COLD CHAIN BARRIER WALL PACKAGING SYSTEM

Abstract

A cold chain packaging system is disclosed that includes a first enclosure for receiving a payload, a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.

Claims

1. A cold chain packaging system comprising: a) a first enclosure constructed from a corrugated board material for receiving a payload, the first enclosure having an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material; b) a second enclosure constructed from a corrugated board material for receiving the first enclosure, the second enclosure having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material; c) a third enclosure constructed from a corrugated board material for receiving the second enclosure, the third enclosure having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material; and d) a fourth enclosure constructed from a corrugated board material for receiving a phase change material, the fourth enclosure having an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material, and wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.

2. The cold chain packaging system as recited in claim 1, wherein the first enclosure is adapted and configured to create a moat between the exterior surface of the first enclosure and the interior surface of the second enclosure for receiving a phase change material.

3. The cold chain packaging system as recited in claim 1, further comprising a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.

4. The cold chain packaging system as recited in claim 2, wherein the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.

5. The cold chain packaging system as recited in claim 4, wherein the first enclosure comprises integral support flanges extending outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.

6. The cold chain packaging system as recited in claim 3, wherein the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material, wherein the top and bottom trays both have interior and exterior surfaces, and wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.

7. The cold chain packaging system as recited in claim 6, wherein the interior surfaces of the top and bottom trays are lined with an insulating panel constructed from a foam core material.

8. The cold chain packaging system as recited in claim 6, wherein each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.

9. A cold chain packaging system comprising: a) a first enclosure for receiving a payload; b) a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material; c) a third enclosure for receiving the second enclosure; d) a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure; and e) a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.

10. The cold chain packaging system as recited in claim 9, wherein the first enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material.

11. The cold chain packaging system as recited in claim 9, wherein the second enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material.

12. The cold chain packaging system as recited in claim 9, wherein the third enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material.

13. The cold chain packaging system as recited in claim 9, wherein the fourth enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material.

14. The cold chain packaging system as recited in claim 9, wherein the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.

15. The cold chain packaging system as recited in claim 14, wherein the first enclosure comprises integral support flanges extending outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.

16. The cold chain packaging system as recited in claim 15, wherein the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material, wherein the top and bottom trays both have interior and exterior surfaces, and wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.

17. The cold chain packaging system as recited in claim 16, wherein the interior surface of the top and bottom trays is lined with an insulating panel constructed from a foam core material.

18. The cold chain packaging system as recited in claim 16, wherein each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.

19. A cold chain packaging system comprising: a) a first corrugated paper board blank for constructing a first enclosure for receiving a payload; b) a second corrugated board blank for constructing a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material; c) a third corrugated board blank for constructing a third enclosure for receiving the second enclosure; d) a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure; and e) a fourth corrugated board blank for constructing a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.

20. The cold chain packaging system as recited in claim 19, wherein each of the first corrugated board blank, the second corrugated board blank, the third corrugated board blank, and the fourth corrugated board blank has an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of at least one of the first corrugated board blank, the second corrugated board blank, the third corrugated board blank, and the fourth corrugated board blank is lined with a radiant barrier material.

21-38. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] So that those having ordinary skill in the art will readily understand how to make, assemble and use the cold chain packaging system subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to the figures wherein:

[0026] FIG. 1 is a fully exploded perspective view of the cold chain packaging system of the subject invention with all of the component parts thereof separated from one another for ease of illustration;

[0027] FIG. 2 is another exploded perspective view of the cold chain packaging system of the subject invention in a partially assembled condition;

[0028] FIG. 3 is yet another exploded perspective view the cold chain packaging system of the subject invention in a more fully assembled condition;

[0029] FIG. 4 is a perspective view the cold chain packaging system of the subject invention in a fully assembled condition;

[0030] FIG. 5 is a plan view of a blank for forming the first enclosure of the cold chain packaging system of the subject invention, which receives the payload;

[0031] FIG. 6 is a perspective view of the first enclosure in an open condition with the bottom panel separated from the enclosure;

[0032] FIG. 7 is a plan view of a blank for forming the second enclosure of the cold chain packaging system of the subject invention, which receives the first enclosure;

[0033] FIG. 8 is a perspective view of the second enclosure in an open condition;

[0034] FIG. 9 is a plan view of a blank for forming the fourth enclosure of the cold chain packaging system of the subject invention, which receives the phase change material and is positioned within the second enclosure above the first enclosure;

[0035] FIG. 10 is a perspective view of the fourth enclosure in an open condition;

[0036] FIG. 11 is a plan view of a blank for forming the top and bottom trays of the cold chain packaging system of the subject invention, which secures the second enclosure;

[0037] FIG. 12 is a perspective view of the insulating panel for lining the top and bottom trays;

[0038] FIG. 13 is an exploded perspective view of a tray with the insulating panel separated therefrom for ease of illustration;

[0039] FIG. 14 is a perspective view of a tray with the insulating panel installed therein;

[0040] FIG. 15 is a plan view of a blank for forming the third enclosure of the cold chain packaging system of the subject invention, which receives the second enclosures;

[0041] FIG. 16 is a perspective view of the second enclosure in an open condition; and

[0042] FIG. 17 is a perspective view of one of the spaced blocks shown in FIG. 3 that is used to encapsulate the second enclosure within the third enclosure to create a void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] Referring now to the drawings wherein like reference numerals identify similar structural features or elements of the subject invention, there is illustrated in FIGS. 1-4, the cold chain packaging system of the subject invention, which is designated generally by reference numeral 10. Packaging system 10 is adapted and configured to shipping and storing a payload at ultra-low temperatures, such as, for example, pharmaceutical products.

