US 20100326993A1
`
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2010/0326993 A1
`
` Mayer et a]. (43) Pub. Date: Dec. 30, 2010
`
`
`(54)
`
`lVIODULAR CUBOIDAL PASSIVE
`TEMPERATURE CONTROLLED SHIPPING
`CONTAINER
`
`(76)
`
`Inventors:
`
`William T. Mayer, Stacy, MN
`(US); Jacob Corder, Mound, MN
`
`(22)
`
`Filed:
`
`Feb. 20, 2009
`
`Publication Classification
`
`(51 )
`
`Int. Cl.
`B65D 81/38
`B23P 11/00
`
`(2006.01)
`(2006.01)
`
`(Us)
`
`(52) U.S. Cl.
`
`.................... 220/592.27; 220/5922; 29/428
`
`Correspondence Address:
`SHERRILL LAW OFFICES
`4756 BANNING AVE, SUITE 212
`
`WHITE BEAR LAKE’ MN 55110'3205 (US)
`
`(21) Appl. No.:
`
`12/389,438
`
`ABSTRACT
`(57)
`A kit comprising a plurality of separate and distinct identi-
`cally sized phase change material-containing panels shaped
`as a frustum of a right pyramid, a method of asscmbling a
`thermal insulating enclosure from such panels and the result—
`ant assembled thermal insulting enclosure.
`
`100
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`Patent Application Publication
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`Dec. 30, 2010 Sheet 1 0f 2
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`US 2010/0326993 A1
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`Patent Application Publication
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`Dec. 30, 2010 Sheet 2 0f 2
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`US 2010/0326993 A1
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`US 2010/0326993 A1
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`Dec. 30, 2010
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`MODULAR CUBOIDAL PASSIVE
`TEMPERATURE CONTROLLED SHIPPING
`CONTAINER
`
`BACKGROUND
`
`[0001] The shipment of temperature-sensitive goods is
`extremely difficult when the shipping container itself is not
`independently temperature-controlled; ie., does not have an
`independent power source for maintaining interior tempera-
`tures within close parameters. Of course, if it
`is merely
`desired to maintain an object to be shipped at a nominally
`cooled temperatureirelative to the ambient exterior tern-
`peratureia common practice is to pack a shipping container
`with ice, and hope that the ice will remain in a frozen state
`during transit so that the object shipped will arrive at its
`destination still cooled below ambient temperature. This can
`be an adequate technique for shipping objects where tempera -
`ture control is not critical. However, even in this case, the
`temperatures at different points inside the shipping container
`will vary widely, with parts of the interior of the container
`becoming quite cool, and other parts of the interior wanning
`to various degrees, depending on time and the distance and
`spatial relationship of the shipped object to the cooling ice
`which remains in the container.
`
`[0002] Goods such as medical supplies, blood, and vac—
`cines are often extremely temperature sensitive and need to be
`maintained within a given temperature range. Transport is
`particularly challenging. Such temperature sensitive goods
`are shipped to a variety of destinations where the ambient
`outside temperature varies from extreme cold to extreme heat.
`
`SUMMARY OF THE INVENTION
`
`[0003] A first aspect of the present claimed invention is a
`thermal insulating kit. The kit includes an outer shell and at
`least four separate and distinct identically sized phase change
`material-containing panels wherein each panel is shaped as a
`frustum ofa right pyramid.
`[0004] A second aspect of the present claimed invention a
`method of assembling a thermal insulating enclosure. The
`method includes the steps of: (i) obtaining an outer shell
`defining a retention chamber having a top, bottom and at least
`four sides, (b) obtaining at least four separate and distinct
`identically sized thennally conditioned phase change mate-
`rial-containing panels wherein each panel is shaped as a frus-
`tum of a right pyramid; and (c) placing the thermally condi-
`tioned phase—change material—containing panels within the
`retention chamber of the outer shell with each panel abutting
`at least two other panels to define a thermal controlled interior
`volume defining a top, a bottom and at least four sides.
`[0005] A third aspect of the present claimed invention is a
`thermal insulating enclosure. The enclosure is formed from
`and includes at least five separate and distinct identically
`sized thermally conditioned phase change material—contain—
`ing panels each shaped as a frustum of a right pyramid
`wherein each panel abuts at least three other panels to define
`a thermal controlled interior volume.
