US20220289450A1 - Box-in-a-box shipper - Google Patents

Abstract

Methods, systems, devices and/or apparatuses for a shipping container are provided herein. The shipping container includes an outer enclosure having a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure has multiple panels and various configurations. Phase-change material inserts may be received within the multiple panels. The inner enclosure defines a payload area that is configured to hold a payload.

Description

CROSS REFERENCE TO RELATED APPLICATION
• This application claims the benefit of U.S. Provisional Patent Application No. 63/159,859, filed Mar. 11, 2021, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
• This specification relates to a system, an apparatus and/or a method for fixating and/or stabilizing a payload within the shipping container to protect the payload when the shipping container moves during transport and/or storage.
BACKGROUND
• In the health, medical, pharmaceutical and/or life science industry, the safe storage of the payload in a temperature-controlled and watertight environment is an important aspect of the industry. Typically, when a payload is shipped, the shipper packs the payload into an enclosure, which is non-reusable, such as a carboard box and may pack shipping material, such as a polystyrene foam container and/or dry ice, around the payload to maintain the temperature. The shipper may place or scoop dry ice pellets or blocks into an inner packaging made of an insulating material, such as the polystyrene foam, and around the payload to maintain the temperature of the payload. The shipper may place the inner packaging within an outer enclosure, such as a sturdy cardboard box, and partially seal the outer enclosure. Due to this configuration, the payload floats within the shipping material and when the shipping container is jostled, reoriented and/or or otherwise moved, the payload may move or shift during transport, which may cause instability of the payload during transport.
• Accordingly, there is a need for a system, apparatus and/or method for a shipping container that stabilizes the payload within the shipping container to protect the payload.
SUMMARY
• In general, one aspect of the subject matter described in this specification is embodied in a shipping container. The shipping container includes an outer enclosure having a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure has multiple panels and multiple phase-change material inserts that are received within the multiple panels. The multiple panels define a payload area that is configured to hold a payload.
• These and other embodiment may optionally include a base and a lid. The lid may be removable to access the inner enclosure when the inner enclosure is within the cavity of the outer enclosure. Each panel of the multiple panels may have an angled edge that forms a channel. The channel may be configured to slidably receive a phase-change material insert.
• The multiple panels may include a top panel, multiple side panels and a bottom panel. The bottom panel may be opposite the top panel. Edges of the multiple side panels may interface with edges of the top panel and edges of the bottom panel. The multiple side panels may be positioned between the top panel and the bottom panel. The multiple panels and the multiple phase change material inserts may be removable.
• The outer enclosure may be made from an insulative, nonmetallic material that may be designed to withstand shocks and vibrations at cryogenic temperatures. The insulative, nonmetallic material may be a polycarbonate or other polymer. The multiple panels may be positioned along or adjacent to an inner surface of walls of the outer enclosure and may be made from a nonmetallic material.
• In another aspect, the subject matter is embodied in a shipping container. The shipping container includes an outer enclosure having a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure has a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray. The nested enclosure has a payload area that is configured to receive a payload.
• In another aspect, the subject matter is embodied in a shipping container. The shipping container has an outer enclosure having a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure has multiple concave walls that define a payload area that is configured to receive a container.
• In another aspect, the subject matter is embodied in a shipping container. The shipping container includes an outer enclosure having a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure includes multiple brackets. The multiple brackets define a receiving area configured to receive a payload.
• In another aspect, the subject matter is embodied in a shipping container. The shipping container includes an outer enclosure. The outer enclosure has a cavity. The shipping container includes an inner enclosure positioned within the cavity of the outer enclosure. The inner enclosure has a top covering and a base. The shipping container includes multiple pillars. The multiple pillars are positioned on and upright along the base of the inner enclosure. The multiple pillars define a payload area to receive a payload.
• A method is also disclosed. The method may be for maintaining a payload area of a shipping container within a predetermined temperature range during shipping of a payload in the shipping container. The method may include various aspects. For instance, the method may include providing an outer enclosure having side walls and a base defining a cavity in the outer enclosure. An inner enclosure may be inserted into the cavity of the outer enclosure and may define a payload area inside the inner enclosure. A phase change material may also be inserted into the shipping container. A payload may be placed into the payload area of the inner enclosure and a lid may be attached on a top of the outer enclosure to cover the cavity of the outer enclosure containing the inner enclosure. The payload area may be cooled by the phase change material to maintain the payload area within the predetermined temperature range.
