EP4288351A1

EP4288351A1 - Passive thermally controlled condition-in-place shipping container

Info

Publication number: EP4288351A1
Application number: EP22750610.2A
Authority: EP
Inventors: Kai Goellner; George Hays; Gareth AUCKLAND; Sean Austerberry
Original assignee: Peli Biothermal LLC
Current assignee: Peli Biothermal LLC
Priority date: 2021-02-03
Filing date: 2022-01-31
Publication date: 2023-12-13
Also published as: WO2022170309A1

Abstract

A passive thermally insulated shipping container (100) with an access door (125), method of repairing the container (100), and method of thermally conditioning the container (100). The container (100) includes at least one of the novel features selected from (i) a quick repair wall panel (121), (ii) puncture resistant wall panels (121), and (iii) chill-in-place phase change thermal control panels (140).

Description

PASSIVE THERMALLY CONTROLLED CONDITION-IN-PLACE SHIPPING

CONTAINER

BACKGROUND

[0001] The shipment of temperature - sensitive goods is difficult when the shipping container itself is not independently temperature - controlled; i.e., does not have an independent power source for maintaining interior temperatures within close parameters.

[0002] Goods such as medical supplies, blood, and vaccines are often extremely temperature sensitive and need to be maintained within a given temperature range. Transport of such goods is particularly challenging. Such temperature sensitive goods are shipped to a variety of destinations where the ambient outside temperature varies from extreme cold to extreme heat.

[0003] One known solution is to use shipping containers with internal phase change material panels surrounded by exceptionally thick layers of insulation. However, the small ratio of payload chamber volume to container volume results in excessively complicated and expensive storage, handling and transport of the containers.

[0004] Another solution is to use shipping containers with internal phase change material panels surrounded by superior thermal insulation panels (i.e., vacuum insulation panels). A number of such shipping containers have been developed over the years including those disclosed and described in US Patents 7,500,593, 7,422,143, 7,257,963, 7,908,870, 7,950,246, 9,751,682, 8,424,335 and 10,766,685 the disclosures of which are hereby incorporated by reference.

[0005] One of the drawbacks associated with passive thermal controlled shipping containers that rely upon phase change material panels (PCM panels) to control the temperature of the payload chamber is the logistic complications and high labor costs associated with the thermal lifecycle of the PCM panels. Each PCM panel must be (i) constantly tracked and its thermal conditioned status monitored during thermal conditioning of the panel within a refrigeration/freezer unit, (ii) identified as a fully thermally conditioned panel and transported from the refrigeration/freezer unit to an assembly site for insertion into the container, (ii) removed from the container when thermally spent, and (iv) returned to a refrigeration/freezer unit for thermal conditioning. [0006] Hence, a substantial need exists for improving and simplifying the thermal lifecycle of PCM panels so as to simplify logistics and reduce labor costs associated with the thermal lifecycle of the PCM panels.

SUMMARY OF THE INVENTION

[0007] A first aspect of the invention is a passive thermally insulated shipping container with an access door and a quick repair wall panel.

[0008] A second aspect of the invention is a method of replacing insulation in the wall of a passive thermally controlled shipping container in accordance with the first aspect of the invention.

[0009] A third aspect of the invention is a chill-in-place passive thermally controlled shipping container with an access door.

[0010] A fourth aspect of the invention is a method of thermally conditioning a passive thermally controlled shipping container in accordance with the third aspect of the invention.

[0011] A fifth aspect of the invention is a passive thermally controlled shipping container with an access door and a quick disconnect phase change thermal control panel.

[0012] A sixth aspect of the invention is a chill-in-place passive thermally controlled shipping container with an access door and a thermal conditioning management system.

[0013] A seventh aspect of the invention is a puncture resistant passive thermally insulated shipping container.

[0014] A first embodiment of the first aspect of the invention has a frame defining wall openings, and wall panels releasably secured to the frame over each wall opening defining an enclosed thermally insulated chamber. At least one of the wall panels is a quick repair wall panel that includes (A) an inner structural layer and an outer structural layer defining a void volume gap therebetween having at least one open edge, and (B) a layer of thermal insulation positioned within the void volume gap wherein the thermal insulation layer is fixed in position within the void volume gap when the at least one quick repair wall panel is secured to the frame, and removable from the void volume gap through the open edge between the layers when the at least one quick repair wall panel is detached from the frame.

[0015] The layer of thermal insulation within each quick repair wall panel of the first embodiment of the first aspect of the invention preferably comprises one or more insulation cartridges with each cartridge comprising a plurality of vacuum insulation panels secured together in-edge-to-edge arrangement and insertable into and removable from the void volume gap as a single unit.

[0016] A second embodiment of the first aspect of the invention further includes at least one phase change thermal control panel lining the thermally insulated chamber to define a thermal controlled chamber. The at least one phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

[0017] A first embodiment of the second aspect of the invention includes the steps of (-) detaching a quick repair wall panel from the frame of a passive thermally insulated shipping container in accordance with the first embodiment of the first aspect of the invention having one or more insulation cartridges within each quick repair wall panel, (-) pulling the insulation cartridge out from the void volume gap between the inner structural layer and the outer structural layer of the detached wall panel through the open edge, (-) inserting a new insulation cartridge into the void volume gap between the inner structural layer and the outer structural layer of the detached wall panel through the open edge, and (-) reattaching the detached wall panel to the frame

[0018] A second embodiment of the second aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to the entry coupling and the return coupling on a container in accordance with the second embodiment of the first aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0019] A first embodiment of the third aspect of the invention has walls defining an enclosed chamber, thermal insulation lining the chamber to define a thermally insulated chamber, and at least one phase change thermal control panel lining the thermal controlled chamber to define a thermal controlled chamber. The at least one phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tubeside outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

[0020] The first embodiment of the third aspect of the invention preferably includes an entry coupling and a return coupling in fluid communication with the tube-side inlet and the tube-side outlet respectively, wherein the couplings are accessible from exterior the container for cycling coolant from a source of chilled coolant through the tube.

[0021] A second embodiment of the third aspect of the invention has wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, and a phase change thermal control panel secured to an inner structural layer of one of the wall panels selected from the wall panels forming the sidewalls and the top, the phase change thermal control panel. The wall panels forming the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

[0022] The second embodiment of the third aspect of the invention preferably includes an entry coupling and a return coupling in fluid communication with the tube- side inlet and the tube-side outlet respectively, wherein the couplings are accessible from exterior the container for cycling coolant from a source of chilled coolant through the tube.

[0023] A third embodiment of the third aspect of the invention has wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, and a phase change thermal control panel secured to the inner structural layer of each of at least two of the wall panels selected from the wall panels forming the sidewalls and the top. The wall panels forming the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within each sealed volume and defining a tube- side coolant flow path through the shell from a tube- side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The tubes of at least two phase change thermal control panels on different wall panels are in fluid communication with one another and with a single entry coupling and a single return coupling accessible from external the container.

[0024] A fourth embodiment of the third aspect of the invention has wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, and a plurality of phase change thermal control panels secured to the inner structural layer of one wall panel selected from the wall panels forming the sidewalls and the top. The wall panels forming the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer. Each phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The tubes of the phase change control panels are in fluid communication with one another and with a single entry coupling and a single return coupling accessible from external the container.

