US20130228583A1 - Passive thermally regulated knockdown shipping container - Google Patents

Abstract

A stackable, passive thermally regulated, knockdown shipping container. The container includes (i) a pair of separate and independent interchangeable end panels, each carrying a detachable panel of fragile thermal insulation, and (ii) a plurality of separate and independent sidewall components each having at least two hingedly interconnected structural panels which carry a detachable panel of fragile thermal insulation. The end panels are each configured and arranged with (a) an external set of projections operable for stably supporting the container on a planar surface, and (b) an external set of depressions. The depressions are configured and arranged such that each projection on the panel, if inverted, would nest within a corresponding depression on the panel upon rotation of the inverted set of projections a defined angular distance about a longitudinal axis of the container relative to the set of depressions.

Description

BACKGROUND
• Thermally labile goods are frequently transported or shipped in passive thermally regulated shipping containers (i.e., a thermally insulated container containing a thermally conditioned phase change material such as ice). While generally effective for maintaining an object to be shipped at a nominally heated or cooled temperature, the storage and return transport of empty containers remains an ongoing issue.
• Efforts to construct foldable or knockdown passive thermally regulated shipping containers in an effort to minimize the space occupied by empty containers have meet with limited success as such containers tend to provide limited thermal regulation, are labor intensive and/or require trained technicians to assemble and disassemble.
• Accordingly, a substantial need continues to exist for knockdown passive thermally regulated shipping container that provides superior thermal regulation and is quick and easy to assemble and disassemble without error.
SUMMARY OF THE INVENTION
• A first aspect of the invention is a sidewall component suitable for use in construction of a passive thermally regulated knockdown shipping container. The sidewall component includes at least two hingedly interconnected structural panels, each carrying a detachable panel of fragile thermal insulation.
• A second aspect of the invention is a passive thermally regulated knockdown shipping container. The container includes (i) a pair of separate and independent interchangeable end panels, each carrying a detachable panel of fragile thermal insulation, (ii) a plurality of separate and independent sidewall components in accordance with the first aspect of the invention, (iii) a plurality of primary connection mechanisms, each operable for affecting border to border interconnection of a pair of sidewall components pivoted into a use configuration to form an encircling sidewall assembly, and (iv) a plurality of secondary connection mechanisms, each operable for attaching one of the end panels to the sidewall assembly over an open end of the assembly to form an enclosure defining a thermally regulated payload retention chamber.
• A third aspect of the invention is a stackable panel. The panel is configured and arranged with (i) a set of projections extending longitudinally from a first major surface of the panel operable for stably supporting the panel on a planar surface, and (ii) a set of longitudinally inset depressions in the first major surface. The depressions are configured and arranged on the panel such that each projection on the panel, if inverted, would nest within a corresponding depression in the panel upon rotation of the inverted set of projections a defined angular distance about a longitudinal axis of the panel relative to the set of depressions.
• A fourth aspect of the invention is a stackable container. The container has one or more sidewalls longitudinally separating identically configured and arranged top and bottom panels. The top and bottom panels are each configured and arranged with (i) an external set of projections operable for stably supporting the container on a planar surface, and (ii) an external set of depressions. The depressions are configured and arranged such that each projection on the panel, if inverted, would nest within a corresponding depression on the panel upon rotation of the inverted set of projections a defined angular distance about a longitudinal axis of the container relative to the set of depressions.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is an exploded isometric view of one embodiment of the invention.
• FIG. 2 is an isometric view of the container depicted inFIG. 1 fully assembled.
• FIG. 2A is a top view of the assembled container depicted inFIG. 1.
• FIG. 2B is a side view of the assembled container depicted inFIG. 2A.
• FIG. 3 is an isometric view of one of the sidewall components depicted inFIG. 1 disposed in a planar storage position.
• FIG. 4 is a cross-sectional side view of the sidewall component depicted inFIG. 3 taken along line4-4.
• FIG. 4A₁is a grossly enlarged portion of the cross-sectional side view of the sidewall component depicted inFIG. 4 for purposes of allowing depiction of one means for detachably attaching the thermal insulation panel to the structural sidewall panel.
