Foam-Absorbed Phase Change Packaging to Prevent Slumping and Leakage
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Solution Overview
Problem
Existing thermal control devices for shipping and transportation of temperature-sensitive products are inefficient due to issues like slumping, leakage, and limited temperature control precision, particularly for pharmaceutical and food products that require specific temperature ranges.
Innovation Solution
A phase change device using a foam material with both macropores and micropores, where the phase change material is absorbed into the foam and encased in a protective covering, optimizing weight-to-volume characteristics and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gel-based devices are used for thermal control, then cooling capacity is provided, but slumping occurs in the shape during phase change
Solution Approach 1:
The patent uses open-cell foam material as a porous substrate to contain the phase change material. The foam structure provides rigidity and shape stability while allowing the phase change material to be absorbed and distributed throughout the cells, preventing slumping during phase change while maintaining cooling capacity.
Solution Approach 2:
The invention creates a composite structure combining the foam material (providing structural integrity) with the phase change material (providing thermal control). This composite approach allows both shape stability and effective thermal control to be achieved simultaneously.
2Temperature
If dry ice blocks are used for thermal control, then low temperature cooling is achieved, but carbon dioxide accumulates at pressure causing safety concerns
Solution Approach 1:
The patent uses phase change materials that undergo controlled phase transitions (typically solid-liquid) at desired temperature ranges. Unlike dry ice sublimation which produces pressurized gas, these materials transition in a controlled manner within the closed foam structure, avoiding pressure buildup and CO2 accumulation while maintaining effective cooling temperatures.
3Temperature
If wet ice is used for thermal control, then cooling is provided, but leakage occurs when not handled properly
Solution Approach 1:
The open-cell foam structure absorbs and contains the phase change material within its cellular structure, preventing leakage. The material is held in place by capillary forces and the physical structure of the foam, eliminating the handling issues associated with wet ice while maintaining effective cooling.
4Quantity of substance
If phase change materials are absorbed into foam using vacuum and greater-than-atmospheric pressure, then absorption is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent performs the absorption process during the foam manufacturing step itself, before the foam is finalized and packaged. The phase change material is introduced to the foam structure during production when the foam is still forming or freshly created, allowing absorption to occur as part of the manufacturing process rather than as a separate post-processing step, thereby reducing overall manufacturing complexity.
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 solution provides improved thermal control with enhanced cooling efficiency, longevity, and precise temperature maintenance, minimizing weight and shipping costs while preventing leakage and slumping, thus ensuring the integrity of temperature-sensitive products during transport.
Implementation Method 1
Phase change materials are known in the art as materials which use changes in physical phase to absorb or release heat at a relatively constant temperature. Typically, phase change materials undergo the physical transformation known as fusion (freezing/melting), which carries an associated latent heat.
Implementation Method 2
phase change materials undergo the physical transformation known as fusion (freezing/melting), which carries an associated latent heat
Implementation Method 3
They must be adapted to a substrate or other carrier which contains the phase change material in a defined form and at a defined location within the packaging. For some phase change materials a porous substrate has been used as an absorbing and carrying medium.
Data Source
AI summary
A phase change device for controlling temperature within a confined environment, comprising a foam material, a phase change material, the phase change material being absorbed into the foam, and a protective covering encasing the foam material/phase change material. A method for making a phase change device for controlling temperature within a confined environment, comprising providing a phase change material, providing a foam material, absorbing the phase change material into the foam material, and sealing the foam material/phase change material within a protective covering.