[0044] The packing system 10 includes a first or innermost enclosure 12 constructed from a corrugated board material for receiving a payload of a vaccine or other pharmaceutical product. An exemplary pharmaceutical payload might include several stacked trays of vials, with each tray holding up to 195 multiple dose vials. The first enclosure 12 has an interior surface 14 and an exterior surface 16, wherein the exterior surface 14 of the first enclosure 12 is lined with a radiant barrier material, as best seen in FIG. 6. It is envisioned however that both the interior and exterior surfaces 14, 16 of the first enclosure 12 could be lined with the radiant barrier material.

[0045] A used herein, the term “corrugated board” for use in the packaging system 10 of the subject invention shall be understood to refer to and include corrugated packaging material that is made from corrugated containerboard, paperboard, cardboard, fiberboard or the like. As used herein, a suitable “radiant barrier material” for use in the packaging system 10 of the subject invention is manufactured by WestRock and is marketed under the tradename InsulShield™ system, which uses fiber-based corrugated board for strength and durability and added Met-PET (metalized polyester) laminated liners and inserts to provide steady temperature maintenance.

[0046] The packaging system 10 further includes a second or intermediate enclosure 22 constructed from a corrugated board material for receiving the first enclosure 12. The second enclosure 22 is designed to be sift resistant and it has an interior surface 24 and an exterior surface 26, wherein the interior and exterior surfaces of the second enclosure 22 are both lined with a radiant barrier material, as best seen in FIG. 8. The packaging system 10 includes a third or outermost enclosure 32 that is constructed from a corrugated board material for receiving the second enclosure 22. The third enclosure 32 is also designed to be sift resistant and it has an interior surface 34 and an exterior surface 36, wherein the interior and exterior surfaces of the third enclosure 32 are both lined with a radiant barrier material, as best seen in FIG. 16.

[0047] The packaging system 10 includes a fourth enclosure 42 constructed from a corrugated board material for receiving a phase change material, such as, for example, dry ice in a pelletized or granulated form. It is envisioned that the fourth enclosure 42 would be dimensioned and configured to store approximately 10 kg of pelletized or granulated dry ice.

[0048] As best seen in FIG. 10, the fourth enclosure 42 has an interior surface 44 and an exterior surface 46, wherein the interior surface 44 of the fourth enclosure 42 is lined with a radiant barrier material, and wherein the fourth enclosure 42 is dimensioned and configured to be received within the second enclosure 22 positioned above the first enclosure 12. The radiant barrier material on the interior surface 44 of the fourth enclosure serves to retard the rate at which the dry ice stored therein will sublimate.

[0049] Preferably, the first enclosure 12 is adapted and configured to create a moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 for receiving a phase change material, such as, for example, pelletized or granulated dry ice, as described in more detail below. The packaging system 10 further includes a plurality of plastic spacer blocks 50 for encapsulating the second enclosure 22 within the third enclosure 32 to create a void barrier or insulating air gap between the exterior surface 26 of the second enclosure 22 and the interior surface 34 of the third enclosure 32. The void barrier or air gap functions to advantageously mitigate heat transfer from the second enclosure 22 to the ambient environment. It is envisioned that the spaced blocks 50 could be constructed from a different structural material, such as a foam core material or the like.

[0050] As best seen in FIG. 6, the first enclosure 12 is defined by a rectangular sleeve 13 having an integral top closure panel 15 and a separate bottom closure panel 17. The bottom closure panel 17 is supported within the rectangular sleeve 13 by a plurality of inwardly projecting integral corner tabs 18. The first enclosure 12 also includes a plurality of integral support flanges 19 that extend outwardly from a bottom end thereof to center the first enclosure 12 within the second enclosure 22 and to define the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22.

[0051] As noted above, the moat is deigned to receive a phase change material, such as, for example, pelletized or granulated dry ice. In this regard, approximately 1 kg of pelletized dry ice can be stored in the moat, and in the cavity created within the first enclosure 12 beneath the separable bottom panel 17. The radiant barrier material that delimits the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 serves to advantageously retard the rate at which the dry ice stored therein will sublimate.

[0052] As best seen in FIG. 13, the second enclosure 22 is defined by a rectangular sleeve 23 that is secured between a top tray 60 constructed from a corrugated board material and a bottom tray 70 that is constructed from a corrugated board material. The top and bottom trays 60, 70 both have interior and exterior surfaces, i.e., surfaces 62, 64 and 72, 74, respectively. The exterior surfaces 64, 74 of the top and bottom 60, 70 trays are each lined with a radiant barrier material. The top and bottom trays 60, 70 are preferably friction fit on to the upper and lower portion of the second enclosure 22 during assembly of the packaging system 10 and they serve to secure and seal the upper and lower end of the second enclosure 22.