• In various embodiments, the method includes one or more further aspect. For example, the phase change material may be inserted between the inner enclosure and the outer enclosure. The predetermined temperature range may be below 0 degrees Celsius. The predetermined temperature range may be below about 0 degrees Celsius. The predetermined temperature range may be between 25 degrees Celsius to −80 degrees Celsius. The predetermined temperature range may be between about 25 degrees Celsius to about −80 degrees Celsius. The predetermined temperature range may be between −150 degrees Celsius to −190 degrees Celsius. The predetermined temperature range may be between about −150 degrees Celsius to about −190 degrees Celsius. The predetermined temperature range may be below about −150 degrees Celsius. The predetermined temperature range may be below −150 degrees Celsius. The inner enclosure may have a plurality of panels, the plurality of panels defining the payload area. The payload may be stabilized by the plurality of panels of the inner enclosure. Each panel of the plurality of panels may have an angled edge that forms a channel and the method may include slidably inserting the phase-change material insert into the channel.
• The method may be implemented with various configurations of inner enclosures. For example, the inner enclosure may have a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure defining the payload area, wherein the payload is stabilized by the nested enclosure of the inner enclosure. The inner enclosure may include a plurality of concave walls, the plurality of concave walls defining the payload area. The inner enclosure may have a plurality of brackets, the plurality of brackets defining the payload area configured to receive a payload. The inner enclosure may have a top covering and a base; and a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining the payload area to receive a payload.
• As previously indicated, one aspect of the subject matter described in this specification is embodied in a shipping container. The shipping container may be have different configurations. For instance, the shipping container may have an outer enclosure having side walls and a base, wherein the side walls and the base defining a cavity in the outer enclosure. The shipping container may have a lid attachable to the sidewalls of the outer enclosure to cover the cavity in the outer enclosure. The shipping container may have an inner enclosure disposed inside the cavity and configured to provide a payload area for a payload within the inner enclosure.
• The inner enclosure of the shipping container may be configured in various ways. For instance, the inner enclosure may include a plurality of panels, the plurality of panels defining the payload area. The inner enclosure may include a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure defining the payload area. The inner enclosure may include a plurality of concave walls, the plurality of concave walls defining the payload area. The inner enclosure may include a plurality of brackets, the plurality of brackets defining the payload area configured to receive the payload. The inner enclosure may include a base, a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining the payload area to receive a payload, and a top covering opposite the base, wherein the pillars extend between the top covering and the base.
BRIEF DESCRIPTION OF THE DRAWINGS
• Other systems, methods, features, and advantages of the present invention will be apparent to one skilled in the art upon examination of the following figures and detailed description. Component parts shown in the drawings are not necessarily to scale, and may be exaggerated to better illustrate the important features of the present invention.
• FIG. 1A shows an example of a shipping container that has multiple panels and multiple phase-change material inserts according to an aspect of the invention.
• FIG. 1B shows a close-up perspective view of a panel and a phase-change material insert of the shipping container ofFIG. 1A according to an aspect of the invention.
• FIG. 2 shows an example of a shipping container that has a nested container according to an aspect of the invention.
• FIG. 3 shows an example of a shipping container that has a star-shaped inner enclosure according to an aspect of the invention.
• FIG. 4 shows an example of a shipping container that has an inner enclosure with multiple brackets according to an aspect of the invention.
• FIG. 5 shows an example of a shipping container that has an inner enclosure with pillars according to an aspect of the invention.
• FIG. 6 shows a method for maintaining a payload area of a shipping container within a predetermined temperature range during shipping of a payload in the shipping container according to an aspect of the invention.
DETAILED DESCRIPTION
• Disclosed herein are systems, devices and/or methods for a shipping container (or “shipper”) that maintains the temperature within the payload area and stabilizes the payload within the payload area. The shipper may be designed to have an outer enclosure and an inner enclosure within the cavity of the outer enclosure to stabilize and protect the payload placed within the payload area of the inner enclosure. The outer and/or inner enclosures may be made from a metallic or nonmetallic material, such as from a hardened material, such as a polycarbonate, polyethylene or other polymer, which protects the payload in the payload from environmental factors, such as shock and vibrations. The material may be designed to withstand cryogenic temperatures so that the exposure to extremely cold temperatures does not make the material brittle and susceptible to shocks and vibrations that occur during storage and/or transport.
