CONTAINER FOR TRANSPORTING TEMPERATURE-CONTROLLED ITEMS

Abstract

A container for transporting materials in a temperature-controlled manner.

Claims

1. A container comprising: (a) an outer container including four sides and a bottom constructed from a self-reinforced composite material and/or self-reinforced polymer material; (b) an inner container including a vacuum packed insulative material; (c) said outer container comprising a single sheet of said self-reinforced composite material and/or self-reinforced polymer material with a plurality of tabs that overlap with a plurality of sides of said container; (d) wherein said outer container does not include any interior overlapping seams.

2. The container of claim 1 wherein said self-reinforced composite material and/or said self-reinforced polymer material is a woven thermoplastic composite material having a tape yarn construction.

3. The container of claim 1 wherein said self-reinforced composite material and/or said self-reinforced polymer material has a crystal extrusion.

4. The container of claim 1 wherein said self-reinforced composite material and/or said self-reinforced polymer material includes a multi-layer construction, with an outer layer having a melt point at a lower temperature than a core material sandwiched therein.

5. The container of claim 1 wherein said multi-layer construction results in a substantially rigid material.

6. The container of claim 1 wherein said self-reinforced composite material and/or said self-reinforced polymer material is constructed from a tape yarn construction having a tensile modulus of 10 GPa or more, a shrinkage at 130 degrees C. of 6% or less, a sealing temperature of 120 degrees C. or more, and a denier of 900 or more.

7. The container of claim 6 wherein said self-reinforced composite material and/or said self-reinforced polymer material has a thickness of less than 1.0 mm.

8. The container of claim 7 wherein said self-reinforced composite material and/or said self-reinforced polymer material has a density of greater than 800.

9. The container of claim 1 wherein said self-reinforced composite material and/or said self-reinforced polymer material has a tensile modulus GPa between 3 and 35.

10. The container of claim 6 wherein said self-reinforced composite material and/or said self-reinforced polymer material has a tensile strength MPA of greater than 100.

11. The container of claim 6 wherein said self-reinforced composite material and/or said self-reinforced polymer material has an edgewise notched Izod impact strength at 20 degrees C. (J/m) of greater than 100 and less than 6000.

12. The container of claim 1 wherein said plurality of tabs that overlap with said plurality of sides of said container are secured together using adhesive.

13. The container of claim 1 wherein said plurality of tabs that overlap with said plurality of sides of said container are secured together using heat.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0006] FIG. 1 illustrates a cardboard box.

[0007] FIG. 2 illustrates a cardboard box with an insulated thermal chamber therein.

[0008] FIG. 3 illustrates a protective chamber.

[0009] FIG. 4 illustrates a thermal isolation chamber panel.

[0010] FIG. 5 illustrates a sheet.

[0011] FIG. 6 illustrates the sheet partially folded.

[0012] FIG. 7 illustrates the right side of the folded sheet.

[0013] FIG. 8 illustrates the left side of the folded sheet.

[0014] FIG. 9 illustrates the back side of the folded sheet.

[0015] FIG. 10 illustrates the folded sheet being formed into a container.

[0016] FIG. 11 illustrates a front side of the sheet folded into the container.

[0017] FIG. 12 illustrates a back side of the sheet folded into the container.

[0018] FIG. 13 illustrates a right side of the sheet folded into the container.

[0019] FIG. 14 illustrates a left side of the sheet folded into the container.

[0020] FIG. 15 illustrates a bottom side of the sheet folded into the container.

[0021] FIG. 16 illustrates a top side of the sheet folded into the container.

[0022] FIG. 17 illustrates the container with a temperature sensor.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0023] Referring to FIG. 1, one manner of providing a thermal protection system for a temperature sensitive product includes a cardboard or a corrugated plastic box 100, that includes a set of upper flaps 110, 112, 114 that may be folded over to secure the top of the cardboard box 100.

