Patent Publication Number: US-7905075-B2

Title: Method of packaging thermally labile goods employing color-coded panels of phase change material

Description:
This application is a continuation of prior application Ser. No. 11/927,890 filed Oct. 30, 2007 and claims the benefit of U.S. Provisional Application No. 60/866,241, filed Nov. 17, 2006. 
    
    
     BACKGROUND 
     A wide variety of goods are thermally labile and therefore need to be maintained above and/or below a target temperature to prevent spoilage, decomposition, deactivation, transformation, conversion, breakdown, etc. Exemplary thermally labile goods include blood, blood products such as red blood cells (RCBs) and blood platelets, transplantable organs, biological tissue, vaccines, antigens, antibodies, bacteriological samples, immunoassays, pharmaceuticals, enzymes, and single-use chromogenic thermometers. 
     Transportation of thermally labile goods is particularly challenging, especially when the thermally labile goods must be maintained within a narrow temperature range. Numerous insulated shipping containers have been developed over the years, with those deploying a phase change material generally providing superior temperature control over extended periods. A nonexhaustive list of United States Patents and Published Patent Applications disclosing insulated shipping containers employing a phase change material include U.S. Pat. Nos. 4,145,895; 4,579,170; 4,923,077; 4,931,333; 5,626,936; 5,899,088; 6,209,343 and 6,718,776, and United States Patent Application Publications 2005/0188714; 2004/0079794; 2004/0079793 and 2002/0050147. 
     Insulated shipping containers employing a phase change material can be deployed for a wide range of thermally labile goods over a wide range of target temperatures by using different phase change materials. For example, H 2 O melts at 0° C., D 2 O melts at +4° C., a 20% ethylene glycol solution melts at −8° C. and a 50% ethylene glycol solution melts at −37° C. This permits use of insulted shipping containers for a broad range of thermally labile goods. However, packaging mistakes can occur when different thermally labile goods requiring use of different phase change materials are packaged at a single location, such as placement of thermally labile goods in an insulated shipping container charged with the wrong phase change material. 
     Accordingly, a substantial need exists for a straightforward, fool-proof system that ensures proper matching of thermally labile goods and phase change materials in an insulated shipping container. 
     SUMMARY OF THE INVENTION 
     The invention is a method of packaging thermally labile goods. The method includes the steps of: (a) obtaining a thermally insulated container defining a retention chamber, (b) obtaining thermally labile goods to be packaged, (c) obtaining a legend correlating some listed thermally labile goods with a first color and other listed thermally labile goods with a second color, (d) locating the thermally labile goods to be packaged on the legend and identifying the correlated color, (e) selecting thermally conditioned panels displaying the correlated color from a supply of thermally conditioned panels with some panels displaying the first color and other panels displaying the second color wherein the displayed color corresponds to the phase change temperature of the phase change material contained within the panels, (f) lining the retention chamber with the obtained thermally conditioned panels, (g) placing the thermally labile goods to be packaged into the lined retention chamber, and (h) closing the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is front view of one embodiment of an assembly and packaging area useful in practicing the invention with portions of the refrigeration units removed to facilitate viewing of the contents. 
         FIG. 2A  is a front view of one embodiment of a legend useful in practicing the invention. 
         FIG. 2B  is a front view of a second embodiment of a legend useful in practicing the invention. 
         FIG. 3  is a cross-sectional side view of one embodiment of a thermally insulated container useful in practicing the invention. 
         FIG. 4A  is a cross-sectional side view of the thermally insulated container of  FIG. 3  packaged with a first thermally labile good in accordance with the invention. 
         FIG. 4B  is a cross-sectional side view of the thermally insulated container of  FIG. 3  packaged with second and third thermally labile goods in accordance with the invention. 
         FIG. 4C  is a cross-sectional side view of the thermally insulated container of  FIG. 3  packaged with a fourth thermally labile good in accordance with the invention. 
     