[0025] A fifth embodiment of the third aspect of the invention has wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, and at least three phase change thermal control panels secured to the inner structural layer of one or more wall panels selected from the wall panels forming the sidewalls and the top. The wall panels forming the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer. Each phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The phase change thermal control panels are grouped into two separate and distinct sets with (a) a first set of one or more phase change thermal control panels in fluid communication with one another to define a common first set tube-side coolant flow path through a first set of tubes from a common first tube-side inlet to a common first tube-side outlet, and (ii) a second set of one or more phase change thermal control panels in fluid communication with one another to define a common second set tubeside coolant flow path through a second set of tubes from a common second tube-side inlet to a common second tube-side outlet.

[0026] The fifth embodiment of the third aspect of the invention can optionally include either (1) a single entry coupling and a single return coupling accessible from exterior the container in fluid communication with both the first set of tubes and the second sets of tubes, or (2) a first pair of entry and return couplings accessible from exterior the container in fluid communication with the common first tube-side inlet and the common first tube-side outlet respectively, and a second pair of entry and return couplings accessible from exterior the container in fluid communication with the common second tube-side inlet and the common second tube-side outlet respectively, with the first pair of couplings and the second pair of couplings operable for separately and independently cycling thermally conditioning coolant through each of the first set of tubes and the second set of tubes respectively.

[0027] When the fifth embodiment of the third aspect of the invention includes a single entry coupling and a single return coupling the invention preferably includes one or more valves selectively operable between three settings selected from (i) a first setting providing fluid communication from the single entry coupling to the tubes of both the first set and the second set of phase change thermal control panels, (ii) a second setting providing fluid communication from the single entry coupling to the tubes of only the first set of phase change thermal control panels to the exclusion of the second set of phase change thermal control panels, and (iii) a third setting providing fluid communication from the single entry coupling to the tubes of only the second set of phase change thermal control panels to the exclusion of the first set of phase change thermal control panels.

[0028] A sixth embodiment of the third aspect of the invention has a frame defining wall openings, wall panels releasably secured to the frame over each wall opening defining an enclosed thermally insulated chamber, and at least one phase change thermal control panel lining the thermal controlled chamber to define a thermal controlled chamber. At least one of the wall panels is a quick repair wall panel that includes (A) an inner structural layer and an outer structural layer defining a void volume gap therebetween having at least one open edge, and (B) a layer of thermal insulation positioned within the void volume gap wherein the thermal insulation layer is fixed in position within the void volume gap when the at least one quick repair wall panel is secured to the frame, and removable from the void volume gap through the open edge between the layers when the at least one quick repair wall panel is detached from the frame. The at least one phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

[0029] A first embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the preferred version of the passive thermally controlled shipping container in accordance with the first embodiment of the third aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0030] A second embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the preferred version of the passive thermally controlled shipping container in accordance with the second embodiment of the third aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0031] A third embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the passive thermally controlled shipping container in accordance with the third embodiment of the third aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0032] A fourth embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the passive thermally controlled shipping container in accordance with the fourth embodiment of the third aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel. [0033] A first alternative fifth embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to the single entry coupling and the single return coupling on a container in accordance with the fifth embodiment of the third aspect of the invention equipped with a single entry coupling and a single return coupling and at least one valve, (-) setting the valve to one of the three settings, and (-) cycling chilled coolant from the chiller through the tubes of one or both of the first set and the second set of phase change thermal control panels based upon valve setting, on the passive thermally controlled shipping container

[0034] A second alternative fifth embodiment of the fourth aspect of the invention includes the steps of (-) connecting a first outlet line and a first return line of a chiller to the first entry coupling and the first return coupling on a container in accordance with the fifth embodiment of the third aspect of the invention equipped with first and second pairs of entry and return couplings, (-) connecting a second outlet line and a second return line of a chiller selected from the same chiller and a different chiller, to the second entry coupling and the second return coupling on the container respectively, and (-) cycling chilled coolant from the one or more chillers through the tubes of the first set and the second set of phase change thermal control panels.

[0035] A sixth embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the passive thermally controlled shipping container in accordance with the sixth embodiment of the third aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0036] A seventh embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the passive thermally controlled shipping container in accordance with the first embodiment of the fifth aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

[0037] An eighth embodiment of the fourth aspect of the invention includes the steps of (-) connecting an outlet line and a return line of a chiller to entry and return couplings respectively on the passive thermally controlled shipping container in accordance with the second embodiment of the fifth aspect of the invention, and (-) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel. [0038] A first embodiment of the fifth aspect of the invention has a hollow core frame defining wall openings, wall panels releasably secured to the frame over each wall opening defining an enclosed chamber, at least one phase change thermal control panel lining the chamber to define a thermal controlled chamber, a coolant entry coupling and a coolant return coupling accessible from exterior the container, a first length of conduit extending within the hollow core frame placing the coolant entry coupling in fluid communication with a tube-side inlet on the at least one phase change thermal control panel, a second length of conduit extending within the hollow core frame placing a tube-side outlet on the at least one phase change thermal control panel in fluid communication with the coolant return coupling, and a disconnect coupling proximate each of the tube-side inlet and tube-side outlet for disconnecting the tube from the first and second lengths of conduit. The at least one phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

[0039] A second embodiment of the fifth aspect of the invention has a hollow core frame defining wall openings, wall panels releasably secured to the frame over each wall opening defining an enclosed thermally insulated chamber, a phase change thermal control panel secured to an inner structural layer of one of the wall panels, an entry coupling and a return coupling accessible from exterior the container, a first length of conduit extending within the hollow core frame placing the coolant entry coupling in fluid communication with a tube-side inlet on the phase change thermal control panel, a second length of conduit extending within the hollow core frame placing a tube-side outlet on the phase change thermal control panel in fluid communication with the coolant return coupling, and an in-line disconnect coupling proximate each of the tube-side inlet and tube-side outlet for disconnecting the tube from the first and second lengths of conduit for facilitating installation, removal and replacement of the phase change thermal control panel. A majority of the wall panels comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. Thermally conditioning coolant from a source of chilled coolant connected to the couplings can be cycled through the tube for thermally conditioning the supply of phase change material retained within the shell. The in-line disconnect couplings facilitate installation, removal and replacement of the phase change thermal control panel.

[0040] A first embodiment of the sixth aspect of the invention is a container having walls that define an enclosed chamber, thermal insulation lining the chamber to define a thermally insulated chamber, a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, and a thermal conditioning management system. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The thermal conditioning management system includes at least one temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and a controller operable for periodically receiving the transmitted measured temperature throughout a thermal conditioning period and discontinuing flow of chilled coolant through the tube when the measured temperature is below a threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid.

[0041] A second embodiment of the sixth aspect of the invention is a container having walls that define an enclosed chamber, thermal insulation lining the chamber to define a thermally insulated chamber, a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, and a thermal conditioning management system. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The thermal conditioning management system includes a temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and a controller operable for periodically receiving the transmitted measured temperature throughout a thermal conditioning period and a thermally conditioned maintenance period for (i) actuating flow of chilled coolant through the tube when the measured temperature is above a first threshold value indicative of commencement of phase change transition of the phase change material retained within the sealed volume from a solid to a liquid, and (ii) discontinuing flow of chilled coolant through the tube when the measured temperature is below a second threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid.

