PCM Bladder Shipper Design to Reduce Pre-Conditioning and Storage Cost
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Solution Overview
Problem
Current temperature-controlled product shippers require pre-conditioning and storage of large volumes of phase change material (PCM) gel packs, which is expensive and inefficient, especially in cold-chain applications.
Innovation Solution
A novel phase change material (PCM) bladder designed to receive and hold a 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 shapes to accommodate different product boxes, including asymmetrical and dual-chamber configurations with flutes for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If pre-conditioned gel packs are used to maintain controlled temperatures, then the desired temperature profile is achieved, but the cost and complexity of pre-conditioning and storing large volumes of gel packs increases
Solution Approach 1:
The patent changes the physical state of the PCM from solid gel packs to liquid form, allowing it to be stored at ambient temperature and then pumped into the bladder where it undergoes phase change to solid, providing the required thermal control without pre-conditioning
Solution Approach 2:
The system performs preliminary action by pre-freezing the liquid PCM in storage tanks before shipment, so that when pumped into the bladder during packaging, it immediately provides the required cooling effect without requiring pre-conditioned gel packs
2Temperature
If pre-conditioned gel packs are used, then temperature control is maintained, but the expense of pre-conditioning and storing gel packs increases
Solution Approach 1:
The liquid PCM system allows the packaging facility to self-serve by pumping and filling PCM directly into bladders at the point of use, eliminating the need for external pre-conditioning services and reducing associated costs
Solution Approach 2:
The system performs preliminary freezing of liquid PCM in storage tanks before shipment, so that when pumped into the bladder during packaging, it immediately provides the required cooling effect without requiring expensive pre-conditioned gel packs
3Temperature
If uniform thermal profile is provided around product box, then temperature control effectiveness is improved, but the complexity of bladder configuration increases
Solution Approach 1:
The patent employs asymmetrical bladder configurations with varying thicknesses in different regions to compensate for heat transfer variations, providing uniform thermal protection without requiring complex multi-chamber designs
Solution Approach 2:
The patent transitions from two-dimensional flat gel packs to three-dimensional bladder configurations that can be strategically positioned and shaped to optimize thermal distribution around the product box
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 the need for pre-conditioning and storage of gel packs, providing a cost-effective and efficient method for maintaining controlled temperatures in product shippers by allowing on-site filling and uniform thermal profiling.
Implementation Method 1
phase change material (PCM) bladder which is designed and configured to receive and hold a flowable PCM
Implementation Method 2
phase change materials (PCM's) in the form of gel packs or gel bricks are used to heat or cool the interior of a temperature controlled product shipper
Implementation Method 3
The flowable PCM is pumped from storage tanks into the bladder chamber
Data Source
AI summary
A temperature-controlled product shipper includes a phase change material bladder which can be filled at the point of packaging. The shipper includes an internal product box and an outer box where the product box is received within the outer box. The phase change material bladder is received within a cavity defined between the outer surface of the product box and the inner surface of the outer box. The shipper may also include an insulated liner which is received between the product box and the bladder.