Insulated Shipping Container With Compressed Pellet Insulation
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Solution Overview
Problem
Conventional insulated shipping containers are not environmentally friendly due to non-biodegradable and non-recyclable materials, leading to increased costs and disposal issues, especially when using polyurethane foam, which adheres to cardboard boxes, preventing recycling.
Innovation Solution
A biodegradable or recyclable insulated shipping container design featuring an exterior cardboard box with an air-permeable flexible casing containing particulate insulating pellets, and interlocking channel members that apply compressive stress to prevent pellet migration and void formation during transit, ensuring uniform insulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyurethane foam is used for insulation, then thermal insulating properties are improved, but recyclability and biodegradability deteriorate
Solution Approach 1:
The patent changes the material parameter from synthetic polyurethane foam to biodegradable particulate insulation material (such as starch-based or cellulose-based pellets), fundamentally altering the material composition to achieve both thermal insulation and environmental compatibility
Solution Approach 2:
The patent enables recovery and recycling of container components by using separable, biodegradable materials. The particulate insulation can be easily removed and disposed of or composted, while the cardboard box can be recycled independently, unlike the bonded polyurethane foam system
2Ease of manufacture
If loose-fill insulation material is used, then ease of manufacture is improved, but pellet migration and void formation occur during transit
Solution Approach 1:
The patent introduces a flexible netting or mesh structure that confines the particulate insulation material. This flexible confinement prevents pellet migration and void formation while maintaining the ease of manufacture advantage, as the netting can be easily integrated into the packaging process
Solution Approach 2:
The flexible netting acts as an intermediary between the loose-fill insulation material and the container space, providing mechanical restraint to prevent migration while allowing the insulation material to maintain its loose-fill configuration for easy manufacturing
3Ease of manufacture
If biodegradable materials are used, then environmental friendliness is improved, but insulation performance may deteriorate
Solution Approach 1:
The patent uses composite particulate insulation materials such as starch-based or cellulose-based pellets that combine biodegradability with effective thermal insulation properties. These composite materials achieve R-values comparable to traditional foams while maintaining environmental compatibility
Solution Approach 2:
The patent optimizes parameters of biodegradable materials including particle size, density, and composition to maximize thermal insulation performance while maintaining biodegradability, thereby achieving both environmental friendliness and adequate insulation performance
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 effective temperature regulation, shock absorption, and prevents the development of 'hot spots' while being environmentally friendly by allowing for recycling or biodegradation, reducing disposal issues and compliance costs.
Implementation Method 1
temperature regulation through the use of a combination of particulate insulation (i.e., insulation pellets)
Implementation Method 2
cooperating wall structure receiving the pillow therebetween and sandwiching the pillow for applying a selected compressive stress and strain to the insulating material within the pillow
Implementation Method 3
interlocking channel members that apply compressive stress to prevent pellet migration and void formation during transit
Implementation Method 4
an air-permeable flexible casing containing particulate insulating pellets
Data Source
AI summary
An improved shock absorbing insulated shipping container including an external corrugated cardboard box, receiving a product box therein. Peripheral spaced, and upper and lower spaced between the external box and the product box receive insulating pellets, which are maintained under a compressive force in order to interlock these insulating pellets and prevent their migration during transit of the shipping container. By preventing migration of the insulating pellets, the formation of a void (or voids) in the insulation of the container is prevented, and the formation of a hot spot (or hot spots) within the container which could degrade or damage the product in transit is prevented. A most preferred embodiment utilized insulating pellets made of puffed vegetable starch, so that substantially the entire container can be recycled, is biodegradable, or can be composted.