Patent Publication Number: US-2013228583-A1

Title: Passive thermally regulated knockdown shipping container

Description:
BACKGROUND 
     Thermally labile goods are frequently transported or shipped in passive thermally regulated shipping containers (i.e., a thermally insulated container containing a thermally conditioned phase change material such as ice). While generally effective for maintaining an object to be shipped at a nominally heated or cooled temperature, the storage and return transport of empty containers remains an ongoing issue. 
     Efforts to construct foldable or knockdown passive thermally regulated shipping containers in an effort to minimize the space occupied by empty containers have meet with limited success as such containers tend to provide limited thermal regulation, are labor intensive and/or require trained technicians to assemble and disassemble. 
     Accordingly, a substantial need continues to exist for knockdown passive thermally regulated shipping container that provides superior thermal regulation and is quick and easy to assemble and disassemble without error. 
     SUMMARY OF THE INVENTION 
     A first aspect of the invention is a sidewall component suitable for use in construction of a passive thermally regulated knockdown shipping container. The sidewall component includes at least two hingedly interconnected structural panels, each carrying a detachable panel of fragile thermal insulation. 
     A second aspect of the invention is a passive thermally regulated knockdown shipping container. The container includes (i) a pair of separate and independent interchangeable end panels, each carrying a detachable panel of fragile thermal insulation, (ii) a plurality of separate and independent sidewall components in accordance with the first aspect of the invention, (iii) a plurality of primary connection mechanisms, each operable for affecting border to border interconnection of a pair of sidewall components pivoted into a use configuration to form an encircling sidewall assembly, and (iv) a plurality of secondary connection mechanisms, each operable for attaching one of the end panels to the sidewall assembly over an open end of the assembly to form an enclosure defining a thermally regulated payload retention chamber. 
     A third aspect of the invention is a stackable panel. The panel is configured and arranged with (i) a set of projections extending longitudinally from a first major surface of the panel operable for stably supporting the panel on a planar surface, and (ii) a set of longitudinally inset depressions in the first major surface. The depressions are configured and arranged on the panel such that each projection on the panel, if inverted, would nest within a corresponding depression in the panel upon rotation of the inverted set of projections a defined angular distance about a longitudinal axis of the panel relative to the set of depressions. 
     A fourth aspect of the invention is a stackable container. The container has one or more sidewalls longitudinally separating identically configured and arranged top and bottom panels. The top and bottom panels are each configured and arranged with (i) an external set of projections operable for stably supporting the container on a planar surface, and (ii) an external set of depressions. The depressions are configured and arranged such that each projection on the panel, if inverted, would nest within a corresponding depression on the panel upon rotation of the inverted set of projections a defined angular distance about a longitudinal axis of the container relative to the set of depressions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded isometric view of one embodiment of the invention. 
         FIG. 2  is an isometric view of the container depicted in  FIG. 1  fully assembled. 
         FIG. 2A  is a top view of the assembled container depicted in  FIG. 1 . 
         FIG. 2B  is a side view of the assembled container depicted in  FIG. 2A . 
         FIG. 3  is an isometric view of one of the sidewall components depicted in  FIG. 1  disposed in a planar storage position. 
         FIG. 4  is a cross-sectional side view of the sidewall component depicted in  FIG. 3  taken along line  4 - 4 . 
         FIG. 4A   1  is a grossly enlarged portion of the cross-sectional side view of the sidewall component depicted in  FIG. 4  for purposes of allowing depiction of one means for detachably attaching the thermal insulation panel to the structural sidewall panel. 
         FIG. 4A   2  is a grossly enlarged portion of the cross-sectional side view of the sidewall component depicted in  FIG. 4  for purposes of allowing depiction of another means for detachably attaching the thermal insulation panel to the structural sidewall panel. 
         FIGS. 5A-D  depict various arrangements of variously shaped projections and depressions on structural end panels of various cross-sectional shapes that permit stable nestable stacking of containers employing identical structural end panels as both the top and bottom of the containers. 
     
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Definitions 
     As utilized herein, including the claims, the term “detachable” means capable of being detached without application of violent force and without damage to or destruction of either the item being detached or the substrate from which the item is being detached. 
     Nomenclature 
     
