PLA Foam Thermal Shipper with Stand-offs
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Solution Overview
Problem
Existing molded foam articles, such as EPS-based thermal shippers, face challenges in maintaining thermal integrity and structural integrity due to material mismatch, leading to increased weight, size, and shipping costs, as well as environmental impact, while alternatives like molded pulp and thermoformed PET require additional components and sacrifice thermal or impact protection.
Innovation Solution
Molded foam articles formed from polylactic acid-based molded bead foam, allowing for self-adhesion and the creation of containers with variable wall thickness and size, incorporating stand-offs for air pockets to enhance thermal insulation, and using heat-sealing without adhesives to form tamper-evident seals and reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If EPS-based foam articles are used for thermal shipping, then thermal insulation is provided, but additional materials (corrugate, tape, straps, shrink sleeve) are required to maintain structural integrity, increasing device complexity and weight
Solution Approach 1:
The patent combines multiple functions into a single molded foam article made from polylactic acid. The foam article simultaneously provides thermal insulation, structural integrity, and sealing capabilities, eliminating the need for separate corrugate layers, tapes, straps, and shrink sleeves that were previously required with EPS-based solutions.
Solution Approach 2:
The patent uses a homogeneous material (polylactic acid foam) throughout the entire shipping container structure, replacing the heterogeneous combination of EPS foam, corrugated cardboard, tapes, and other materials. This single-material approach simplifies the overall device while maintaining both thermal and structural performance.
2Strength
If additional materials are used to compensate for EPS drawbacks, then structural integrity is improved, but weight and shipping costs increase
Solution Approach 1:
The polylactic acid foam article integrates structural support and thermal insulation functions into a single component, eliminating the need for additional reinforcing materials such as corrugate layers and straps. This integration reduces the total weight while maintaining structural integrity throughout the shipping process.
3Reliability
If molded pulp or thermoformed PET is used as alternatives to EPS, then environmental recyclability or material homogeneity is improved, but thermal protection or impact protection is sacrificed
Solution Approach 1:
The patent changes the material parameters by using polylactic acid foam with specific cellular structure and density properties that provide superior thermal insulation compared to molded pulp or thermoformed PET. The foam's closed-cell structure and air-trapping capabilities deliver the necessary thermal protection while maintaining environmental recyclability.
4Duration of action of moving object
If thermal shipment packages are over-engineered to account for variability, then thermal energy retention is improved, but weight and size increase resulting in higher shipping costs
Solution Approach 1:
The patent optimizes the foam density, cell structure, and wall thickness parameters to achieve the minimum necessary thermal protection duration. This parameter optimization allows the package to provide adequate thermal insulation for the required shipment timeframe without the excessive weight and size that result from over-engineering with traditional materials.
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 solution results in more efficient thermal energy retention, reduced shipping costs and carbon footprint, and improved structural integrity, enabling longer thermal protection durations and lighter, customizable shippers without the need for additional materials.
Implementation Method 1
The molded foam articles are used in a variety of diverse industries including thermal insulation
Implementation Method 2
incorporating stand-offs for air pockets to enhance thermal insulation
Data Source
AI summary
Molded foam articles in the form of containers are provided. The containers have at least two portions formed from polylactic acid-based molded bead foam and joined together using a heat-seal. The at least two portions are tailor-made to have a specific size and shape suitable for thermally sensitive commodities and may be customized based on the intended destination for the commodities and potential changes in weather in route. The containers may include one or more stand-offs for providing additional thermal energy protection, further enhancing the customizability of the containers. The containers may be formed from a single, flat foam panel that is cut and formed into a container on site, dramatically increasing the versatility of the container and reducing the carbon footprint associated with the container.