Thermally insulated package

Abstract

A thermally insulating package comprises an outer shell (6) formed from a foam insulating material, a plurality of vacuum insulated panels (12) removably received on the walls of the outer shell (6) and a plurality of phase change material panels (18) arranged within the vacuum insulated panels (12) to define a payload space.

Claims

1. A thermally insulating package comprising: an outer shell having a first coefficient of thermal conductivity, the outer shell having walls, corner elements and an interior that includes a payload space, one or more of the walls of the outer shell having a pocket defined between two of the corner elements and bordered by an interior surface of the wall, each pocket having an open side opposite the interior surface of the wall, the open side facing the payload space; a plurality of insert panels having a second coefficient of thermal conductivity which is lower than the first coefficient of thermal conductivity, wherein each of the plurality of insert panels is received within a respective one of the pockets of the walls of the outer shell and the plurality of insert panels are arranged at least partially around a volume containing the payload space; and a plurality of phase change material (PCM) panels arranged within the volume that the plurality of insert panels are arranged at least partially around, each PCM panel being at least partially received within a respective one of the pockets, wherein each of the two corner elements that define a corresponding one of the pockets extend inward from the interior surface of the wall towards the payload space, and has a side surface facing the corresponding one of the pockets, and wherein both a corresponding one of the insert panels and a corresponding one of the PCM panels are received in a corresponding one of the pockets and are each at least partially located between the side surfaces of the two corner elements that the corresponding one of the pockets is defined between.

2. A thermally insulating package as claimed in claim 1, wherein the insert panels are removably received in the pockets.

3. A thermally insulating package as claimed in claim 1, wherein the outer shell is formed from a foam material.

4. A thermally insulating package as claimed in claim 3, wherein the foam material comprises expanded polystyrene (EPS), graphite impregnated EPS, EPS with a polyethylene additive, polyurethane (PUR) or polypropylene.

5. A thermally insulating package as claimed in claim 1, wherein the insert panels comprise vacuum insulated panels, each vacuum insulated panel having an encapsulated evacuated core.

6. A thermally insulating package as claimed in claim 1, wherein the insert panels are free of vacuum.

7. A thermally insulating package as claimed in claim 6, wherein the insert panel comprises polyurethane, a polyurethane based aerogel, or other Nano porous material.

8. A thermally insulating package as claimed in claim 1, wherein the insert panels are dimensioned such that they are received in the pockets with a push fit.

9. A thermally insulating package as claimed in claim 1, wherein the outer shell comprises a main body having a base wall and four or more side walls upstanding from the base wall, and a lid removably received on the main body.

10. A thermally insulating package as claimed in claim 9 wherein the main body is a unitary body.

11. A thermally insulating package as claimed in claim 1, wherein the pockets formed in one or more of the walls of the outer shell comprise a plurality of pockets formed in each of one or more walls of the outer shell.

12. A thermally insulating package as claimed in claim 1, wherein pockets are formed in all the walls and a lid of the outer shell.

13. A thermally insulating package as claimed in claim 12, wherein each of the pockets formed in the walls of the outer shell has an open upper end.

14. A thermally insulating package as claimed in claim 1, wherein each corner element comprises a corner column formed in the outer shell and the respective pockets are separated by the corner columns formed in the outer shell.

15. A thermally insulating package as claimed in claim 1, wherein the corner elements that define each of the pockets have side surfaces that define a pair of opposed sides of the pocket, and respective slots extending vertically along the opposed sides of the pocket.

16. A thermally insulating package as claimed in claim 1, wherein the walls of the outer shell comprise a base wall and a plurality of side walls that are fixed to each other in a unitary structure around the payload space.

17. A thermally insulating package as claimed in claim 1, wherein the walls of the outer shell comprise a plurality of side walls around the payload space, and wherein each corner element is fixed to each pair of adjacent walls in the plurality of side walls, and wherein each insert panel is separated from an adjacent one of the insert panels by one of the corner elements.

18. A thermally insulating package as claimed in claim 1, wherein each pocket has an open top and wherein each of the insert panels and PCM panels is removable from the pocket in which it is received, through the open top of the pocket.

19. A thermally insulating package as claimed in claim 1, further comprising a panel protection element arranged within each pocket, between the insert panel and the PCM panel received in the pocket.

