Temperature controlled product shipper with a dual phase change material liquid suspension
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Solution Overview
Problem
Conventional phase change materials (PCMs) in temperature-controlled shippers require separate preconditioning and disposal, leading to high energy consumption and waste generation, especially when multiple temperature profiles are needed for shipping temperature-sensitive products like diagnostic blood samples.
Innovation Solution
A dual phase change material liquid suspension is used in reusable, identical mating blow-molded containers and clamshell insulating portions, pre-conditioned and stored at a single temperature, reducing energy consumption and simplifying logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate PCM packs or bricks are used for different temperature profiles, then temperature control capability is improved, but energy consumption for preconditioning increases and waste generation increases
Solution Approach 1:
The patent combines multiple PCM materials with different phase change temperatures into a single integrated container. The container holds both PCM materials in direct thermal contact, allowing them to work together as one system rather than requiring separate preconditioning of multiple packs. This merging eliminates the need for separate preconditioning processes while maintaining the ability to provide multiple temperature profiles.
Solution Approach 2:
The single container is designed to perform multiple functions by incorporating different PCM materials that can provide different temperature profiles. The same container can be used for various shipping requirements by adjusting the ratio or selection of PCM materials, making it a universal solution for different temperature control needs without requiring multiple specialized packs.
2Temperature
If separate PCM packs or bricks are used for different temperature profiles, then temperature control capability is improved, but waste generation increases
Solution Approach 1:
By merging multiple PCM materials into a single reusable container, the patent eliminates the need to dispose of multiple separate packs. The integrated container can be returned, reused, and refilled, significantly reducing waste generation compared to the disposable nature of conventional separate PCM packs.
Solution Approach 2:
The patent implements a recovery system where the container is collected after use and returned for refilling with PCM materials. This closed-loop approach allows the container to be reused multiple times, recovering the investment in the container and minimizing waste, unlike conventional disposable packs that are discarded after a single use.
3Temperature
If multiple PCM materials are preconditioned separately at different temperatures, then temperature profile accuracy is improved, but device complexity increases
Solution Approach 1:
The patent merges the preconditioning process into a single step by placing multiple PCM materials in the same container. The container can be preconditioned once at a reference temperature, and the different PCM materials will naturally reach their respective phase change temperatures during the shipping process based on the ambient temperature profile, eliminating the need for complex separate preconditioning procedures.
Solution Approach 2:
The container is pre-filled with the appropriate ratio of PCM materials during manufacturing, so that when preconditioned at a reference temperature, the materials are already positioned to provide the desired temperature profiles during shipping. This preliminary preparation eliminates the need for complex field preconditioning operations.
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 allows for efficient temperature maintenance between 6° C. and 37° C. for up to 24 hours while reducing energy consumption and waste, by using a dual PCM liquid suspension in reusable containers and insulating clamshell portions.
Implementation Method 1
An exemplary dual phase change material liquid suspension comprises a first liquid phase change material having a first phase change temperature and a second microencapsulated phase change material having a second phase change temperature
Implementation Method 2
phase change materials (PCMs) in the form of packs or bricks are used to heat or cool the interior of temperature-controlled product shippers
Implementation Method 3
identical mating clamshell insulating portions further enclose and protect the PCM bottles
Data Source
AI summary
A temperature-controlled shipper for shipping diagnostic blood samples is disclosed. The shipper must remain at a temperature between 6° C. and 37° C. for up to 24 hours while in transit. The shipper includes identical mating PCM blow-molded bottles which enclose and protect diagnostic blood sample vials. Identical mating clamshell insulating containers further enclose and protect the PCM bottles. Both the bottles and clamshell containers can be re-used. A dual PCM liquid suspension is utilized in the PCM bottles and is preconditioned and stored at a single temperature.