United States Patent (19)
`Combs et al.
`
`73 Assignee:
`
`(54) INSULATED SHIPPING CONTAINER
`75) inventors: Cathy M. Combs, Antioch; Joseph K.
`Duffy, Lake Forest; Mark Thoene,
`Ingleside, all of Ill.
`Baxter Travenol Laboratories, Inc.,
`Deerfield, Ill.
`2) Appl. No.: 705,584
`22 Filed:
`Feb. 26, 1985
`51) Int. Cl." ................................................ F25D 3/08
`52 U.S. Cl. ........................................ 62/372; 62/388;
`62/457
`58) Field of Search ................. 62/384, 388, 459, 463,
`62/372, 457
`
`56
`
`References Cited
`U.S. PATENT DOCUMENTS
`2,400,742 5/1946 Clerc ..................................... 62/388
`3,866,435 2/1975 Frank et al. ...................... 62A388 X
`3,889,486 6/1975 Hinckley et al. ................. 62/388 X
`4.294,079 10/1981 Benson .................................. 62/388
`4,457, 42 7/1984 Bucher .................................. 62/388
`
`Patent Number:
`11)
`(45) Date of Patent:
`
`4,576,017
`Mar. 18, 1986
`
`Primary Examiner-Lloyd L. King
`Attorney, Agent, or Firm-Paul C. Flattery; John P.
`Kirby, Jr.
`ABSTRACT
`(57)
`A container is disclosed for maintaining its contents at a
`desired temperature for an extended period of time such
`as for use in shipping contents in a frozen condition. The
`container includes an outer shell which is substantially
`airtight and which has an inner surface; a passive heat
`exchange medium; a support structure for the heat ex
`change medium; and means for maintaining an air space
`between the contents of the container and substantially
`the entire inner surface of the outer shell of the con
`tainer and between the contents of the container and the
`support structure for the heat exchange medium for
`allowing convection current to develop in the air space
`which circulates past the heat exchange medium and
`maintains a substantially uniform temperature around
`the contents of the container.
`
`11 Claims, 8 Drawing Figures
`
`
`
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`U.S. Patent Mar. 18, 1986
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`U.S. Patent Mar. 18, 1986
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`Sheet 3 of 5
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`U.S. Patent Mar 18, 1986
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`Sheet 4 of 5
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`4,576,017
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`1
`
`INSULATED SHIPPING CONTAINER
`
`5
`
`O
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`4,576,017
`2
`shipped by air and arrive at its destination in the desired
`frozen cold, warm or hot condition.
`It is another object of the present invention to pro
`vide a container which more efficiently uses dry ice,
`ordinary ice or a warm or hot material to keep the
`contents of the container at a desired temperature.
`It is another object of the invention to provide a
`container which allows convection within the container
`in space around the contents to allow convection to
`maintain a substantially uniform temperature through
`out the contents of the container.
`DESCRIPTION OF THE DRAWINGS
`FIG. 1 is an isometric view of a first preferred em
`bodiment of an insulated shipping container.
`FIG. 2 is another isometric view of the container of
`FIG. 1, showing interior components of the container.
`FIG. 3 is a cross sectional view of the outer shell of
`the container shown in FIGS. 1 and 2.
`FIG. 4 is an isometric view of the containers of
`FIGS. 1 and 2, with sections of the outer shell removed.
`FIG. 5 is a top view of a component of the container
`of FIGS. 1-4.
`FIG. 5a is a cross-sectional view of FIG. 5 along the
`line 5a-5a.
`FIG. 6 is an exploded view of a second embodiment
`of the present invention.
`FIG. 7 is an isometric view of the container of FIG.
`
`The present invention relates to a container for main
`taining the contents of the container at a desired temper
`ature for an extended period of time. In addition, the
`invention relates to a container for maintaining the con
`tents at a substantially uniform temperature throughout
`the container. For example, the present invention is
`directed to a shipping container for maintaining all of
`the contents of the container in a frozen or cold condi
`tion or in a warm or hot condition for a period of up to
`ninety hours in order to enable the contents to be
`shipped by air and arrive at the destination in the de
`15
`sired frozen, cold, warm or hot condition.
`The container comprises: an outer shell which is
`substantially airtight and which has an inner surface; a
`passive heat exchange medium; a support structure for
`the heat exchange medium; and means for maintaining
`20
`space between the contents of the container and sub
`stantially the entire inner surface of the sides and bot
`tom of the outer shell of the container and between the
`contents of the container and the support structure for
`the heat exchange medium. The space allows convec
`25
`tion in the space. The convection maintains a substan
`tially uniform temperature throughout the contents of
`the container.
