Patent Publication Number: US-2009230138-A1

Title: Temperature Maintaining Shipping Package

Description:
RELATED APPLICATIONS 
     This applications claims priority from U.S. Provisional Patent Application No. 60/991,658, filed Nov. 30, 2007, and hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention is directed to a package, such as used during transport, for a temperature sensitive payload and a method of use. More particularly, the present invention relates to a package and method of use for shipping temperature sensitive materials via common carrier. 
     BACKGROUND OF THE INWENTION 
     Packages incorporating phase change materals for transport of temperature sensitive payloads are well known. A phase change material (PCM) is a substance with a high heat of fusion which, upon melting and solidifying at certain temperatures, is capable of storing or releasing large amounts of energy. Initially, solid-liquid PCMs perform somewhat like conventional storage materials: their temperature nrses as they absorb heat. Unlike conventional storage materials, however, when such PCMs reach their phase change temperatures (i.e., melting point temperature) they absorb large amounts of heat without a significant rise in temperature. When the ambient temperature around a lquid material falls, the PCM solidifiesv releasing its stored latent heat. Certain PCMs store 5 to 14 times more heat per unit volume than conventional storage materials such as iron, masonry, or rock. 
     Transporting temperature sensitive materials through environments having extreme ambient temperatures in a manner that does not require a power source or other mechanical device is desirable. Various methods have been advanced for this purpose. For example, prior known devices have employed phase change materials in liquid form to encase a payload to protect materials from colder ambient temperatures and phase change materials in solid form to encase a payload to protect materals from hotter ambient temperatures. 
     PCMs can be broadly grouped into two categories: “Organic Compounds” (such as polyethylene glycol) and “Salt-based Products” (such as Glauber&#39;s salt). The most commonly used PCMs are salt hydrides, fatty acids and esters, and various paraffins (such as octadecane). Ionic liquids have also been investigated as novel PCMs. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates to a package and method of thermally protecting a payload with phase change materals and an outer container, wherein the PCM material is provided in segmented panels. In one embodiment, a payload is surrounded with phase change material contained within segmented PCM panels that are wrapped around a payload. A package in accordance with the present invention may include multiple segmented panels of phase change material. 
     It is particularly desirable to have a storage or shipping container capable of thermally protecting a payload such as, but not limited to, a bottle or bottles of pills. An embodiment of the present invention relates includes a package defined by an outer container, such as an envelope, which contains one or more flexible, segmented PCM panels surrounding a payload. In one example, the segments are defined by bondings between panel surfaces. Such a bond can be formed via a thermal bonding procedure. One embodiment of the present invention utilizes multiple panels of generally similar form to define a plurality of segmented PCM portions. 
     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
       For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which: 
         FIG. 1  is an view of a package assembly in a disassembled state in accordance with the present invention. 
         FIG. 2  is a view of a portion of the package assembly of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of the package assembly taken along lines A-A of  FIG. 1 . 
         FIG. 4  is a cross-sectional view of the package assembly taken along lines B-B of  FIG. 2 . 
         FIG. 5  is a view of a portion of the package assembly of  FIG. 1  during an assembly process. 
         FIG. 6  is a view of the package assembly of  FIG. 5  during the assembly process. 
         FIG. 7  is a view of the package assembly of  FIG. 1  in a ready-to-ship state. 
         FIGS. 8-11  are views of another embodiment of a package assembly in accordance with the present invention. 
         FIGS. 12-14  are graphs of test data collected during actual shipments of packages in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1 , there is shown one embodiment of a package  10  in a disassembled state. Package  10  includes outer container  11  and a pair of phase change material (PCM) panels  13 . A payload is provided, which in this example, is a pair of bottles  16 . As disclosed hereinafter, payload  16  is contained within rolled PCM panels  13  and container  11  upon assembly. 
     In the illustrated embodiment, container  11  is an envelope. Container  11  may be insulated or uninsulated. In other embodiments, container  11  may assume alternative forms, including, but not limited to, nonrectangular forms. Container  11  may be of plastic or polymer material, corrugated paper or corrugated plastic or other suitable material. 
     PCM panels  13  may assume different shapes or forms in alternative embodiments. Panels  13  contain a plurality of PCM segments  18 . In the illustrated embodiments of  FIGS. 1-11 , a pair of flexible, segmented PCM panels  13  are employed in package  10 . In the embodiment of  FIGS. 1-7 , panels  13  are segmented in two generally orthogonal directions, for simplicity sake referred to herein as “horizontal” and “vertical” directions. In comparison, the embodiment of  FIGS. 8-11  utilize panels  13  which are segmented in a single directions, e.g., vertical. As shown in  FIGS. 1 and 2 , panels  13  of are segmented in both horizontal and vertical directions. 
