Thermally insulated container
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Solution Overview
Problem
Passive insulated shipping containers require double handling and lengthy chilling processes for cool packs, leading to inefficiencies and delayed availability for use, as they need to be chilled to low temperatures and then brought back up to maintain products at a constant temperature during transportation.
Innovation Solution
A thermally insulated container design featuring a barrier phase change material (PCM) layer that allows cool packs to be inserted at low temperatures, with the barrier layer maintaining even distribution of phase change material within a flexible envelope, enabling immediate use and reducing the need for double handling and storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cool packs are chilled to low temperatures (e.g., -18°C) to ensure product safety, then product protection is improved, but the cool packs must be brought back up to about 0°C before use, resulting in double handling and time loss
Solution Approach 1:
The invention divides the cool pack into two separate layers: a main PCM layer and a barrier PCM layer. The main PCM layer is chilled to low temperatures for product protection, while the barrier PCM layer remains at higher temperatures to prevent the main layer from becoming too cold. This segmentation allows the main layer to be prepared at optimal chilling temperatures without requiring subsequent warming, eliminating double handling.
Solution Approach 2:
The barrier PCM layer acts as an intermediary between the main PCM layer and the product. It mediates the thermal interaction by absorbing excess cold from the main PCM layer, ensuring the product is protected from temperatures below 0°C while allowing the main layer to maintain its low temperature for effective product protection.
2Reliability
If cool packs are chilled to low temperatures to ensure product safety, then product protection is improved, but storage space requirements increase due to the need for separate chilling and storage areas
Solution Approach 1:
By segmenting the cool pack into main and barrier layers with different temperature requirements, the system allows the main PCM layer to be stored at low temperatures for product protection while the barrier layer can be stored at higher temperatures, reducing the need for dedicated low-temperature storage space for the entire cool pack assembly.
3Reliability
If a barrier PCM layer is added to prevent product from dropping below specified temperatures, then product temperature control is improved, but the container structure becomes more complex
Solution Approach 1:
The barrier PCM layer is contained within a flexible envelope that can conform to the container's geometry and the main PCM layer's shape. This flexible film approach provides the necessary thermal barrier function without requiring rigid structural components, thereby minimizing the increase in device complexity while maintaining improved temperature control.
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 barrier PCM layer ensures products are maintained at the desired temperature without dropping below specified limits, allowing for quick preparation and reduced PCM material requirements, enhancing container performance and availability.
Implementation Method 1
the barrier PCM layer comprises of an envelope in which the phase change material of the barrier PCM layer is contained and the barrier PCM layer is configured to maintain the phase change material with a relatively even distribution within the envelope
Implementation Method 2
These may be cooled until a phase change occurs in the phase change material in the cool packs, from a liquid to a solid, so that the subsequent phase change back from a solid to a liquid acts to maintain the contents of the container at a constant temperature
Implementation Method 3
the phase change that occurs in the material in these, to maintain the product at the correct temperature during transportation
Implementation Method 4
an insulated container comprising an insulating outer casing
Data Source
AI summary
The present invention provides a thermally insulated shipping container 1 comprising a thermally insulating layer 5 defining a first void, a main layer 9, 10, 11 containing phase change material (main PCM layer) within the first void and defining a second void within the first void, a barrier layer 12 containing phase change material (barrier PCM layer) within the second void and distinct from the main PCM layer, the barrier PCM layer 12 defining a third void within the second void, the container being arranged to receive a product for transportation inside of the third void, wherein the main PCM layer 9, 10, 11 has an average thickness greater than the average thickness of the barrier PCM layer 12, the barrier PCM layer 12 comprises of an envelope in which the phase change material of the barrier PCM layer 12 is contained and the barrier PCM layer 12 is configured to maintain the phase change material with a relatively even distribution within the envelope.