• FIG. 4A₂is a grossly enlarged portion of the cross-sectional side view of the sidewall component depicted inFIG. 4 for purposes of allowing depiction of another means for detachably attaching the thermal insulation panel to the structural sidewall panel.
• FIGS. 5A-D depict various arrangements of variously shaped projections and depressions on structural end panels of various cross-sectional shapes that permit stable nestable stacking of containers employing identical structural end panels as both the top and bottom of the containers.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENTDefinitions
• As utilized herein, including the claims, the term “detachable” means capable of being detached without application of violent force and without damage to or destruction of either the item being detached or the substrate from which the item is being detached.
Nomenclature
• 10 Passive Thermally Regulated Shipping Container
• 19 Payload Retention Chamber
• 20 Outer Structural Shell
• 21 Structural End Panel
• 21₁Upper Structural End Panel
• 21₂Lower Structural End Panel
• 21iInterior Major Surface of Structural End Panel
• 21jExterior Major Surface of Structural End Panel
• 21pProjections Extending from the Exterior Major Surface of Structural End Panel
• 21dDepressions in the Exterior Major Surface of Structural End Panel
• 22 Structural Sidewall Component
• 22iInterior Major Surface of Structural Sidewall Component
• 22jExterior Major Surface of Structural Sidewall Component
• 23 Sidewall Panel on Structural Sidewall Component
• 23iInterior Major Surface of Structural Sidewall Panel
• 24 Live Hinge Interconnecting First and Second Structural Sidewall Panels on Structural Sidewall Component
• 30 Thermal Insulation Panel
• 30bBorder Area of Thermal Insulation Panel
• 40 Phase Change Material Panels (PCM Panel)
• 50 Means for Detachably Attaching Thermal Insulation Panel to a Structural Panel
• 50₁Hook and Loop Tape
• 50₂Pressure Sensitive Adhesive
• 60 Connection Mechanism for Attaching Structural Sidewall Components
• 70 Connection Mechanism for Attaching Structural End Panel to Erected Structural Sidewall Assembly
• x10 Longitudinal Axis of Shipping Container
• x21 Longitudinal Axis of Structural End Panel
Construction
• Referring generally toFIG. 1, the present invention is directed to various components of a modular kit operable for assembly into a passive thermally regulatedstackable shipping container10, and ashipping container10 assembled therefrom.
• When assembled, theshipping container10 includes an outerstructural shell20, a layer ofthermal insulation30, and optionally a layer of phase change material (not shown) retained withinPCM panels40, defining a passive thermally regulatedpayload retention chamber19.
• The outerstructural shell20 may be solid or hollow and may be made from any material possessing sufficient structural integrity, including specifically but not exclusively, cellulosic materials such as paperboard and cardboard, engineered wood products such as laminated and unlaminated fiberboard and plywood, wood, plastics such as polyethylene, polypropylene, polyethylene terephthalate, nylon polycarbonates and phenolic resins, wood-plastic composites, metals such as aluminum, copper, brass and steel, glass, ceramics, combinations thereof, and the like.
• The outerstructural shell20 is divided into separate and independentstructural end panels21 and at least onestructural sidewall component22. These units are capable of being repeatedly attached to and detached from one another.
• Assembly of ashipping container10 requires twostructural end panels21—one to cover the top21₁and another to cover the bottom21₂. The top21₁and bottom21₂structural end panels are preferably interchangeable with one another so that only a singlestyle end panel21 need be manufactured and stocked. Use of interchangeable top21₁and bottom21₂structural end panels also simplifies assembly of theshipping container10 as there is no need to obtain and identify separate top21₁and bottom21₂structural end panels. A technician assembling ashipping container10 need only obtain twostructural end panels21.
• The exteriormajor surface21jof thestructural end panels21 may be contoured with a set of rotationally spacedlongitudinal projections21pand rotationally displaced “matching” set oflongitudinal depressions21dwhereby (i) theprojections21pterminate along a single horizontal plane such that thestructural end panel21 can rest stably upon theprojections21pwhen placed upon a flat horizontal surface, and (ii) theprojections21pon bothstructural end panels21, disposed with their exteriormajor surfaces21jfacing one another, will nest within correspondingdepressions21don the other facingstructural end panel21 when one of the facingpanels21 is rotated a defined angular distance about the longitudinal axis x21 of thepanel21. This permits interchangeable top21₁and bottom21₂structural end panels to be used in assembling ashipping container10 while still allowing such assembledshipping containers10 to be stably and nestably stacked upon one another by simply rotating an overlying shipping container10 a defined angular distance about the longitudinal axis x10 of theshipping container10 relative to the immediatelyunderlying shipping container10.
• Exemplary operable arrangements of variously shapedprojections21panddepressions21donstructural end panels21 having various cross-sectional shapes are depicted inFIGS. 5A-D, whereindepressions21dare shaded andprojections21pare unshaded. Each is described in further detail in TABLE ONE.