20. A thermally insulating package as claimed in claim 1, wherein the insert panels and PCM panels are removably received within the pockets.

21. A thermally insulating package as claimed in claim 1, wherein the corner elements that define each of the pockets have side surfaces that define a pair of opposed sides of the pocket.

22. A thermally insulating package comprising: an outer shell formed from a foam insulating material, the outer shell having a plurality of walls around a payload space, and corner elements, the plurality of walls being fixed to each other as a single unitary structure; a plurality of thermal insulation panels removably received on the walls of the outer shell; and a plurality of phase change material (PCM) panels arranged within the thermal insulation panels to define the payload space; wherein the walls of the outer insulating shell are provided with respective pockets into which the thermal insulation panels and the PCM panels are received, each pocket is formed in a different respective one of the walls and is defined between two of the corner elements and bordered by an interior surface of the wall in which it is formed, each pocket has an open side opposite the interior surface of the wall, the open side facing the payload space, wherein each of the two corner elements that define a corresponding one of the pockets extend inward from the interior surface of the wall towards the payload space, and has a side surface facing the corresponding one of the pockets, and wherein both a corresponding one of the thermal insulation panels and a corresponding one of the PCM panels are received in a corresponding one of the pockets and are each at least partially located between the side surfaces of the two corner elements that the corresponding one of the pockets is defined between.

23. A thermally insulating package as claimed in claim 14, wherein each of the corner columns is arranged between a pair of the insert panels and between a pair of PCM panels, at a corner of the outer shell interior.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A preferred embodiment of the invention will now be described by way of example only with reference to the accompanying drawings in which:

(2) FIG. 1 is an exploded view of a package in accordance with the invention;

(3) FIG. 2 is an exploded view of the package of FIG. 1, partially assembled;

(4) FIG. 3 shows the package of FIG. 1 with its outer carton removed and ready for closing;

(5) FIG. 4 shows a perspective view of the outer shell of the package of FIG. 1;

(6) FIG. 5 is a top plan view of the outer shell shown in FIG. 4;

(7) FIG. 6 is a vertical cross section of the assembled outer shell and lid of the package of FIG. 1 with the internal components of the package removed;

(8) FIG. 7 is a perspective cross sectional view of the package;

(9) FIG. 8 shows an exploded view of the lid of FIG. 7;

(10) FIG. 9 shows the lid with the components mounted therein;

(11) FIG. 10 shows an assembled vacuum insulated panel and protection element;

(12) FIG. 11 shows a cross section through an alternative embodiment of the invention;

(13) FIG. 12 shows a cutaway view of another package in accordance with the invention; and

(14) FIG. 13 shows a PCM panel for use in an embodiment of the invention.

DETAILED DESCRIPTION

(15) With reference to FIG. 1, a package 2 in accordance with the invention is illustrated in an exploded view.

(16) The package 2 comprises an external container 4, in this case a simple corrugated cardboard box. Inside the external container 4 is provided an outer shell 6 (shown in cross section in FIG. 6) comprising a main body 8 (shown in FIG. 4) and a lid 10. The main body 8 and the lid 10 are moulded components formed from an insulating foam material such as expanded polystyrene (EPS), graphite impregnated EPS (e.g. Neopor), EPS with a polyethylene additive (e.g. Arcel), polyurethane (PUR) or polypropylene. Preferably the lid 10 and the main body 8 are made from the same foam material.

(17) Arranged within the outer shell are arrays of vacuum insulated panels 12, vacuum insulated panel protection elements 14, 16, PCM panels 18 and a payload container 20.

(18) As can best be seen from FIGS. 4 to 6, main body 8 is a unitary body and comprises a base wall 22 and four upstanding side walls 24. The base wall 22 is formed with a central, square sectioned, upwardly open pocket 26. Each side wall 24 is provided with a pocket 28. The top 30 and inwardly facing side of each side wall pocket 28 is open. The adjacent side wall pockets 28 are separated by generally square section corner posts 32 formed in the body of the outer shell. The pockets 26, 28 are preferably integrally moulded into the main body 8. A lip 34 projects upwardly around the upper edge of the main body 8, with platforms 36 being formed atop the corner posts 22.

