Insulated Tote with Phase Change Material for Multi-Zone Cold Storage

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Solution Overview

Problem

Automated retail supply chain systems face challenges in maintaining different temperature zones for storing and transporting products, as existing systems lack efficient solutions for handling goods at ambient, chilled, and frozen temperatures, leading to issues with temperature control and condensation.

Innovation Solution

The implementation of an automated order fulfillment system with temperature-controlled containers and robots capable of operating in various temperature zones, utilizing insulated panels, thermal inserts, and distributed temperature regulation systems to maintain ambient, chilled, and frozen conditions, along with phase change materials for temperature control and condensation mitigation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional storage structures are used without temperature control, then device complexity is reduced, but temperature control capability is lost leading to product quality deterioration

Engineering Contradiction:

Improvetemperature controlVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent implements nested temperature control by placing phase change material containers inside insulated panels, which are then integrated into tote walls. This nested structure provides multi-level temperature management (ambient, chilled, frozen zones) within a single container system, achieving complex temperature control without proportionally increasing overall system complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The system achieves different temperature zones by changing the phase state of materials within the totes. Phase change materials transition between solid and liquid states at specific temperatures, creating ambient, chilled, and frozen zones through parameter changes rather than complex mechanical cooling systems

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If phase change materials are used for temperature control, then temperature stability is improved, but device complexity increases due to additional components

Engineering Contradiction:

Improvetemperature stabilityVSAvoidcontainer structure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the functions of insulation and active temperature control by integrating phase change material containers directly into the insulated panel structure. The insulated panels and phase change materials work together as a unified thermal management system, reducing overall complexity compared to separate insulation and cooling systems

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Phase change materials provide self-regulating temperature control by automatically absorbing or releasing heat during phase transitions. This passive thermal regulation maintains temperature stability without requiring external power sources or active control mechanisms, reducing system complexity while improving temperature stability

Inventive Principle:

Principle #25Self-service

3Loss of energy

If insulated panels with thermal inserts are used, then heat transfer resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat transfer resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The insulated panels are segmented into modular sections with integrated phase change material containers. This segmentation allows for standardized manufacturing of individual panel modules that can be assembled into complete totes, reducing overall manufacturing complexity while maintaining effective heat transfer resistance through the insulated structure

Inventive Principle:

Principle #1Segmentation

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 solution enables efficient storage and transportation of temperature-sensitive goods by maintaining precise temperature control and minimizing condensation, ensuring the freshness and quality of products across different temperature zones.

Implementation Method 1

The thermal insert comprises a material configured to maintain a temperature within the container below ambient temperature

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 2

a cold air source configured to cool and regenerate the material to a temperature below a predetermined phase transition temperature of the material

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

the sidewalls comprising one or more insulated wall panels configured to insulate an interior of the container against heat transfer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11685588B2Tote handling for chilled or frozen goods

Publication Date: 2023.06.27 SYMBOTIC LLC

AI summary

An automated order fulfillment system is disclosed having different temperature zones and robots and containers capable of and/or configured to work in these different temperature zones. Containers include insulated wall panels and a thermal insert which may be chilled to maintain a temperature within the container below ambient temperature. Structure within a storage location for the containers may be used to open and close the containers to facilitate cooling of the thermal insert.