Modular Thermal Packaging With PCM Inserts for Orientation Stability

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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 time-at-temperature, and do not maintain performance when packages are not oriented upright, posing challenges for regulatory compliance and product integrity.

Innovation Solution

A modular, platform-based cold-chain container 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

VSEngineering Contradiction Analysis

1Reliability

If custom-designed thermally controlled containers are used for specific payloads, then temperature control reliability is improved, but device complexity and manufacturing time increase

Engineering Contradiction:

Improvetemperature control reliabilityVSAvoidcontainer design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The container is divided into modular components: interchangeable phase change elements (PCEs) that can be selected based on temperature requirements, and adjustable buffer inserts that define payload volume. This segmentation allows standardization of container structures while customizing thermal properties through component selection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single container design serves multiple functions by accommodating different PCE types (different phase change temperatures), various payload sizes through adjustable buffer inserts, and different shipping orientations. The universal container platform reduces design complexity while maintaining reliability across applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If fixed configuration containers are used, then manufacturing simplicity is improved, but adaptability to different temperature ranges and payload sizes deteriorates

Engineering Contradiction:

Improvecontainer manufacturing simplicityVSAvoidtemperature range and payload size variability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The container configuration is made dynamic through interchangeable PCEs and adjustable buffer inserts. The buffer inserts can be repositioned to define different payload volumes, and PCEs can be swapped to achieve different temperature ranges, allowing a single manufactured container to adapt to multiple specifications without requiring custom manufacturing.

Inventive Principle:

Principle #15Dynamics

3Temperature

If traditional PCM-based insulated containers are used, then temperature maintenance capability is improved, but performance consistency across different orientations deteriorates

Engineering Contradiction:

Improvetemperature maintenance capabilityVSAvoidperformance consistency across orientations

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The container design incorporates asymmetric thermal management by positioning phase change elements and buffer inserts to provide stable thermal performance regardless of container orientation. The buffer inserts create defined spaces that ensure PCEs maintain optimal thermal contact with the payload in various orientations, making the system reliable whether shipped upright or on its side.

Inventive Principle:

Principle #4Asymmetry

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 and duration settings, and ensures consistent performance across different orientations, enhancing regulatory compliance and product integrity during transportation.

Implementation Method 1

at least two first phase change elements including a first phase change material and disposed within the enclosure

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

insulated containers using specialty phase change materials (PCM) may be employed that can maintain the temperature of the product during transport

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

enclosure sides may be made of an insulating material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS8938986B2Modular system for thermally controlled packaging devices

Publication Date: 2015.01.27 THERMOSAFE TECHNOLOGIES INC

AI summary

A modular container for maintaining an article under controlled temperature conditions includes a generally rectangular box-shaped enclosure defining an interior volume, wherein at least one enclosure side includes 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 modular container further includes at least two first phase change elements including a first phase change material, wherein each of said at least two first phase change elements is positioned adjacent one of a pair of opposed enclosure sides, at least two buffer inserts disposed within said enclosure, and at least two second phase change elements including a second phase change material, to one of the at least two buffers inserts wherein the second phase change material changes phase at a different temperature than the first phase change material.