Thermally insulated VIP sandwich shipper

Abstract

A thermally insulated VIP sandwich shipper for a temperature sensitive payload is provided. The shipper comprises an outer shell, an inner shell and vacuum insulated panels sandwiched therebetween. The outer shell and the inner shell may be unitary rigid structures made of an expanded foam material and comprising a bottom having a perimeter and sides extending from the bottom perimeter and terminating in a rim. The inner shell rim may be spaced from the outer shell rim to define a gap, the gap being sealed to create an enclosed space within which the vacuum insulated panels are located. Each vacuum insulated panel may be oriented substantially orthogonally to at least one adjacent vacuum insulated panel and have an edge that abuts the adjacent vacuum insulated panels.

Claims

1. A packaging system for shipping a temperature sensitive payload, the packaging system comprising: a rigid unitary outer shell made of an expanded foam material and comprising a bottom having an upper facing surface and a perimeter and four sides extending from the bottom perimeter and terminating in a rim, the outer shell having a first R value, the outer shell defining an interior; a rigid unitary inner shell made of an expanded foam material and located within the outer shell interior, the inner shell comprising a bottom having a perimeter and sides extending from the bottom perimeter and terminating in an inner shell rim, the inner shell having a second R value, the outer shell and the inner shell defining an enclosed space; and a vacuum insulation panel housing comprising a bottom vacuum insulation panel and four individual side vacuum insulation panels, the vacuum insulation panel housing being completely encapsulated within the enclosed space between the outer shell and the inner shell, each vacuum insulation panel having a third R value greater than the R values of the outer shell and the inner shell, each of the bottom vacuum insulation panel and four side vacuum insulation panels comprising a rigid, highly-porous core surrounded by an enclosure, wherein: each vacuum insulation panel comprises four peripheral edges; and the vacuum insulation panels are wedged against each other so that at least one peripheral edge of each side vacuum insulation panel directly contacts an adjacent vacuum insulation panel.

2. The packaging system of claim 1 wherein: the inner shell has a lip extending outwardly from the inner shell rim; the bottom vacuum insulation panel covers the entire upper facing surface of the outer shell bottom; and each side vacuum panel has a bottom edge that abuts the bottom vacuum insulation panel and a top edge that abuts the inner shell.

3. The packaging system of claim 1 wherein the outer shell, inner shell and vacuum insulation panels define a box, the packaging system further comprising: a lid that fits onto the box.

4. The packaging system of claim 3 wherein the box and lid together define a payload compartment.

5. The packaging system of claim 4 wherein the lid comprises: a vacuum insulated panel sealed between an outer panel and a bottom panel.

6. The packaging system of claim 1 wherein: the vacuum insulated panels occupy the entire enclosed space between the outer shell and the inner shell.

7. The packaging system of claim 1 wherein: the outer shell and the inner shell are sealed together along a perfect seal line.

8. A packaging system comprising: a container comprising a unitary outer shell, a unitary inner shell, a bottom vacuum insulation panel and four side vacuum insulation panels; the unitary rigid outer shell made of an expanded foam material and comprising a bottom and four sides extending upward from the bottom; the unitary rigid inner shell made of an expanded foam material and comprising a bottom and four sides extending upward from the bottom; the outer shell and the inner shell defining a box-shaped space therebetween; the bottom vacuum insulation panel and the four individual side vacuum insulation panels forming a five sided housing located within the box-shaped space, each of the bottom vacuum insulation panel and four side vacuum insulation panels comprising a rigid, highly-porous core surrounded by an enclosure, the vacuum insulated panels occupying the entire box-shaped space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an exploded perspective view of a thermally insulated VIP sandwich shipper according to the invention.

(2) FIG. 2 is an exploded perspective view of the lid of the thermally insulated VIP sandwich shipper of FIG. 1.

(3) FIG. 3 is a perspective view of the thermally insulated VIP sandwich shipper of FIG. 1 shown assembled.

(4) FIG. 4 is a cross-sectional view of the thermally insulated VIP sandwich shipper of FIG. 3 taken along line 4-4.

(5) FIG. 5 is a cross-sectional view of the thermally insulated VIP sandwich shipper of FIG. 3 taken along line 5-5.

(6) FIG. 6 is a schematic diagram showing a method of making the thermally insulated VIP sandwich shipper of FIG. 1.

(7) FIG. 7 is a graph comparing the thermal performance of a VIP sandwich shipper according to the disclosure to a PUR shipper for a winter ambient profile.

(8) FIG. 8 is a graph comparing the thermal performance of a VIP sandwich shipper according to the disclosure to a PUR shipper for a summer ambient profile.