[0024] Referring to FIG. 2, the thermal protection system may include an insulated thermal chamber 200. The insulated thermal chamber 200 may include a plurality of insulated panels, namely a bottom panel 210, a top panel 212, a left panel 214, a forward panel 216, a right panel 218, and a back panel 220. In combination, the panels 210, 212, 214, 216, 218, 220, form a closed chamber. Each of the panels may be a vacuum insulated panel consisting of a cell foam core material to which a vacuum is applied surrounded by a gas tight outer film. Each of the panels and outer film may be encased within a protective sleeve to help protect the gas tight outer film. Other insulated materials may likewise be used, such as for example, Styrofoam, if desired.

[0025] Referring to FIG. 3, a protective chamber 300 may be sized suitable to be maintained within the insulated thermal chamber 200. The protective chamber 300 may also include a corresponding lid sized to fit on top of the protective chamber 300. The protective chamber may be molded from plastic, or any other suitable material.

[0026] Referring to FIG. 4, one or more thermal isolation chamber panels 400 may be included, if desired. The thermal isolation chamber panel 400 includes phase change material therein, where the latent heat of going from a solid to a liquid phase provides extended temperature control. For example, for warm weather conditioning (outside temperature above 39 degrees F.), the panel may be placed in a 5 degrees F. to −22 degrees F. freezer for 8 hours until the panel is frozen. Then the panel is removed from the freezer to warm up to an operating temperature of 34 degrees F. by letting it stand at a room temperature of 71 degrees for approximately 15 minutes. The panel will them maintain that temperature within 5 degrees for several hours. For example, for cold weather conditioning (outside temperature below 34 degrees F.), the panel may be placed in a 39 degrees F. to 46 degrees F. refrigerator for 4 to 8 hours.

[0027] The thermal isolation chamber panel 400 is placed within the protective chamber 300 which is placed within the insulated thermal chamber 200 which is placed within the cardboard box 100. Alternatively, the thermal isolation chamber panel 400 is placed within the insulated thermal chamber 200 which is placed within a hard plastic high density polyethylene case or a roto-molded polypropylene based case.

[0028] In the case of blood, vaccines, food, breast milk, metals, and/or other products for transportation, a cold chain process is employed. The blood cold chain (including or alternatively other products) is a systematic process for the safe storage and transportation of blood from its collection from the donor to its administration to a patient who requires transfusion. It is referred to as a ‘cold chain’ because blood, being a biological substance, must be kept cold in order to reduce bacterial contamination and to prolong its life. Whole blood is warm when collected but must be cooled down to 4° C. and kept at this temperature until the point of transfusion. The purpose of a transfusion is to provide blood components that improve the hematological status of the patient. Whole blood can be used to yield various blood components. Most blood banks are able to separate red cells and plasma components. Some are able to prepare other products, such as platelet concentrates and cryoprecipitate. These products are often referred to as “wet products”. Other plasma products, generally referred to as plasma derivatives, can be extracted from plasma by a pharmaceutical process called plasma fractionation. All of these products have a specific benefit to the patient. However, in order for the blood component or plasma derivative to provide that benefit, it must be transfused in a viable state. Blood must be stored and transported in equipment that meets defined standards of performance, and by staff who correctly follow established procedures at all times.

[0029] One of the key aspects to such blood cold chain is the packing and transportation required to move blood components safely through the blood cold chain, and in particular, the packing for safely transporting the blood to the patient, which may be in a remote location, using a portable transportation box. By way of example, this may include a medic in a forward military location, a paramedic, and/or a fire fighter responding to a car wreck, who is carrying the blood in the portable transportation box for emergency usage. The blood should be maintained at a temperature range between 38 degrees F. to 40 degrees F., for 12 to 120 hours, for increased effectiveness.

[0030] In a harsh environment, the cardboard box 100 tends to get wet and soggy, substantially degrading its structural integrity. Also, the cardboard box 100 has a substantial likelihood of being damaged as a result of shipping. With a decreased structural integrity of the cardboard box 100, the insulated thermal chamber 200 tends to be prone to puncture. Upon being punctured, the insulated thermal chamber 200 loses its vacuum seal thus compromising its insulative characteristics. In the case of a hard plastic box made from high density polythene, it tends to be brittle with relatively low impact resistance, which again the insulated thermal chamber 200 tends to be prone to puncture. Roto-molded boxes tend to be strong but are excessively heavy and bulky.