• TABLE ONE
  				NECESSARY

  PROJECTIONS

  ANGULAR

  		CROSS-		ROTATION
  		SECTIONAL	SHAPE OF	TO ACHIEVE
  FIG. #	#	SHAPE	PANEL	NESTING
  5A	4	Square	Rectangle	180°
  5B	4	Triangle	Square	90°
  5C	3	Circle	Square	180°
  5D	3	Hexagon	Hexagon		60°

• Assembly of ashipping container10 also requires at least threestructural sidewall panels23.
• Structural sidewall panels23 are grouped together onstructural sidewall components22, with thestructural sidewall panels23 on eachstructural sidewall component22 interconnected by ahinge24, such as a live hinge.
• Thestructural sidewall components22 can be constructed with any number of hingedly interconnectedstructural sidewall panels23 on eachstructural sidewall component22. However, as the number ofpanels23 on eachcomponent22 increases, so too does the difficulty and complexity of storing and handling thestructural sidewall component22. A nonexhaustive listing of various geometric and configurational options for thestructural sidewall components22 andshipping containers10 constructed therefrom is provided below in table TWO.

• TABLE TWO
  SIDEWALL
  COMPONENT	SHIPPING CONTAINER

  # of Panels	# of Sidewall	Cross-Sectional
  on Each	Components	Shape
  2	2	Square
  2	3	Hexagon
  2	4	Octagon
  2	5	Decagon
  3	1	Triangle
  3	2	Hexagon
  3	3	Nonagon
  4	1	Square
  4	2	Octagon
  5	1	Pentagon
  5	2	Decagon