(9) FIG. 9 is a schematic diagram showing an alternative (automated) method of making the thermally insulated VIP sandwich shipper of FIG. 1.

(10) FIG. 10 is an exploded view of a molding assembly such as might be used to create the box portion of the thermally insulated VIP sandwich shipper of FIG. 1 via an automated process.

DETAILED DESCRIPTION OF THE INVENTION

(11) While this invention may be embodied in many forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that this disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the illustrated embodiments.

(12) The Thermally Insulated VIP Sandwich Shipper

(13) Turning to the drawings, there is shown in the figures one embodiment of the present invention, a thermally insulated VIP sandwich shipper for temperature sensitive products. As best shown in FIG. 1, the thermally insulated VIP sandwich shipper 10 comprises an outer shell 12, an inner shell 14 and one or more panels of insulation material such as vacuum insulated panels (VIPs) 16 located (“sandwiched”) between the outer and inner shells 12, 14. Together the outer shell 12, inner shell 14 and VIPs 16 form a box or carton 22 onto which a lid 18 can be fitted to form the shipper 10. The box 22 and lid 18 together define a payload compartment 20.

(14) The outer shell 12 may be made of expanded foam (such as EPS, EPP, EPS/PE) or other suitable insulative material and is basically in the shape of an open topped box. The outer shell may comprise a bottom 24 and four sides 26 extending upward from the periphery of the bottom 24 and terminating in a rim 28.

(15) Likewise, the inner shell 14 may be made of expanded foam (such as EPS, EPP, EPS/PE) or other suitable insulative material and is basically in the shape of an open topped box, albeit smaller than the outer shell 12 so that the inner shell 14 can nest within the outer shell 12, leaving a gap therebetween for accommodating the VIP panels 16. The inner shell 14 may comprise a bottom 32 and four sides 34 extending upward from the periphery of the bottom 32 and terminating in a rim 36.

(16) In the assembled shipper 10, the VIP panels 16 are located between the nested outer and inner shells 12, 14, which protects the VIP panels 16 from punctures or tearing. Preferably the VIP panels 16 are wedged against each other together so that the edge 40 of one VIP panel 16 abuts an adjacent VIP panel 16, thereby reducing or eliminating edge leaks. A sealant may be applied along the top rim of the shipper 10 between adjoining faces of the outer shell 12 and inner shell 14 to seal off the VIP panels 16 so they are completely enclosed. Alternatively, the lid 18 may be used to seal off the VIP panels 16 so they are completely enclosed. In yet another alternative, the outer shell 12 and inner shell 14 are sealed together along a perfect seal line 58 during the molding process.

(17) FIG. 2 is an exploded perspective view of a lid 18 for use with the thermally insulated VIP sandwich shipper 10 of FIG. 1. The lid 18 may comprise a VIP panel 16 sandwiched between a top or outer panel 42 and a bottom or inner panel 44. The VIP panel 16 may be completely enclosed in the assembled lid 18 to prevent puncturing or tearing of the VIP panel 16.

(18) FIG. 3 is a perspective view of an assembled thermally insulated VIP sandwich shipper 10. The VIP panels 16 surround the payload compartment 20 on at least one and as many as six sides but cannot be seen in FIG. 3.

(19) FIG. 4 is a cross-sectional view of the thermally insulated VIP sandwich shipper 10 of FIG. 3 taken along line 4-4. The VIP panels 16 are wedged between the outer panel 12 and the inner panel 14, preferably so that there is no space between the VIP panels 16 and the outer shell 12 or inner shell 14. In other words, the VIP panels 16 occupy the entire gap or void between the outer shell 12 and the inner shell 14. Preferably the vertical edges 40 of each VIP side panel 16 abut any orthogonally adjoining VIP side panels 16.

(20) FIG. 5 is a cross-sectional view of the thermally insulated VIP sandwich shipper 10 of FIG. 3 taken along line 5-5. Preferably the VIP side panels 16 extend from the VIP bottom panel 16 adjacent the outer shell bottom 24 to the top rim 36 of the inner shell 14.

(21) The thermally insulated VIP sandwich shipper 10 may be used to package and ship temperature sensitive products. Typically these products have a specified or required temperature range that must be maintained during a specific shipping duration and while the thermally insulated VIP sandwich shipper is subject to various ambient temperature conditions. For example, a product may be expected to be shipped for 120 hours and be exposed to ambient temperatures of between −20 C and 45 C (−4 F and 113 F), but have a temperature tolerance of between 0 C and 15 C (32 F and 59 F). A thermally insulated VIP sandwich shipper according to the present disclosure may be designed to accommodate these requirements.

