BACKGROUND
[0001] 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.
[0002] 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.
[0003] 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
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] The following aspects are preferred embodiments of the invention.
- 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 of aspect 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 of aspect 1 wherein the structural panels are comprised
of a plastic material and are interconnected by a live hinge.
- 4. The sidewall component of aspect 1 wherein the component has two structural panels.
- 5. The sidewall component of aspect 1 wherein the panels of fragile thermal insulation
are vacuum insulated panels.
- 6. The sidewall component of aspect 1 wherein the panels of fragile thermal insulation
are attached to the structural panels with hook and loop tape.
- 7. The sidewall component of aspect 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 with
aspect 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 of aspect 8 further including panels
of phase change material lining the payload retention chamber.
- 10. The thermally regulated shipping container of aspect 8 wherein the structural
panels are comprised of a plastic material and are interconnected by a live hinge.
- 11. The thermally regulated shipping container of aspect 8 wherein each sidewall component
has two structural panels.
- 12. The thermally regulated shipping container of aspect 8 wherein the panels of fragile
thermal insulation are vacuum insulated panels.
- 13. The thermally regulated shipping container of aspect 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 of aspect 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is an exploded isometric view of one embodiment of the invention.
[0010] Figure 2 is an isometric view of the container depicted in FIG. 1 fully assembled.
[0011] Figure 2A is a top view of the assembled container depicted in FIG. 1.
[0012] Figure 2B is a side view of the assembled container depicted in FIG. 2A.
[0013] Figure 3 is an isometric view of one of the sidewall components depicted in FIG.
1 disposed in a planar storage position.
[0014] Figure 4 is a cross-sectional side view of the sidewall component depicted in FIG.
3 taken along line 4-4.
[0015] Figure 4A
1 is a grossly enlarged portion of the cross-sectional side view of the sidewall component
depicted in FIG. 4 for purposes of allowing depiction of one means for detachably
attaching the thermal insulation panel to the structural sidewall panel.
[0016] Figure 4A
2 is a grossly enlarged portion of the cross-sectional side view of the sidewall component
depicted in FIG. 4 for purposes of allowing depiction of another means for detachably
attaching the thermal insulation panel to the structural sidewall panel.
[0017] Figures 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 EMBODIMENT
Definitions
[0018] 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
[0019]
- 10
- Passive Thermally Regulated Shipping Container
- 19
- Payload Retention Chamber
- 20
- Outer Structural Shell
- 21
- Structural End Panel
- 211
- Upper Structural End Panel
- 212
- Lower Structural End Panel
- 21i
- Interior Major Surface of Structural End Panel
- 21j
- Exterior Major Surface of Structural End Panel
- 21p
- Projections Extending from the Exterior Major Surface of Structural End Panel
- 21d
- Depressions in the Exterior Major Surface of Structural End Panel
- 22
- Structural Sidewall Component
- 22i
- Interior Major Surface of Structural Sidewall Component
- 22j
- Exterior Major Surface of Structural Sidewall Component
- 23
- Sidewall Panel on Structural Sidewall Component
- 23i
- Interior Major Surface of Structural Sidewall Panel
- 24
- Live Hinge Interconnecting First and Second Structural Sidewall Panels on Structural
Sidewall Component
- 30
- Thermal Insulation Panel
- 30b
- Border Area of Thermal Insulation Panel
- 40
- Phase Change Material Panels (PCM Panel)
- 50
- Means for Detachably Attaching Thermal Insulation Panel to a Structural Panel
- 501
- Hook and Loop Tape
- 502
- Pressure 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
[0020] Referring generally to FIG. 1, the present invention is directed to various components
of a modular kit operable for assembly into a passive thermally regulated stackable
shipping container
10, and a shipping container
10 assembled therefrom.
[0021] When assembled, the shipping container
10 includes an outer structural shell
20, a layer of thermal insulation
30, and optionally a layer of phase change material (not shown) retained within PCM
panels
40, defining a passive thermally regulated payload retention chamber
19.
[0022] The outer structural shell
20 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.
[0023] The outer structural shell
20 is divided into separate and independent structural end panels 21 and at least one
structural sidewall component
22. These units are capable of being repeatedly attached to and detached from one another.
[0024] Assembly of a shipping container
10 requires two structural end panels
21 - one to cover the top
211 and another to cover the bottom
212. The top
211 and bottom
212 structural end panels are preferably interchangeable with one another so that only
a single style end panel
21 need be manufactured and stocked. Use of interchangeable top
211 and bottom
212 structural end panels also simplifies assembly of the shipping container
10 as there is no need to obtain and identify separate top
211 and bottom
212 structural end panels. A technician assembling a shipping container
10 need only obtain two structural end panels
21.