[0031] With such boxes made from cardboard and high density polythene being unsuitable for hard environments to protect the integrity of the insulated thermal chamber 200, a different approach is desirable that provides sufficient impact resistance, relatively thin material suitable for being carried by a medic, provides sufficient puncture resistance, sufficiently flexible to absorb impact, strong enough to sufficiently resist compressive impacts, and sufficiently smooth so that the insulated thermal chamber 200 is not abraded, all of which provide protection to the insulated thermal chamber 200 to protect the blood therein in a cold chain environment.

[0032] Referring to FIG. 5, a preferred material includes a woven thermoplastic composite material, of a tape yarn construction, that provides impact resistance and stiffness while having a light weight. Some types of self-reinforced composites and/or polymers may use other types of construction, including for example, crystal extrusions, and traditional thread. The woven thermoplastic composite material preferably includes a multi-layer construction, with an outer layer preferably having a melt point at a lower temperature than a core material sandwiched therein. The multiple layers of the fabric are stacked together and heat and pressure is applied to form a substantially rigid, impact resistant, material. For example, a homogenous glue may be coated on a fiber or tape, and then the fire or tape is woven together, and then the layers of the fabric are composited through heat and pressure. Some types of the material, for example, may be constructed from a tape with a tensile modulus of 10 GPa or more, a shrinkage at 130 degrees C. of 6% or less, a sealing temperature of 120 degrees C. or more, and/or a denier of 900 or more. A single layer of the fabric preferably has a thickness of less than 1.0 mm. In general, self-reinforced polymeric materials (e.g., self-reinforced composite fabric) may be used, which may include one or more components, with the spatial alignment of the reinforcing phase in the matrix in 1D, 2D, or 3D.

[0033] By way of example, the woven thermoplastic composite material may start out a series of polypropylene (PP) films that form a tape yarn within a polymer matrix—for composite processing—before being woven into fabric. This is then pressed under heat and pressure to form a single piece approximately 0.005 inch (0.13 mm) that weighs just 0.02 lbs/sq.ft (0.11 kg/sq.Math.m). Multiple layers are added depending on the desired thickness. The multi-layers are melted together. From there, the sheet can be formed into a variety of shapes using heat and pressure, depending on the mold. The end result contains no fragment-producing glass, unlike carbon fiber or various glass type structures, has high impact resistance and retains strength from around +180 degrees F. down to −40 degrees F.

[0034] By way of example, the self-reinforced composite materials may include a density (kg/m3) of greater than 800, and more preferably greater than 900. By way of example, the self-reinforced composite materials may include a tensile modulus (GPa) between 3 and 35, and more preferably between 3 and 30. By way of example, the self-reinforced composite materials may include a tensile strength (MPa) of greater than 100, and more preferably greater than 125, and less than 500, and more preferably less than 400. By way of example, the self-reinforced composite materials may include an edgewise notched Izod impact strength at 20 degrees C. (J/m) of greater than 100 and less than 6000, and more preferably greater than 1250 and less than 5000. Also, hybrid SRC composite materials together with carbon or ultra-high molecular weight polyethylene (e.g., 3 to 8 million amu) may be used. By way of example, he UHMWPE powder grade GUR 4120 (molecular weight of approximately 5.0×106 g/mol) may be used to produce an isotropic part of the multilayered sample. The powder may be heated up to 180° C. at a pressure of 25 MPa in a stainless-steel mold to produce 80×10×2 mm3 rectangular samples, with fibers having an average diameter of 15 μm (e.g., 10-20 μm) and a linear density of 220 Dtex (e.g., 150-300 Dtex).

