Modular Thermal Packaging With Interchangeable Phase-Change Elements
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Solution Overview
Problem
Current thermally controlled shipping systems are limited by the need for custom designs, lack of variability in temperature ranges and payload sizes, and do not maintain temperature consistency when packages are not oriented upright, posing challenges for regulatory compliance and product integrity.
Innovation Solution
A modular packaging system using standard phase change materials and configurations that can be quickly customized for various temperature and duration requirements, featuring interchangeable phase change elements and buffer inserts to maintain temperature control regardless of orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom thermally controlled shipping systems are designed for specific payloads, then temperature control reliability is improved, but device complexity and development time increase
Solution Approach 1:
The thermally controlled shipping system is divided into modular components: interchangeable phase change elements (solid and liquid), buffer inserts, and container sections. This segmentation allows customers to assemble different configurations for various payloads without requiring complete custom design, thus maintaining reliability while reducing complexity and development time.
Solution Approach 2:
The system employs universal container designs that can accommodate multiple payload types and sizes through interchangeable phase change elements and adjustable buffer inserts. A single container platform serves multiple functions across different shipping scenarios, reducing the need for custom designs while maintaining temperature control reliability for various payloads.
2Temperature
If traditional phase change material packages are used, then temperature range control is improved, but adaptability to different temperature ranges and durations is limited
Solution Approach 1:
The system offers phase change elements with different melting points (e.g., -20°C, -10°C, 0°C, 10°C, 20°C) and varying thermal capacities to accommodate different temperature ranges and duration requirements. Customers can select and interchange elements based on specific shipping needs, enabling adaptability across multiple temperature ranges while maintaining precise control.
Solution Approach 2:
The system combines different types of phase change materials (solid PCM blocks, liquid PCM in collapsible bags) with varying thermal properties within the same container. This composite approach allows customization for different temperature ranges and durations by mixing and matching materials with complementary characteristics.
3Ease of manufacture
If packages are designed for upright orientation only, then manufacturing simplicity is improved, but reliability under various shipping orientations deteriorates
Solution Approach 1:
The container design creates equipotential thermal conditions by surrounding the payload with phase change elements on all sides (top, bottom, and lateral surfaces). This symmetric thermal environment ensures that temperature control reliability is maintained regardless of the container's orientation during shipping, as heat transfer paths are balanced in all directions.
Solution Approach 2:
The system employs cylindrical or rounded container geometries with phase change elements positioned to provide uniform thermal protection in all orientations. This curved, omnidirectional design ensures that the payload receives consistent thermal protection whether the container is upright, tilted, or inverted, maintaining reliability without complicating manufacturing.
4Productivity
If off-the-shelf container solutions are used, then productivity and time-to-market are improved, but adaptability to specific customer requirements deteriorates
Solution Approach 1:
The system incorporates dynamic, reconfigurable elements including interchangeable phase change components and adjustable buffer inserts that can be modified based on customer requirements. This dynamic adaptability allows the same base container design to be quickly customized for different payloads, maintaining high productivity while meeting specific customer needs.
Solution Approach 2:
The system uses standardized, replicable container platforms and components that can be quickly copied and assembled for different applications. These modular copies maintain consistent quality and performance while being adaptable to various customer requirements, thus improving time-to-market without sacrificing adaptability.
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 system reduces the need for custom designs, allows for a range of temperature control options, and ensures consistent temperature maintenance across different orientations, enhancing regulatory compliance and product integrity during shipping.
Implementation Method 1
at least two first phase change elements comprising a first phase change material... at least two second phase change elements including a second phase change material... wherein the second phase change material changes phase at a different temperature than the first phase change material
Implementation Method 2
enclosure sides are made of an insulating material
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A modular container for maintaining an article under controlled temperature conditions, which may include a generally rectangular box-shaped enclosure defining an interior volume, wherein at least one enclosure side may include an access opening to allow for insertion or removal of the article within the interior volume, and wherein enclosure sides may be made of an insulating material. The container may include first and second phase change materials and buffer inserts.