[0042] A third embodiment of the sixth aspect of the invention is a container having walls that define an enclosed chamber, thermal insulation lining the chamber to define a thermally insulated chamber, a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, and a thermal conditioning management system. The phase change thermal control panel is a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube- side inlet to a tube- side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume. The thermal conditioning management system includes a flow control valve for governing flow of coolant through the tube, a temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and a controller in communication with the flow control valve and the temperature sensor for periodically receiving the transmitted measured temperature throughout a thermal conditioning and thermally conditioned maintenance period and instructing the flow control valve to regulating flow of coolant as between (i) a first high flow rate of chilled coolant through the tube when the measured temperature is above a first threshold value indicative of commencement of phase change transition of the phase change material retained within the sealed volume from a solid to a liquid, and (ii) a second low or zero flow rate of chilled coolant through the tube when the measured temperature is below a second threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid.

[0043] A first embodiment of the seventh aspect of the invention is a container having a top, bottom and sidewalls defining an enclosed chamber, thermal insulation lining the chamber to define a thermally insulated chamber, openings below the bottom of the container configured and arranged to accommodate a pair of forks on a forklift for lifting and transporting the container, and a protective layer of an aromatic polyamide fiber sheet covering at least a portion of the outer exterior surface of at least two of the sidewalls.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 is a perspective view of one embodiment of a thermally controlled shipping container in accordance with the invention with the both halves of the vertically split access door fully open.

[0045] Figure 2 is a perspective view of the thermally controlled shipping container depicted in Figure 1 with both halves of the vertically split access door closed and a portable chiller in fluid communication with the entry and return couplings on the container.

[0046] Figure 3 is a perspective view of the frame component of the thermally controlled shipping container depicted in Figure 1.

[0047] Figure 4 is a perspective view of the thermally controlled shipping container depicted in Figure 1 depicting detachment of a side wall panel and removal of an insulation cartridge.

[0048] Figure 5A is an enlarged cross-sectional side view of a portion of a quick repair wall panel in accordance with the invention with the insulation layer inserted.

[0049] Figure 5B is an enlarged cross-sectional side view of a portion of the quick repair wall panel depicted in Figure 5A with the insulation layer removed.

[0050] Figure 6 is a flat pattern schematic view of the interior of the container walls depicting a first group of phase change thermal control panels connected in series to the top wall, a second group of phase change thermal control panels connected in parallel to one sidewall, and a third group of phase change thermal control panels connected in parallel to another sidewall. [0051] Figure 7 is a schematic side view of one embodiment of a phase change thermal control panel sans phase change material and with a portion of the shell removed to facilitate viewing of the internal structure.

[0052] Figure 8A is a cross-sectional view of one embodiment of a phase change thermal control panel sans phase change material with fully symmetrical heat exchange fins.

[0053] Figure 8B is a cross-sectional view of another embodiment of a phase change thermal control panel sans phase change material with heat exchange fins asymmetrical about a vertical plane.

[0054] Figure 9 is a schematic cross-sectional view of one embodiment of a hollow core frame with conduit extending therethrough.

[0055] Figure 10 is a schematic view of one embodiment of an entry and return coupling board.

[0056] Figure 11 is a side view of one embodiment of a bank of outlet and return lines on a chiller.

[0057] Figure 12 is a program flowchart for one embodiment of a control program for automatic cold thermal conditioning and cold thermal maintenance of a phase change thermal control panel.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Definitions

[0058] As utilized herein, including the claims, the term “symmetrical”, unless otherwise specified, means symmetrical about both a vertical axis of symmetry and a horizontal axis of symmetry.

[0059] As utilized herein in reference to a component of a container, including the claims, the term “vertically symmetrical” means symmetrical about an axis of symmetry parallel to the direction of gravity when the container is resting on a flat surface in an upright position.

[0060] As utilized herein in reference to a component of a container, including the claims, the term “horizontally symmetrical” means symmetrical about an axis of symmetry perpendicular to the direction of gravity when the container is resting on a flat surface in an upright position. [0061] As utilized herein, including the claims, the term “asymmetrical” , unless otherwise specified, means lack of symmetry about both a vertical axis of symmetry and a horizontal axis of symmetry.

[0062] As utilized herein in reference to a component of a container, including the claims, the term “vertically asymmetrical” means lack of symmetry about an axis of symmetry parallel to the direction of gravity when the container is resting on a flat surface in an upright position.

[0063] As utilized herein in reference to a component of a container, including the claims, the term “horizontally asymmetrical” means lack of symmetry about an axis of symmetry perpendicular to the direction of gravity when the container is resting on a flat surface in an upright position.

[0064] As utilized herein, including the claims, the phrase “thermal insulating” means a “k” value of less than 0.06 W/mK and a layer is a layer of thermal insulation when the layer is constructed of a material that is thermal insulating.

Nomenclature Construction

Base Shipping Container

[0065] We have invented a passive thermally insulated shipping container 100 that includes at least one of the novel features selected from a quick repair wall panel 121, puncture resistant wall panels 121, and a chill-in-place phase change thermal control panel 140.

[0066] Referring to Figures 1-4, the shipping container 100 is preferably cuboidal with a cuboidal payload chamber 129. The payload chamber 129 preferably has a floor 124 sized and dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container 100.

[0067] The shipping container 100 is formed of wall panels 121 configured to form a top wall 120t, a bottom wall 120b and sidewalls 120s that define an enclosed chamber 1291. Each wall 120t, 120b and 120s can comprise a single wall panel 121 or a plurality of edge-to- edge arranged wall panels 121.

[0068] One of the sidewalls 120s comprises an access door 125. The access door 125 can be a vertically split door 125 with each door half 125i and 1252 pivotable about a respective vertical axis 125zi and 125zi between an open position and a closed position. When the shipping container 100 is cuboidal each door half 125i and 1252 is preferably pivotable approximately 270° against a corresponding sidewall wall 123 of the shipping container 100. Automatic door holders 126 can be employed to hold the door halves 125i and 1252 in the fully open position to prevent the door halves 125i and 1252 from prematurely pivoting towards the closed position during loading of the container 100. Suitable door holders include the various widely available commercial grade magnetic and mechanical door holders.

[0069] Referring to Figures 1 and 2, a door open sensor 172 can be provided for detecting the position of the access door 125 as between the open position and the closed position and generating at least one audibly and/or visually perceptible signal selected from a first signal when the door 125 is in the open position and a second signal when the door 125 is in the closed position. The first signal is preferably generated only when the door 125 is arrested in the fully open position.

[0070] Referring to Figures 1-4 with specific reference to Figure 3, the walls 120t, 120b and 120s can be secured directly to one another to form the container 100. Alternatively, the walls 120 may each be secured to a solid or hollow core frame 110 with each wall 120, comprised of one or more wall panels 121, covering a wall opening 119 defined by the frame 110 (e.g., a top wall 120t comprised of one or more top wall panels 121t covering a top wall opening 119t, a bottom wall 120b comprised of one or more bottom wall panels 121b covering a bottom wall opening 119b and sidewall walls 120s each comprised of one or more sidewall panels 121s covering sidewall wall openings 119s). The frame 110 can be constructed from any material capable of providing the necessary structural integrity, with metal such as aluminum generally preferred.

