Modular Foam Pallet Shipper Edge Leak Prevention
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Solution Overview
Problem
Existing temperature-controlled pallet shippers face challenges such as high weight, edge leaks, manual labor requirements, and transportation issues due to their bulky and complex designs, which affect insulation efficiency and durability.
Innovation Solution
A modular, easily assembled pallet shipper with a base and corner structures featuring tongue-and-groove and flanged seams that create tortuous paths for heat transfer, eliminating edge leaks and allowing for expansion from quarter to half sizes by adding sidewalls, thus reducing weight and tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional passive pallet shippers are constructed by molding one panel at a time and assembling six walls, then manufacturing flexibility is maintained, but edge leaks occur between walls reducing insulation efficiency
Solution Approach 1:
The patent merges multiple wall panels into a single monolithic molded structure. Instead of assembling six separate walls that create edge leaks, the entire box is molded as one continuous piece, eliminating gaps between panels and preventing edge leaks while maintaining manufacturing feasibility through large-format molding techniques
Solution Approach 2:
The patent segments the monolithic structure into functional zones during the molding process, allowing different sections of the box to have optimized thicknesses and insulation properties tailored to specific thermal requirements, while still being produced as a single integrated piece that eliminates edge leaks
2Loss of energy
If additional thermal insulation is added to the pallet shipper enclosure, then insulation properties improve, but weight increases significantly affecting air transportation cost
Solution Approach 1:
The patent applies local quality by varying the thickness and insulation density at different locations within the box structure. Critical areas with higher heat transfer risks receive enhanced insulation, while less critical areas use standard thickness, optimizing the balance between thermal performance and weight for air transportation
Solution Approach 2:
The patent utilizes composite material structures combining different foam densities and potentially multiple material layers within the monolithic mold. This allows high-performance insulation in key thermal zones while using lighter materials in other areas, reducing overall weight while maintaining energy retention
3Reliability
If the pallet shipper structure is made more robust and sturdy to withstand transportation and vibration, then durability improves, but weight and size increase
Solution Approach 1:
The patent incorporates preliminary reinforcement features directly into the monolithic molding process. Rib structures, corner strengtheners, and vibration-resistant geometries are built in during manufacturing rather than added later, providing robust protection against transportation stresses without requiring additional heavy components that would increase weight
4Productivity
If manual assembly processes are simplified for pallet shipping, then assembly time reduces, but manufacturing precision may decrease
Solution Approach 1:
The patent combines multiple assembly steps into a single molding operation. By integrating what would traditionally require assembling six separate walls into one monolithic piece, the system eliminates complex joining operations while maintaining precise dimensional control through the molding process, thereby improving both assembly speed and precision
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 modular design enhances insulation efficiency, reduces weight by up to 37%, simplifies assembly, and minimizes edge leaks, while maintaining structural integrity and ease of use, making it suitable for shipping temperature-sensitive materials.
Implementation Method 1
The modular design enhances insulation efficiency... tongue-and-groove and flanged seams that create tortuous paths for heat transfer
Data Source
Figure 1
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AI summary
A thermally insulated pallet shipper (10) is provided for use in any industry where temperature sensitive products are shipped, including the pharmaceutical, hospital and food industries, particularly for shipping payloads by air. The pallet shipper (10) is made from just four individual foam molded structures: a base (12), a first corner structure (16), a second corner structure (18) and a lid (14).