[0053] In addition, an interior surfaces 62, 72 of the top and bottom trays 60, 70 are each lined with an insulating panel 80 constructed from a foam core material, such as for example, styrene or a similar material, as best seen in FIG. 14. The foam core panels 80 lining the top and bottom trays 60, 70 help to seal the upper and lower end portions of the second enclosure 22 and provide a cushion for impact and shock resistance during transit and storage.

[0054] Preferably, each of the plurality of spacer blocks 50, which are best seen in FIG. 17, is adapted and configured to engage a respective corner of the top and bottom trays 60, 70 to create the void barrier between the exterior surface 26 of the second enclosure 22 and the interior surface 34 of the third enclosure 32 to mitigate heat transfer from the second enclosure 22.

[0055] Referring now to FIGS. 5 and 6, the first enclosure 12 is constructed from a first corrugated paper board blank 112, wherein the exterior surface of the first blank 112 is lined with a radiant barrier material. The first blank 112 is of the style commonly referred to as a tuck top blank, which includes four primary side panels 11a-11d that are configured to form the rectangular sleeve structure 13 of the first enclosure 12, the integral top closure panel 15 and the separable bottom closure panel 17. A glue flap 11e extends outwardly from the side panel 11d of blank 112 for constructing the rectangular sleeve 13 of the first enclosure 12.

[0056] A plurality of inwardly projecting integral corner tabs 18a-18c are formed in the first blank 112, between adjoining side panels to support the bottom closure panel 17 within the rectangular sleeve 13. The first blank 112 further includes plurality of integral support flanges 19a-19d that extend outwardly from a bottom end thereof to center the first enclosure 12 within the second enclosure 22 and to define the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22.

[0057] Referring to FIGS. 7 and 8, the second enclosure 22 is constructed from a second corrugated board blank 122, wherein the interior and exterior surfaces of the second blank 122 are lined with a radiant barrier material. The second blank 122 is of the type commonly referred to as a CSSC blank, which includes four primary side panels 21a-21d that are configured to form the rectangular sleeve structure 23 of the second enclosure 22. A glue flap 21e extends outwardly from the side panel 21d of blank 122 for constructing the rectangular sleeve 23 of the second enclosure 22.

[0058] Referring to FIGS. 9 and 10, the fourth enclosure 42 is constructed from a fourth corrugated board blank 422, wherein the interior surface of the fourth blank 422 is lined with a radiant barrier material. The fourth blank 422 is of the type commonly referred to as a 2-sided roll over with a cherry tuck top blank.

[0059] Referring to FIGS. 11-14, the top and bottom trays 60 and 70 are constructed from identical corrugated board blanks designated generally by reference numeral 522, shown in FIG. 11, wherein the exterior surfaces of these blanks 522 are lined with a radiant barrier material. The foam core insulating panel 80 for lining the interior surfaces of the top and bottom trays 60 and 70 is illustrated in FIGS. 12 and 13.

[0060] Referring now to FIGS. 15 and 16, the third or outermost enclosure 32 is constructed from a third corrugated board blank 322, wherein the interior and exterior surfaces of the third blank 322 are lined with a radiant barrier material. The third blank 322 is also of the type commonly referred to as a CSSC blank, which includes four primary side panels 31a-31d that are configured to form the rectangular sleeve structure 33 of the third enclosure 32. A glue flap 31e extends outwardly from the side panel 31d of blank 322 for constructing the rectangular sleeve 33 of the second enclosure 32.

[0061] To assemble cold chain packaging system 10 of the subject invention, the first enclosure 12 is constructed from the corrugated board blank 122, the second enclosure 22 is constructed from the corrugated board blank 222, third enclosure 32 is constructed from the corrugated board blank 322 and the fourth enclosure 42 is constructed from the corrugated board blank 422. Then the top and bottom trays 60 and 70 are constructed from two corrugated board blank 522.

[0062] Thereafter, the first enclosure 12 is centered within the second enclosure 22, the fourth enclosure 42 is positioned above the first enclosure 12 within the second enclosure 22, the top and bottom trays 60 and 70 are both lined with foam core inserts 80, and then the top and bottom trays 60 and 70 are secured to the top and bottom portions of the second enclosure 22 by a friction fit. At such a time, the second enclosure 22 is encapsulated within the third enclosure 32 using a plurality of corner blocks 50 to create a void barrier between an exterior surface of the second enclosure 22 and an interior surface of the third enclosure 32.

[0063] The method also includes the steps of loading a payload into the first enclosure 12, storing a phase change material in the moat between the exterior surface of the first enclosure 12 and the interior surface of the second enclosure 22, and storing a phase change material in the fourth enclosure 42. The method can also include the steps of replenishing the phase change material in the moat between the exterior surface of the first enclosure 12 and the interior surface of the second enclosure 22 after a period of time, and replenishing the phase change material in the fourth enclosure 42 after a period of time.

[0064] While the cold chain packaging system of the subject disclosure has been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.