(19) The opposed sides 38 of each side wall pocket 28 defined by the corner posts 32 are provided with slots 40 along their length. As best seen in FIG. 7, the base wall 22 is also provided with respective slots 42 aligned with the side wall slots 40 to form a generally U-shaped slot in each side wall 24. In addition, the back surface 44 of each side wall pocket 28 is formed with a shallow recess 46. The base wall 22 is also provided on one or more sides, preferably on two opposed sides, with recesses 48. The purpose of these various formations will be described further below.

(20) As will be best understood from FIG. 1, the base wall pocket 26 receives, from the bottom up, a square vacuum insulated panel 12, a square vacuum insulated panel protection element 16 and a square PCM panel 18. Although shown as square in this embodiment, the respective panels may be other shapes, for example rectangular, in other embodiments.

(21) The vacuum insulated panel 12 is preferably a slight push fit in the pocket 26 to firmly locate the panel 12. The vacuum insulated panel 12 is, as is are the other vacuum insulated panels 12 in the package, of a standard industry construction, namely an evacuated porous core for example of fumed silica encapsulated in an airtight film, more particularly a metallised foil film. The various vacuum insulated panels 12 are all of the same shape and size in this embodiment, but depending on the shape of the payload, the vacuum insulated panels 12 may be of different shapes and sizes.

(22) As illustrated in FIG. 1, the vacuum insulated panel protection element 16 is a square section of corrugated board material, for example E flute (2 mm) or B flute (3 mm) corrugated board material which may be coated on one or preferably both faces with a metallised foil film and/or a waterproof coating. This will protect the vacuum insulated panel 12 from the PCM panel 18 above.

(23) The PCM panel 18 in this embodiment is formed from a PCM material encapsulated in a plastics film. The particular PCM used will depend on the desired temperature for the payload, but in this embodiment it is tetradecane. This material has a phase change point of 4.5 C. making it suitable for a payload requiring a temperature range of 2-8 C. Other phase change materials, such as mixtures of salt hydrates, have phase change points ranging, depending on their composition, from 20 C. to +20 C.

(24) As can be seen from, for example, FIG. 2, the PCM panel 18 has a peripheral flange 50 which extends generally co-planar with one face of the PCM panel 18. This flange 50 is formed from the encapsulating film material of the PCM panel 18 and is formed during the PCM panel manufacturing process.

(25) The PCM panel 18 is preferably sized slightly smaller than the base wall pocket 26 such that there is sufficient space around the periphery of the PCM panel 18 to allow the flange 50 to flex upwardly as the PCM panel 18 is inserted into the pocket 26. This flange 50 will help locate the PCM panel in the pocket 26.

(26) The various PCM panels 18 of this embodiment are all of the same shape and size in this embodiment, but depending on the shape of the payload, the PCM panels 18 may be of different shapes and sizes.

(27) The recesses 48 provided in the base wall pocket 26 allow a user to insert his or her fingers under the vacuum insulated panel 12 and PCM panel 18 in order to remove the panel from the pocket 26.

(28) Turning to the side wall pockets 28, as can be seen from for example FIG. 3, these each receive, from back to front, a vacuum insulated panel 12, a vacuum insulated panel protection element 14 and a PCM panel 18.

(29) As discussed above, the vacuum insulated panel 12 and the PCM panels used in this embodiment are the same as those used in the base wall 22 and the lid 10. However, the vacuum insulated panel protection element 14 is different from those used in the base wall 22 and the lid 10. The vacuum insulated panel protection element 14 can be seem most clearly in FIG. 10 where it is shown in position around a vacuum insulated panel 12. The vacuum insulated panel protection element 14 is made from a corrugated board material, for example E (2 mm) flute or B (3 mm) flute corrugated board with a foil e.g. a metallised film, and/or waterproof plastics coating on one or preferably both sides. The element 14 has a first panel 52 which covers the front face 54 of the associated vacuum insulated panel 12 and extends beyond the lateral and bottom edges thereof. Hingedly attached to the first panel 52 is a second panel 56 which covers the upper edge 58 of the vacuum insulated panel 12. Hingedly attached to the second panel is a third panel 60 which extends over only an upper part of the rear face 62 of the vacuum insulated panel 12.

