PCM Bladder Filling Design for Uniform Cold-Chain Shipping
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Solution Overview
Problem
Current phase change materials (PCMs) in gel packs require costly pre-conditioning and storage before use in temperature-controlled product shippers, especially in cold-chain applications, due to the need for precise temperature maintenance.
Innovation Solution
A novel phase change material (PCM) bladder designed to receive and hold flowable PCM at the point of packaging, eliminating the need for pre-conditioned gel packs, with various embodiments featuring single or dual chambers, filling ports, and structural designs to provide uniform thermal profiles and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-conditioned gel packs are used to maintain target temperature, then temperature control reliability is improved, but pre-conditioning and storage costs increase
Solution Approach 1:
The patent applies preliminary action by pre-freezing water in the bladder at the manufacturing stage rather than requiring pre-conditioning of gel packs before each use. The bladder is shipped in a frozen state and requires only brief placement in a freezer before use, eliminating the need for expensive pre-conditioning infrastructure while maintaining reliable temperature control.
Solution Approach 2:
The patent employs a disposable or single-use bladder system that is pre-filled with frozen water during manufacturing. This eliminates the need for expensive, reusable gel packs that require pre-conditioning and storage infrastructure. The bladder is designed to be used once and then discarded, converting the recurring cost of pre-conditioning into a one-time manufacturing cost.
2Manufacturing precision
If uniform thermal profile is achieved around product box, then temperature distribution homogeneity is improved, but bladder construction complexity increases
Solution Approach 1:
The patent applies local quality by creating different bladder configurations for different sides of the product box. The bladder can have varying thicknesses in different regions, with thicker sections placed where additional cooling is needed and thinner sections where less cooling is required. This achieves uniform thermal profiles across the product while maintaining relatively simple construction using basic lamination techniques.
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 PCM bladder system reduces pre-conditioning and storage costs by allowing on-site filling and uniform temperature distribution around the product, enhancing thermal management efficiency in temperature-controlled shipments.
Implementation Method 1
the bladder chamber is configured so that it has a substantially uniform thickness when filled with the flowable PCM whereby the bladder provides a substantially uniform thermal profile around all sides of the product box
Implementation Method 2
Phase change material (PCM) bladder for use in a temperature controlled product shipper
Data Source
AI summary
A phase change material (PCM) bladder is provided for use in a temperature controlled product shipper. The PCM bladder includes a bladder chamber having a filling port and is configured to receive and hold a flowable phase change material, such as an ice slurry, which can be pumped into the bladder at the point of packaging.