Sandwich PUR Shipper Assembly for VIP Edge Leak Protection
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Solution Overview
Problem
Existing thermally insulated containers, particularly those using Vacuum Insulated Panels (VIP), face issues with edge leaks, knife defects, puncture defects, and manual labor requirements, which compromise their thermal performance and structural integrity during transportation.
Innovation Solution
A thermally insulated sandwich polyurethane (PUR) shipper design featuring an outer corrugated box, an inner corrugated box with adhered insulating panels, and PUR foam filling the gaps between the panels, which reduces edge leaks and enhances structural robustness, using a method that involves adhering VIP panels to the inner box and filling the gaps with PUR foam to create a more reliable and efficient insulation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If VIP panels are assembled manually with tape or straps, then the shipper can be constructed, but edge leaks occur between panels reducing overall R-value from 40 to 25-30
Solution Approach 1:
The patent combines multiple VIP panels into a single integrated VIP assembly where panels are bonded together with adhesive and recessed into a common plane. This merging eliminates the edge leaks that occur between separately assembled panels while maintaining high R-value thermal performance.
Solution Approach 2:
The VIP panels are pre-assembled and bonded together in a controlled manner before being installed into the shipper. The panels are recessed into a common plane during this preliminary assembly, ensuring proper alignment and eliminating gaps before the final installation step.
2Reliability
If VIP panels are used for insulation, then thermal insulation performance is improved, but the panels are vulnerable to knife defects and puncture defects during transportation
Solution Approach 1:
The integrated VIP assembly is recessed into the wall structure of the shipper, creating a protective cavity that cushions the VIP panels against external impacts, knife defects, and punctures during transportation. This recessed positioning protects the vulnerable VIP panels before damage can occur.
Solution Approach 2:
The shipper wall is constructed as a composite structure combining the VIP insulation assembly with the shipper wall material itself. This composite construction provides both thermal insulation and structural protection, making the overall assembly more resistant to damage while maintaining insulation performance.
3Reliability
If standard PUR foam is used for insulation, then the shipper achieves adequate thermal performance, but the size and weight of the shipper increase
Solution Approach 1:
The patent changes the insulation parameter by using VIP panels with R-value of 35-40 per inch compared to standard PUR foam with R-value of 5-6 per inch. This parameter change allows for thinner insulation layers that achieve the same or better thermal performance while reducing the overall size and weight of the shipper.
Solution Approach 2:
The VIP panels are applied selectively to specific surfaces of the inner box that require enhanced insulation, rather than uniformly insulating the entire shipper. This localized quality approach optimizes thermal performance where needed while minimizing added weight and size.
4Ease of manufacture
If individual VIP panels are assembled together, then the shipper can be constructed, but significant manual labor is required for assembly
Solution Approach 1:
Multiple VIP panels are merged into a single pre-assembled integrated VIP assembly that functions as one unit. This reduces the number of separate assembly steps required, eliminating the need to individually position and secure multiple panels, thereby reducing manual labor and assembly time.
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 significantly improves the thermal performance and structural integrity of the shipper, maintaining temperature-sensitive payloads within specified ranges for extended periods, while reducing size and weight, and mitigating the risks associated with transportation vibrations and handling.
Implementation Method 1
The PUR foam fills the space between the insulating panels and the outer box
Implementation Method 2
Vacuum Insulated Panel (VIP) shippers. A vacuum insulated panel is a product composed of a rigid, highly-porous nano size material core
Data Source
AI summary
A thermally insulated sandwich polyurethane (PUR) shipper for a temperature sensitive payload is provided. The sandwich PUR shipper comprises an outer corrugated box, an inner corrugated box, vacuum insulated panels (such as VIP panels) and PUR foam. The inner box is nested within the outer box and has a bottom, sides and a top. The inner box defines a payload compartment. The VIP panels are adhered to the outer facing surfaces of the inner box. Preferably the VIP panels are wedged against each other so that a side edge of one VIP panel abuts an adjacent VIP panel. The PUR foam fills the space between the VIP panels and the outer box. The PUR foam may cover the top edges of the VIP panels.