`Previously used containers do not provide a means
`for maintaining space around the contents of the con
`30
`tainer. Nor do the previously used containers provide
`any other means for allowing convection within the
`container. As a result previously used containers suffer
`from the disadvantage that a uniform temperature is not
`maintained throughout the contents of the container.
`35
`For example, in a previously used container for main
`taining contents in a cold or frozen condition, dry ice is
`sometimes used in the container. The dry ice is located
`in one section of the container. The contents of the
`container which are closest to the dry ice are main
`40
`tained at a lower temperature than the contents of the
`container which are furthest away from the dry ice. For
`containers intended for use in shipment in airplanes,
`there usually are restrictions on the amount of dry ice
`which can be used because dry ice releases carbon diox
`45
`ide as it melts.
`In previously used containers, the contents of the
`container are allowed to rest on the bottom inner sur
`face of the container. As a result, there is no air space
`between the contents and the bottom of the inner sur
`50
`face of the container. As a result, convection cannot
`develop around or past the bottom portion of the con
`tents and the bottom inner surface of the container. In
`other containers, the contents are allowed to fill up
`substantially the entire space within the container, with
`no air space between the contents and the sides of the
`container. As a result, convection cannot develop be
`tween the contents and the sides of the container. Thus,
`previously used containers do not maximize the effi
`ciency which can be obtained when using dry ice, mea
`60
`sured in terms of the length of time for which a given
`quantity of dry ice is capable of maintaining the con
`tents of the container in a frozen or cold condition.
`It is an object of the present invention to provide a
`shipping container for maintaining the contents of the
`container in a frozen condition or in a cold condition or
`in a warm condition or in a hot condition for a period of
`up to ninety hours in order to enable the contents to be
`
`6.
`
`DESCRIPTION OF PREFERRED EMBODIMENT
`EXAMPLE NO. 1
`An example of a preferred embodiment of the present
`invention, adapted for use for the shipment of frozen
`products in an airplane, is illustrated in FIGS. 1-4. The
`outer dimensions of the insulated shipping container,
`indicated generally by the numeral 2, are adapted to
`conform to the size requirements of commercial air
`craft. In its assembled condition for the shipment of
`frozen products, the container 2 is 55 inches high, 50
`inches wide, and 55 inches long. Slats 4 of wood or
`other material are fastened to the bottom outer surface
`of the container 2 in order to enable the container 2 to
`be handled by a forklift.
`Referring to FIG. 3, the outer shell 6 of the container
`2 comprises an impact resistant outer layer 8; a rigid
`high-strength layer 10 next to the outer layer 8; an inner
`layer 12; and an insulating layer 14 between the rigid,
`high-strength layer 10 and the inner layer 12. The im
`pact resistant outer layer 8 is made of a plastic material,
`is about one-eighth inch thick and has a silver or white
`coating on its outer surface to reflect heat. The rigid,
`high-strength layer 10 next to the outer layer 8 is made
`of three-quarter inch plywood of high quality, such as
`marine grade plywood. The inner layer 12 is made of a
`plastic material, is one-eighth inch thick, and the inner
`surface of the inner layer is painted black to absorb heat.
`The insulating layer 14 is made of a insulating material
`such as a foam plastic and is two to four inches thick.
`Referring to FIGS. 1, 2 and 4, the sides of the outer
`shell 6 of the container 2 are made in sections. The
`sections can be assembled together when the container
`2 is used for shipping product. The container 2 can be
`disassembled when not in use for the shipment of prod
`uct, Some of the sections of the outer shell 6 can be
`stored inside of other sections of the outer shell 6. The
`container 2 in its disassembled condition occupies a
`
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`smaller volume, such as, about half the volume in its
`assembled condition. Compression locks 7 and gaskets
`are used to achieve a substantially airtight condition
`when the container 2 is assembled. Referring to FIG. 3,
`the sections of the outer shell 6 have sealing means in
`the form of a tongue and groove aluminum molding 15
`on the edges to achieve an air tight fit.
`Referring to FIGS. 1 and 2, in its assembled condition
`the container 2 has blocks 16 arranged on the inner
`surface of the outer shell 6 which maintain a space 20
`between the inner surface of the outer shell 6 and the
`contents 22. In this embodiment, the contents are in the
`form of corrugated cardboard cartons. Referring to
`FIG. 2, a total of eight spacer blocks 16 are used. The
`spacer blocks 16 are positioned so that each spacer
`block 16 touches the corner of four cardboard cartons.