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Nomenclature 
                                     10   Thermally Insulated Container        10t   Top of Container        19   Retention Chamber defined by Container        20   Outer Shell        20t   Top of Outer Shell        21   Cover Flaps for Top of Outer Shell        30   Insulating Panels        30t   Top Insulating Panel        40   Panels of Phase Change Material        40t   Top Panel of Phase Change Material        40 Red     Red Panels of First Phase Change Material        40 White     White Panels of Second Phase Change Material        40 Blue     Blue Panels of Third Phase Change Material        50   Phase Change Material       100   Legend       200   Thermally Labile Goods       201   First Type of Thermally Labile Goods       202   Second Type of Thermally Labile Goods       203   Third Type of Thermally Labile Goods       204   Fourth Type of Thermally Labile Goods       300   Computer       301   Central Processing Unit       302   Monitor       303   Keyboard       304   Mouse       400   First Refrigeration Unit for Thermally Labile Goods       401   First Refrigeration Chamber       402   Second Refrigeration Chamber       403   Third Refrigeration Chamber       404   Fourth Refrigeration Chamber       500   Second Refrigeration Unit for Panels of Phase Change Material       501   First Refrigeration Chamber       502   Second Refrigeration Chamber       503   Third Refrigeration Chamber       600   Work Table                    
Construction
 