         
           10  Passive Thermally Regulated Shipping Container 
           19  Payload Retention Chamber 
           20  Outer Structural Shell 
           21  Structural End Panel 
           21   1  Upper Structural End Panel 
           21   2  Lower Structural End Panel 
           21   i  Interior Major Surface of Structural End Panel 
           21   j  Exterior Major Surface of Structural End Panel 
           21   p  Projections Extending from the Exterior Major Surface of Structural End Panel 
           21   d  Depressions in the Exterior Major Surface of Structural End Panel 
           22  Structural Sidewall Component 
           22   i  Interior Major Surface of Structural Sidewall Component 
           22   j  Exterior Major Surface of Structural Sidewall Component 
           23  Sidewall Panel on Structural Sidewall Component 
           23   i  Interior Major Surface of Structural Sidewall Panel 
           24  Live Hinge Interconnecting First and Second Structural Sidewall Panels on Structural Sidewall Component 
           30  Thermal Insulation Panel 
           30   b  Border Area of Thermal Insulation Panel 
           40  Phase Change Material Panels (PCM Panel) 
           50  Means for Detachably Attaching Thermal Insulation Panel to a Structural Panel 
           50   1  Hook and Loop Tape 
           50   2  Pressure Sensitive Adhesive 
           60  Connection Mechanism for Attaching Structural Sidewall Components 
           70  Connection Mechanism for Attaching Structural End Panel to Erected Structural Sidewall Assembly 
         x 10  Longitudinal Axis of Shipping Container 
         x 21  Longitudinal Axis of Structural End Panel 
       
    
     Construction 
     Referring generally to  FIG. 1 , the present invention is directed to various components of a modular kit operable for assembly into a passive thermally regulated stackable shipping container  10 , and a shipping container  10  assembled therefrom. 
     When assembled, the shipping container  10  includes an outer structural shell  20 , a layer of thermal insulation  30 , and optionally a layer of phase change material (not shown) retained within PCM panels  40 , defining a passive thermally regulated payload retention chamber  19 . 
     The outer structural shell  20  may be solid or hollow and may be made from any material possessing sufficient structural integrity, including specifically but not exclusively, cellulosic materials such as paperboard and cardboard, engineered wood products such as laminated and unlaminated fiberboard and plywood, wood, plastics such as polyethylene, polypropylene, polyethylene terephthalate, nylon polycarbonates and phenolic resins, wood-plastic composites, metals such as aluminum, copper, brass and steel, glass, ceramics, combinations thereof, and the like. 
     The outer structural shell  20  is divided into separate and independent structural end panels  21  and at least one structural sidewall component  22 . These units are capable of being repeatedly attached to and detached from one another. 
     Assembly of a shipping container  10  requires two structural end panels  21 —one to cover the top  21   1  and another to cover the bottom  21   2 . The top  21   1  and bottom  21   2  structural end panels are preferably interchangeable with one another so that only a single style end panel  21  need be manufactured and stocked. Use of interchangeable top  21   1  and bottom  21   2  structural end panels also simplifies assembly of the shipping container  10  as there is no need to obtain and identify separate top  21   1  and bottom  21   2  structural end panels. A technician assembling a shipping container  10  need only obtain two structural end panels  21 . 
     The exterior major surface  21   j  of the structural end panels  21  may be contoured with a set of rotationally spaced longitudinal projections  21   p  and rotationally displaced “matching” set of longitudinal depressions  21   d  whereby (i) the projections  21   p  terminate along a single horizontal plane such that the structural end panel  21  can rest stably upon the projections  21   p  when placed upon a flat horizontal surface, and (ii) the projections  21   p  on both structural end panels  21 , disposed with their exterior major surfaces  21   j  facing one another, will nest within corresponding depressions  21   d  on the other facing structural end panel  21  when one of the facing panels  21  is rotated a defined angular distance about the longitudinal axis x 21  of the panel  21 . This permits interchangeable top  21   1  and bottom  21   2  structural end panels to be used in assembling a shipping container  10  while still allowing such assembled shipping containers  10  to be stably and nestably stacked upon one another by simply rotating an overlying shipping container  10  a defined angular distance about the longitudinal axis x 10  of the shipping container  10  relative to the immediately underlying shipping container  10 . 
     Exemplary operable arrangements of variously shaped projections  21   p  and depressions  21   d  on structural end panels  21  having various cross-sectional shapes are depicted in  FIGS. 5A-D , wherein depressions  21   d  are shaded and projections  21   p  are unshaded. Each is described in further detail in TABLE ONE. 
     