[0071] Referring to Figures 5A and 5B, a layer of thermal insulation 130 lines the chamber 129i to define a thermally insulated chamber 1292. The layer of thermal insulation 130 can be a component of the wall panels 121, such as a layer sandwiched between an inner structural layer 120i and an outer structural layer 120o.

[0072] The inner and outer structural layers 120i and 120o can be selected from any material having sufficient structural integrity including wood panels, wood composite panels, plastic panels and plastic composite panels. A particularly suited lightweight yet structurally robust material is a plastic composite panel comprising a thermoplastic honeycomb core fused between plastic face sheets commercially available from a number of suppliers including Composites GmbH & Co KG of Rottenbach, Germany under the brand MONOPAN, and Hangzhou Holycore Composite Materials Co. Ltd of Hangzhou, China under the brand HOLYPAN.

[0073] Vacuum insulation panels 132 are the preferred thermal insulation material due to their superior thermal resistance (i.e., low thermal k values).

[0074] Referring to Figures 1, 2 and 4, openings 128 configured and arranged to accommodate insertion of the forks of a forklift for lifting and transporting the container 100 can be provided below the floor 124 of the container 100.

Quick Repair Wall Panel 120

[0075] Vacuum insulation panels are notorious for premature loss of insulating value. The panels are prone to loss of vacuum, often as a result of a breach through the enclosing membrane caused by normal wear and tear, which results in a substantial loss in thermal resistance. Hence, vacuum insulation panels require periodic inspection and replacement of spent panels (i.e. panels no longer under sufficient vacuum). [0076] Referring to Figures 4, 5A and 5B, one of the novel features is a quick repair wall panel 121 that permits quick and easy access to and replacement of spent vacuum insulation panels 132 in the quick repair wall panel 121 even though the vacuum insulation panels 132 are protectively hidden between an inner structural layer 121i and an outer structural layer 121o of the quick repair wall panel 121.

[0077] The quick repair wall panel 121 has an inner structural layer 121i and an outer structural layer 121o that define a void volume gap therebetween 121vv with at least one open edge (not shown). The layer of thermal insulation 130, typically a plurality of edge-to- edge arranged vacuum insulation panels 132, is positioned within the void volume gap 121vv. The layer of thermal insulation 130 is fixed in position within the void volume gap 121vv when the quick repair wall panel 121 is secured to the frame 110, and removable from and insertable into the void volume gap 121vv through the open edge between the inner structural layer 121i and the outer structural layer 121o when the quick repair wall panel 121 is detached from the frame 110. Once removed the thermal insulation 130 can readily be inspected, and spent or otherwise damaged thermal insulation panels replaced. The quick repair wall panel 121 can permit insertion and removal of the layer of thermal insulation 130 without a tool once the wall panel 121 is detached from the frame 110.

[0078] Vacuum insulation panels 132 can be formed into a unitary thermal insulation cartridge 135 to facilitate removal from and insertion into the void volume gap 120vv. A thermal insulation cartridge 135 comprises a plurality of vacuum insulation panels 132 secured together in-edge-to-edge arrangement for insertion into and removal from the void volume gap 120vv as a single unit. The plurality of vacuum insulation panels 132 can be retained within a peripheral frame 136. The frame 136 can include a grippable element 137, such as finger divots, a recessed handle or the like.

[0079] One, some or all of the wall panels 121 of the thermally insulated shipping container 100 can be quick repair wall panels 121.

Puncture Resistant Wall Panels 120

[0080] Referring to Figures 5A and 5B, the wall panels 121 of the shipping container 100 can be protected against damage from a strike or blow, such as a strike from a fork of a moving forklift, by covering at least a portion of the exterior surface of at least two and preferably all of the sidewalls 120s of the shipping container 100 with a protective layer of an aromatic polyamide fiber sheet 300. [0081] Aromatic polyamide fiber, typically referenced as aramid fiber, suitable for use in manufacture of the exterior protective aromatic polyamide fiber sheets are available from a number of commercial sources including DuPont under the marks Kevlar and Nomex, Twaron BV under the mark Twaron, Kolon Industries under the mark Heracron, Hyosung Advanced Materials under the mark Alkex, Teijin Aramid under the mark Technora, Kerrnel Company under the mark Kerrnel, Warwicj Mills, Inc. under the mark Conex, and Tantai Tayho Advanced Materials Co., Ltd under the mark Newstar.

[0082] The aromatic polyamide fiber sheet 300 preferably covers at least the bottom third of the exterior surface of the sidewalls 120s.

Phase Change Thermal Control Panel 140

Panel 140 Construction

[0083] Referring to Figure, 5A, 5B and 6, the shipping container 100 can include at least one phase change thermal control panel 140, preferably at least one phase change thermal control panel 140 secured to each of at least two of the walls 120, and most preferably at least one phase change thermal control panel 140 secured to each of at least two of the sidewalls 120s and the top wall 121t so as to line the thermally insulated chamber 1292 of the container 100 to define a thermal controlled chamber 129 .

[0084] Referring to Figures 7, 8 A and 8B, the phase change thermal control panel 140 is a shell and tube heat exchanger that includes a shell 142 surrounding at least one tube 144. The shell 142 defines a sealed volume 143 with a supply of phase change material 150 retained within the sealed volume 143. The tube(s) 144 is in heat exchange communication with the supply of phase change material 150 retained within the sealed volume 143. The tube(s) 144 defines a tube-side coolant flow path 145 through the shell 142 from a tube-side inlet 145i to a tube-side outlet 1452 for allowing flow of coolant (not shown) through the tube(s) 144 to effect thermal cooling of the phase change material 150 retained within the sealed volume 143.

Layout and Coolant Fluid Flow Through Panels 140

[0085] Referring to Figure 10, to facilitate cycling of coolant (not shown) from a source of chilled coolant 500 through the tube side channel(s) 145 in order to thermally condition the phase change material 150 within the shell 142, the tube-side inlet 145i and the tube-side outlet 1452 are preferably in fluid communication with an entry coupling 161 and a return coupling 162 accessible from exterior the container 100, respectively. The entry coupling 161 and return coupling 162 are preferably quick-disconnect couplings to facilitate connection and disconnection thereof to the outlet line 501 and return line 502 of a chiller 500, respectively.

[0086] Referring to Figures 7, 9 and 10, the tube-side inlet 145i and tube-side outlet

1452 can be placed in fluid communication with an entry coupling 161 and a return coupling 162, respectively, by employing a hollow core 118 frame 110, and running conduit 164 within the hollow core 118, with a first length of conduit 164i extending from the entry coupling 161 to the tube-side inlet 145i and a second length of conduit 1642 extending from the tube-side outlet 1452 to the return coupling 162. An in-line disconnect coupling 147, such as a quick disconnect coupling or an AN fitting, can be provided at the end of the tube-side inlet 145i and tube-side outlet 1452 for facilitating connection and disconnection of the tube 144 from each of the first and second lengths of conduit 164i and 1642. The in-line disconnect couplings 147 facilitate installation, removal and replacement of phase change thermal control panels 140.

[0087] Referring to Figure 6, when a phase change thermal control panel 140 is secured to each of several walls 120 of the shipping container 100, the tubes 144 of the plurality of phase change thermal control panels 140 can be placed in fluid communication with one another, either in series or in parallel, and with a single entry coupling 161 and a single return coupling 162 accessible from external the container 100.