     The invention is directed to a method of packaging thermally labile goods  200  in thermally insulated shipping containers  10  equipped with panels of phase change material  40  (hereinafter PCM panels) when the temperature range within which the thermally labile goods  200  must be maintained (hereinafter target temperature range) can vary from container  10  to container  10 . 
     The steady-state temperature maintained within the thermally insulated shipping container  10  can be adjusted to match the target temperature range of the thermally labile goods  200  by using PCM panels  40  containing different phase change materials. For example, PCM panels  40  containing frozen D 2 O provide a steady-state temperature at about +4° C. (the melt temperature of D 2 O), while PCM panels  40  containing frozen H 2 O provide a steady-state temperature at about 0° C. (the melt temperature of H 2 O), PCM panels  40  containing a frozen 20% ethylene glycol solution provide a steady-state temperature at about −8° C. (the melt temperature of a 20% ethylene glycol solution) and PCM panels  40  containing a frozen 50% ethylene glycol solution provide a steady-state temperature at about −37° C. (the melt temperature of a 20% ethylene glycol solution). 
     The method includes the preliminary steps of obtaining a thermally insulated container  10  defining a retention chamber  19 , and obtaining thermally labile goods  200  to be packaged. Substantially any thermally insulated container  10  configured and arranged for retaining thermally labile goods  200  and one or more PCM panels  40  are suitable for use in the present process. An exemplary thermally insulated container  10  comprising an outer cardboard shell  20  with cover flaps  21  over the top  20   t  of the shell  20 , and a lining of insulating panels  30  is depicted in  FIG. 3 . Other suitable thermally insulated containers  10  are described in U.S. Pat. Nos. 4,145,895; 4,579,170; 4,923,077; 4,931,333; 5,626,936; 5,899,088; 6,209,343 and 6,718,776, and United States Patent Application Publications 2005/0188714; 2004/0079794; 2004/0079793 and 2002/0050147. 
     In order to simplify the packaging process and limit the number of different items that need to be ordered and retained in inventory, it is generally desired to use the same thermally insulated containers  10  for packaging all of the various thermally labile goods  200  to be packaged at the particular location. 
     A wide variety of thermally labile goods  200  requiring storage within a given target temperature range are used across various industry segments ranging from blood to thermometers. A nonexhaustive list of thermally labile goods  200  which may be quickly, conveniently and reliably packaged using the method of this invention include blood, blood products such as red blood cells (RCBs) and blood platelets, transplantable organs, biological tissue, vaccines, antigens, antibodies, bacteriological samples, immunoassays, pharmaceuticals, enzymes, and single-use chromogenic thermometers. 
     For purposes of facilitating further discussion of the invention, the invention will be described in connection with the packaging of mythical thermally labile goods  200  identified simply as   and   (thermally labile goods having a target temperature of 4° C.),   and ΔΔΔ (thermally labile goods having a target temperature of 0° C.), and ⊙⊙⊙ and   (thermally labile goods having a target temperature of −20° C.). 
     The method includes the additional preliminary steps of obtaining a legend  100  correlating listed thermally labile goods  200  with a color (e.g., black or white), or color scheme (e.g., black and white stripes or red and yellow checkerboard pattern) based upon the target temperature of the thermally labile goods  200 . Exemplary legends  100  are depicted in  FIGS. 2A and 2B  wherein   and   (thermally labile goods  200  having a target temperature of 4° C.) are correlated to the color red,   and ΔΔΔ (thermally labile goods  200  having a target temperature of 0° C.) are correlated to the color white, and ⊙⊙⊙ and   (thermally labile goods  200  having a target temperature of −20° C.) are correlated to the color blue. The correlation may be represented in any suitable fashion with two acceptable representations shown in  FIG. 2A  (individually depicting each thermally labile good  200  with the correlated color or color scheme) and  FIG. 2B  (grouping thermally labile goods  200  by correlated color or color scheme). 
     The legend  100  may be made available in any desired form including printed hardcopy or electronic form. Referring to  FIG. 1 , hardcopy versions are inexpensive and permit posting of the legend  100  in appropriate locations around the packaging area, such as proximate the access doors (not numbered) on the various refrigeration units  400  and  500 , while electronic versions require access to a computer  300  but facilitate updating of the legend  100  and permit keyword searches to facilitate location of particular thermally labile goods  200  on the legend  100 . 
     Once the legend  100  has been obtained, the thermally labile goods  200  to be packaged can be located on the legend and the correlated color or color scheme identified. The identified color or color scheme indicates the color or color scheme of the PCM panel  40  to be deployed in the thermally insulted container  10  for the thermally labile goods  200 . The thermally conditioned PCM panels  40  of the correlated color or color scheme, containing a phase change material  50  providing the appropriate steady state temperature for the thermally labile goods  200  being packaged, can then be withdrawn from the appropriate refrigeration chamber  501 ,  502  or  503  and inserted into the retention chamber  19  of a thermally insulated container  10 . As shown in  FIGS. 4A ,  4 B and  4 C, the PCM panels  40  preferably line the retention chamber  19 . 
     The thermally labile goods  200  to be packaged can finally be placed into the retention chamber  19  and the container  10  closed. 
     EXAMPLES 
     Example 1 
     (Prophetic) 
     Referring to  FIG. 1 , a packaging area (unnumbered) is equipped with (i) a computer  300  including a central processing unit  301 , monitor  302 , keyboard  303  and mouse  304 , (ii) a first refrigeration unit  400  with three separate independently controlled refrigeration chambers  401 ,  402  and  403 , (iii) a second refrigeration unit  500  with three separate independently controlled refrigeration chambers  501 ,  502  and  503 , and (iv) a work table  600 . 
     As represented in  FIG. 1 , a supply of cardboard outer shells  20  and complimentary insulating panels  30  are provided in the work area. 
     Referring to  FIG. 1 , this facility currently ships four different thermally labile goods  201 ,  202 ,  203  and  204 . A supply of each of these thermally labile goods  201 ,  202 ,  203  and  204  is stored in the four refrigeration chambers  401 ,  402 ,  403  and  404  of the first refrigeration unit  400  respectively, with each refrigeration chamber  401 ,  402 ,  403  and  404  maintained within the target temperature range of the thermally labile goods stored therein. (i. e., the first refrigeration chamber  401  containing the first thermally labile good  201  ( ) maintained at 4° C., the second refrigeration chamber  402  containing the second thermally labile good  202  (ΔΔΔ) maintained at 0° C., and the third refrigeration chamber  403  containing the third thermally labile good  203  ( ) maintained at 0° C.) and the fourth refrigeration chamber  404  containing the fourth thermally labile good  204  ( ) maintained at −35° C.). 
     Referring to  FIG. 1 , in order to accommodate packaging of the four different thermally labile goods  201 ,  202 ,  203  and  204  shipped at the facility, three different PCM panels  40   Red ,  40   White  and  40   Blue  are stored in the three refrigeration chambers  501 ,  502  and  503  of the first refrigeration unit  500  respectively, with each refrigeration chamber  501 ,  502  and  503  maintained at a temperature below the freezing point of the phase change material  50  retained within the PCM panel  40  (i.e., the first refrigeration chamber  501  containing the red colored PCM panels  40   Red  filled with D 2 O phase change material  50  maintained at 2° C., the second refrigeration chamber  502  containing white colored PCM panels  40   White  filled with H 2 O phase change material  50  maintained at −2° C., and the third refrigeration chamber  503  containing the blue colored PCM panels  40   Blue  filled with a 40% solution of ethylene glycol phase change material  50  maintained at −40° C.). 
     An order is received to ship ten units of the first thermally labile good  201  ( ), six units of the second thermally labile good  202  (ΔΔΔ), three units of the third thermally labile good  203  ( ) and nine units of the fourth thermally labile good  204  ( ) to a single site. 
     The ordered thermally labile goods  200  are located on the legend  100  and the corresponding PCM panel color ascertain from the legend  100  as set forth below. 
     