     Panels  13  are defined by a plurality of separated PCM-containing segments  18 . These segments  18  are separated by linear voids  19 . Voids  19  may be defined during a thermal bonding manufacturing process. For example, the voids  19  and cavity forming segments  18  may be formed from a pair of thermoplastic sheet material brought together during a thermal bonding/filling process. Voids  19  may be continuous, that is to say each segment  18  is separated from each other and PCM is prevented from flowing from one segment  18  to an adjacent segment  18 . In another embodiment, voids  19  may be non-continuous and PCM is able to flow from one segment into another segment  18  when an external force is supplied. In short, the interior volumes of segments  18  may be either separated or provided in fluid communication with each other. 
       FIGS. 3 and 4  represent cross-sectional views taken along lines A-A and B-B in  FIGS. 1 and 2 , respectively. Each segment  18  contains a quantity of PCM held between upper and lower films  20 ,  21 . In one embodiment, segments  18  are defined between pairs of void regions  19  wherein film layers  20 ,  21  are brought together during a sealing/filling process. PCM is held within volumes contained between film layers  20 ,  21 . The size of segments  18  could depend on a variety considerations including, but not limited to, temperature constraints of payload and/or anticipated ambient temperature during shipping, size of payload, size or weight limitations of shipper, etc. It should be appreciated that alternative segment  18  designs could also be utilized depending, for example, on the geometry of the payload, thermal constraints, etc. As suggested by  FIG. 5 , slits or perforations may be formed in upper and/or lower segment portions such as indicated by numeral  29 . Such slits or perforations  29  may be beneficial during a panel  13  rolling process as further disclosed herein. Slits or perforations  29  are shown in phantom line to indicate that for other embodiments of panel  13 , slits or perforations  29  may or may not be present. 
     FIGS.  2  and  4 - 6  depict the process of assembling package  10 . In  FIG. 2 , payload  16  has been placed upon upper film surface  20  of segmented panel  13 . Prior to assembly, panels  13  have desirably been thermally conditioned. Assuming the same PCM material is used in the pair of panels  13 , one the panels may be preconditioned to be solid and the other panel may be preconditioned to be liquid. Panels  13  are preconditioned depending on the temperature constraints of a given package. In other embodiments, more than two PCM panels  13  could be used. 
       FIG. 4  depicts rolling one of the PCM panels  13  around payload  16 . Next the other PCM panel  13  is rolled around the first PCM panel  13 .  FIG. 5  depicts the combination of PCM panels and payload  16  as inserted into container  11 . Flap  30  of container  11  is subsequently folded into adhesive contact with a panel surface.  FIG. 7  depicts package  10  as assembled and ready to ship. Package  10  may be adapted to be mailed as-is, or alternatively package  10  or a plurality of packages  10  may be contained in yet another larger package (not shown), such as a box. Container  11  may be adapted to directly receive a label, stamps or other indicia utilized during the shipping process. 
     Referring to  FIGS. 5 and 6 , because payload  16  does not extend to edges of panel  13 , end portions of panels  13  may be folded over to fully enclose payload  16 . In comparison, the panels  13  of a second embodiment as shown in  FIGS. 8-11  are not folded over. 
       FIGS. 8-11  illustrate another embodiment of package  100 .  FIG. 8  depicts a disassembled package  100  including a pair of flexible, PCM panels  13  and container  110 . In comparison to package  10  of the first embodiment, PCM panels  13  are defined by a plurality of vertical voids  190 . As shown in  FIGS. 9 and 10 , payload  160  extends substantially across panel  130 . When panels  13  are wrapped around payload  160 , ends of payload  160  may be visible as shown in  FIG. 11 . 
     The present invention is also directed to a package and method for encasing a payload cavity with flexible, segmented panels  13  containing phase change material. In one example, a water based phase change material is combined with another phase change material to provide thermal protection for the payload. By properly selecting the phase change materials, a package can be configured to provide maximum thermal protection for a temperature sensitive product during delivery. Employing a combination of solid and liquid phase change materials in the container can provide protection from both hotter and colder ambient temperatures during delivery, and a beneficial reduction in the amount of certain phase change materials can result. 
     Embodiments of the present invention may include two or more different phase change materials. In one embodiment, a water-based phase change material is utilized along with a 2 nd , non-water-based phase change material. In one embodiment, a temperature sensitive product is protected against thermal damage from the water-based phase change material by an intermediate phase change material. Depending on the desired temperature range, a variety of different phase change materials may be utilized to keep a temperature sensitive product warm or cold during shipment through an environment having substantially different temperatures than desired. For example, prior to shipment one or both of the phase change materials  13  can be preconditioned so that phase change material is in liquid form or solid form. Depending on the anticipe mate a e eeture profile, the most effective combination of solid and liquid phase change material can be selffecte combination is needed, auxiliary phase change material in solid, liquid, or solid and liquid phase can be added to augment the thermal capabilities of the container. 