• Other benefits and advantages may include the use of a phase-change material. The use of the phase-change material maintains the temperature within the payload area of the shipper, and consequently, the temperature of a payload positioned within the payload area. By using the phase-change material, the shipper may maintain and/or manage the temperature within the payload area. The temperature within the payload area may not be limited to a single temperature range, e.g., limited to the temperature of the dry ice when dry ice is used as the temperature control medium. Instead, the shipper may have the flexibility to maintain the temperature of the payload at various different temperature ranges, which may be set using phase-change material as the temperature control medium.
• FIG. 1A shows an exploded view of theshipper100. Theshipper100 maintains a temperature controlled environment for a payload within a payload area. Theshipper100 may include anouter enclosure102 and aninner enclosure104. Theouter enclosure102 may be shaped as a rectangular cube with abase114, alid116 that may be removable andmultiple sidewalls118. Moreover, theouter enclosure102 may be made from an insulative, metallic or a nonmetallic material, such as a polycarbonate or other polymer. Theouter enclosure102 may be designed withstand shocks and vibrations at cryogenic temperatures that occur during transport and/or storage.
• Thebase114, thelid116 and/or themultiple sidewalls118 may form or define acavity110 that receives theinner enclosure104 within thecavity110. Thelid116 may be removable to allow access to theinner enclosure104. Thelid116 may couple to themultiple sidewalls118 via one or more hinges, latches and/or connectors and/or may be sized and shaped to fit to rest on themultiple sidewalls118 to enclose and/or surround thecavity110. This allows thelid116 to be removable and/or to be moved between an open position and a closed position to provide access to thecavity110 and the contents within thecavity110.
• Theinner enclosure104 and the payload may be placed within thecavity110. Thelid116 may be placed on top of theinner enclosure104 to prevent access to and seal or partially seal theinner enclosure104 and/or the payload within thecavity110. Thus, theouter enclosure102 may protect theinner enclosure104 and the payload that is placed within thecavity110 from shocks and/or vibrations during storage and transport.
• Theshipper100 includes theinner enclosure104. Theinner enclosure104 may includemultiple panels106 and/or multiple phase change material (PCM) inserts108. Themultiple panels106 and/or the PCM inserts108 may be positioned along and/or adjacent to the inner surface of thebase114, themultiple sidewalls118 and/or thelid116 within thecavity110. Themultiple panels106 and/or the PCM inserts108 define apayload area112 that may receive and enclose a payload that is placed within thepayload area112.
• Themultiple panels106 may be made from a metallic or a non-metallic material, such as a polycarbonate or other insulative non-metallic material that may withstand cryogenic temperatures. Themultiple panels106 may include a bottom panel, multiple side panels, and a top panel that is opposite the bottom panel. Each of themultiple panels106 may have one or more inwardangled edges120 that form achannel122, which may slidably receive acorresponding PCM insert108, as shown inFIG. 1B for example. The edges of each of the multiple side panels may interface with edges of the top panel and edges of the bottom panel and may be positioned in between the top panel and the bottom panel to form theinner enclosure104 and define thepayload area112.
• The PCM insert108 includes a phase-change material, which is a substance which releases and/or absorbs sufficient energy at phase transition to provide useful heat and/or cooling. The phase-change material may transition between a solid and a liquid. Different phase-change materials may be designed to maintain the temperature within thepayload area112 at and/or within different temperature ranges and/or bands.
• The correspondingPCM insert108 may be slid into thechannel122 to integrate thePCM insert108 with thecorresponding panel106. For example, the edges of thePCM insert108 may be slid into thechannel122 to position thePCM insert108 within thechannel122 and to be secured to thepanel106. When the PCM inserts108 are received within themultiple panels106 and themultiple panels106 and/or the PCM inserts108 are inserted into the cavity of theouter enclosure102 to form theinner enclosure104, apayload area112 is defined, which may receive and enclose a payload. Each of the PCM inserts108 and each of themultiple panels106 may be shaped similarly, such as in a pyramidal frustum, to allow for interchangeability among the various components, and thus, allowing themultiple panels106 and/or the PCM inserts108 to be removable and interchangeable with each other.
• In another aspect of the invention,FIG. 2 shows ashipper200. Theshipper200 maintains a temperature controlled environment for a payload within a payload area. Theshipper200 includes an outer enclosure (not shown) and aninner enclosure201. Theinner enclosure201 is positioned in the cavity of the outer enclosure and stores or surrounds a payload that is placed within.
• Theinner enclosure201 has atop tray202, abottom tray204 and a nested enclosure or container (“nested container”)206 within. Thetop tray202 may be positioned opposite thebottom tray204, and the nestedcontainer206 may be positioned in between thetop tray202 and thebottom tray204. The sides of thetop tray202 and the sides of thebottom tray204 may interface and substantially contact with the sidewalls of the outer enclosure so that thetop tray202 and thebottom tray204 do not move within the cavity of the outer enclosure when placed within the cavity of the outer enclosure. This fixates theinner enclosure201 within the outer enclosure so that theinner enclosure201 remains still within the outer enclosure during transport.
