Vacuum-Insulated Shipping Box for 96-Hour Passive Cold Chain
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Solution Overview
Problem
Existing shipping systems for temperature-sensitive materials are costly due to the use of active temperature-control devices, and passive systems face challenges in maintaining desired temperature ranges for extended periods.
Innovation Solution
A shipping system comprising an insulation unit with a base and lid assembly, including vacuum insulated panels, a compressible pad, and temperature-control members, designed to maintain temperature-sensitive materials within a desired range using a cost-effective, passive approach.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active temperature-control devices are used, then temperature maintenance reliability is improved, but cost increases
Solution Approach 1:
The patent replaces active mechanical temperature control devices with a passive thermal system using vacuum insulated panels and phase change materials. The VIPs provide superior thermal insulation without requiring power sources, motors, or control systems, thereby eliminating the cost and complexity associated with active temperature control while maintaining reliable temperature ranges for extended periods.
Solution Approach 2:
The patent changes the thermal insulation parameter by using vacuum insulated panels with extremely low thermal conductivity values. The VIPs create a vacuum barrier that dramatically reduces heat transfer, allowing the system to maintain desired temperature ranges for up to 96 hours without active intervention, thus achieving reliable temperature maintenance through parameter optimization rather than active control.
2Device complexity
If passive thermal shipping system is used, then cost is reduced, but temperature maintenance duration is limited
Solution Approach 1:
The patent employs a nested configuration where vacuum insulated panels form an outer insulating structure, and phase change materials are positioned within the insulated cavity. This nested arrangement maximizes thermal protection by combining the advantages of vacuum insulation with the temperature-buffering capacity of phase change materials, thereby extending the duration of temperature maintenance without increasing system cost.
Solution Approach 2:
The patent uses composite thermal management by combining vacuum insulated panels with phase change materials. The VIPs provide structural insulation while the phase change materials (such as gel packs or refrigerant bricks) absorb and release latent heat during phase transitions. This composite approach extends the effective temperature maintenance duration beyond what either component could achieve alone, while remaining cost-effective compared to active systems.
3Reliability
If vacuum insulated panels are used, then thermal insulation performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the insulation system into separate vacuum insulated panel segments that can be manufactured independently and then assembled into the shipping container. This segmentation allows for standardized production of VIPs using established vacuum insulation technologies, reducing overall manufacturing complexity while maintaining superior thermal insulation performance across the entire shipping system.
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 system effectively maintains temperature-sensitive materials within a desired range for up to 96 hours, reducing costs by eliminating the need for active temperature-control devices while ensuring thermal stability.
Implementation Method 1
the base comprising one or more base vacuum insulated panels configured to define a base cavity
Implementation Method 2
an insulation unit, the insulation unit comprising (i) a base, the base comprising one or more base vacuum insulated panels
Implementation Method 3
one or more passive temperature-control members may be packaged passive temperature-control members, such as, but not limited to, ice packs, gel packs, refrigerant bricks
Implementation Method 4
the one or more passive temperature-control members may be unpackaged passive temperature-control members, such as loose dry ice, loose wet ice
Data Source
AI summary
Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls and bottom and top closure flaps. An insulation unit is positioned within the outer box. The insulation unit includes a base and a lid assembly hingedly connected to the base. The base includes vacuum insulated panels arranged to define a cavity and an inner shield mounted within the cavity. The lid assembly includes a support hingedly connected to the base. A vacuum insulated panel and a protective cover are mounted on a bottom surface of the support. A compressible pad is mounted on a top surface of the support, and a cover sheet is mounted over the compressible pad. The cover sheet includes an integral handle. A plurality of temperature-control members and a product box may be removably positioned in a cavity defined by the inner shield.