(22) Method of Making the Thermally Insulated VIP Sandwich Shipper

(23) FIG. 6 is a schematic diagram showing a method of making a thermally insulated VIP sandwich shipper 10. The thermally insulated VIP sandwich shipper 10 may be made using a steam chest molding machine to mold the expanded foam components s explained further below. The shipper 10 can also be constructed using individual panels of expanded polystyrene foam (EPS) or any other suitable thermally insulated panels including but not limited to extruded polystyrene (XPS).

(24) Construction of the Box

(25) The method of making the thermally insulated VIP sandwich shipper 10 may comprise the following steps:

(26) Step 100: Mold the EPS outer shell 12 on a steam chest molding machine.

(27) Step 102: Mold the inner EPS shell 14. This can be done on the same steam chest molding machine as was used to make the outer shell 12 (by using two different cavities) or on a different machine.

(28) Step 104: Bring the outer shell from step 100 to the next work station and insert five (5) VIP panels (one for each of the four sides 26 of the outer shell 12 and one for the bottom 24) into the outer shell 12 so that the edges 40 of each VIP panel are pressed against the adjacent VIP panel 16 as shown in FIGS. 4 and 5. The VIP panels 16 are flexible and have resilience. They can be press fitted against each other and against the outer shell 12 and inner shell 14 to minimize or eliminate edge leaks.

(29) Step 106: Slide the inner shell from step 102 into the outer shell assembly from step 104 (with VIP panels 16 along the four sides and bottom).

(30) Step 108: Once both the inner shell 14 and the outer shell 12 have been combined to form the box 22, apply a bead of sealant between the adjoining faces of the inner shell 14 and the outer shell 12 near their respective rims.

(31) This method of manufacture minimizes or eliminates edge leaks because the VIP panels 16 are wedged between the molded foam walls of the outer shell 12 and the inner shell 14 and are secured therebetween. After step 106, pressure may be applied to further press the VIP panels 16 against the walls of the outer shell 12 and the inner shell 16, thus eliminating edge leaks all together. The VIP's 16 will be protected and will be completely invisible (hidden) between the walls of the outer shell and the inner shell 14.

(32) Construction of the Lid

(33) Step 110: Mold the outer (top) panel 44 and the inner (bottom) panel 46 of the lid 18.

(34) Step 112: Insert a VIP panel 16 into the outer panel 44 and assemble all three pieces as shown in FIG. 2.

EXAMPLES

(35) As the following examples show, the thermally insulated VIP sandwich shipper may have thermal characteristics superior to those of conventional polyurethane (PUR) shippers.

(36) Case Study 1—Box Size, Weight and Thermal Comparison

(37) In case study 1, a reduction in container size of 40% was achieved while improving system insulation value (R value) by 55% and reducing weight by 40%. These improvements resulted in a VIP sandwich shipper that is easy to pack, lower in weight and has better thermal performance.

(38) TABLE-US-00001 TABLE 1 Shipper Shipper Shipper VIP PUR EPS Box size R value weight Type Thickness Thickness Thickness Box Size, Inches reduction improvement reduction PUR Not 3 inch Not 22.75 × 20.25 × 19.75 shipper Present PUR wall Present Shipper 0.5 inch Not 2 inch 21 × 18.5 × 14 40% 55% 35-40% according Present to the disclosure

(39) Case Study 2—Winter Ambient Profile Performance

(40) In case study 2, a VIP sandwich shipper was compared to a PUR shipper in conditions simulating a winter ambient temperature profile. The box size and wall thickness of the PUR shipper and the VIP sandwich shipper was kept similar. The objective was to provide a shipper for keeping pharmaceutical products between 2-8 degrees C. for a minimum 96 hours of shipping. As shown in FIG. 7, the PUR shipper failed after only 8 hours in service as the inner temperature dropped below 2 degrees C. By contrast, the VIP sandwich shipper maintained the temperature of the product between 3-5 deg C. for 96 hours.

(41) Case Study 3—Summer Ambient Profile Performance

(42) In case study 3, a VIP sandwich shipper was compared to a PUR shipper for a summer ambient temperature profile. The objective was to provide a shipper for keeping pharmaceutical products at temperature less than −20 degrees C. for a minimum of 96 hours. As shown in FIG. 8, the temperature inside the VIP sandwich shipper was much colder at all times and the duration below −20 degrees C. was 12 hours longer than with the PUR shipper. This improvement with the VIP sandwich shipper is very important because ambient temperature profiles often vary and the shipper can get exposed to harsh environments during summer days. The VIP sandwich shipper in case study 3 was also 20% smaller in volume and 18% lower in weight.