• Thetop tray202 and/or thebottom tray204 may have one or more handles208. The one ormore handles208 may be openings within the sidewalls of thetop tray202 and/or thebottom tray204. The one ormore handles208 allow a user to grasp or insert their hands through the openings on the sidewalls of thetop tray202 and/or thebottom tray204 to hold, lift, move or otherwise position theinner enclosure202 within the cavity of the outer enclosure and/or to remove theinner enclosure202 from the cavity of the outer enclosure. In some implementations, thetop tray202 and/or thebottom tray204 may or may not be removable from the cavity of the outer enclosure. For example, thebottom tray204 may be fixated within, integrally molded with or integrally formed with the outer enclosure and not be separable from the bottom or sides of the cavity of the outer enclosure.
• Thetop tray202 may have one ormore openings210 at the base of thetop tray202. The one ormore opening210 may be positioned in the center of thetop tray202 and may be sized and shaped similarly to the nestedcontainer206. The one ormore openings210 allow a container or a payload to be inserted into thepayload area212 of the nestedcontainer206 without the need to remove thetop tray202.
• The nestedcontainer206 may be integrally formed with, fixated on or be removable from thebottom tray204 and/or thetop tray202. The nestedcontainer206 may be centrally positioned in between thetop tray202 and thebottom tray204. The nestedcontainer206 may have a perimeter that is less than that of thetop tray202 and/or thebottom tray204 to allow for dry ice or other cooling material or substance to be placed between the nestedcontainer206 and the sidewalls of the outer enclosure. That is, the nestedcontainer206 may not contact or interface with the sidewalls of the outer enclosure.
• The nestedcontainer206 may be formed frommultiple sidewalls216 that define apayload area212. Themultiple sidewalls216 may surround and/or enclose a payload that is placed or positioned within thepayload area212. Themultiple sidewalls216 may have one ormore leaf springs218 or portion thereof that is cutout from each of thesidewalls216 and/or is coupled or otherwise fastened to each of thesidewalls216 and angles, flexes or is bent inwards to contact the walls of the payload that is placed, positioned or received within thepayload area212. The one ormore leaf springs218 may be compressible or flexible to absorb shocks or other movements of the payload that is positioned within while being rigid enough to secure or stabilize the payload within thesidewalls216 of the nestedcontainer206. The nestedcontainer206 may be made from a metallic or nonmetallic material, such as a polycarbonate, to withstand cryogenic temperatures.
• Theinner enclosure201 may have one or more centering guides214. The one or more centeringguides214 may be positioned on the inner surface of thetop tray202 and/or thebottom tray204. The one or more centeringguides214 may be formed from a first wall and a second wall. The two walls may be integrally formed and the second wall may be perpendicular to the first wall and may form a right angle where the second wall and the first wall are joined together, molded together or otherwise positioned adjacent to each other to form a corner. The one or more centeringguides214 may be positioned around the perimeter of thesidewalls216 of the nestedcontainer206 when the nestedcontainer206 rests in between thetop tray202 and/or thebottom tray204. One wall may be molded, fixated or positioned on thetop tray202 and/or thebottom tray204 with the other wall being positioned parallel to and adjacent to a portion of the nested container. The wall that is positioned parallel to and adjacent to the portion of the nested container may only contact the payload a small portion, approximately along less than 15% of the wall of the nested container. The one or more centeringguides214 may only be along some of the walls of the nested container and not all of the walls of the nested container. The one or more centeringguides214 allow for the nestedcontainer206 to be positioned centrally on thebottom tray204 and underneath the one ormore openings210 of thetop tray202 so that dry ice or other substance may be placed around the nestedcontainer206 to maintain the payload at the cryogenic temperature.
• In another aspect of the invention,FIG. 3 shows ashipper300 with a star-shapedinner enclosure304. Theshipper300 maintains a temperature controlled environment for a payload within a payload area. Theshipper300 includes anouter enclosure302 and aninner enclosure304. Theouter enclosure302 may be made from one or more layers. The layers may include a layer of insulative foam and/or a layer of polycarbonate or other polymer or nonmetallic that may withstand cryogenic temperatures. Theouter enclosure302 may have multiple walls that define acavity303. Thecavity303 may be sized and shaped to receive theinner enclosure304. For example, thecavity303 may be defined by the multiple walls being formed in a rectangle, cubicle or other polygonal shape.
• Theinner enclosure304 may be positioned in thecavity303 of theouter enclosure302. Theinner enclosure304 may havemultiple walls310 or blades (hereinafter, “walls”) andmultiple vertices308 where two adjacent walls are joined or meet. Thewalls310 and/or thevertices308 may be made from a metallic or nonmetallic material, such as a polycarbonate or the polymer shape. Themultiple walls310 are in between two ormore vertices308 of themultiple vertices308. In some implementations, theinner enclosure304 includes four vertices and four walls that are concave shaped forming a star-shape and contact thepayload306 at the inward-mostcurved portion314.