       FIGS. 12-14  illustrate test data associated with three test shipments of a package in accordance with the present invention. Three packages were transported to either Florida or New York from Minneapolis using ordinary available shippers. Temperature of the payload was monitored as well as the ambient temperature as felt by the outer container. Data was measured by two temperature sensing/recording devices contained within container. Temperature and time as collected during the tests are provided in graph form. Each test package maintained the payload within a 5 deg. C. temperature band (25.0-20.0 deg. C.) over at least a two day period while the ambient temperature dipped above or below the temperature band. Test success for a package was defined by the package maintaining the payload within the desired temperature band for at least two days during the transport process. 
     Selection of the phase change materials may include consideration of multiple factors including, but not limited to, the desired protected temperature range, anticipated ambient temperatures during shipment, thermal properties of the different phase change materials, thermal properties of the container and/or insulation panels, and thermal properties of the temperature sensitive product being shipped. The design and sizing of containers of for the phase change material and the insulation panels could vary depending on these factors as well. 
     A temperature maintaining packaging system in accordance with the present invention includes an insulated or non-insulated outer container, including but not limited to a box or envelope made of plastic film, metallic foil or other suitable material, a phase change material panel or panels consisting of a sealed cavity or cavities within a plastic film or other suitable material that is/are preconditioned to be solid, liquid, or solid and liquid in varying predetermined combinations covering or mostly covering the interior of the outer container or envelope, and possibly a secondary phase change material sealed within a plastic film or other suitable material having a single cavity or multiple cavities that is/are preconditioned to be solid, liquid, or solid and liquid in varying predetermined combinations covering or mostly covering the interior of the first phase change material panel or panels all to thermally protect a payload within the center of the package. 
     A temperature maintaining packaging system in accordance with the present invention includes an outer rigid or semi-rigid tube or hollow container made of paper, plastic or other suitable material along with suitable caps for enclosing the package, a suitable insulation such as a plastic foam capable of wrapping around a phase change material panel or panels and a payload container, a phase change material panel or panels consisting of a sealed cavity or cavities within a plastic film or other suitable material that is/are preconditioned to be solid, liquid, or solid and liquid in varying predetermined combinations covering or mostly covering the interior of the outer container, and possibly a secondary phase change material sealed within a plastic film or other suitable material having a single cavity or multiple cavities that is/are preconditioned to be solid, liquid, or solid and liquid in varying predetermined combinations covering or mostly covering the interior of the first phase change material panel or panels all to thermally protect a payload within the center of the package. 
     The temperature maintaining package system in accordance with the present invention includes PCM panels wherein the phase change materials are preconditioned to be solid, liquid, or both solid and liquid. 
     The invention is directed to a method of preparing, packaging and shipping a container or envelope to thermally protect a payload of temperature sensitive materials including: wrapping the payload material to be thermally protected in a phase change material panel with one or more segments of phase change material conditioned to be solid or liquid; wrapping the payload and initial phase change material panel in a secondary phase change material panel with one or more segments of phase change material conditioned to be solid or liquid; as needed, wrapping the payload and panels with successive layers of phase change material panels as space and temperature protection demands; placing the payload wrapped with phase change material panels into the outer container or envelope; and sealing the payload and phase change material panels inside the container and performing any necessary operations to complete the package such as but not limited to placing shipping information on the package, placing postage and instructions on the package, or puncturing a vacuum sealed outer envelope to allow expansion of the insulation material. 
     Another method of preparing, packaging and shipping a container to thermally protect a payload of temperature sensitive materials includes: wrapping the payload material to be thermally protected in a phase change material panel with one or more cavities of phase change material conditioned to be solid or liquid; wrapping the payload and initial phase change material panel in a secondary phase change material panel with one or more cavities of phase change material conditioned to be solid or liquid; as needed, wrapping the package in successive layers of phase change material panels as space and temperature protection demands; wrapping the payload wrapped with phase change material panels inside the with suitable insulation such as foam insulation; and sealing the payload, phase change material panels, and insulation inside the container and performing any necessary operations to complete the package such as but not limited to attaching end caps to the container, placing shipping information on the package, or placing postage and instructions on the package. 
     The PCM panels may include phase change materials that have been preconditioned separately to be solid and liquid by adding heat energy to phase change material containers until the phase change material is completely liquid and conditioning the liquid phase change material to be at an acceptable temperature for packaging; or removing heat energy from phase change material containers until the phase change material is completely solid and conditioning the solid phase change material to be at an acceptable temperature for packaging. 
     Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.