[0088] When more than one phase change thermal control panel 140 is secured to the same wall 120 of the shipping container 100, the tubes 144 of the plurality of phase change thermal control panels 140 on the same wall 120 can be placed in fluid communication with one another, either in series or in parallel, and with a single entry coupling 161 and a single return coupling 162 accessible from external the container 100.

[0089] When the container 100 is equipped with three or more phase change thermal control panels 140, the phase change thermal control panels 140 can be grouped into two or more separate and distinct sets 140_n (e.g., a first set 140i, a first set 1402, a first set 140s, etc.) for separate thermal conditioning (i.e., the tubes 144 of the phase change thermal control panels 140 in each set 140_n are in fluid communication with one another and define a common tube-side coolant flow path through that set 140_n from a common tube-side inlet

1453 to a common tube-side outlet 1454.). When grouped into sets, the tubes 144 of each set 140_n can be plumbed so that each set 140_n is never in fluid communication with another set 140_n, or alternatively the sets 140_n are plumbed so that each set 140_n can be selectively placed in fluid communication with another set 140_n via flow control valves 174 operable for permitting fluid communication between sets 140_n when open and prohibiting fluid communication between sets 140_n when closed.

[0090] Referring to Figure 10, when the container 100 is equipped with separate sets 140n of phase change thermal control panels 140, each set 140n can be in fluid communication with a dedicated pair of entry and return couplings 161_n and 162_n accessible from exterior the container 100. This configuration allows cycling of different temperature coolants (not shown) through different sets 140_n.

[0091] Alternatively, the sets 140_n of phase change thermal control panels 140 can be in common fluid communication with a single pair of entry and return couplings 161 and 162 accessible from exterior the container 100, with flow of coolant (not shown) through a given set 140_n controlled via one or more flow control valves 174 operable for permitting coolant fluid flow into a given set 140_n when open and prohibiting coolant fluid flow into a given set 140_n when closed.

[0092] In a specific embodiment, the flow control valve 174 can be a valve selectively operable between three settings selected from (i) a first setting providing fluid communication from the single entry coupling 161 to the tubes 144 of both a first set and a second set of phase change thermal control panels 140i and 1402, (ii) a second setting providing fluid communication from the single entry coupling 161 to the tubes 144 of only the first set of phase change thermal control panels 140i to the exclusion of the second set of phase change thermal control panels 1402, and (iii) a third setting providing fluid communication from the single entry coupling 161 to the tubes 144 of only the second set of phase change thermal control panels 1402 to the exclusion of the first set of phase change thermal control panels 140i.

[0093] Referring to Figures 5A and 5B, a shield plate 127 can sandwich the phase change thermal control panel 140 between the shield plate 127 and the wall panels 121 forming the walls 120 of the container 100 to protect the phase change thermal control panel 140 from damage caused by striking the phase change thermal control panel 140 during loading, unloading and/or shifting of the payload during transport.

[0094] In a preferred embodiment at least some of the wall panels 121 forming the walls 120 of the container 100 comprise thermal insulation 130 sandwiched between an inner structural layer 121i and an outer structural layer 121o, and a phase change thermal control panel 140 is secured to the inner structural layer 121i of a wall panel 121. A phase change thermal control panel 140 is preferably secured to a wall panel 121 forming a sidewall 120s and/or a top wall 120t of the container 100.

[0095] Referring to Figures 7, 8 A and 8B, the tube(s) 144 preferably have heat exchange fins 148 extending radially from the tube(s) 144 into the sealed volume of the shell 142 for enhancing heat transfer between the coolant (not shown) flowing through the tube(s) 144 and the phase change material 150 retained within the sealed volume 143. The heat exchange fins 148 may be branched 149 to further enhance heat transfer.

[0096] The heat exchange fins 148 may be configured and arranged in a symmetrical pattern about the circumference of the tube(s) 144 to provide uniform heat exchange in all radial directions from the tube(s) 144, or configured and arranged in an asymmetrical pattern about a vertical or horizontal plane passing through the center of the tube(s) 144 so as to influence a greater heat exchange in a particular radial segment extending from the tube(s) 144.

[0097] The heat exchange fins 148 are preferably axially elongated ribs circumferentially spaced about the tube(s) 144, with a cross-section capable of unitary one- piece extrusion of both tube 144 and fins 148.

Auto Control to Thermally Condition a Panel 140

[0098] Referring to Figures 7, 10 and 12, a container 100 equipped with a phase change thermal control panel 140 can further include a system for controlling thermal conditioning of the phase change material 150 within the shell 142 of the phase change thermal control panel 140. The thermal conditioning system includes a temperature sensor 176 and a controller 178. The temperature sensor 176 is placed to periodically measure the temperature of the phase change material 150 retained within the shell 142 of the phase change thermal control panel 140 and transmit the measured temperature to the controller 178.

[0099] To thermally condition the phase change material 150 retained within the shell 142 of a phase change thermal control panel 140, the controller 178 periodically receives the transmitted measured temperature from the temperature sensor 176 throughout a thermal conditioning period, and discontinues flow of chilled coolant (not shown) through the tube 144 of the phase change thermal control panel 140 when the measured temperature T_n is below a first threshold value TFrozen, wherein the first threshold value TFrozen is selected so that a measured temperature T_n falling below the first threshold value Trrozen is indicative of completion of phase change transition of the phase change material 150 retained within the shell 142 of the phase change thermal control panel 140 from a liquid to a solid. The controller 178 can discontinue flow of chilled coolant (not shown) by closing one or more coolant flow control valves 174 or by shutting off the pump (not separately shown) on the chiller 500.

[0100] Alternatively, instead of discontinuing flow of chilled coolant (not shown) through the tube 144 of the phase change thermal control panel 140 when the measured temperature T_n is below a first threshold value Trrozen, the controller 178 can restrict flow of chilled coolant (not shown) by partially closing one or more coolant flow valves 174. The restricted flow option facilitates maintenance of the phase change material 150 in the thermally conditioned frozen state while the container 100 awaits commencement of transport.

[0101] Multiple temperature sensors 176 can be spaced along a given single phase change thermal control panel 140, with the controller 178 programmed to discontinue flow of chilled coolant (not shown) through the tubes 144 when a plurality of the temperature sensors 176, or even all of the temperature sensors 176 on the given single phase change thermal control panel 140 are transmitting a measured temperature T_n below the first threshold value TF rozen.

[0102] When the container 100 is equipped with multiple phase change thermal control panels 140 having tubes 144 in common fluid communication with one another, a temperature sensor 176 can be employed with one, some or all of the phase change thermal control panels 140. When multiple temperature sensors 176 are employed, the controller 178 can discontinue flow of chilled coolant (not shown) through the tubes 144 when all temperature sensors 176 are transmitting a measured temperature T_n below the first threshold value TF rozen.

[0103] When the container 100 is equipped with zoned phase change thermal control panels 140 (i.e., phase change thermal control panels 140 grouped into two or more separate and distinct sets 140_n for separate thermal conditioning), a temperature sensor 176 can be employed for at least one of the phase change thermal control panels 140 in each set 140_n, with flow of chilled coolant (not shown) through the tubes 144 of each set 140_n discontinued for that set 140_n and only that set 140_n, when the temperature T_n measured by the temperature sensor 176 associated with that set 140_n is below the first threshold value TFrozen.