• Thewalls310 of theinner enclosure304 enclose or surround thepayload306 that is placed within. Thewalls310 may be concaved shaped so that thepayload306 does not substantially contact the entire surface of each of thewalls310. Instead, the concaved shaped walls may contact thepayload306 only along the inward-mostcurved portion314 of the concaved shaped wall. The inward-mostcurved portion314 of the concaved shaped wall fixates, stabilizes and orients thepayload306 in the center of theinner enclosure304.
• Theinner enclosure304 may be positioned and oriented within theouter enclosure302 such that themultiple vertices308 are positioned in the corners of theouter enclosure302 where two adjacent walls are joined or meet. This fixates and centers theinner enclosure304 within thecavity303 of theouter enclosure302. And so, since thecontainer306 is positioned within and stabilized within theinner enclosure304 and theinner enclosure304 is fixated and centered within thecavity303, thepayload306 remains stabilized in the center of thecavity303 of theouter enclosure302. Moreover, since theinner enclosure304 may be concave-shaped with its vertices in the corners of theouter enclosure302, dry ice or other cooling material may be placed in theinterstitial spaces316 in between theinner enclosure304 and the walls of theouter enclosure302 and in between theinner enclosure304 and thepayload306.
• In another aspect of the invention,FIG. 4 shows ashipper400 with one ormore brackets406 that together form aninner enclosure404. Theshipper400 maintains a temperature controlled environment for a payload within a payload area. Theshipper400 includes anouter enclosure402 and aninner enclosure404. Theouter enclosure402 may be made from one or more layers. The layers may include a layer of insulative foam and/or a layer of polycarbonate or other polymer or nonmetallic that may withstand cryogenic temperatures. Theouter enclosure402 may havemultiple walls412 that define acavity403. Thecavity403 may be sized and shaped to receive theinner enclosure404. For example, thecavity403 may be defined by themultiple walls412 being formed in a rectangle, cubicle or other polygonal shape.
• Theinner enclosure404 may be positioned in thecavity403 of theouter enclosure402. Theinner enclosure404 may havemultiple brackets406. Themultiple brackets406 may be formed frommultiple blades408 and awall410 in between. For example, a bracket may be formed from a first blade that is angled inward from a corner of thecavity403 of theouter enclosure402, a second blade that is angled inward from a second corner of thecavity403 of theenclosure402 and awall410 that is coupled to, integrally formed with and/or in between the first blade and the second blade. Theinner enclosure404 may have two ormore brackets406 that are positioned opposite one another in thecavity403 on opposite walls of theouter enclosure402. In some implementations, the two ormore brackets406 may be positioned on each wall of theouter enclosure402.
• Eachwall410 may be concave-shaped and have a inward curved portion. Eachblade408 may have a proximal portion coupled to thewall410, which is adjacent to thewall412 of theouter enclosure402, and a distal portion that is directed toward a center of thecavity403 and contacts a payload that may be received within theinner enclosure404. Dry ice or other material to maintain the cryogenic temperatures may be placed within theinterstitial spaces414 between the one ormore blades408, the one ormore walls410 of the one ormore brackets406 and/or thewalls412 of theouter enclosure402.
• The one ormore brackets406 may be compressible or flexible and may be made from a metallic or nonmetallic material, such as a polycarbonate or other polymer, which resists brittleness at cryogenic temperatures. The payload may exert a force against the one ormore brackets406 when the payload is placed in between the one ormore brackets406 within theinner enclosure404. The one ormore brackets406 may bend slightly inward or exert an opposing force to maintain the position of the payload within theinner enclosure404 to stabilize the payload within the payload area of theinner enclosure404.
• In another aspect of the invention,FIG. 5 shows ashipper500 with one ormore pillars512. Theshipper500 maintains a temperature controlled environment for a payload within a payload area. Theshipper500 includes anouter enclosure502 and aninner enclosure504. Theouter enclosure502 and/or theinner enclosure504 may be made from a metallic or nonmetallic material, such as a polycarbonate or other polymer that withstands cryogenic temperatures. Theouter enclosure502 may have multiple walls that define acavity503. The multiple walls may be positioned to form a rectangular cavity within to receive theinner enclosure504 and the payload.
• Theinner enclosure504 may have atop covering506 and abase508. The base508 may be fixated, integrally formed with, and/or otherwise positioned at the bottom of theouter enclosure502. The walls of the base508 may be adjacent to and/or in contact with the sidewalls of theouter enclosure502 such that thebase508 does not move or change positions within the bottom of theouter enclosure502. In some implementations, there is a gap in between the walls of thebase508 and the sidewalls of theouter enclosure502 so that dry ice or other substance material may be placed in between. The base508 may have a recess orcavity510 within. The recess orcavity510 may be filled with dry ice or other substance material to cool the payload that is received within thepayload area514 from underneath.
