Integrated Vial Rack with Temperature Suppressing Material
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Solution Overview
Problem
Traditional methods for maintaining the temperature of biological substances in vials are inefficient due to the separation of vial holding and temperature control components, leading to ineffective heat transfer and increased package size.
Innovation Solution
A system comprising a two-piece carrier and one-piece vial rack with interlocking surfaces and foam insulating material, where the vial rack is filled with temperature suppressive material, allowing direct contact and reducing void spaces for enhanced thermal transfer and compact packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional separate components for vial holding and temperature control are used, then the system is simple in structure, but the heat transfer efficiency deteriorates and package size increases
Solution Approach 1:
The patent combines the vial rack and temperature suppressive material into a single integrated unit. The temperature suppressive material is contained within the rack structure itself, eliminating the need for separate cooling components. This integration directly improves heat transfer efficiency by ensuring intimate thermal contact between the vials and cooling material, while the unified structure actually simplifies the overall package design.
Solution Approach 2:
The vial rack serves multiple functions simultaneously: it provides structural support for the vials, acts as a container for the temperature suppressive material, and functions as a thermal transfer medium. This multi-functionality resolves the contradiction by consolidating what would traditionally be separate components into a single element that performs both mechanical and thermal roles.
2Volume of stationary object
If traditional separate components for vial holding and temperature control are used, then the components are easy to manufacture separately, but the overall package size increases
Solution Approach 1:
By merging the vial rack and temperature suppressive material into one integrated component, the patent eliminates the void spaces that would exist between separate components. This integration reduces the overall package volume by approximately 50% as stated in the patent, while the manufacturing process is simplified through injection molding or similar techniques that can create complex integrated structures in a single operation.
3Reliability
If void spaces are maintained between vials and cooling agent, then the system is simple to assemble, but temperature control efficiency deteriorates
Solution Approach 1:
The integration of the temperature suppressive material within the rack structure eliminates void spaces between the cooling agent and vials. The material is contained in a reservoir or cavity formed as part of the rack, ensuring direct thermal contact with the vials. This design maintains assembly simplicity because the entire unit is pre-assembled as a single component, requiring no separate assembly steps for positioning cooling material.
4Loss of energy
If the vial rack and temperature suppressive material are integrated, then heat transfer efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes material science advances to create temperature suppressive materials with specific thermal properties that enable efficient heat transfer. By selecting materials with appropriate thermal conductivity, heat capacity, and phase change characteristics, the integrated design achieves superior heat transfer efficiency without requiring overly complex manufacturing processes. The manufacturing complexity is managed through standard plastic molding techniques.
Solution Approach 2:
The integrated rack structure likely employs composite construction, combining materials with different properties - such as a rigid outer structure for mechanical support and a thermal material for temperature control. This composite approach optimizes both heat transfer efficiency and manufacturability by using materials that are easy to process while achieving the desired thermal 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 system effectively maintains predetermined temperatures for biological substances by combining vial holding and temperature control functions, reducing package size by approximately 50% and ensuring efficient temperature retention for up to 24 hours.
Implementation Method 1
including a foam insulating material that is disposed in the internal space provided between the separate housing halves
Implementation Method 2
including a temperature suppressive material that is disposed in the inner space provided between the separate carrier halves
Implementation Method 3
the one piece vial rack has a plurality of vial passages each for accommodating an elongated vial that contains the biological substance
Implementation Method 4
the respective interlocking surfaces, when the housing halves are joined, are interlocked to maintain the housing halves in place; wherein the interlocking surfaces include a tongue and groove engagement surface
Data Source
AI summary
A system for holding a plurality of vials of a fluid that consists of a biological substance for the purpose of maintaining a predetermined temperature of the biological substance over a predetermined period of time. The system includes a two piece carrier in combination with a one piece vial rack supported by the two piece carrier. The one piece vial rack has a plurality of vial passages each for accommodating an elongated vial that contains the biological substance.