       
         
           
               
               
               
               
               
             
               
                 TABLE ONE 
               
             
            
               
                   
               
               
                   
                   
                   
                   
                 NECESSARY 
               
            
           
           
               
               
               
               
            
               
                   
                 PROJECTIONS 
                   
                 ANGULAR 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 CROSS- 
                   
                 ROTATION 
               
               
                   
                   
                 SECTIONAL 
                 SHAPE OF 
                 TO ACHIEVE 
               
               
                 FIG. # 
                 # 
                 SHAPE 
                 PANEL 
                 NESTING 
               
               
                   
               
               
                 5A 
                 4 
                 Square 
                 Rectangle 
                 180° 
               
               
                 5B 
                 4 
                 Triangle 
                 Square 
                  90° 
               
               
                 5C 
                 3 
                 Circle 
                 Square 
                 180° 
               
               
                 5D 
                 3 
                 Hexagon 
                 Hexagon 
                  60° 
               
               
                   
               
            
           
         
       
     
     Assembly of a shipping container  10  also requires at least three structural sidewall panels  23 . 
     Structural sidewall panels  23  are grouped together on structural sidewall components  22 , with the structural sidewall panels  23  on each structural sidewall component  22  interconnected by a hinge  24 , such as a live hinge. 
     The structural sidewall components  22  can be constructed with any number of hingedly interconnected structural sidewall panels  23  on each structural sidewall component  22 . However, as the number of panels  23  on each component  22  increases, so too does the difficulty and complexity of storing and handling the structural sidewall component  22 . A nonexhaustive listing of various geometric and configurational options for the structural sidewall components  22  and shipping containers  10  constructed therefrom is provided below in table TWO. 
     
       
         
           
               
               
             
               
                 TABLE TWO 
               
             
            
               
                   
               
               
                 SIDEWALL 
                   
               
               
                 COMPONENT 
                 SHIPPING CONTAINER 
               
            
           
           
               
               
               
            
               
                 # of Panels 
                 # of Sidewall 
                 Cross-Sectional  
               
               
                 on Each 
                 Components 
                 Shape 
               
               
                   
               
               
                 2 
                 2 
                 Square 
               
               
                 2 
                 3 
                 Hexagon 
               
               
                 2 
                 4 
                 Octagon 
               
               
                 2 
                 5 
                 Decagon 
               
               
                 3 
                 1 
                 Triangle 
               
               
                 3 
                 2 
                 Hexagon 
               
               
                 3 
                 3 
                 Nonagon 
               
               
                 4 
                 1 
                 Square 
               
               
                 4 
                 2 
                 Octagon 
               
               
                 5 
                 1 
                 Pentagon 
               
               
                 5 
                 2 
                 Decagon 
               
               
                   
               
            
           
         
       
     
