COMPOSITE CONTAINER

Abstract

There is disclosed composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container. The thermally insulated inner container is configured to receive one or more phase change material (PCM) elements to define a payload enclosure. The one or more PCM elements are configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. The composite container can be used to ship temperature-sensitive payloads such as perishable goods (e.g., a COVID-19 vaccine such as the Moderna COVID-19 vaccine).

Claims

1. A composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure.

2. The container of claim 1, wherein one or both of the thermally insulated inner container and the thermally insulated outer container are made from a foam material.

3. The container of claim 2, wherein the foam material is selected from the group consisting of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyethylene (EPE), porous EPP and expanded PS/PE.

4. The container of claim 2, wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from a different foam.

5. The container of claim 2, wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from EPP.

6. The container of claim 2, wherein the foam material has a density of at least about 1.5 pcf.

7. The container of claim 1, wherein the inner container is separable from the outer container.

8. The container of claim 1, wherein at least one of the inner container and the outer container is integral.

9. The container of claim 1, wherein the inner container comprises an inner container lid element removably coupled to an inner container receptacle element.

10. The container of claim 1, wherein the inner container is shaped as a cube or rectangular cuboid.

11. The container of claim 1, wherein the outer container comprises a an outer container lid element removably coupled to an container receptacle element

12. The container of claim 1, wherein the outer container is shaped as a cube or rectangular cuboid.

13. The container of claim 1, wherein the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −25° C.

14. The container of claim 1, wherein one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −30° C.

15. The container of claim 1, comprising a plurality of phase change material (PCM) elements combining to define the payload enclosure.

16. The container of claim 15, wherein a first phase change material (PCM) element is configured to be in abutting relationship with a second phase change material (PCM).

17. The container of claim 15, wherein a first phase change material (PCM) element is configured to be in a detachably coupled relationship with a second phase change material (PCM).

18. The container of claim 1, wherein the phase change material (PCM) element comprises a rigid container have disposed therein a gel material.

19. The container of claim 1, wherein the container is configured to comply with ISTA 3A Test Procedure.

20. The container of claim 1 wherein the container is used to transport payload disposed in the payload enclosure from a shipping location to a destination location.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:

[0024] FIG. 1 is a perspective exploded view of a preferred embodiment of the present composite container; and

[0025] FIGS. 2A-2B and 3A-3B illustrate the result of testing preferred versions of the composite container illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] The present invention relates to a composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. Preferred embodiments of the present composite container may include any one or a combination of any two or more of any of the following: [0027] one or both of the thermally insulated inner container and the thermally insulated outer container are made from a foam material; [0028] the foam material is selected from the group consisting of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyethylene (EPE), porous EPP and expanded PS/PE; [0029] the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from a different foam; [0030] the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from EPP; [0031] the foam material has a density of at least about 1.5 pcf; [0032] the foam material has a density of at least about 1.6 pcf; [0033] the foam material has a density of at least about 1.7 pcf; [0034] the foam material has a density of at least about 1.75 pcf; [0035] the inner container is separable from the outer container; [0036] at least one of the inner container and the outer container is integral; [0037] the inner container comprises a an inner container lid element removably coupled to an inner container receptacle element. [0038] the inner container is shaped as a cube or rectangular cuboid; [0039] outer container comprises a an outer container lid element removably coupled to an container receptacle element; [0040] outer container is shaped as a cube or rectangular cuboid; [0041] the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −25° C.; [0042] the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −30° C.; [0043] the composite container comprising a plurality of phase change material (PCM) elements combining to define the payload enclosure; [0044] a first phase change material (PCM) element is configured to be in abutting relationship with a second phase change material (PCM); [0045] a first phase change material (PCM) element is configured to be in a detachably coupled relationship with a second phase change material (PCM); and/or [0046] the phase change material (PCM) element comprises a rigid container have disposed therein a gel material.

[0047] The present composite may be used to transport payload disposed in the payload enclosure from a shipping location to a destination location. The payload maybe a perishable product, preferably a pharmaceutical product, preferably a vaccine product such as product such as COVID-19 vaccine product (e.g., the Moderna vaccine described above).

[0048] The present composite container comprises a thermally insulated inner container disposed within a thermally insulated outer container. Preferably, one or both, more preferably both, of the thermally insulated inner container disposed and the thermally insulated outer container are made of foam.

[0049] Some details of preferred embodiments of the present composite container may be found in International Publication Number WO2016/008057A1.

[0050] In a preferred embodiment, the present composite container is configured to comply with ISTA 3A Test Procedure.