[0025] The exterior major surface
21j of the structural end panels
21 may be contoured with a set of rotationally spaced longitudinal projections
21p and rotationally displaced "matching" set of longitudinal depressions
21d whereby (i) the projections
21p terminate along a single horizontal plane such that the structural end panel
21 can rest stably upon the projections
21p when placed upon a flat horizontal surface, and (ii) the projections
21p on both structural end panels
21, disposed with their exterior major surfaces
21j facing one another, will nest within corresponding depressions
21d on the other facing structural end panel
21 when one of the facing panels
21 is rotated a defined angular distance about the longitudinal axis
x21 of the panel
21. This permits interchangeable top
211 and bottom
212 structural end panels to be used in assembling a shipping container
10 while still allowing such assembled shipping containers
10 to be stably and nestably stacked upon one another by simply rotating an overlying
shipping container
10 a defined angular distance about the longitudinal axis
x10 of the shipping container
10 relative to the immediately underlying shipping container
10.
[0026] Exemplary operable arrangements of variously shaped projections
21p and depressions
21d on structural end panels
21 having various cross-sectional shapes are depicted in FIGs 5A-D, wherein depressions
21d are shaded and projections 21p are unshaded. Each is described in further detail
in TABLE ONE.
TABLE ONE
FIG# |
PROJECTIONS |
SHAPE OF PANEL |
NECESSARY ANGULAR ROTATION TO ACHIEVE NESTING |
# |
CROSS-SECTIONAL SHAPE |
5A |
4 |
Square |
Rectangle |
180° |
5B |
4 |
Triangle |
Square |
90° |
5C |
3 |
Circle |
Square |
180° |
5D |
3 |
Hexagon |
Hexagon |
60° |
[0027] Assembly of a shipping container
10 also requires at least three structural sidewall panels
23.
[0028] Structural sidewall panels
23 are grouped together on structural sidewall components 22, with the structural sidewall
panels
23 on each structural sidewall component
22 interconnected by a hinge
24, such as a live hinge.
[0029] The structural sidewall components
22 can be constructed with any number of hingedly interconnected structural sidewall
panels
23 on each structural sidewall component
22. However, as the number of panels
23 on each component
22 increases, so too does the difficulty and complexity of storing and handling the
structural sidewall component
22. A nonexhaustive listing of various geometric and configurational options for the
structural sidewall components
22 and shipping containers
10 constructed therefrom is provided below in table TWO.
TABLE TWO
SIDEWALL COMPONENT |
SHIPPING CONTAINER |
# of Panels on Each |
# of Sidewall Components |
Cross-Sectional 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 |
[0030] When the shipping container
10 is constructed from two or more structural sidewall components
22 the structural sidewall components
22, as with the end panels
21, are preferably interchangeable with one another so that only a single style structural
sidewall component
22 need be manufactured and stocked.
[0031] The structural sidewall panels
23 on each structural sidewall component
22 are configured and arranged such that the structural sidewall panels
23 can be pivoted relative to one another as between a planar storage configuration
in which the structural sidewall panels
23 do not contact one another, and a three-dimensional use configuration in which the
and structural sidewall panels
23 abut one another along a length of a border area thereof.
[0032] A panel of thermal insulation
30 is detachably attached to the interior major surface
21i of each structural end panel
21 and the interior major surface
23i of each structural sidewall panel
23 on each structural sidewall component
22. The panels of thermal insulation
30 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.
[0033] The panels of thermal insulation
30 are aligned on the structural sidewall panels
23 so that the panels of thermal insulation
30 do not contact one another when the structural sidewall panels
23 are disposed in the planar storage configuration, but abut one another along a length
of a border area
30b thereof when the structural sidewall panels
23 are disposed in the three-dimensional use configuration.
[0034] In a similar fashion, the panels of thermal insulation
30 are aligned on the structural end panels
21 so that the panels of thermal insulation
30 on the end panels
21 abut the panels of thermal insulation
30 attached to the structural sidewall panels
23 along a length of a border area thereof when the structural end panel
21 is attached to the assembled structural sidewall panels
23.
[0035] Preferred materials for use as the thermal insulating panels
30 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 insulating panels
30 and resultant loss of insulating value. In order to facilitate replacement of damaged
and/or failing thermal insulating panels
30 without requiring replacement of an entire structural end panel
21 or structural sidewall panel
23, the thermal insulating panels
30 are detachably attached to the structural end panels
21 and structural sidewall panels
23.
[0036] A wide variety of options are available for detachably attaching the thermal insulating
panels
30 to the interior major surface
21i of each structural end panel
21 and the interior major surface
23i of each structural sidewall panel
23. A preferred option is hook and loop tape
501 such as shown in FIG. 4A
1. Another preferred option is double-sided pressure sensitive adhesive tape
502 such as shown in FIG. 4A
2. Yet another preferred attachment means is a layer of pressure sensitive adhesive
coated directly upon the structural end panel
21, structural sidewall panel
23, and/or thermal insulating panel
30. 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 insulating panels
30 when the container
10 is fully assembled, leaving a gap in the layer of thermal insulation through which
significant heat loss can occur.