Auto Control to Maintain Panel 140 in a Thermal Conditioned State

[0104] Referring to Figures 7, 10 and 12, a container 100 equipped with a phase change thermal control panel 140 can further include a system for maintaining the phase change material 150 within the shell 142 of the phase change thermal control panel 140 in a thermally conditioned frozen state while awaiting commencement of transport. The thermal conditioning system includes a temperature sensor 176 and a controller 178. The temperature sensor 176 is placed to periodically measure the temperature of the phase change material 150 retained within the shell 142 of the phase change thermal control panel 140 and transmit the measured temperature to the controller 178.

[0105] To maintain the phase change material 150 retained within the shell 142 of a phase change thermal control panel 140 in a fully thermally conditioned state, the controller 178 periodically receives the transmitted measured temperature from the temperature sensor 176 throughout a thermal conditioning period, and restart flow of chilled coolant (not shown) through the tube 144 of the phase change thermal control panel 140 when the measured temperature T_n is above a second threshold value TMeit, wherein the second threshold value TMeit is selected so that a measured temperature Tn falling above the second threshold value TMeit is indicative of a commencement of a phase change transition of the phase change material 150 retained within the shell 142 of the phase change thermal control panel 140 from a solid to a liquid. The controller 178 can restart flow of chilled coolant (not shown) by opening one or more coolant flow control valves 174 or by turning on the pump (not separately shown) on the chiller 500.

[0106] Multiple temperature sensors 176 can be spaced along a given single phase change thermal control panel 140, with the controller 178 programmed to restart flow of chilled coolant (not shown) through the tubes 144 when a plurality of the temperature sensors 176, or even all of the temperature sensors 176 on the given single phase change thermal control panel 140 are transmitting a measured temperature T_n above the second threshold value TMeit.

[0107] When the container 100 is equipped with multiple phase change thermal control panels 140 having tubes 144 in common fluid communication with one another, a temperature sensor 176 can be employed with one, some or all of the phase change thermal control panels 140. When multiple temperature sensors 176 are employed, the controller 178 can restart flow of chilled coolant (not shown) through the tubes 144 when one, some or all of the temperature sensors 176 are transmitting a measured temperature T_n above the second threshold value TMeit.

[0108] When the container 100 is equipped with zoned phase change thermal control panels 140 (i.e., phase change thermal control panels 140 grouped into two or more separate and distinct sets 140_n for separate thermal conditioning), a temperature sensor 176 can be employed for at least one of the phase change thermal control panels 140 in each set 140_n, with flow of chilled coolant (not shown) through the tubes 144 of each set 140_n restarted for that set 140_n and only that set 140_n, when the temperature T_n measured by the temperature sensor 176 associated with that set 140_n is above the second threshold value TMeit.

Method of Wall Repair

[0109] Referring to Figures 4, 5 A and 5B, the thermal insulation in a quick repair wall panel 121 of a passive thermally insulted or passive thermally controlled shipping container 100 can be removed for inspection and replacement by (-) detaching the quick repair wall panel 121 from the frame 110, and (-) pulling the insulation cartridge 135 out from the void volume gap 121vv between the inner structural layer 121i and the outer structural layer 121o of the detached wall panel 121 through the open edge.

[0110] When the insulation cartridge 135 is excessively worn or spent, the detached quick repair wall panel 121 can be repaired by (-) inserting a new insulation cartridge 135 into the void volume gap 121vv through the open edge, and (i) reattaching the detached quick repair wall panel 121 to the frame 110.

Method of Thermal Conditioning and Thermal Maintenance

[0111] Referring to Figures 2, 10 and 11, a container 100 equipped with a chill-in- place phase change thermal control panel 140 can be thermally conditioned by (i) connecting the outlet and return lines 501 and 502 of a chiller 500 to the entry and return couplings 161 and 162 on the container 100 respectively, and (ii) cycling chilled coolant (not shown) from the chiller 500 through the tube 144 of the phase change thermal control panel 140.

[0112] A container 100 equipped with separate sets 140n of phase change thermal control panels 140, each in fluid communication with a corresponding dedicated pair of entry and return couplings 161_n and 162_n, can be thermally conditioned by (i) connecting a different pair of an outlet line 501n and return line 502_n of a chiller 500 to each corresponding dedicated pair of an entry coupling 161_n and a return coupling 162_n on the container 100, and (ii) cycling chilled coolant (not shown) from the same or different chillers 500 through the tubes 144 of each set 140_n of phase change thermal control panels 140 through their corresponding dedicated pair of entry and return couplings 161_n and 162_n.

[0113] A container 100 equipped with separate sets 140_n of phase change thermal control panels 140, each in common fluid communication with a single pair of entry and return couplings 161 and 162 with coolant (not shown) flow to each set 140_n controlled via one or more flow control valves 174, can be thermally conditioned by (i) connecting an outlet line 501 and a return line 502 of a chiller 500 to the single entry coupling 161 and the single return coupling 162 on the container 100, respectively, and (ii) setting the one or more flow control valves 174 to selectively permit or prohibit flow of coolant (not shown) through each set 140n of phase change thermal control panels 140.

[0114] The chiller 500 can be a portable chiller 500, such as those available from Friedrich W. Lbbbe GmbH of Germany and Advantage Engineering Inc. of Indiana.

[0115] Chilled coolant (not shown) should be cycled through the tube 144 of the phase change thermal control panel 140 for a sufficient duration to solidify the entire supply of phase change material 150 retained within the shell 142 of the phase change thermal control panel 140 prior to shipping a thermally labile payload in the container 100, and is preferably solidified prior to loading a thermally labile payload into the thermally controlled chamber 1293 of the container 100.

Claims

We claim:

1. A passive thermally controlled shipping container, comprising:

(a) a container having walls defining an enclosed chamber wherein one of the walls comprises an access door,

(b) thermal insulation lining the chamber to define a thermally insulated chamber, and

(c) at least one phase change thermal control panel lining the thermally insulated chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having a shell and a tube with (i) the shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

2. The passive thermally controlled shipping container of claim 1 wherein the container is cuboidal.

3. The passive thermally controlled shipping container of claim 1 wherein the thermal controlled chamber is cuboidal.

4. The passive thermally controlled shipping container of claim 2 wherein the thermal controlled chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

5. The passive thermally controlled shipping container of claim 1 further comprising a sensor for detecting the position of the access door as between an open position and a closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

6. The passive thermally controlled shipping container of claim 1 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between an open position and a closed position.

7. The passive thermally controlled shipping container of claim 6 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

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8. The passive thermally controlled shipping container of claim 7 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

9. The passive thermally controlled shipping container of claim 1 wherein the thermal insulation is vacuum insulation panels.

10. The passive thermally controlled shipping container of claim 1 further comprising an entry coupling and a return coupling in fluid communication with the tube-side inlet and the tube-side outlet respectively, wherein the couplings are accessible from exterior the container for cycling coolant from a source of chilled coolant through the tube.

11. The passive thermally controlled shipping container of claim 10 wherein the couplings are quick-disconnect couplings.

12. The passive thermally controlled shipping container of claim 1 further comprising a plurality of heat exchange fins extending radially from the tube into the sealed volume of the shell.