• When theshipping container10 is constructed from two or morestructural sidewall components22 thestructural sidewall components22, as with theend panels21, are preferably interchangeable with one another so that only a single stylestructural sidewall component22 need be manufactured and stocked.
• Thestructural sidewall panels23 on eachstructural sidewall component22 are configured and arranged such that thestructural sidewall panels23 can be pivoted relative to one another as between a planar storage configuration in which thestructural sidewall panels23 do not contact one another, and a three-dimensional use configuration in which the andstructural sidewall panels23 abut one another along a length of a border area thereof.
• A panel ofthermal insulation30 is detachably attached to the interior major surface21iof eachstructural end panel21 and the interiormajor surface23iof eachstructural sidewall panel23 on eachstructural sidewall component22. The panels ofthermal insulation30 may be constructed of any material having good thermal insulating qualities, (i.e., having a high thermal resistance “R”), such as Styrofoam, vacuum insulated panels, or the like.
• The panels ofthermal insulation30 are aligned on thestructural sidewall panels23 so that the panels ofthermal insulation30 do not contact one another when thestructural sidewall panels23 are disposed in the planar storage configuration, but abut one another along a length of aborder area30bthereof when thestructural sidewall panels23 are disposed in the three-dimensional use configuration.
• In a similar fashion, the panels ofthermal insulation30 are aligned on thestructural end panels21 so that the panels ofthermal insulation30 on theend panels21 abut the panels ofthermal insulation30 attached to thestructural sidewall panels23 along a length of a border area thereof when thestructural end panel21 is attached to the assembledstructural sidewall panels23.
• Preferred materials for use as the thermal insulatingpanels30 tend to be fragile and/or frangible (e.g., panels of Styrofoam or vacuum insulated panels). This results in all too frequent damaging of the thermal insulatingpanels30 and resultant loss of insulating value. In order to facilitate replacement of damaged and/or failing thermal insulatingpanels30 without requiring replacement of an entirestructural end panel21 orstructural sidewall panel23, the thermal insulatingpanels30 are detachably attached to thestructural end panels21 andstructural sidewall panels23.
• A wide variety of options are available for detachably attaching the thermal insulatingpanels30 to the interior major surface21iof eachstructural end panel21 and the interiormajor surface23iof eachstructural sidewall panel23. A preferred option is hook andloop tape50₁such as shown inFIG. 4A₁. Another preferred option is double-sided pressure sensitiveadhesive tape50₂such as shown inFIG. 4A₂. Yet another preferred attachment means is a layer of pressure sensitive adhesive coated directly upon thestructural end panel21,structural sidewall panel23, and/or thermal insulatingpanel30. Mechanical fasteners may also be used, such as elastic straps, reversible snap fit, reversible press-fit, etc. However, such mechanical fasteners should generally be avoided as they tend to prevent direct contact between the thermal insulatingpanels30 when thecontainer10 is fully assembled, leaving a gap in the layer of thermal insulation through which significant heat loss can occur.
• Referring toFIG. 1, thepayload retention chamber19 can be lined with panels of phase change material (PCM panels)40. ThePCM panels40 can be filled with any suitable phase change material, such as water or various hydrocarbons.
• Either of thestructural end panels21 on theshipping container10 can be selectively removable from the sidewall assembly for allowing insertion and removal of goods from thepayload retention chamber19.PCM panels40 deployed within thepayload retention chamber19 may similarly be removed for thermal conditioning.
• Aprimary connection mechanism60 releasably attachesstructural sidewall components22 to one another. Asecondary connection mechanism70 releasably attachesstructural end panels21 to the longitudinal ends of a fully assembled sidewall assembly. Both the primary60 and secondary70 connection mechanisms can be selected from the wide variety of known mechanical type fasteners capable of repetitive attachment and detachment of components. A nonexhaustive list of such fasteners includes bolts, buckles, catches, clamps, clasps, hasps, latches, hook and loop tape, and the like.
Assembly and Use
• For simplification purposes only, assembly, use and disassembly of ashipping container10 in accordance with this invention shall be based upon theshipping container10 depicted inFIGS. 1,2,2A and2B.
• The shipping container10 depicted inFIGS. 1,2,2A and2B can be rapidly assembled by (i) obtaining a pair of structural end panels21 and a pair of structural sidewall components22, (ii) placing one of the structural end panels21 onto a planar horizontal surface (not shown) with the interior major surface21iof the selected end panel21 facing upward to establish a bottom structural end panel21₂, (iii) placing both structural sidewall components22—pivoted into the three-dimensional use position—into orthogonal fitted engagement with the periphery of the interior major surface21iof the bottom structural end panel21₂and into orthogonal fitted engagement with one another to define a payload retention chamber19, (iv) securing the structural sidewall components22 together with the primary connection mechanisms60 to form an encircling structural sidewall assembly, (v) securing the structural sidewall assembly to the bottom structural end panel21₂with the lower sets of secondary connection mechanisms70, (vi) placing the other structural end panel21 over the open longitudinal end of the structural sidewall assembly in orthogonal fitted engagement with the structural sidewall components22 to establish a top structural end panel21₁, and (vii) securing the top structural end panel21₁to the structural sidewall assembly with the upper sets of secondary connection mechanisms70.
• Loading thermally labile goods (not shown) into an assembledshipping container10 for transport includes the steps of: (a) detaching the topstructural end panel21₁from the structural sidewall assembly by disengaging the upper sets ofsecondary connection mechanisms70, (b) removing the detached topstructural end panel21₁from the structural sidewall assembly for providing access to thepayload retention chamber19, (c) optionally lining thepayload retention chamber19 with thermally conditionedPCM panels40, (d) placing the payload of thermally labile goods (not shown) into the lined or unlinedpayload retention chamber19, (e) optionally covering the open top of the loadedpayload retention chamber19 with a thermally conditionedPCM panel40, (f) placing the topstructural end panel21₁back over the open longitudinal end of the structural sidewall assembly, and (g) securing the topstructural end panel21₁to the structural sidewall assembly with the upper sets ofsecondary connection mechanisms70.
• Unloading thermally labile goods (not shown) from ashipping container10 includes the steps of: (A) detaching the topstructural end panel21₁from the structural sidewall assembly by disengaging the upper sets ofsecondary connection mechanisms70, (B) removing the detached topstructural end panel21₁from the structural sidewall assembly, (C) removing anyunderlying PCM panel40 for providing access to thepayload retention chamber19, and (D) removing the payload of thermally labile goods (not shown) from thepayload retention chamber19.
• Knocking down an unloadedshipping container10 for return transport includes the steps of (1) removing anyPCM panels40 still in thepayload retention chamber19, (2) detaching thestructural sidewall components22 from one another by disengaging theprimary connection mechanisms60, (3) detaching thestructural sidewall components22 from the bottomstructural end panel21₂by disengaging the lower sets ofsecondary connection mechanisms70, and (4) removing thestructural sidewall components22 from the bottomstructural end panel21₂.