• The top covering506 of theinner enclosure504 may be removable and may slide within thecavity503 of theouter enclosure502 to fit on top of thebase508 and surround, enclosure and/or define apayload area514, which receives the payload when inserted within. The top covering506 of theinner enclosure504 may similarly have multiple walls that are sized and shaped similarly as thecavity503 of theouter enclosure502 so that the multiple walls of the top covering506 are adjacent to the walls of theouter enclosure502.
• Theshipper500 may have one ormore pillars512. The one ormore pillars512 may be formed from a first wall and a second wall. The two walls may be made from a metallic or nonmetallic material, such as a polycarbonate or other polymer. The two walls may be integrally formed and the second wall may be perpendicular to the first wall and may form a right angle where the second wall and the first wall are joined together, molded together or otherwise positioned adjacent to each other to form a corner. The one ormore pillars512 may be positioned upright and parallel to the walls of the top covering506 and around the perimeter of thecavity510 of thebase508. The one ormore pillars512 may be fastened, molded or otherwise coupled to thebase508, and may define thepayload area514 that receives the payload when the payload is inserted into theinner enclosure504. In some implementations, the one ormore pillars512 may be positioned on a lid (not shown) that is positioned on top of the top covering506 and extend downwards toward thebase508.
• When the payload is inserted, the one ormore pillars512 may receive the one or more corners of the payload, such that the one ormore pillars512 only contact a portion of the wall of the payload, such as approximately less than 15% of each wall of the payload. The one ormore pillars512 stabilize the payload within thepayload area514 so that the payload does not jostle or otherwise move during transport of theshipper500. There may be one or more gaps or interstitial spaces between the payload within thepayload area514 and the walls of theinner enclosure504 and/or theouter enclosure502 to allow for dry ice or other substance material to be placed in between to maintain the cryogenic temperatures. Moreover, the dry ice or other substance material may be positioned within thecavity510 and/or on top of the payload when positioned within thepayload area514.
• With reference now toFIG. 6, amethod600 is provided. The method may be for maintaining a payload area of a shipping container within a predetermined temperature range during shipping of a payload in the shipping container. The method may include providing an outer enclosure (block602). The outer enclosure may have side walls and a base defining a cavity in the outer enclosure. The method may include inserting an inner enclosure into the cavity of the outer enclosure (block604). In various instances the inner enclosure defines a payload area inside the inner enclosure. The method may include inserting a phase change material into the shipping container (block606). The phase change material may be liquid nitrogen or another cryogen. The phase change material may be solid carbon dioxide (e.g., dry ice). The phase change material may be frozen water (e.g., ice), or any other material suitable for maintaining the payload area of the shipping container within the predetermined temperature range.
• The method may include placing a payload into the payload area of the inner enclosure (block608) and attaching a lid on a top of the outer enclosure to cover the cavity of the outer enclosure containing the inner enclosure (block610). The method may include cooling the payload area by the phase change material to maintain the payload area within the predetermined temperature range (block610).
• In connection with the method, various aspects of the different embodiments may be incorporated. For example, the phase change material may be inserted between the inner enclosure and the outer enclosure. The predetermined temperature range may be below 0 degrees Celsius. The predetermined temperature range may be below about 0 degrees Celsius. The predetermined temperature range may be between 25 degrees Celsius to −80 degrees Celsius. The predetermined temperature range may be between about 25 degrees Celsius to about −80 degrees Celsius. The predetermined temperature range may be between −150 degrees Celsius to −190 degrees Celsius. The predetermined temperature range may be between about −150 degrees Celsius to about −190 degrees Celsius. The predetermined temperature range may be below about −150 degrees Celsius. The predetermined temperature range may be below −150 degrees Celsius. The inner enclosure may have a plurality of panels, the plurality of panels defining the payload area, wherein the payload is stabilized by the plurality of panels of the inner enclosure. Each panel of the plurality of panels may have an angled edge that forms a channel. The phase change material may be slidably inserted into the channel. The inner enclosure may have a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure defining the payload area, wherein the payload is stabilized by the nested enclosure of the inner enclosure. The inner enclosure may have a plurality of concave walls, the plurality of concave walls define the payload area. The inner enclosure may have a plurality of brackets, the plurality of brackets defining the payload area configured to receive a payload. The inner enclosure may have a top covering and a base; and a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining the payload area to receive a payload.
• Exemplary embodiments of the methods/systems have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a non-limiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed, and that that scope shall not be restricted, except in light of the appended claims and their equivalents.