`
`
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective view of one embodiment of a
`[0006]
`single, phase change material-containing panel of the present
`claimed invention.
`
`FIG. 2 is an exploded perspective View of a plurality
`[0007]
`of panels configured and arranged to form a thermal insulat—
`ing enclosure.
`[0008]
`FIG. 3 depicts a plurality of panels of FIG. 1 inter-
`locked to form a thermal retention chamber.
`
`DETAILED DESCRIPTION OF A PREFERRED
` EMBODIMENT
`
`Nomenclature
`
`10 Phase Change Material-Containing Panel
`12 Top Phase Change Material-Containing Panel
`14 Side Phase Change Material—Containing Panel
`16 Bottom Phase Change Material-Containing
`
`[0009]
`[0010]
`[0011]
`[0012]
`Panel
`17 Inner Surface of Phase Change Material-Con-
`[0013]
`taining Panel
`[0014]
`18 Outer Surface of Phase Change Material-Con-
`taining Panel
`[0015]
`19 Fill Port Collar (Pinched and Sealed)
`[0016]
`20 Beveled Side
`
`22 Panel Edge
`[0017]
`30 Thermal Insulation Panels
`[0018]
`[0019]
`40 Outer Shell
`[0020]
`100 Thermal Insulating Enclosure
`[0021]
`102 Thermal Controlled Interior Volume
`
`Construction
`
`[0022] Referring to FIGS. 1-3 the invention is directed to a
`thermal insulating enclosure 100 comprising a plurality of
`separate and distinct phase change material-containing pan-
`els 10 (hereinafter “PCM panels”) all configured and
`arranged to form a retention chamber 102. The PCM panel 10
`is a frustum ofa right pyramid and all four edges 22 of the top
`12, bottom 16 and side panels 14 are 45° angles or bevels 20.
`[0023] The present claimed invention depicts a thermal
`shipping container 100 comprising the PCM panels 10 defin—
`ing an inner surface 17 and an outer surface 18. The PCM
`panels 10 are filled with a phase change material. The con-
`tainer 1 00 may have an outside shell 40 made from corrugated
`cardboard or the like holding the interconnected PCM panels
`10 in a cube structure. Inserted snugly into the outer shell 40
`is insulation 30 which at least partially covers the outer sur-
`face 18 of the PCM panels 10. The insulation may be a
`vacuum insulated panel 30, Styrofoam or the like, or any
`material having, good insulation qualities, ie., having a high
`thermal resistance “R”. The article to be shipped is typically
`placed in the retention chamber 102, and then the thermal
`insulating enclosure 100 is sealed and shipped.
`[0024] All of the abutting edges 22 of the PCM panels 10
`are 45° bevels 20. Uniform side edges 22 at 45° bevels 20 may
`sealingly fit with any other 45° beveled edge 22 to form a
`retention chamber 102. This uniformity allows a user to easily
`construct a thermal insulating container 100 because all pan-
`els 10 are the same dimensions and are interchangeable.
`Replacement ofdamaged panels 10 is also simplified because
`all panels 10 are interchangeable due to the uniform abutting
`edges 22.
`[0025] One embodiment of the thermal insulating enclo-
`sure 100 allows for six identical PCM panels 10 to interlock
`together inside an outer shell 40. Insulation 30 may be placed
`between the interlocking PCM panels 10 and the outer shell
`40. Foam, thermal insulation panels 30 or other known insu-
`lation materials may be used. The PCM panels 10, filled with
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`US 2010/0326993 A1
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`a temperature controlling phase change material, form a
`retention chamber 102 that completely and efficiently sur—
`rounds the article to be shipped. An efficient cube structure
`maximizes thermal performance of the thermal insulating
`enclosure 100 by minimizing thermal leakage from the cor—
`ners and panel edges 22. The 45° bevels 20 seal the PCM
`panels 10 together so that there are no major areas that hot or
`cold air can bypass and affect the payload directly keeping the
`retention chamber 102 at a stable temperature. The 45° bevels
`20 act as uniform mating surfaces for the interconnecting
`PCM panels 10 allowing for simple and easy replacement of
`damaged panels 10.
