Passive Temperature-Control Carton With Replaceable Vacuum Panels
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Solution Overview
Problem
Existing temperature control systems for transporting thermally sensitive goods are prone to failure due to damage, gas leakage, and temperature excursions, leading to costly discards and logistical challenges, especially in ultra-low temperature conditions.
Innovation Solution
A method for manufacturing a sealed insulation panel arrangement using vacuum insulation panels secured with adhesive tape, facilitated by a mandrel system, ensuring easy assembly and replacement of damaged panels, and minimizing gas passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum insulation panels are used for thermal insulation, then temperature control reliability is improved, but the panels are susceptible to damage from punctures and gas leakage
Solution Approach 1:
The vacuum insulation system is divided into multiple replaceable panels rather than a single integrated structure. This segmentation allows individual damaged panels to be replaced without discarding the entire insulation system, maintaining reliability while reducing waste.
Solution Approach 2:
The patent implements a panel replacement system where damaged vacuum insulation panels can be discarded and replaced with new ones. The sealing structure is designed to facilitate easy removal and replacement of panels, recovering the functional integrity of the insulation system without requiring replacement of the entire structure.
2Ease of manufacture
If traditional sealing methods are used for insulation panels, then assembly is simple, but gas leakage occurs and temperature control fails
Solution Approach 1:
A sealing member acts as an intermediary element between the vacuum insulation panels and the container walls. This sealing member creates a gas-tight barrier that prevents leakage while maintaining the structural integrity and thermal insulation performance, resolving the contradiction between simple assembly and reliable sealing.
3Loss of energy
If vacuum insulation panels are used, then thermal insulation performance is improved, but the panels are vulnerable during manufacture, transport, and fabrication
Solution Approach 1:
The patent designs the vacuum insulation panels with protective features and a sealing structure that accommodates panel replacement. This beforehand preparation cushions against the vulnerability to damage during manufacture and transport, allowing the high-performance insulation to be maintained while protecting against the inherent fragility of vacuum panels.
4Ease of repair
If insulation panels are designed for easy replacement, then maintenance ease is improved, but assembly complexity increases
Solution Approach 1:
The sealing structure is designed with dynamic characteristics that allow it to accommodate panel removal and reinstallation. The sealing member can be temporarily disengaged during panel replacement and then re-engaged to restore the gas-tight seal, providing ease of repair while managing assembly complexity through a standardized process.
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
Provides reliable temperature control with reduced gas leakage and ease of panel replacement, maintaining thermally sensitive goods within predefined temperature ranges, even in extreme conditions.
Implementation Method 1
the tape being folded or wrapped over the edge to secure the side panels to the base
Implementation Method 2
A vacuum insulated panel (VIP) comprises a special composite made of core materials surrounded by an external impermeable, protective sleeve
Implementation Method 3
The vacuum insulation, provided with getters to associate and absorb any gasses that may have leaked through or have off-gassed from the protective sleeve, effectively prevent convective heat transfer
Implementation Method 4
These cooling agents have typically been, for example, a frozen gel, dry ice, or wet ice, placed within an insulator packing agent, such as cotton or, latterly, plastics materials such as expanded polystyrene foam, wherein heat is absorbed by such cooling agents
Implementation Method 5
Multilayer insulation (MLI) is the most common passive thermal control element used in transport. MLI seeks to prevent both heat losses to the environment and excessive heating from the environment
Data Source
AI summary
A method of providing an insulating carton (40) for use in a cubic cold-chain container, the insulating carton (40) being formed of four lateral insulating panels (44) about an axis, together with a base (46) insulating panel arranged orthogonally to the axis, with each insulating panel having four edges, with respective adjacent panel edges mutually abutting, the carton (40) having side walls with mutually orthogonal first and second parallel edges of first and second lengths (LI & L2) with the side panels extending a depth (D) to the base, the panels having a thickness (T); wherein the method comprises the VIP steps of: selecting a cubic former (50) for the insulating carton, having external dimensions in correspondence with the dimensions of an interior cavity of the insulating carton; placing the panels about the former (50), whereby an inside face of each panel is directed towards a corresponding outside face of the former and an external face of each panel is directed away from the axis; applying adhesive tape (61) about the external faces of the panels, the tape having a width greater than the depth of the side panels; and, folding tape (61) extending from the sides of the towards the base, to secure the side panels to the base, and a system for providing an such a carton.