`Additional spacer blocks 16 may be used in other loca
`tions on the inner surface of the outer shell 6. A wide
`variety of spacing devices may be used to maintain the
`space 20. The container 2 also includes plastic slats 5 on
`the botton inner surface of the shell 6. The contents 22
`rest on the slats 5 and the slats 5 maintain a space of
`about one inch or more between the bottom surface of
`25
`the contents 22 and the inner surface of the shell 6.
`Preferably, the space 20 maintained is about one inch or
`slightly more around the contents 22. Such a space 20
`is maintained around all sides between the contents 22
`and the inner surface of the shell 6, between the bottom
`30
`of the contents 22 and the inner surface of the bottom of
`the outer shell 6 and between the top surface of the
`contents 22 and the support structure 28 for the heat
`exchange medium.
`Referring to FIGS. 2 and 5, the support structure 28
`for the heat exchange medium is a tray arranged near
`the top of the outer shell 6. The support structure 28 has
`a solid surface adjacent to the outer shell 6 and an ar
`rangement of fins 30 on the bottom surface of the sup
`port structure 28. Preferably, the passive heat exchange
`40
`; medium is dry ice. The dry ice is placed on the top side
`of the support structure 28. The fins 30 maximize the
`surface area available to convection which developes in
`space 20 around the contents 22 and passes between the
`contents 22 and the support structure 28, Heat from
`45
`convection is conducted by the fins 30 through the top
`surface of the support structure 28 and is absorbed by
`the dry ice. The term "passive', used to describe the
`heat exchange medium, refers to the fact that there is no
`50
`mechanical or electrical mechanism associated with the
`heat exchange medium.
`The fins 30 also act as a spacing device. The lower
`edge of the fins 30 rests on the top of the contents 22 and
`position the support structure about an inch, an inch and
`55
`one-half or slightly more above the contents 22. A space
`is provided between the top surface of the support
`structure 28 and the top of the outer shell 6 sufficient to
`accommodate the dry ice or other passive heat ex
`change medium. The brackets also position the support
`60
`structure 28 in a position to allow one inch or slightly
`more of space between the fins 30 and the top of the
`contents 22.
`The present invention may be used for shipment of
`products on transportation other than air or for use in
`65
`the storage of products, even where no shipment is
`contemplated. Other dimensions for the outer shell 6
`may be used.
`
`35
`
`4
`EXAMPLE NO. 2
`FIGS. 6 and 7 illustrate a second embodiment of the
`present invention in which the container 40 is adapted
`to be disposable. Referring to FIG. 6, the container 40
`includes a top cover 42 which is made of aluminum or
`other metal, a top panel 44 which is made of foam or
`other insulating material, and a support structure in the
`form of a tray 46 to hold the passive heat exchange
`medium, such as dry ice. The tray 46 is made of alumi
`num or other metal and includes fins 48 on its bottom
`surface to provide maximum surface area to the convec
`tion current. The container 40 also includes two end
`panels 50 and front and back panels 52 which are dis
`posed on the sides of the container 40 and are made of
`foam or other insulating material. The container 40 also
`includes a bottom panel 54 which is made of foam or
`other insulating material and a bottom tray 56 which is
`made of aluminum or other metal. There are plastic slats
`58 on the top surface of the bottom panel 54 which are
`made of foam and serve to establish the space between
`the contents of the container and the bottom panel 54.
`There are also slats 60 on the bottom exterior surface of
`the tray 56 which are made of wood, such as 2'X4'
`lumber, and enable the container 40 to be moved by a
`forklift.
`Referring to FIG. 7, when the container 40 is assem
`bled the components of the container 40 are held to
`gether by multiple bands 62, typically metal bands,
`which pass around the container 40 and apply a slight
`compressive force all around to achieve a substantially
`airtight condition. Reinforcing corner guards 64 are
`mounted at each corner. The exterior surface of the
`container 40 has a protective panel of aluminum or
`other metal as the top panel 44 and the bottom tray 56.
`It has foam panels 52 and 54 around the sides, protected
`at the corners by aluminum or other metal corner
`guards 64.