`[0026]
`Further insulation may be provided by inserting
`thermal insulated panels 3 0 between the outer shell 40 and the
`outer surface 18 ofthe PCM panel 1 0. The vacuum or thermal
`insulated panels 30 may insulate all sides 14, top 12 and
`bottom 16 ofthe enclosure 100.
`
`[0027] A second embodiment ofthe present invention com—
`prises using only four interconnected PCM panels 10 as the
`side panels 14 of the retention chamber 102. Vacuum insu—
`lated panels 30, rather than PCM panels 10, can be used for
`the top 12 and bottom 16 of the thermal insulating enclosure
`100. The enclosure 100 is sealed within an outer shell 40. The
`given embodiment does not provide optimal
`insulation
`because of the top 12 and bottom 16 of the enclosure 100 are
`insulted by only thermal
`insulated panels 30. However,
`because of the presence of PCM panels 10 insulating four
`sides of the enclosure 100, the overall insulation quality is
`increased when compared to altemative enclosures with only
`vacuum or thermal insulated panels 30.
`[0028] The identical phase change material containing
`PCM panels 10 cut costs associated with tooling and manu—
`facturing since only one PCM panel 10 size must be pro-
`duced. Also, an end user need only store a single type of PCM
`panel 10 since any PCM panel 10 is interchangeable with
`another at any position on the retention chamber 102.
`[0029] The PCM panels 10 may contain different phase
`change material. lee can be referred to as a phase change
`material (hereafter “PCM”), which is characterized as a mate—
`rial which changes frorn a solid to a liquid at a “melting point”
`temperature, or from a liquid to a solid at the same “melting
`poin ” temperature, as thermal energy is either absorbed or
`released by the PCM, thus acting as a heat source or heat sink,
`depending on the circumstances.
`[0030] Most solids are characterized by crystalline form,
`wherein the angles between adjoining faces are definite for a
`given type of crystal, and cleavage planes exist along which
`the crystal may be split. The structure is made up of units,
`(molecules, atoms or ions) arranged in a fixed, symmetrical
`lattice, the shape of which is dependent on the size and
`arrangement of the underlying units which are packed
`together. As a solid, the underlying molecules or other con—
`stituents are no longer able to move freely, as they are in the
`gaseous or liquid states.
`[0031] When a crystalline solid is heated to a fixed tem—
`perature, it melts, or changes to a liquid. The “melting point”
`is a definite temperature for a given substance, and may be
`defined as the temperature when a solid and liquid are at
`equilibrium. For example, if the substance is a mixture of
`water and ice, at its melting point (0° C.), the ice and water
`remain in contact, with no tendency for one state to change to
`the other. This is the only temperature at which this condition
`
`exists; at temperatures above it the substance becomes liquid
`water, and at temperatures below it the substance becomes
`ice.
`
`[0032] At the melting point temperature, the vapor pres-
`sures ofthe solidand liquidforrns of a substance are the same;
`otherwise, one state would be converted into the other by
`passing through the gaseous condition. “When liquids are
`cooled to the melting point and further quantities of heat are
`removed the liquid generally freezes with some liquid
`remaining. This solid and liquid mixture is at an equilibrium
`and at the same melting point temperature. However, if no
`solid crystals are present and if the liquid is not agitated, the
`temperature of liquids may be lowered below their normal
`freezing points without solidifying. These “supercooled” liq-
`uids have a higher vapor pressure than the solid form of the
`substance and hence a condition of equilibrium cannot exist.
`[0033] Although molecules or other units of solids cannot
`move freely, nevertheless they possess thermal energy of
`motion in the form of vibration about fixed positions in the
`lattice structure. Heat must be supplied to a solid in order to
`raise its temperature to the melting point, where it transforms
`from a solid to a liquid, remaining at the melting point tem—
`perature until the transformation,
`is complete. If heat is
`removed from a liquid, its temperature drops until it reaches
`the melting point, and the liquid remains at the melting point
`temperature until
`it becomes transformed into a solid.
`Increase oftemperature causes the molecules to vibrate more
`and more, until, at the melting point, this motion overcomes
`the binding forces in the crystal and the substance gradually
`passes into the liquid state. Therefore, a definite amount of
`heat, called the “heat of fusion”, is required to separate par—
`ticles from the crystal lattice. The “heat of fusion“ is defined
`as the amount of heat (in calories) required to change one
`gram ofthe solid to a liquid, at the melting point. For ice, the
`heat of fusion is 79 calories (144 Btu/pound).