(30) The vacuum insulated panel protection element not only acts to protect the vacuum insulated panel 12 in situ in the package 2, but also facilitates its handling. Specifically, a user can fold the vacuum insulated panel protection element 14 around the vacuum insulated panel 12 and then grip the vacuum insulated panel 12 between the first and third panels 52, 60 for assembly of the vacuum insulated panel 12 into the package 2.

(31) Moreover, as can be seen from FIG. 5, for example, the vacuum insulated panel protection element 14 also acts to help retain the vacuum insulated panel 12 in the side wall pocket 28. The portion 64 of the vacuum insulated panel protection element 14 which projects beyond the vacuum insulated panel 12 engages in the slots 40 formed in the corner posts 32. The lower projecting part will engage in the slot 42 formed in the base wall 28. Thus, even though the vacuum insulated panel 12 may be a slight push fit in the side wall pocket 28, the vacuum insulated panel protection element also helps retain the vacuum insulated panel 12 in position.

(32) The vacuum insulated panel 12 and vacuum insulated panel protection element 14 may be assembled into the pocket 28 from the top of the pocket 28. Alternatively, they may be assembled consecutively. In that case the vacuum insulated panel 12 may be slid into the pocket 28 from above or pushed in from the open face of the pocket 28, and the vacuum insulated panel protection element 14 then slid into the slot 40.

(33) It will be understood that, when assembled, the third panel of the vacuum insulated panel protection element 14 is received within the recess 46 formed in the base wall of the pocket 28. The recess 46 is of substantially the same shape and depth as the third panel 60. This allows the major part of the rear surface 62 of the vacuum insulated panel 12 to closely engage the rear wall of the side wall pocket 28.

(34) The side wall pockets 28 also receive the PCM panels 18. It will be seen again from FIG. 5 that the peripheral flange 50 of the PCM panel 18 is received in the slots 40 formed in the corner posts 32. The lower edge of the flange 50 will be received in the base wall slot 42. This interengagement of the flange 50 within the slots 40, 42 helps retain the PCM panels 18 within its side wall pocket 28. In assembly, the PCM panel 18 may simply be slid into position from above.

(35) The PCM panels 18 are dimensioned such that after assembly they will lie generally flush with or project slightly beyond the faces of the corner posts 22.

(36) As can be understood from FIG. 5, when the base wall pocket 26 and side wall pockets 28 have been filled with the appropriate vacuum insulated panels 12, vacuum insulated panel protection elements 14, 16 and PCM panels 18, the payload container 20 may be placed in the payload space defined between the PCM panels 18. The corners of the payload container 20 may engage tips 64 of the corner posts 22 for location purposes. The payload container 20 is preferably of a board material, particularly a corrugated board material, which may be provided on one or preferably both surfaces with a foil, for example a metallised film coating and/or with a waterproof plastics coating, the latter to protect from any moisture which may accumulate in use.

(37) When the payload container is positioned within the payload space, the lid 10 of the package 2 may be fitted.

(38) The lid 10 is also moulded from a foam material, preferably the same foam material as the main body 8. As can be seen in FIG. 3 for example, it has opposed handle cut outs 70 and recesses 72 for receiving for example an RFID tag or other logging device. The external container 4 has handling openings aligned with the handle cut outs 70.

(39) As shown in FIGS. 7 to 9, the lid 10 has a depending land 76 which extends around its entire periphery and which locates within the lip 34 of the main body 8. The land 76 is provided with a relief groove 78 which receives the upwardly projecting flanges 50 of the PCM panels 18 mounted in the side wall pockets 28. The lid 10 also has a pocket 80 for receiving a vacuum insulated panel 12, vacuum insulated panel protection element 16 and PCM panel 18. The vacuum insulated panel 12 may be a tight fit within the pocket 80. The vacuum insulated panel protection element is the same as that provided in the base wall 22. The PCM panel 18 is sized such that the flange 50 thereof will fold inwardly as the PCM panel 18 is inserted into the pocket 80 whereby, as shown in FIG. 9, the flange 50 will tend to splay outwardly into the walls of the pocket 80 to assist in retaining the PCM panel 18 in the pocket. Specifically, the lower edge of the folded down flange 50 will tend to dig into the walls of the pocket 80 to provide resistance to the PCM panel falling out of the pocket 80.

