in the process
Implementation Method 4
The plates may contact the cold pack on at least one of a top and bottom face, causing heat to be transferred efficiently and the cold pack to freeze rapidly
Implementation Method 5
Water has a Latent Heat of Fusion of 334 J/g as it changes phase from solid (ice) to liquid. This high Latent Heat of Fusion allows water, through changes in its phase, to absorb a significant amount of heat per unit mass
Data Source
AI summary
A system and method for freezing cold packs. The system includes two or more plates containing a low-temperature refrigerant and a mechanical refrigeration system. The system is configured to receive a cold pack between two of the plates and simultaneously freeze the cold pack on two faces of the cold pack.