Insulated Shipping Container Insert for Recyclable Cold Chain Packaging
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Solution Overview
Problem
Conventional insulated shipping containers face issues with recyclability and temperature control, as the foamed polymer material bonds to cardboard boxes, making them non-recyclable and prone to thermal inconsistencies due to airflow pathways created by plastic film folding, which can compromise the integrity of temperature-sensitive materials during transport.
Innovation Solution
The design incorporates an insulated shipping container with a unitary insulated insert featuring 'top-hat' shaped coolant cavities and a removable lid, utilizing foamed polyurethane encased in a thin, flexible polymer bag, along with coolant bricks and saddlebags, to maintain temperature stability and allow for recyclability by minimizing foam contact with cardboard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If foamed polymer material is used to insulate the container, then thermal insulation performance is improved, but recyclability deteriorates because the foam bonds to cardboard boxes and cannot be separated
Solution Approach 1:
The container is divided into separate components: an outer box, an inner box, and a foam insert. The foam insert is detached from the boxes, allowing the cardboard boxes to be recycled separately while the foam insert can be reused or recycled independently. This segmentation resolves the contradiction by enabling recyclability without sacrificing insulation performance.
Solution Approach 2:
A release agent or barrier layer is introduced between the foam and cardboard surfaces during the foaming process. This intermediary prevents direct bonding between the foam and cardboard, allowing the foam to maintain its insulating properties while enabling easy separation for recycling purposes.
2Ease of manufacture
If plastic film is bunched within the container to separate foam from boxes, then recyclability is improved, but temperature control deteriorates due to folds and fissures creating airflow pathways
Solution Approach 1:
A smooth, flexible plastic bag is used as a containment structure for the foam insert. The bag is designed to be free of folds and fissures, providing a continuous barrier that prevents airflow pathways while still allowing the foam to be easily removed for recycling. The flexibility of the bag accommodates the foam shape without creating thermal weaknesses.
3Device complexity
If foam is allowed to bond directly to boxes during manufacturing, then manufacturing simplicity is improved, but product reliability deteriorates due to thermal inconsistencies from airflow pathways
Solution Approach 1:
A release agent or barrier layer is applied to the inner box surfaces before the foam is injected. This intermediary prevents direct bonding between foam and cardboard, eliminating thermal inconsistencies caused by airflow pathways, while adding minimal complexity to the manufacturing process.
Solution Approach 2:
A smooth plastic bag is placed inside the container to act as a barrier between the foam and the boxes. This eliminates airflow pathways and thermal inconsistencies while maintaining manufacturing simplicity through a straightforward assembly process.
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
This configuration effectively maintains temperatures between 2° C. and 8° C. for 48 hours under various ambient conditions, ensuring the integrity of temperature-sensitive materials while allowing for recyclable components, reducing the risk of thermal hotspots and improving container durability.
Implementation Method 1
the void space is filled with a foamed-in-place polymer material, said foamed-in-place polymer material typically being a light-to-medium density foamed polyurethane material
Implementation Method 2
the foamed polymer material bonds directly to the inner and outer cardboard boxes
Data Source
AI summary
Insulated shipping container and method of making the same. In a preferred embodiment, the insulated shipping container includes an outer box, an insulated insert, an insulated cover, a payload container and a plurality of coolant members. The insulated insert is snugly, but removably, disposed within the outer box and is shaped to include a plurality of sides and a top. The top includes a raised peripheral edge and a recessed shelf. A large rectangular prismatic cavity surrounded by a plurality of smaller cavities extends downwardly from the recessed shelf. The large cavity of the insulated insert is adapted to receive a payload container. Each of the smaller cavities of the insulated insert has a “top hat” shape when viewed from above that includes a crown portion and a brim portion.