(40) As illustrated in FIG. 6, the lid 10 is also provided with opposed recesses 82 which will allow a user to insert his or her fingers under the PCM panel 18 and the vacuum insulated panel 12 to facilitate their removal.

(41) With the lid 10 positioned on the main body 8, the external container 4 may be closed for shipping.

(42) It will be understood that after use, the package 2 may be reused, the PCM panels 18 being suitably reconditioned. The other components may be reused substantially as they are.

(43) The above description relates to just one embodiment of the invention. However, it will be appreciated that modifications may be made to that embodiment without departing from the scope of the invention.

(44) For example, as discussed above, the various panels need not be square but could be rectangular. Also, the package need not be cubic, but could be a rectangular cuboid in shape.

(45) Also, depending on the size of the container, the manufacture of the main body 8 may be simplified by forming it in two or more parts. Such an arrangement is illustrated in FIG. 11.

(46) In this construction the main body 8 is formed from a base part 8a and an annular upper part 8b. The base part 8a has an upstanding lip 82 which receives a depending lip 84 of the upper part 8b. The upper part 8b receives the lid 10 as in the earlier embodiment. The shapes of the pockets 26, 28, 80 are unchanged from the earlier embodiment and the same vacuum insulated panels 12, protection elements 14, 16 and PCM panels 18 are used. This construction is useful for larger packages where mould size restriction may not allow the full height of the main body 8 to be formed in a single operation.

(47) It will also be understood that more than one pocket 26, 28, 80 may be provided in one or more of the side walls 24, base wall 22 and lid 10. Such an embodiment is illustrated in FIG. 12.

(48) In this embodiment, each side wall 24 is provided with two side wall pockets 28, separated by a rib 90. Opposed faces of the rib 90 are provided with slots 92 for receiving the vacuum insulated panel protection element 14 and flanges 50 of the PCM panels 18. The base wall 24 and lid 10 are provided with four pockets 28, 80.

(49) Of course, the number of pockets provided on each wall may be varied to give a package of the desired dimensions. For example, if a rectangular container is required, the respective side walls 24 may each have different numbers of pockets 28.

(50) It will also be appreciated that each PCM panel 18 may contain more than one PCM element. For example two or more PCM elements may be received one above the other in the side wall pockets 28. To facilitate such a construction, a plurality of PCM elements may be mounted to a common support, as shown in FIG. 13.

(51) In this embodiment, two PCM elements 118, each having a peripheral flange 150, are mounted, e.g. bonded, to a support member 100. The support member 100 may be a sheet material such as cardboard, corrugated cardboard or corrugated plastics, and it has a peripheral flange 102 on at least one pair of opposed side edges which receive the flanges 150 of the PCM elements 118. This flange 102 may be received within the slots 40 provided in the side wall pockets 28 to assist in supporting the PCM elements 118.

(52) In a yet further modification, the materials of the outer shell 6 and the panels 12 may be chosen so as to provide a desired thermal conductivity. In particular, the insert panels 12 may be made from a material which has a lower coefficient of thermal conductivity than that of the outer shell 6.

(53) Thus the outer shell 6 may be made from expanded polystyrene (EPS) which typically has a thermal conductivity of about 0.036 W/m-K, graphite impregnated EPS (e.g. Neopor) which typically has a thermal conductivity of about 0.032 W/m-K, EPS with a polyethylene additive (e.g. Arcel) which typically has a thermal conductivity of about 0.038 W/m-K, or polyurethane (PUR) which typically has a thermal conductivity of about 0.022 W/m-K. In the case of an EPS based outer shell material, the insert panel 12 may be PUR which, as can be seen has a lower coefficient of thermal conductivity. In the case of any of the outer shell materials used, the insert panels 12 may be a Nano porous material such as BASF Slentite which typically has a thermal conductivity of about 0.016 W/m-K. A typical vacuum insulated panel will typically have a thermal conductivity of about 0.004 W/m-K. Thus the materials of the outer shell 6 and the thermal insulation insert panels 12 may be chosen to give the desired thermal conductivity.

(54) Such embodiments may use any of the constructional features described above, the only difference lying in the nature of the materials used.