`There are spacing devices on the interior surfaces of
`the container 40 to provide a space 66 of about one inch
`or slightly more between the contents 68 inside the
`container 40 and substantially the entire inner surface of
`the sides and bottom of the container 40, and between
`the contents 68 of the container 40 and the support
`structure 70 for the heat exchange medium in a manner
`similar to the preferred embodiment described in Exam
`ple 1. Such spacing 66 is provided substantially all
`around the contents 68 including the bottom, the top
`and the sides, by blocks and fins similar to those used on
`Example 1.
`
`DETAILED DESCRIPTION
`The present invention may be used for shipment of
`products by transportation other than air or for use in
`the storage of products, even where no shipment is .
`contemplated. Other dimensions for the outer shell 6
`may be used. For other containers within the scope of
`the present invention, ordinary ice may be used instead
`of dry ice to maintain the contents of the container 2
`and 40 cold. If the container is intended to maintain the
`contents warm, the passive heat exchange medium may
`be blocks of warm or hot material. It has been found
`that a container of the present invention will maintain
`frozen products in a frozen condition for up to ninety
`hours. This is significant because it is more than suffi
`cient to allow frozen products to be shipped on com
`mercial airplanes. Typically, the time periods for ship
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`ment by air are in the range of twenty-four hours, forty
`a support structure for the heat exchange medium;
`eight hours or sixty hours.
`and
`It has been discovered that an arrangement which
`means for maintaining a space between the contents
`provides space between the contents of the container
`of the container and substantially the entire inner
`and substantially the entire inner surface of the sides and
`surface of the sides and bottom of the outer shell of
`bottom of the outer shell and between the contents of
`the container and between the contents of the con
`the container and the support structure for the heat
`tainer and the support structure for the heat ex
`exchange medium drastically increases the efficiency of
`change medium for allowing convection in said
`the container in maintaining the contents at a desired
`space to maintain a substantially uniform tempera
`temperature for an extended period of time. The space
`ture throughout the contents of the conter;
`allows convection to develop around the contents, in
`said spacer means comprising blocks, each block
`cluding all sides, the top and the bottom of the contents.
`having a side which faces said side wall of said
`The convection maximizes the efficiency of the passive
`container and a side which faces said contents, each
`heat exchange medium in keeping the contents frozen,
`of said sides of said blocks having a surface area
`or cold, warm, or hot. The convection drastically im
`which is less than 70% of the surface area of the
`15
`proves the ability of the container to maintain a uniform
`adjacent side wall of said container.
`temperature throughout the contents. For example, it
`2. The container according to claim 1 wherein said
`support structure for the heat exchange medium com
`has been discovered that if the contents are allowed to
`prises an arrangement of fins on the inner side of said
`rest on the bottom inner surface of the container with
`no space between the bottom inner surface of the con
`support structure adapted to maximize conductivity
`20
`tainer and the contents, there will be a much larger
`between the heat exchange medium and the space.
`difference in temperature between the temperature of
`3. The container according to claim 1 wherein said
`the contents adjacent to the bottom surface of the con
`outer shell comprises: an impact resistant outer layer; a
`tainer and the temperature of the contents adjacent to
`rigid, high-strength layer next to said outer layer; an
`the top surface of the container. If the container 40 is
`inner layer; and an insulating layer between said rigid,
`used for the shipment of frozen products, dry ice at the
`high-strength layer and said inner layer.
`top of the container will not be able to maintain prod
`4. The container according to claim 1 wherein said
`ucts adjacent to the bottom of the container in a frozen
`passive heat exchange medium is a refrigerant medium
`condition for as long as the dry ice can maintain the
`and said container is adapted for maintaining the con
`products adjacent to the top of the container in a frozen
`tents of the container in a frozen condition for up to
`ninety hours.
`condition.
`The container is particularly useful for the shipment
`5. The container according to claim 1 wherein said
`of premixed frozen drugs. Many drugs lose their po
`passive heat exchange medium is dry ice and said con
`tency within a short period of time, such as a few hours
`tainer is adapted for shipment in a commercial airplane
`after the drugs have been mixed in a diluent solution for
`and for maintaining the contents of the container in a
`injection intravenously into the veins of a patient. As a
`frozen condition for up to ninety (90) hours.
`result, a therapy has been developed by which manufac
`6. The container according to claim 1 wherein said
`turers of I.V. solutions supply premixed drugs in frozen
`outer shell comprises a series of sections whereby the
`condition to hospitals. The frozen condition inhibits loss
`container can be broken down into a smaller volume
`of potency of the drug. The frozen drugs are thawed in
`after use and whereby some sections of the outer shell
`the hospital just prior to use. There is a need to ship
`may be stored inside of the container when the con
`such premixed frozen drugs by air or other expedited
`tainer is not in use.
