Insulated Pallet Shipper With Zoned Coolant Layout for 2-8°C Transport
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Solution Overview
Problem
Current insulated shipping containers are not well-suited for transporting large payloads, such as pallet-sized items, and fail to maintain a consistent temperature range of 2° C. to 8° C. for extended periods under varying ambient conditions.
Innovation Solution
An insulated pallet shipper design featuring a container with coolant members, including coolant bricks encased in cardboard, strategically positioned within the cavity to maintain temperature, along with a coolant tray and corrugated cardboard construction for enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional insulated shipping containers are used, then they can maintain temperature for small packages, but they cannot accommodate large pallet-sized payloads
Solution Approach 1:
The container is divided into multiple compartments including a payload compartment for the pallet and a coolant compartment for temperature control. This segmentation allows the container to accommodate large payloads while maintaining temperature through dedicated coolant placement in separate sections.
Solution Approach 2:
The coolant members are positioned within the container cavity in a nested arrangement around the payload compartment. The coolant bricks are encased in cardboard containers that fit within the available space, maximizing thermal coverage without compromising payload capacity.
2Duration of action of stationary object
If traditional insulated containers are used, then they have simple construction, but they fail to maintain consistent temperature range of 2°C to 8°C for extended periods under varying ambient conditions
Solution Approach 1:
Coolant members are pre-positioned within the container at specific locations around the payload compartment before shipping. The coolant bricks are encased in cardboard containers that are pre-assembled and strategically placed to ensure optimal temperature distribution throughout the extended shipping period.
Solution Approach 2:
The container utilizes a composite structure combining corrugated cardboard for insulation and structural support, with foam materials for additional thermal insulation. This multi-material approach extends temperature maintenance duration while managing structural complexity through the use of readily available composite materials.
3Stability of the object's composition
If more coolant members are added to maintain temperature, then temperature stability improves, but the container structure becomes more complex
Solution Approach 1:
Coolant members are strategically positioned at specific locations within the container cavity based on thermal analysis requirements. The coolant bricks are encased in cardboard containers that fit into predetermined positions, providing localized temperature control where most needed while simplifying the overall arrangement.
Solution Approach 2:
The coolant bricks are encased in disposable cardboard containers that are inexpensive and easily replaced. This approach allows for multiple coolant members to be used for temperature stability without significantly increasing complexity, as each unit is a simple, replaceable component.
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 effectively maintains a temperature range of 2° C. to 8° C. for up to 120 hours under both summer and winter-like conditions, accommodating pallet-sized payloads by utilizing a combination of foamed polyurethane insulation and corrugated cardboard for structural support and thermal management.
Implementation Method 1
The insulated insert is made of a foamed polyurethane body... an insulated container shaped to include a bottom wall, a top wall, a left side wall, a right side wall, a rear wall and a front wall
Implementation Method 2
a plurality of coolant members positioned within the cavity, each of the coolant members including a plurality of coolant bricks
Data Source
AI summary
Insulated pallet shipper and methods of making and using the same. The insulated pallet shipper includes an insulated container shaped to include a bottom wall, a top wall, a left side wall, a right side wall, a rear wall and a front wall, the walls collectively defining a cavity; a plurality of coolant members positioned in the cavity, each of the coolant members including a plurality of coolant bricks encased within a cardboard container, at least some of the coolant members being preconditioned at a refrigerating temperature and at least some of the coolant members being preconditioned at a freezing temperature; an inner pallet seated on the bottom wall; and an outer pallet upon which the container is seated.