     When the shipping container  10  is constructed from two or more structural sidewall components  22  the structural sidewall components  22 , as with the end panels  21 , are preferably interchangeable with one another so that only a single style structural sidewall component  22  need be manufactured and stocked. 
     The structural sidewall panels  23  on each structural sidewall component  22  are configured and arranged such that the structural sidewall panels  23  can be pivoted relative to one another as between a planar storage configuration in which the structural sidewall panels  23  do not contact one another, and a three-dimensional use configuration in which the and structural sidewall panels  23  abut one another along a length of a border area thereof. 
     A panel of thermal insulation  30  is detachably attached to the interior major surface  21   i  of each structural end panel  21  and the interior major surface  23   i  of each structural sidewall panel  23  on each structural sidewall component  22 . The panels of thermal insulation  30  may be constructed of any material having good thermal insulating qualities, (i.e., having a high thermal resistance “R”), such as Styrofoam, vacuum insulated panels, or the like. 
     The panels of thermal insulation  30  are aligned on the structural sidewall panels  23  so that the panels of thermal insulation  30  do not contact one another when the structural sidewall panels  23  are disposed in the planar storage configuration, but abut one another along a length of a border area  30   b  thereof when the structural sidewall panels  23  are disposed in the three-dimensional use configuration. 
     In a similar fashion, the panels of thermal insulation  30  are aligned on the structural end panels  21  so that the panels of thermal insulation  30  on the end panels  21  abut the panels of thermal insulation  30  attached to the structural sidewall panels  23  along a length of a border area thereof when the structural end panel  21  is attached to the assembled structural sidewall panels  23 . 
     Preferred materials for use as the thermal insulating panels  30  tend to be fragile and/or frangible (e.g., panels of Styrofoam or vacuum insulated panels). This results in all too frequent damaging of the thermal insulating panels  30  and resultant loss of insulating value. In order to facilitate replacement of damaged and/or failing thermal insulating panels  30  without requiring replacement of an entire structural end panel  21  or structural sidewall panel  23 , the thermal insulating panels  30  are detachably attached to the structural end panels  21  and structural sidewall panels  23 . 
     A wide variety of options are available for detachably attaching the thermal insulating panels  30  to the interior major surface  21   i  of each structural end panel  21  and the interior major surface  23   i  of each structural sidewall panel  23 . A preferred option is hook and loop tape  50   1  such as shown in  FIG. 4A   1 . Another preferred option is double-sided pressure sensitive adhesive tape  50   2  such as shown in  FIG. 4A   2 . Yet another preferred attachment means is a layer of pressure sensitive adhesive coated directly upon the structural end panel  21 , structural sidewall panel  23 , and/or thermal insulating panel  30 . Mechanical fasteners may also be used, such as elastic straps, reversible snap fit, reversible press-fit, etc. However, such mechanical fasteners should generally be avoided as they tend to prevent direct contact between the thermal insulating panels  30  when the container  10  is fully assembled, leaving a gap in the layer of thermal insulation through which significant heat loss can occur. 
     Referring to  FIG. 1 , the payload retention chamber  19  can be lined with panels of phase change material (PCM panels)  40 . The PCM panels  40  can be filled with any suitable phase change material, such as water or various hydrocarbons. 
     Either of the structural end panels  21  on the shipping container  10  can be selectively removable from the sidewall assembly for allowing insertion and removal of goods from the payload retention chamber  19 . PCM panels  40  deployed within the payload retention chamber  19  may similarly be removed for thermal conditioning. 
     A primary connection mechanism  60  releasably attaches structural sidewall components  22  to one another. A secondary connection mechanism  70  releasably attaches structural end panels  21  to the longitudinal ends of a fully assembled sidewall assembly. Both the primary  60  and secondary  70  connection mechanisms can be selected from the wide variety of known mechanical type fasteners capable of repetitive attachment and detachment of components. A nonexhaustive list of such fasteners includes bolts, buckles, catches, clamps, clasps, hasps, latches, hook and loop tape, and the like. 
     Assembly and Use 
     For simplification purposes only, assembly, use and disassembly of a shipping container  10  in accordance with this invention shall be based upon the shipping container  10  depicted in  FIGS. 1 ,  2 ,  2 A and  2 B. 
     The shipping container  10  depicted in  FIGS. 1 ,  2 ,  2 A and  2 B can be rapidly assembled by (i) obtaining a pair of structural end panels  21  and a pair of structural sidewall components  22 , (ii) placing one of the structural end panels  21  onto a planar horizontal surface (not shown) with the interior major surface  21   i  of the selected end panel  21  facing upward to establish a bottom structural end panel  21   2 , (iii) placing both structural sidewall components  22 —pivoted into the three-dimensional use position—into orthogonal fitted engagement with the periphery of the interior major surface  21   i  of the bottom structural end panel  21   2  and into orthogonal fitted engagement with one another to define a payload retention chamber  19 , (iv) securing the structural sidewall components  22  together with the primary connection mechanisms  60  to form an encircling structural sidewall assembly, (v) securing the structural sidewall assembly to the bottom structural end panel  21   2  with the lower sets of secondary connection mechanisms  70 , (vi) placing the other structural end panel  21  over the open longitudinal end of the structural sidewall assembly in orthogonal fitted engagement with the structural sidewall components  22  to establish a top structural end panel  21   1 , and (vii) securing the top structural end panel  21   1  to the structural sidewall assembly with the upper sets of secondary connection mechanisms  70 . 
     Loading thermally labile goods (not shown) into an assembled shipping container  10  for transport includes the steps of: (a) detaching the top structural end panel  21   1  from the structural sidewall assembly by disengaging the upper sets of secondary connection mechanisms  70 , (b) removing the detached top structural end panel  21   1  from the structural sidewall assembly for providing access to the payload retention chamber  19 , (c) optionally lining the payload retention chamber  19  with thermally conditioned PCM panels  40 , (d) placing the payload of thermally labile goods (not shown) into the lined or unlined payload retention chamber  19 , (e) optionally covering the open top of the loaded payload retention chamber  19  with a thermally conditioned PCM panel  40 , (f) placing the top structural end panel  21   1  back over the open longitudinal end of the structural sidewall assembly, and (g) securing the top structural end panel  21   1  to the structural sidewall assembly with the upper sets of secondary connection mechanisms  70 . 
     Unloading thermally labile goods (not shown) from a shipping container  10  includes the steps of: (A) detaching the top structural end panel  21   1  from the structural sidewall assembly by disengaging the upper sets of secondary connection mechanisms  70 , (B) removing the detached top structural end panel  21   1  from the structural sidewall assembly, (C) removing any underlying PCM panel  40  for providing access to the payload retention chamber  19 , and (D) removing the payload of thermally labile goods (not shown) from the payload retention chamber  19 . 
     Knocking down an unloaded shipping container  10  for return transport includes the steps of (1) removing any PCM panels  40  still in the payload retention chamber  19 , (2) detaching the structural sidewall components  22  from one another by disengaging the primary connection mechanisms  60 , (3) detaching the structural sidewall components  22  from the bottom structural end panel  21   2  by disengaging the lower sets of secondary connection mechanisms  70 , and (4) removing the structural sidewall components  22  from the bottom structural end panel  21   2 .