`transportation. The container of the present invention is
`7. The container according to claim 1 wherein said
`especially useful in the shipment of such premixed fro
`outer shell comprises compression locks and sealing
`zen drugs in commercial airplanes or other common
`means for maintaining a substantially airtight condition.
`45
`carrier.
`8. The container according to claim 1 wherein said
`Typically the premixed frozen drugs are packaged in
`outer shell comprises: a top cover; a top panel; end
`plastic bags. The bags are packaged in cardboard corru
`panels; front and back panels; a bottom panel; and a
`gated containers. The corrugated containers are packed
`bottom tray.
`in a shipping container of the present invention and are
`9. The container according to claim 8 wherein the
`shipped by commercial aircraft. It is absolutely essential
`components of the container are held together by multi
`that the contents of the shipping container, the frozen
`ple bands which pass around the container.
`drugs, remain in a frozen condition for twenty-four
`10. A container for maintaining its contents in a fro
`hours, or forty-eight hours, or sixty hours, or seventy
`zen condition for an extended period of time compris
`two hours, or for up to ninety hours, during shipment
`1ng:
`by air. It has been found that a container of the present
`an outer shell which is substantially airtight and has
`invention will maintain frozen products in a frozen
`side walls and inner surfaces;
`condition for up to ninety hours. This is significant
`said outer shell comprising an impact resistant outer
`layer; a rigid, high-strength layer next to said outer
`because it is more than sufficient to allow frozen prod
`ucts to be shipped on commercial airplanes. Typically,
`layer; an inner layer; and an insulating layer be
`60
`the time periods for airshipment are in the range of
`tween said rigid, high-strength layer and said inner
`twenty-four hours, forty-eight hours and sixty hours.
`layer;
`a passive heat exchange medium in the form of dry
`We claim:
`1. A container for maintaining its contents at a desired
`1ce;
`temperature for an extended period of time, comprising:
`a support structure for the heat exchange medium
`an outer shell which is substantially airtight and
`having an arrangement of fins on the inner side of
`which has side walls and inner surfaces;
`said support structure adapted to maximize con
`a passive heat exchange medium;
`ductivity between the dry ice;
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`4,576,017
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`7
`spacer means for maintaining space between the con-
`an outer shell which is substantially airtight and
`tents of the container and substantially the entire
`which has an inner surface;
`A.
`a passive heat exchange medium;
`inner surface of the sides and bottom of the outer
`a support structure for the heat exchange medium;
`shell of the container and between the contents of 5
`means for maintaining a space between the contents
`the container and the support structure for the dry
`of the container and substantially the entire inner
`ice for allowing convection in said air space to
`surface of the sides and bottom of the outer shell of
`the container and between the contents of the con
`maintain a substantially uniform temperature
`A.
`tainer and the support structure for the heat ex
`throughout the contents of the container;
`-
`change medium for allowing convection in said
`space to maintain a substantially uniform tempera
`said spacer means comprising blocks, each block
`having a side which faces said side wall of said
`ture throughout the contents of the container;
`container and a side which faces said contents, each
`wherein said outer shell comprises separable compo
`of said sides of said blocks having a surface area
`nents, including: a top cover; a top panel; end pan
`which is less than 70% of the adjacent side wall of
`els; front and back panels; a bottom panel; and a
`said container
`bottom tray; and
`ov.
`A
`V
`means for separation of said components of the con
`11. A container for maintaining its contents at a de-
`tainer comprising multiple bands which pass
`sired temperature for an extended period of time, com-
`around the container.
`prising:
`20
`xk
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`O
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`k
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`25
`
`30
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`35
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`40
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`60
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`UNITED STATES PATENT AND TRADEMARK OFFICE
`CERTIFICATE OF CORRECTION
`PATENT NO. : 4,576,017
`w
`DATED
`March 18, 1986
`Cathy M. Combs, Joseph K. Duffy, Mark Thoene
`NVENTOR(S) :
`It is certified that error appears in the above-identified patent and that said Letters Patent
`are hereby corrected as shown below:
`
`in Claim 1, Column 6, Line 10:
`Change conter to --container--.
`
`SEAL
`
`Attest:
`
`signed and sealed this
`Twenty-ninth Day of July 1986
`
`Attesting Officer
`
`DONALDJ. QUIGG
`Commissioner of fents and 2nderwards
`
`
`
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