(43) Case Study 4—Thermal Characteristics (R Value)

(44) The thermally insulated VIP sandwich shipper may have thermal characteristics superior to those of a conventional VIP shipper as shown in Table 2 below:

(45) TABLE-US-00002 TABLE 2 System R value, VIP EPS Box Size, Ft.sup.2 * Hr * ° F./BTU Shipper Type Thickness Thickness Inches inch VIP shipper   1 inch NA 12 × 10 × 19-28 12 Shipper 0.5 inch 2.5 inch 12 × 10 × 26-30 according to 12 the disclosure
Method of Making the Thermally Insulated VIP Sandwich Shipper—Automatic

(46) FIG. 9 is a schematic diagram showing an alternative (automated) method of making the box portion 22 of the thermally insulated VIP sandwich shipper of FIG. 1. The automated process for making the box 22 may comprise the following steps:

(47) Step 200: Mold an outer shell 12.

(48) Step 202: Place the VIP panels 16 on the inside of the outer shell 12. The VIP panels 16 may be placed against one or more of the outer shell bottom 24 and sides 26 to create an outer shell assembly.

(49) Step 204: Transfer the pre-molded outer shell and VIP panel assembly to an insert molding machine. The insert molding machine may be an EPS or EPP molding machine having insert molding capability as described in more detail below.

(50) Step 206: Position a male plug 54 within the outer shell and VIP panel assembly, leaving a space therebetween.

(51) Step 208: Mold inner shell (14) into the space between the VIP panels 16 and the male plug 54. After molding the inner shell 14, the VIP panels 16 should be sandwiched between the outer shell 12 and inner shell 14 and enclosed therebetween so that the VIP panels 16 cannot be removed or even seen.

(52) Similarly, the automated process for making the lid 18 may comprise the following steps:

(53) Step 210: Mold the lid outer panel 42.

(54) Step 212: Place a VIP panel 16 within the outer panel 42.

(55) Step 214: Transfer the pre-molded outer panel 42 and VIP panel assembly to an insert molding machine.

(56) Step 216: Position a male plug near the outer panel 42 and VIP panel assembly, leaving a space therebetween.

(57) Step 218: Mold the inner shell (44) between the VIP panel and the male plug. After molding the inner shell 44, the VIP panel 16 should be sandwiched between the outer panel 42 and inner panel 44 and enclosed therebetween so that the VIP panel 16 cannot be removed or even seen.

(58) FIG. 10 is an exploded view of a molding assembly 50 such as might be used to create the box 22 via an automated process. The molding assembly 50 comprises components of the thermally insulated VIP sandwich shipper 10 and components of the insert molding machine. The components of the thermally insulated VIP sandwich shipper 10 shown in FIG. 10 are the outer shell 12, the inner shell 14 and five VIP panels 16, consisting of a bottom VIP panel 16 and four side VIP panels 16. The VIP panels 16 are shown as they would be arranged edge to edge within the outer shell 12. The components of the insert molding machine shown in FIG. 10 consist of an aluminum female plug 52, an aluminum male plug 54 and a fill gun 56.

(59) The automated process has a number of advantages:

(60) 1. It can reduce the cycle time and assembly time to make the VIP sandwich shipper 10.

(61) 2. The insert molding can create a perfect seal line 58 between the outer shell 12 and the inner shell 14, making it difficult to distinguish where the outer shell 12 ends and the inner shell 14 starts. This perfect seal line 58 is possible due to the high temperature steam chest molding. The automated process also eliminates use of adhesive to seal the gap between outer shell 12 and the inner shell 14.

(62) 3. During high pressure steam chest molding every void/gap between VIP panels 16 and the walls of the outer shell 12 and the inner shell 14 will be filled with expanded bead foam, thus creating near hermetic seal.

(63) 4. High pressure molding helps push the VIP panels 16 against each other, thus virtually eliminating edge leaks.

INDUSTRIAL APPLICABILITY

(64) The thermally insulated VIP sandwich shipper may be used in any industry where temperature sensitive products are shipped, including but not limited to the pharmaceutical, hospital and food industries.

(65) It is understood that the embodiments of the invention described above are only particular examples which serve to illustrate the principles of the invention. Modifications and alternative embodiments of the invention are contemplated which do not depart from the scope of the invention as defined by the foregoing teachings and appended claims. It is intended that the claims cover all such modifications and alternative embodiments that fall within their scope.