Claims (48)

What is claimed is:

1. A shipping container, comprising:

an outer enclosure having a cavity; and

an inner enclosure positioned within the cavity of the outer enclosure and having a plurality of panels and a plurality of phase-change material inserts that are received within the plurality of panels, the plurality of panels defining a payload area that is configured to hold a payload.

2. The shipping container ofclaim 1, wherein the outer enclosure includes a base and a lid, wherein the lid is removable to access the inner enclosure when the inner enclosure is within the cavity of the outer enclosure.

3. The shipping container ofclaim 1, wherein each panel of the plurality of panels has an angled edge that forms a channel, wherein the channel is configured to slidably receive a phase-change material insert of the plurality of phase-change material inserts.

4. The shipping container ofclaim 1, wherein the plurality of panels include a top panel, a plurality of side panels and a bottom panel that is opposite the top panel, wherein the top panel is opposite the bottom panel and edges of the plurality of side panels interface with edges of the top panel and edges of the bottom panel, wherein the plurality of side panels are positioned between the top panel and the bottom panel.

5. The shipping container ofclaim 4, wherein each of the plurality of panels is removable and each of the plurality of phase-change material inserts are removable.

6. The shipping container ofclaim 1, wherein the outer enclosure is made from an insulative, nonmetallic material that is designed to withstand shocks and vibrations at cryogenic temperatures.

7. The shipping container ofclaim 6, wherein the insulative, nonmetallic material is a polycarbonate or other polymer.

8. The shipping container ofclaim 1, wherein the plurality of panels are positioned along or adjacent to an inner surface of walls of the outer enclosure and are made of a nonmetallic material.

9. A shipping container, comprising:

an outer enclosure having a cavity; and

an inner enclosure positioned within the cavity of the outer enclosure and having a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure having a payload area to receive a payload.

10. The shipping container ofclaim 9, wherein the top tray has an opening to allow the container to be placed within the nested enclosure.

11. The shipping container ofclaim 9, wherein the nested enclosure has one or more leaf springs that are angled inward and that are configured to contact and stabilize the payload within the nested enclosure.

12. The shipping container ofclaim 11, wherein the leaf springs, the top tray and the bottom tray are nonmetallic.

13. The shipping container ofclaim 9, wherein the top tray or the bottom tray has one or more centering guides that receive the nested enclosure and centers the nested enclosure in a center of the top tray or the bottom tray.

14. The shipping container ofclaim 9, wherein the top tray and the bottom are shaped to fit within the shipping container and interface with each wall of a plurality of walls of the outer wall when inserted into the cavity of the outer enclosure.

15. The shipping container ofclaim 9, the top tray or the bottom tray has one or more handles to allow a user to grasp or hold the top tray or the bottom tray.

16. The shipping container ofclaim 9, wherein the bottom tray is fixated within, integrally molded with or integrally formed with the outer enclosure and is not separable from the outer enclosure.

17. The shipping container ofclaim 9, wherein the nested enclosure is integrally formed with or fixated on the bottom tray or the top tray.

18. A shipping container, comprising:

an outer enclosure having a cavity; and

an inner enclosure positioned within the cavity of the outer enclosure and having a plurality of concave walls that define a payload area to receive a container.

19. The shipping container ofclaim 18, the inner enclosure has a plurality of vertices where two adjacent walls of the plurality of concave walls meet, wherein each vertex of the plurality of vertices contacts a corner of cavity of the outer enclosure.

20. The shipping container ofclaim 19, wherein the inner enclosure is star-shaped with four vertices and four concave walls.

21. The shipping container ofclaim 18, wherein the inner enclosure is nonmetallic and is configured to contact the container at an inward-most curved portion of each concave walls of the plurality of concave walls when the container is placed within the payload area of the inner enclosure.

22. The shipping container ofclaim 18, wherein the outer enclosure has a layer of insulative material or a layer of polycarbonate to withstand cryogenic temperatures.

23. A shipping container, comprising:

an outer enclosure having a cavity; and

an inner enclosure positioned within the cavity of the outer enclosure and having a plurality of brackets, the plurality of brackets defining a receiving area configured to receive a container.

24. The shipping container ofclaim 23, wherein the plurality of brackets include a first bracket and a second bracket, wherein the first bracket has a first blade, a second blade and a concave wall positioned in between the first blade and the second blade.