[0037] Referring to FIG 1, the payload retention chamber
19 can be lined with panels of phase change material (PCM panels)
40. The PCM panels
40 can be filled with any suitable phase change material, such as water or various hydrocarbons.
[0038] Either of the structural end panels
21 on the shipping container
10 can be selectively removable from the sidewall assembly for allowing insertion and
removal of goods from the payload retention chamber
19. PCM panels
40 deployed within the payload retention chamber 19 may similarly be removed for thermal
conditioning.
[0039] A primary connection mechanism
60 releasably attaches structural sidewall components
22 to one another. A secondary connection mechanism
70 releasably attaches structural end panels
21 to the longitudinal ends of a fully assembled sidewall assembly. Both the primary
60 and secondary
70 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
[0040] For simplification purposes only, assembly, use and disassembly of a shipping container
10 in accordance with this invention shall be based upon the shipping container
10 depicted in FIGs 1, 2, 2A and 2B.
[0041] The shipping container
10 depicted in FIGs 1, 2, 2A and 2B can be rapidly assembled by (i) obtaining a pair
of structural end panels
21 and a pair of structural sidewall components
22, (ii) placing one of the structural end panels
21 onto a planar horizontal surface (not shown) with the interior major surface
21i of the selected end panel
21 facing upward to establish a bottom structural end panel
212, (iii) placing both structural sidewall components
22 - pivoted into the three-dimensional use position - into orthogonal fitted engagement
with the periphery of the interior major surface
21i of the bottom structural end panel
212 and into orthogonal fitted engagement with one another to define a payload retention
chamber
19, (iv) securing the structural sidewall components
22 together with the primary connection mechanisms
60 to form an encircling structural sidewall assembly, (v) securing the structural sidewall
assembly to the bottom structural end panel
212 with the lower sets of secondary connection mechanisms
70, (vi) placing the other structural end panel
21 over the open longitudinal end of the structural sidewall assembly in orthogonal
fitted engagement with the structural sidewall components
22 to establish a top structural end panel
211, and (vii) securing the top structural end panel
211 to the structural sidewall assembly with the upper sets of secondary connection mechanisms
70.
[0042] Loading thermally labile goods (not shown) into an assembled shipping container
10 for transport includes the steps of: (a) detaching the top structural end panel
211 from the structural sidewall assembly by disengaging the upper sets of secondary
connection mechanisms
70, (b) removing the detached top structural end panel
211 from the structural sidewall assembly for providing access to the payload retention
chamber
19, (c) optionally lining the payload retention chamber
19 with thermally conditioned PCM panels
40, (d) placing the payload of thermally labile goods (not shown) into the lined or
unlined payload retention chamber
19, (e) optionally covering the open top of the loaded payload retention chamber
19 with a thermally conditioned PCM panel
40, (f) placing the top structural end panel
211 back over the open longitudinal end of the structural sidewall assembly, and (g)
securing the top structural end panel
211 to the structural sidewall assembly with the upper sets of secondary connection mechanisms
70.
[0043] Unloading thermally labile goods (not shown) from a shipping container
10 includes the steps of: (A) detaching the top structural end panel
211 from the structural sidewall assembly by disengaging the upper sets of secondary
connection mechanisms
70, (B) removing the detached top structural end panel
211 from the structural sidewall assembly, (C) removing any underlying PCM panel
40 for providing access to the payload retention chamber
19, and (D) removing the payload of thermally labile goods (not shown) from the payload
retention chamber
19.
[0044] Knocking down an unloaded shipping container
10 for return transport includes the steps of (1) removing any PCM panels
40 still in the payload retention chamber
19, (2) detaching the structural sidewall components
22 from one another by disengaging the primary connection mechanisms
60, (3) detaching the structural sidewall components
22 from the bottom structural end panel
212 by disengaging the lower sets of secondary connection mechanisms
70, and (4) removing the structural sidewall components
22 from the bottom structural end panel
212.
1. An article of commerce, comprising a sidewall component suitable for use in construction
of a passive thermally regulated knockdown shipping container, the component comprising
at least two hingedly interconnected structural panels each carrying a detachable
panel of fragile thermal insulation.
2. The article of claim 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 article component of claim 1 wherein the component has two structural panels.
4. An article of commerce, comprising a passive thermally regulated knockdown shipping
container, the container comprising at least:
(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 with
claim 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.
5. The article of claim 4 further including panels of phase change material lining the
payload retention chamber.
6. The article of claim 1 or 4 wherein the structural panels are comprised of a plastic
material and are interconnected by a live hinge.
7. The article of claim 4 wherein each sidewall component has two structural panels.
8. The article of claim 1 or 4 wherein the panels of fragile thermal insulation are vacuum
insulated panels.
9. The article of claim 1 or 4 wherein the panels of fragile thermal insulation are attached
to the structural panels with hook and loop tape.
10. The article of claim 1 or 4 wherein the panels of fragile thermal insulation are adhesively
attached to the structural panels.
11. 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.
12. 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 according to claim 11, 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.