`[0034]
`If it were desired to ship an article in an insulated
`package, and assuming it were necessary to maintain the
`article at a temperature below the expected ambient tempera-
`ture to be encountered along the shipping route, it would be
`the normal practice to place the article and a packet ofice into
`the container and their ship it. The amount of ice required, and
`the size of the shipping container, would be estimated,
`depending upon the shipping time and the expected ambient
`temperature along the route, it being hoped that the article
`would arrive at its destination still cooled to a reasonable
`temperature below ambient.
`[0035] The uncertainties of the foregoing example are evi—
`dent, although the technique is commonly used when main-
`taining the temperature of the article is not critical, or when
`the article is sufiiciently inexpensive to not require better
`handling. Other difficulties exist with the common technique;
`for example, the distribution of temperatures within the con—
`tainer is highly nonuniform. This is because the thermal llux
`entering the container flows from the outside ambient to the
`PCM over many different paths. After flowing through the
`outside, insulating panels, the heat flux flows along various
`paths through the air inside the container, each path having a
`different thermal resistance “R” depending upon path length,
`leading to a different thermal gradient from the insulating
`walls to the article inside the container. Therefore, some parts
`of the article shipped may be at one temperature and other
`parts may be at some other temperature. In particular, if the
`shipped article is placed atop a packet ofice, the underside of
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`the article may be quite cool while the upper portions of the
`article may be excessively warm.
`[0036]
`'ith the foregoing structure, thermal flux enters
`through the corrugated outside walls, and is attenuated
`through the thermal insulated panels 30. It is presumed that
`the PCM filling the PCM panels 10 is initially converted to a
`solid such as ice The thermal flux engages the PCM and
`causes a gradual phase change of the solid into a liquid at the
`melting point ofthe solid. In the case ofwater/ice, the melting
`point is approximately 0° C., and therefore the interior tem-
`perature will remain at 00 C. for so long as it takes for all the
`ice to convert to water (144 Btu’s per pound).
`[0037] The thermal enclosure 1 00 is mo st efficient as a cube
`system, but is not limited to cubes. Side panels 14 can be
`different lengths to create rectangular shape thermal enclo-
`sure as well. Panels 10 that are the same size would be inter—
`changeable still allowing the user to cut costs by storing a
`limited amount of interchangeable replacement panels 10.
`[0038] The present invention may be embodied in other
`specific forms without departing from the spirit or essential
`attributes thereof; and it is, therefore; desired that the present
`embodiment be considered in all respects as illustrative and
`not restrictive, reference being made to the appended claims
`rather than to the foregoing description to indicate the scope
`of the invention.
`
`1. A thermal insulating kit, comprising:
`(a) an outer shell; and
`(b) at least four separate and distinct identically sized phase
`change material-containing panels wherein each phase
`change material-containing panel is shaped as a frustum
`of a right pyramid.
`2. The thermal insulating kit of claim 1 wherein the kit
`includes at least six phase change material-containing panels.
`3. The thermal insulating kit ofclaim 1 wherein each panel
`has a bottom surface, a top surface and side surfaces, and
`wherein the side surfaces join the bottom surface at a 45°
`angle.
`4. The thermal insulating kit of claim 1 further comprising
`panels of thermal insulation.
`5. The thermal insulating kit of claim 4 wherein the panels
`of thermal insulation are vacuum insulated panels.
`6. A method ofassembling a thermal insulating enclosure,
`comprising the steps of:
`(a) obtaining an outer shell defining a retention chamber
`having a top, bottom, and at least four sides;
`(b) obtaining at least four separate and distinct identically
`sized thermally conditioned phase change material-con-
`taining panels wherein each panel is shaped as a frustum
`of a right pyramid; and
`(c) placing the thermally conditioned phase-change mate-
`rial-containing panels within the retention chamber of
`the outer shell with each panel abutting at least two other
`panels to define a thermal controlled interior volume
`defining a top, a bottom and at least four sides.
`7. The method of claim 6, further comprising the steps of:
`(a) obtaining at least one thermal insulating panel, and
`(b) placing the at least one thermal insulating panel within
`the retention chamber of the outer shell so as to ther—
`mally insulate the top or bottom of the thermal con-
`trolled interior volume.