25. The shipping container ofclaim 24, wherein the first blade is positioned within a corner of the cavity of the outer enclosure and protrudes inward toward a center of the cavity and the second blade is positioned within a second corner of the cavity that is opposite the first corner of the cavity of the outer enclosure and protrudes inward toward the center of the cavity of the outer enclosure.

26. The shipping container ofclaim 24, wherein the first blade, the second blade and the concave wall is made from a nonmetallic material.

27. The shipping container ofclaim 24, wherein the first bracket is positioned adjacent to a first wall of the outer enclosure and the second bracket is positioned adjacent to a second wall of the outer enclosure that is opposite the first wall of the outer enclosure.

28. The shipping container ofclaim 23, wherein the outer enclosure is made from a one or more layers of insulative material or polycarbonate material.

29. A shipping container, comprising:

an outer enclosure having a cavity;

an inner enclosure positioned within the cavity of the outer enclosure and having a top covering and a base; and

a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining a payload area to receive a payload.

30. The shipping container ofclaim 29, wherein the plurality of pillars include a first pillar and a second pillar that is opposite the first pillar, wherein the first pillar receives a first corner of the payload and the second pillar receives a second corner of the payload that is opposite the first corner of the payload.

31. The shipping container ofclaim 30, wherein the plurality of pillars contact a portion of a wall of the payload and stabilize the payload so that the payload does not move during transport.

32. The shipping container ofclaim 29, wherein the plurality of pillars are fastened, molded or otherwise coupled to the base.

33. The shipping container ofclaim 29, wherein the plurality of pillars are made from a nonmetallic material.

34. A method for maintaining a payload area of a shipping container within a predetermined temperature range during shipping of a payload in the shipping container, the method comprising:

providing an outer enclosure having side walls and a base defining a cavity in the outer enclosure;

inserting an inner enclosure into the cavity of the outer enclosure, wherein the inner enclosure defines a payload area inside the inner enclosure;

inserting a phase change material into the shipping container;

placing a payload into the payload area of the inner enclosure;

attaching a lid on a top of the outer enclosure to cover the cavity of the outer enclosure containing the inner enclosure; and

cooling the payload area by the phase change material to maintain the payload area within the predetermined temperature range.

35. The method ofclaim 34, wherein the phase change material is inserted between the inner enclosure and the outer enclosure.

36. The method according toclaim 34, wherein the predetermined temperature range is between about 25 degrees Celsius to about −80 degrees Celsius.

37. The method according toclaim 34, wherein the inner enclosure comprises a plurality of panels, the plurality of panels defining the payload area, wherein the payload is stabilized by the plurality of panels of the inner enclosure.

38. The method according toclaim 37, wherein each panel of the plurality of panels has an angled edge that forms a channel, the method further comprising slidably inserting the phase-change material insert into the channel.

39. The method according toclaim 34, wherein the inner enclosure comprises a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure defining the payload area, wherein the payload is stabilized by the nested enclosure of the inner enclosure.

40. The method according toclaim 34, wherein the inner enclosure comprises a plurality of concave walls, the plurality of concave walls defining the payload area.

41. The method according toclaim 34, wherein the inner enclosure comprises a plurality of brackets, the plurality of brackets defining the payload area configured to receive a payload.

42. The method according toclaim 34, wherein the inner enclosure having a top covering and a base; and a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining the payload area to receive a payload.

43. A shipping container comprising:

an outer enclosure having side walls and a base, wherein the side walls and the base define a cavity in the outer enclosure; and

a lid attachable to the sidewalls of the outer enclosure to cover the cavity in the outer enclosure;

an inner enclosure disposed inside the cavity and configured to provide a payload area for a payload within the inner enclosure.

44. The system according toclaim 43, wherein the inner enclosure comprises a plurality of panels, the plurality of panels defining the payload area.

45. The system according toclaim 43, wherein the inner enclosure comprises a top tray, a bottom tray and a nested enclosure positioned in between the top tray and a bottom tray, the nested enclosure defining the payload area.

46. The system according toclaim 43, wherein the inner enclosure comprises a plurality of concave walls, the plurality of concave walls defining the payload area.

47. The system according toclaim 43, wherein the inner enclosure comprises a plurality of brackets, the plurality of brackets defining the payload area configured to receive the payload.

48. The system according toclaim 43, wherein the inner enclosure comprises:

a base;

a plurality of pillars positioned on and upright along the base of the inner enclosure, the plurality of pillars defining the payload area to receive a payload; and

a top covering opposite the base, wherein the pillars extend between the top covering and the base.

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