Claims (16)

We claim:

1. A sidewall component suitable for use in construction of a passive thermally regulated knockdown shipping container, comprising at least two hingedly interconnected structural panels each carrying a detachable panel of fragile thermal insulation.

2. The sidewall component ofclaim 1 wherein the panels of thermal insulation are precisely aligned on the structural panels such that the panels of thermal insulation do not contact one another when the structural panels are disposed in a planar storage configuration, and abut one another along a length of a border area thereof when the structural panels are disposed in a three-dimensional use configuration by pivoting the structural panels about the interconnecting hinge until further pivotal movement is inhibited by the structure of the component.

3. The sidewall component ofclaim 1 wherein the structural panels are comprised of a plastic material and are interconnected by a live hinge.

4. The sidewall component ofclaim 1 wherein the component has two structural panels.

5. The sidewall component ofclaim 1 wherein the panels of fragile thermal insulation are vacuum insulated panels.

6. The sidewall component ofclaim 1 wherein the panels of fragile thermal insulation are attached to the structural panels with hook and loop tape.

7. The sidewall component ofclaim 1 wherein the panels of fragile thermal insulation are adhesively attached to the structural panels.

8. A passive thermally regulated knockdown shipping container, comprising:

(a) a pair of separate and independent interchangeable end panels, each carrying a detachable panel of fragile thermal insulation,

(b) a plurality of separate and independent sidewall components in accordance withclaim 2,

(c) a plurality of primary connection mechanisms, each operable for affecting border to border interconnection of a pair of sidewall components pivoted into the use configuration to form an encircling sidewall assembly, and

(d) a plurality of secondary connection mechanisms, each operable for attaching one of the end panels to the sidewall assembly over an open end of the assembly to form an enclosure defining a thermally regulated payload retention chamber.

9. The thermally regulated shipping container ofclaim 8 further including panels of phase change material lining the payload retention chamber.

10. The thermally regulated shipping container ofclaim 8 wherein the structural panels are comprised of a plastic material and are interconnected by a live hinge.

11. The thermally regulated shipping container ofclaim 8 wherein each sidewall component has two structural panels.

12. The thermally regulated shipping container ofclaim 8 wherein the panels of fragile thermal insulation are vacuum insulated panels,

13. The thermally regulated shipping container ofclaim 8 wherein the panels of fragile thermal insulation are attached to the structural panels with hook and loop tape.

14. The thermally regulated shipping container ofclaim 8 wherein the panels of fragile thermal insulation are adhesively attached to the structural panels.

15. An article of commerce, comprising a stackable panel having longitudinally spaced first and second major surfaces, the panel configured and arranged with a set of projections extending longitudinally from the first major surface of the panel operable for stably supporting the panel on a planar surface and a set of longitudinally inset depressions in the first major surface configured and arranged such that each projection on the panel would nest within a corresponding depression in the panel upon rotation of an inverted set of projections a defined angular distance about a longitudinal axis of the panel relative to the set of depressions.

16. A stackable container defining a longitudinal axis and a payload retention chamber, and comprising one or more sidewalls longitudinally separating identically configured and arranged top and bottom panels, each panel configured and arranged with an external set of projections operable for stably supporting the container on a planar surface and an external set of depressions configured and arranged such that each projection on the panel would nest within a corresponding depression on the panel upon rotation of an inverted set of projections a defined angular distance about the longitudinal axis of the container relative to the set of depressions.

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