`
`8. The method of claim 6, further comprising the steps of:
`(a) obtaining a plurality of thermal insulating panels, and
`(b) placing each ofthe thermal insulating panels within the
`retention chamber of the outer shell so as to thermally
`insulate the top, bottom and each side of the thermal
`controlled interior volume.
`9. A thermal insulating enclosure, formed from and com-
`prising at least five separate and distinct identically sized
`thermally conditioned phase change material—containing
`panels each shaped as a frustum of a right pyramid wherein
`each panel abuts at least three other panels to define a thennal
`controlled interior volume.
`
`10. The thermal insulating enclosure of claim 9 wherein
`each panel has a bottom surface, a top surface and side sur—
`faces, and wherein the side surfaces join the bottom surface at
`a 450 angle.
`1 1. The thermal insulating enclosure ofclaim 9 wherein the
`panels are retained within an outer shell.
`12. The thermal insulating enclosure of claim 11 further
`comprising a layer of themial insulation interposed between
`the thermally conditioned phase change material—containing
`panels and the outer shell.
`13. The thermal insulating enclosure of claim 12 wherein
`the insulation layer is vacuum insulated panels,
`14. A thermal insulating kit, comprising:
`(a) an outer shell; and
`(b) at least four separate and distinct phase change mate-
`rial—containing panels having angled edges, wherein (i)
`each phase change material-containing panel is shaped
`as a frustum of a right pyramid, and (ii) the panels are
`capable of being assembled edge-to-edge to form an
`encircling sleeve.
`15. The thermal insulating kit ofcla im 14 wherein (i) the kit
`includes at least six phase change material-containing panels,
`and (ii) the panels are capable of being assembled edge—to—
`edge to define a fully enclosed chamber.
`16. The thermal insulating kit of claim 14 wherein each
`panel has a bottom surface, a top surface and side surfaces,
`and wherein the side surfaces join the bottom surface at a 45°
`angle.
`17. The thermal insulating kit of claim 14 further compris-
`ing panels of thermal insulation.
`18. The thermal insulating kit of claim 17 wherein the
`panels of thermal insulation are vacuum insulated panels.
`19. A method of as sembling a thermal insulating enclosure,
`comprising the steps of:
`(a) obtaining an outer shell defining a retention chamber
`having a top, bottom, and at least four sides;
`(b) obtaining at least four separate and distinct thermally
`conditioned phase change material—containing panels
`wherein each panel is shaped as a frustum of a right
`pyramid; and
`(c) placing the thermally conditioned phase-change mate-
`rial-containing panels edge-to-edge within the retention
`chamber of the outer shell to define an encircling sleeve
`of phase change material—containing panels.
`20. The method of claim 19, further comprising the steps
`
`of:
`
`(a) obtaining at least one thermal insulating panel, and
`(b) placing the at least one thermal insulating panel within
`the retention chamber of the outer shell so as to ther—
`mally insulate the top or bottom of the thermal con-
`trolled interior volume.
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`21. The method of claim 19, further comprising the steps
`
`of:
`
`(a) obtaining a plurality of thermal insulating panels, and
`(b) placing each of the thermal insulating panels within the
`retention chamber of the outer shell so as to thermally
`insulate the top, bottom and each side of the thermal
`controlled interior voltnne.
`
`22. A thermal insulating enclosure, formed from and com—
`prising at least six separate and distinct thermally conditioned
`phase change material-containing panels each shaped as a
`frustum of a right pyramid wherein the panels are assembled
`to form a rectangular parallelepiped defining a thermal con-
`trolled interior volume.
`
`23. The thermal insulating enclosure of claim 22 wherein
`each panel has a bottom surface, a top surface and side sur-
`faces, and wherein the side surfaces join the bottom surface at
`a 45° angle.
`24. The thermal insulating enclosure ofclaim 22 wherein
`the panels are retained within an outer shell.
`25. The thermal insulating enclosure of claim 24 further
`comprising a layer of thermal insulation interposed between
`the thermally conditioned phase change material-containing
`panels and the outer shell.
`26. The thermal insulating enclosure of claim 25 wherein
`the insulation layer is vacuum insulated panels.
`4=2==x<=x<+
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