Passive Temperature-Control Carton With Replaceable Vacuum Panels
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Solution Overview
Problem
Existing temperature control systems for transporting thermally sensitive goods face challenges in maintaining narrow temperature ranges, are prone to damage, and suffer from gas leakage, leading to potential product loss and increased costs due to temperature deviations.
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 leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum insulation panels are used to provide high-performance thermal insulation, then temperature control reliability is improved, but the panels are susceptible to damage and puncture during manufacture, transport, and fabrication
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 compromising the entire system, addressing the vulnerability to damage while maintaining high insulation performance.
Solution Approach 2:
The patent provides for replacement panels as a pre-prepared backup solution. When damage occurs to a VIP panel during manufacture, transport, or fabrication, a replacement panel can be installed beforehand to restore the thermal insulation integrity, preventing temperature control failures.
2Ease of manufacture
If conventional insulation materials are used, then manufacturing simplicity is maintained, but thermal insulation performance is insufficient for maintaining narrow temperature ranges
Solution Approach 1:
The insulation system uses modular vacuum insulation panels that can be independently manufactured and assembled. This segmentation maintains manufacturing simplicity through standardized components while achieving superior thermal insulation performance compared to conventional materials.
Solution Approach 2:
The patent employs vacuum insulation panels comprising composite structures with core materials (such as porous materials) surrounded by external protective sleeves. This composite design provides both high thermal insulation performance and structural integrity, overcoming the limitations of conventional single-material insulation.
3Use of energy by moving object
If VIP panels are used to achieve high thermal resistance, then energy efficiency is improved, but the barrier film is easily punctured reducing insulation value
Solution Approach 1:
Replacement VIP panels are prepared in advance as backup components. When puncture damage occurs to the barrier film of any panel, the damaged panel can be replaced with a pre-prepared replacement panel, restoring the high thermal resistance and energy efficiency without permanent loss of insulation performance.
Solution Approach 2:
The vacuum insulation system is segmented into multiple independent panels rather than a single large structure. This segmentation isolates puncture damage to individual panels, preventing complete system failure and allowing selective replacement of only the damaged components.
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 within predefined ranges, reduces panel damage, and minimizes gas escape, thereby maintaining product integrity and reducing waste by allowing panel replacement.
Implementation Method 1
A method for manufacturing a sealed insulation panel arrangement using vacuum insulation panels
Implementation Method 2
vacuum insulated panel (VIP) comprises a special composite made of core materials surrounded by an external impermeable, protective sleeve
Implementation Method 3
secured with adhesive tape
Data Source
Figure 1~2b
Figure 3a~3b
Figure 4a~5
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 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.