       
         
           
               
               
             
               
                   
               
             
            
               
                 First Thermally Labile Good 201 (  ) 
                 Red PCM Panels 40 Red   
               
               
                 Second Thermally Labile Good 202 (ΔΔΔ) 
                 White PCM Panels 40 White   
               
               
                 Third Thermally Labile Good 203 (  ) 
                 White PCM Panels 40 White   
               
               
                 Fourth Thermally Labile Good 204 (  ) 
                 Blue PCM Panels 40 Blue   
               
               
                   
               
            
           
         
       
     
     Since the second  202  (ΔΔΔ)and third  203  ( ) thermally labile goods correlate to the same PCM panels  40 , they may be packaged together. Hence, three rather than four cardboard outer shells  20  are obtained, placed on the work table  600  and lined along the bottom (unnumbered) and four sides (unnumbered) with insulating panels  30  to form three thermally insulted containers  10  with open tops  10   t.    
     Thermally conditioned red PCM panels  40   Red  are obtained from the first refrigeration chamber  501  of the second refrigeration unit  500  and one of the thermally insulted containers  10  lined along the bottom and sides with the red PCM panels  40   Red  to form a first PCM lined thermally insulted container  10  with an open top  10   t . Ten units of the first thermally labile good  201  ( ) are withdrawn from the first refrigeration chamber  401  of the first refrigeration unit  400  and placed within the retention chamber  19  defined by the first PCM lined thermally insulted container  10  through the open top  10   t . A top PCM panel  40   t  (also red) and a top insulating panel  30   t  are sequentially placed over the open top  10   t  of the first PCM lined thermally insulated container  10  and the cover flaps  21  on the outer shell  20  closed. The finished container is depicted in  FIG. 4A . 
     In similar fashion, thermally conditioned white PCM panels  40   White  are obtained from the second refrigeration chamber  502  of the second refrigeration unit  500  and a second of the thermally insulted containers  10  lined along the bottom and sides with the white PCM panels  40   White  to form a second PCM lined thermally insulted container  10  with an open top  10   t . Six units of the second thermally labile good  202  (ΔΔΔ) and three units of the third thermally labile good  203  ( ) are withdrawn from the second refrigeration chamber  402  and third refrigeration chamber  403  of the first refrigeration unit  400  respectively, and placed within the retention chamber  19  defined by the second PCM lined thermally insulted container  10  through the open top  10   t . A top PCM panel  40   t  (also white) and a top insulating panel  30   t  are sequentially placed over the open top  10   t  of the second PCM lined thermally insulated container  10  and the cover flaps  21  on the outer shell  20  closed. The finished container is depicted in  FIG. 4B . 
     Lastly, thermally conditioned blue PCM panels  40   Blue  are obtained from the third refrigeration chamber  503  of the second refrigeration unit  500  and the last of the thermally insulted containers  10  lined along the bottom and sides with the blue PCM panels  40   Blue  to form a third PCM lined thermally insulted container  10  with an open top  10   t . Nine units of the fourth thermally labile good  204  ( ) are withdrawn from the fourth refrigeration chamber  404  of the first refrigeration unit  400  and placed within the retention chamber  19  defined by the third PCM lined thermally insulted container  10  through the open top  10   t . A top PCM panel  40   t  (also blue) and a top insulating panel  30   t  are sequentially placed over the open top  10   t  of the third PCM lined thermally insulated container  10  and the cover flaps  21  on the outer shell  20  closed. The finished container is depicted in  FIG. 4C .