[0035] Rather than a case constructed from brittle material that tends to puncture the vacuum packed insulative material, a case constructed from glass based carbon fiber material that tends to puncture the vacuum packed insulative material, or otherwise a structurally collapsible cardboard that tends to degrade making the vacuum packed insulative material readily subject to damage, preferably a case constructed from a self-reinforced polymeric material is used which provides sufficient impact resistance, relatively thin material suitable for being carried by a medic, provides sufficient puncture resistance, sufficiently flexible to absorb impact, strong enough to sufficiently resist compressive impacts, and sufficiently smooth so that the insulated thermal chamber is not abraded during usage.

[0036] Referring again to FIG. 5, a single flat sheet 500 of self-reinforced polymeric material may be cut to have a pattern that is suitable to form an enclosure from the single flat sheet of self-reinforced polymeric material. The sheet 500 may include a pair of first sides 510A, 510B, and a pair of second sides 520A, 520B. The sheet 500 may include a bottom surface 530, a front surface 540, and a rear surface 550. The sheet 500 may include a pair of bottom flaps 560A, 560B. Referring to FIG. 6, FIG. 7, FIG. 8, and FIG. 9, the single flat sheet may be folded, preferably within a press, to fold the flaps 510A, 510B, 520A, 520B, 560A, 560B with respect to the central region 530, 540, 550.

[0037] Referring to FIG. 10, the sheet 500 may be folded so that the front surface 540 and the rear surface 550 are aligned with one another, and the first sides 510A, 510B and second sides 520A, 520B are overlapping with one another. The second sides 520A, 520B are preferably on the exterior of the first sides 510A, 510B, so that a smooth surface is maintained therein without seams. The bottom flaps 560A, 560B are preferably overlapping with the first sides 510A, 510B, so that a smooth surface is maintained therein without seams. The first sides 510A, 510B and the second sides 520A, 520B are adhered to one another, either with adhesive, or with sufficient heat and pressure to form a bond from the material itself. The bottom flaps 560A, 560A and the first sides 510A, 510B are adhered to one another, either with adhesive, or with sufficient heat and pressure to form a bond from the material itself. In this manner, the container is assembled without any interior seams that are likely to puncture the insulative material, and also provides sufficient protection for the insulative material from being punctured. The first sides 510A, 510B may further include hook and loop fabric 1000A, 1000B attached thereto to provide a handle or otherwise secure a lid thereon. Also, the container may include tabs for a locking, substantially waterproof, substantially airtight enclosure.

[0038] Referring to FIG. 11 (front view), FIG. 12 (back view), FIG. 13 (right side view), FIG. 14 (left side view), FIG. 15 (bottom view), and FIG. 16 (top view), is illustrated of the constructed container. The container may include a top flap, or otherwise a lid, if desired. The top flap and/or lid may be secured in any manner, such as a hook and loop strap, or a lock.

[0039] The overall system, that includes the thermal isolation chamber panel 400 placed within the protective chamber 300, if desired, placed within the insulated thermal chamber 200, placed within the self-reinforced polymeric material container may be used to ship blood test samples or other biologic materials, such as CV-19 samples, which reduces the likelihood of damage during transit.

[0040] The overall system, that includes the thermal isolation chamber panel 400 placed within the protective chamber 300, if desired, placed within the insulated thermal chamber 200, placed within the self-reinforced polymeric material container may be used to store breast milk shortly after pumping which reduces the likelihood of spoilage during the day.

[0041] Referring to FIG. 17, the overall system may further include an internal temperature sensor 1700 to track the internal temperature of the container over time. The temperature sensor 1700 may provide the current temperature and also provide the previous temperatures, so that the recipient can verify that the permitted range of temperatures has been maintained during transit. Other temperature sensors may likewise be used, as desired.

[0042] In another embodiment, the container is both sufficiently rugged and lightweight to be suitable for being delivered from a source location to a destination location using a flying vehicle, such as a drone with multiple rotating propellers. The container may be secured to the drone in a manner such that the container is not readily detachable, so that it will not be likely to fall during the flight from the source location to the destination location. The container should include a lid on the container, and in particular, the container should include a lid that is secured in some fashion, such as using a locking mechanism.

[0043] The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.