Hardened reusable modular shipper
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Solution Overview
Problem
Existing shipping containers for temperature-controlled and watertight environments are non-reusable and limited to a single temperature range due to the use of dry ice, requiring frequent refilling and lacking modular and interchangeable components.
Innovation Solution
A hardened, reusable modular shipping container with interchangeable components, including a lid and base enclosure, that uses phase-change materials and vacuum insulated panels to maintain temperature within a range, and incorporates features like a payload holder, dry ice basket, and electronic monitoring devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If dry ice is used for temperature control, then the payload can be maintained at a single temperature range, but the shipper is limited to transporting the payload in only that single temperature range and requires frequent refilling
Solution Approach 1:
The patent applies parameter changes by transitioning from fixed-temperature dry ice to phase change materials with variable melting points. The PCM can be selected or formulated to provide different temperature ranges (e.g., -70°C to -20°C for frozen goods, or 2°C to 8°C for refrigerated goods), allowing the same shipper design to adapt to multiple temperature requirements by simply changing the PCM type.
Solution Approach 2:
The shipper is designed with universal temperature control capability through interchangeable PCM modules. The same base shipper structure can serve multiple temperature control functions by replacing the PCM insert, eliminating the need for different shipper designs for different temperature ranges and removing the limitation of single-temperature dry ice containers.
2Ease of manufacture
If non-reusable cardboard boxes and polystyrene foam containers are used, then the shipping process is simple, but the shippers cannot be reused and generate significant waste
Solution Approach 1:
The patent implements a reusable shipper system where the hardened enclosure and PCM components are designed to be recovered and reused across multiple shipping cycles. The durable construction allows the shipper to withstand repeated use, cleaning, and sterilization, dramatically reducing the waste associated with single-use cardboard boxes and foam containers while maintaining shipping effectiveness.
Solution Approach 2:
The shipper uses composite material construction combining hardened plastic or metal enclosures with phase change material inserts. This composite approach provides both the structural durability needed for reuse and the thermal control properties required for temperature-sensitive cargo, replacing the separate cardboard box and foam insulation combination with an integrated reusable system.
3Ease of manufacture
If simple cardboard boxes are used for shipping, then the manufacturing cost is low, but the shippers lack protection against environmental factors and cannot maintain temperature-controlled environments
Solution Approach 1:
The patent transitions from simple cardboard construction to hardened materials with enhanced protective properties. The hardened plastic or metal enclosure provides superior protection against mechanical damage, moisture, and temperature fluctuations while maintaining cost-effectiveness through efficient design and manufacturing processes. The integrated PCM system actively maintains temperature without requiring complex active cooling mechanisms.
Solution Approach 2:
The shipper employs composite material construction combining hardened structural materials with thermal insulation layers and phase change material inserts. This multi-layer composite structure provides comprehensive environmental protection including mechanical strength, moisture resistance, and active temperature regulation, surpassing the capabilities of simple cardboard boxes while remaining economically viable.
4Adaptability or versatility
If modular components are introduced to enable reusability and flexibility, then the shipper can be reused and adapted to different temperature ranges, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the temperature control system into modular components: a reusable hardened enclosure and interchangeable PCM inserts. This segmentation allows the thermal control function to be separated from the structural container, enabling independent optimization of each component and easy replacement of PCM modules to match different temperature requirements without redesigning the entire shipper.
Solution Approach 2:
The hardened enclosure is designed as a universal platform that can accommodate different PCM inserts for various temperature ranges. This universal design reduces overall system complexity by using a single standardized container structure that serves multiple temperature control functions, rather than requiring separate specialized containers for each application.
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 flexible temperature control across multiple ranges, reusability, and enhanced protection against environmental factors, while providing integrated monitoring and documentation capabilities.
Implementation Method 1
uses phase-change materials and vacuum insulated panels to maintain temperature within a range
Implementation Method 2
uses phase-change materials and vacuum insulated panels to maintain temperature within a range
Implementation Method 3
The shipper may place or scoop dry ice pellets or blocks into an inner packaging made of an insulating material
Data Source
AI summary
Methods, systems, devices and/or apparatuses for a hardened reusable shipping container. The hardened reusable shipping container includes a lid. The lid is configured to be opened and closed. The hardened reusable shipping container includes a base enclosure. The base enclosure is coupled to the lid and has a payload area. The payload area is configured to receive a payload and maintain a temperature of an environment surrounding the payload. The hardened reusable shipping container includes an insert. The insert is configured to be positioned within the payload area to cool or maintain the temperature of the environment surrounding the payload.