[0051] As is known in the art, Test Procedure 3A is a general simulation test for individual packaged-products shipped through a parcel delivery system. The test is appropriate for four different package types commonly distributed as individual packages, either by air or ground. The types include standard, small, flat and elongated packages. Basic Requirements: atmospheric pre-conditioning, random vibration with and without top load, and shock testing. The details of conducting Test Procedure 3A are available from ISTA.

[0052] The phase change material (PCM) element is generally known. A PCM will maintain the temperature of the payload at its stated phase change temperature while undergoing its solid/liquid phase transitions. A PCM will respond to the outside environmental temperature by absorbing or releasing heat as it changes state from solid to liquid and back. The process is reversible and repeatable while always maintaining the same temperature.

[0053] Preferably, the phase change material (PCM) element useful in the present composite container is in the form of a rigid container comprising a cooling gel. In a preferred embodiment, the rigid high-density polyethylene (HDPE) plastic container is sealed to prevent leakage and offers excellent resistance to compression and breakage. Durability also means the product is capable of being cleaned and refrozen for repeated use. It does not change shape when thawed or frozen, helping to prevent contents from shifting.

[0054] A preferred phase change material (PCM) element useful in the present composite container is commercially available from Rapid Aid under the tradename Temp Aid™.

[0055] With reference to FIG. 1, there a perspective exploded view of a preferred embodiment of the present composite container. In a first more preferred embodiment, the phase change material (PCM) elements are specified at −20° C. In a first more preferred embodiment, the phase change material (PCM) elements are specified at 5° C.

[0056] The product changes phase at the specified temperature to provide optimal thermal protection. When the adjacent temperature dips below the phase change temperature, the gel will solidify and release its stored energy. If the surrounding temperature goes above the phase change temperature, it will liquefy and absorb the excess energy.

[0057] The a composite container in accordance with the first more preferred embodiment was tested with a simulated payload (a compartmentalized water blanket modified to include three (3) thermocouples to measure the temperature at the top, middle and bottom of the simulated payload), together with a temperature probe in the product itself. This composite container was subjected to the ISTA 7D Test Procedure.

[0058] The results of the ISTA 7D Test Procedure are illustrated in FIG. 2a (ambient conditions) and FIG. 2b (payload temperature). As shown in the combination of FIGS. 2a and 2b, the composite container in accordance with the first more preferred embodiment was able to maintain the temperature of the top, middle and bottom of the payload deposited at −20° C. between −15° C. and −25° C. for least 48 hours when the composite container was placed in ambient conditions ranging from 22° C. to 35° C.

[0059] The a composite container in accordance with the second more preferred embodiment was tested with a simulated payload (a compartmentalized water blanket modified to include three (3) thermocouples to measure the temperature at the top, middle and bottom of the simulated payload), together with a temperature probe in the product itself. This composite container was subjected to the ISTA 7D Test Procedure.

[0060] The results of the ISTA 7D Test Procedure are illustrated in FIG. 3a (ambient conditions) and FIG. 3b (payload temperature). As shown in the combination of FIGS. 3a and 3b, the composite container in accordance with the second more preferred embodiment was able to maintain the temperature of the top, middle and bottom of the payload deposited at 5° C. between 2° C. and 8° C. for least 48 hours when the composite container was placed in ambient conditions ranging from 22° C. to 35° C.

[0061] The a composite container in accordance with the preferred embodiment illustrated in FIG. 1 was tested for ruggedness with a simulated payload (3.5 kg of sand split between two plastic bags). This composite container was subjected to the ISTA 3A Test Procedure. More specifically, the packaged-product was subjected to each of the following:

[0062] Atmospheric Pre-Conditioning 12 hrs Room Condition.

[0063] First Sequence Shock Test. Results: no puncture of package box (including inside the packaging) greater than 9 square inches or 10% of the damaged box surface, no failure of the tape or seal (include inside the packaging) and no any parts escape the package box.

[0064] Random Vibration with Dynamic Load—Over the Road Trailer Simulation. Results: No abnormality was observed externally on the packaged-product and inside containers of EPP and EPS after completion.

[0065] Random Vibration without Load—Pick-up and Delivery Vehicle Simulation. Results: No abnormality was observed externally on the packaged-product and inside containers of EPP and EPS after completion

[0066] Second Sequence Shock Test. Results: no puncture of package box (including inside the packaging) greater than 9 square inches or 10% of the damaged box surface, no failure of the tape or seal (include inside the packaging) and no any parts escape the package box.

[0067] In summary, the composite container in accordance with the preferred embodiment illustrated in FIG. 1 meet the requirements of the ISTA 3A Test Procedure.

[0068] While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.

[0069] All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.