13. The passive thermally controlled shipping container of claim 12 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

14. The passive thermally controlled shipping container of claim 12 wherein the tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

15. The passive thermally controlled shipping container of claim 13 wherein at least some of the ribs are branching ribs.

16. The passive thermally controlled shipping container of claim 15 wherein the heat exchange fins are symmetrical.

17. The passive thermally controlled shipping container of claim 15 wherein the heat exchange fins are asymmetrical.

18. The passive thermally controlled shipping container of claim 15 wherein the heat exchange fins are vertically asymmetrical.

19. The passive thermally controlled shipping container of claim 15 wherein the heat exchange fins are horizontally asymmetrical.

20. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 10, comprising the steps of:

(a) connecting an outlet line and a return line of a chiller to the entry coupling and the return coupling on the container respectively, and (b) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

21. The method of thermally conditioning a passive thermally controlled shipping container of claim 20 wherein the chiller is a portable chiller and chilled coolant is cycled through the tube of the phase change thermal control panel for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

22. A passive thermally controlled shipping container, comprising:

(a) wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, wherein (i) at least one of the sidewalls is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the container, and (ii) the wall panels comprising the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer, and

(b) a phase change thermal control panel secured to the inner structural layer of one of the wall panels selected from the wall panels forming the sidewalls and the top, the phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

23. The passive thermally controlled shipping container of claim 22 further comprising a shield plate sandwiching the phase change thermal control panel between the shield plate and the inner structural layer and defining a thermal controlled payload chamber.

24. The passive thermally controlled shipping container of claim 22 wherein the container is cuboidal.

25. The passive thermally controlled shipping container of claim 23 wherein the thermal controlled payload chamber is cuboidal.

26. The passive thermally controlled shipping container of claim 25] wherein the thermal controlled pay load chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

27. The passive thermally controlled shipping container of claim 22 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

28. The passive thermally controlled shipping container of claim 22 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

29. The passive thermally controlled shipping container of claim 28 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

30. The passive thermally controlled shipping container of claim 29 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

31. The passive thermally controlled shipping container of claim 22 wherein the thermal insulation is vacuum insulation panels.

32. The passive thermally controlled shipping container of claim 22 further comprising an entry coupling and a return coupling in fluid communication with the tube-side inlet and the tube-side outlet respectively, wherein the couplings are accessible from exterior the container for cycling coolant from a source of chilled coolant through the tube.

33. The passive thermally controlled shipping container of claim 32 wherein the couplings are quick-disconnect coupling.

34. The passive thermally controlled shipping container of claim 22 further comprising a plurality of heat exchange fins extending radially from the tube into the sealed volume of the shell.

35. The passive thermally controlled shipping container of claim 34 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

36. The passive thermally controlled shipping container of claim 34 wherein the tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

37. The passive thermally controlled shipping container of claim 33 wherein at least some of the ribs are branching ribs.

38. The passive thermally controlled shipping container of claim 37] wherein the heat exchange fins are symmetrical.

39. The passive thermally controlled shipping container of claim 37 wherein the heat exchange fins are asymmetrical.

40. The passive thermally controlled shipping container of claim 37 wherein the heat exchange fins are vertically asymmetrical.

41. The passive thermally controlled shipping container of claim 37 wherein the heat exchange fins are horizontally asymmetrical.

42. A method of thermally conditioning a passive thermally controlled shipping container of claim 32, comprising the steps of:

(a) connecting an outlet line and a return line of a chiller to the entry coupling and the return coupling on the container respectively, and

(b) cycling chilled coolant from the chiller through the tube of the phase change thermal control panel.

43. The method of thermally conditioning a passive thermally controlled shipping container of claim 42 wherein the chiller is a portable chiller and chilled coolant is cycled through the tube of the phase change thermal control panel for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

44. A passive thermally controlled shipping container, comprising:

(a) wall panels arranged to form a floor, sidewalls and a top defining an enclosed thermally insulated chamber, wherein (i) at least one of the sidewalls is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the container, and (ii) the wall panels comprising the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer, and

(b) a phase change thermal control panel secured to the inner structural layer of each of at least two of the wall panels selected from the wall panels forming the sidewalls and the top, each phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within each sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow

32 of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(c) wherein the tubes of at least two phase change thermal control panels on different wall panels are in fluid communication with one another and with a single entry coupling and a single return coupling accessible from external the container.

45. The passive thermally controlled shipping container of claim 44 further comprising shield plates sandwiching each phase change thermal control panel between one of the plates and the inner structural layer to which the phase change thermal control panel is secured and defining a thermal controlled payload chamber.

46. The passive thermally controlled shipping container of claim 44 wherein the container is cuboidal.

47. The passive thermally controlled shipping container of claim 45 wherein the thermal controlled payload chamber is cuboidal.

48. The passive thermally controlled shipping container of claim 45 wherein the thermal controlled pay load chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

49. The passive thermally controlled shipping container of claim 44 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

50. The passive thermally controlled shipping container of claim 44 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

51. The passive thermally controlled shipping container of claim 50 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

52. The passive thermally controlled shipping container of claim 51 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

33

53. The passive thermally controlled shipping container of claim 44 wherein the thermal insulation is vacuum insulation panels.

54. The passive thermally controlled shipping container of claim 44 wherein the single entry coupling and single return coupling are operable for cycling thermally conditioning coolant from a pressurized source of chilled coolant through the tubes.

55. The passive thermally controlled shipping container of claim 44 wherein the couplings are quick-disconnect couplings.

56. The passive thermally controlled shipping container of claim 44 further comprising a plurality of heat exchange fins extending radially from each tube into the sealed volume of each shell.

57. The passive thermally controlled shipping container of claim 56 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

58. The passive thermally controlled shipping container of claim 56 wherein each tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

59. The passive thermally controlled shipping container of claim 57] wherein the ribs are branching ribs.

60. The passive thermally controlled shipping container of claim 59 wherein the heat exchange fins are symmetrical.

61. The passive thermally controlled shipping container of claim 59 wherein the heat exchange fins are asymmetrical.

62. The passive thermally controlled shipping container of claim 59 wherein the heat exchange fins are vertically asymmetrical.

63. The passive thermally controlled shipping container of claim 59 wherein the heat exchange fins are horizontally asymmetrical.

64. The passive thermally controlled shipping container of claim 44 wherein the tubes of at least three phase change thermal control panels, each on different wall panels, are in fluid communication with one another and with the single entry coupling and single return coupling.

65. The passive thermally controlled shipping container of claim 44 wherein one of the phase change thermal control panels is secured to the inner structural layer of the wall panel forming the top.

34

66. The passive thermally controlled shipping container of claim 44 wherein at least one phase change thermal control panel is secured to the inner structural layer of two different wall panels forming sidewalls.

67. The passive thermally controlled shipping container of claim 61 wherein at least one phase change thermal control panel is secured to the inner structural layer of two different wall panels forming sidewalls.

68. The passive thermally controlled shipping container of claim 44 wherein the phase change thermal control panels are connected to one another in a sequence selected from series and parallel.

69. The passive thermally controlled shipping container of claim 54 wherein the phase change thermal control panels are connected to one another in series.

70. The passive thermally controlled shipping container of claim 54 wherein the phase change thermal control panels are connected to one another in parallel.

71. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 44, comprising the steps of:

(a) connecting an outlet line and a return line of a chiller to the single inlet coupling and the single outlet coupling on the container respectively, and

(b) cycling chilled coolant from the chiller through the tubes of the phase change thermal control panels.

72. The method of thermally conditioning a passive thermally controlled shipping container of claim 71 wherein the chiller is a portable chiller and chilled coolant is cycled through the tubes of the phase change thermal control panels for a sufficient duration to solidify the entire supply of phase change material retained within each of the shells.

73. A passive thermally controlled shipping container, comprising:

(b) a plurality of phase change thermal control panels secured to the inner structural layer of one wall panel selected from the wall panels forming the sidewalls and the top, each phase change thermal control panel comprising a

35 shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(c) wherein the tubes of the plurality of phase change thermal control panels are in fluid communication with one another and with a single entry coupling and a single return coupling accessible from external the container.

74. The passive thermally controlled shipping container of claim 73 further comprising a shield plate sandwiching the phase change control panels between the plate and the inner structural layer to which the phase change thermal control panels are secured and defining a thermal controlled payload chamber.

75. The passive thermally controlled shipping container of claim 73 wherein the container is cuboidal.

76. The passive thermally controlled shipping container of claim 74 wherein the thermal controlled payload chamber is cuboidal.

77. The passive thermally controlled shipping container of claim 74 wherein the thermal controlled pay load chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

78. The passive thermally controlled shipping container of claim 73 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

79. The passive thermally controlled shipping container of claim 73 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

80. The passive thermally controlled shipping container of claim 79 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

81. The passive thermally controlled shipping container of claim 80 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a

36 first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

82. The passive thermally controlled shipping container of claim 73 wherein the thermal insulation is vacuum insulation panels.

83. The passive thermally controlled shipping container of claim 73 wherein the single entry and single return couplings are operable for cycling thermally conditioning coolant from a pressurized source of chilled coolant through the tubes.

84. The passive thermally controlled shipping container of claim 83 wherein the couplings are quick-disconnect couplings.

85. The passive thermally controlled shipping container of claim 61 further comprising a plurality of heat exchange fins extending radially from each tube into the sealed volume of each shell.

86. The passive thermally controlled shipping container of claim 85 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

87. The passive thermally controlled shipping container of claim 85 wherein each tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

88. The passive thermally controlled shipping container of claim 86 wherein the ribs are branching ribs.

89. The passive thermally controlled shipping container of claim 88 wherein the heat exchange fins are symmetrical.

90. The passive thermally controlled shipping container of claim 88 wherein the heat exchange fins are asymmetrical.

91. The passive thermally controlled shipping container of claim 88 wherein the heat exchange fins are vertically asymmetrical.

92. The passive thermally controlled shipping container of claim 88 wherein the heat exchange fins are horizontally asymmetrical.

93. The passive thermally controlled shipping container of claim 73 wherein the plurality of phase change thermal control panels are secured to the inner structural layer of the wall panel forming the top.

94. The passive thermally controlled shipping container of claim 73 wherein the plurality of phase change thermal control panels are secured to the inner structural layer of the wall panel forming one of the sidewalls.

37

95. The passive thermally controlled shipping container of claim 73 wherein the tubes of the plurality of phase change thermal control panels are fluidly connected to one another in series.

96. The passive thermally controlled shipping container of claim 73 wherein the tubes of the plurality of phase change thermal control panels are fluidly connected to one another in parallel.

97. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 61, comprising the steps of:

(a) connecting an outlet line and a return line of a chiller to the single entry coupling and single return coupling on the container respectively, and

98. The method of thermally conditioning a passive thermally controlled shipping container of claim 97 wherein the chiller is a portable chiller and chilled coolant is cycled through the tubes of the phase change thermal control panels for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

99. A passive thermally controlled shipping container, comprising:

(b) at least three phase change thermal control panels secured to the inner structural layer of one or more of the wall panels selected from the wall panels forming the sidewalls and the top, each phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the sealed volume and defining a tubeside coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

38 (c) wherein the phase change thermal control panels are grouped into two separate and distinct sets with (i) a first set of one or more phase change thermal control panels in fluid communication with one another to define a common first set tube-side coolant flow path through a first set of tubes from a common first tube- side inlet to a common first tube- side outlet, and (ii) a second set of one or more phase change thermal control panels in fluid communication with one another to define a common second set tube-side coolant flow path through a second set of tubes from a common second tube-side inlet to a common second tube-side outlet.

100. The passive thermally controlled shipping container of claim 99 wherein the tubes of the first set of one or more phase change thermal control panels are not in fluid communication with the tubes of the second set of one or more phase change thermal control panels.

101. The passive thermally controlled shipping container of claim 99 further comprising one or more shield plates with each shield plate sandwiching the one or more phase change thermal control panels on one of the wall panels between the plate and the inner structural layer to which the one or more phase change thermal control panels are secured to define a thermal controlled payload chamber.

102. The passive thermally controlled shipping container of claim 99 wherein the container is cuboidal.

103. The passive thermally controlled shipping container of claim 102 wherein the thermal controlled payload chamber is cuboidal.

104. The passive thermally controlled shipping container of claim 103 wherein the thermal controlled pay load chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

105. The passive thermally controlled shipping container of claim 99 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

106. The passive thermally controlled shipping container of claim 99 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

39

107. The passive thermally controlled shipping container of claim 106 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

108. The passive thermally controlled shipping container of claim 107 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

109. The passive thermally controlled shipping container of claim 99 wherein the thermal insulation is vacuum insulation panels.

110. The passive thermally controlled shipping container of claim 99 further comprising (i) a first pair of entry and return couplings accessible from exterior the container in fluid communication with the common first tube-side inlet and the common first tube-side outlet respectively, and (ii) a second pair of entry and return couplings accessible from exterior the container in fluid communication with the common second tube-side inlet and the common second tube-side outlet respectively, whereby the first pair of couplings and the second pair of couplings are operable for separately and independently cycling thermally conditioning coolant through each of the first set of tubes and the second set of tubes respectively.

111. The passive thermally controlled shipping container of claim 110 wherein the first pair of entry and return couplings and the second pair of entry and return couplings are operable for cycling thermally conditioning coolants having different temperatures through each of the first set of tubes and the second set of tubes respectively.

112. The passive thermally controlled shipping container of claim 110 wherein the first pair of entry and return couplings and the second pair of entry and return couplings are operable for cycling different coolants through each of the first set of tubes and the second set of tubes.

113. The passive thermally controlled shipping container of claim 99 further comprising a single entry coupling and a single return coupling accessible from external the container, wherein the first set of tubes and the second sets of tubes are in common fluid communication with the single entry coupling and the single return coupling.

114. The passive thermally controlled shipping container of claim 113 further comprising one or more valves selectively operable between three settings selected from (i) a first setting providing fluid communication from the single entry coupling to the tubes of both the first set and the second set of phase change thermal control panels, (ii) a second setting providing

40 fluid communication from the single entry coupling to the tubes of only the first set of phase change thermal control panels to the exclusion of the second set of phase change thermal control panels, and (iii) a third setting providing fluid communication from the single entry coupling to the tubes of only the second set of phase change thermal control panels to the exclusion of the first set of phase change thermal control panels.

115. The passive thermally controlled shipping container of claim 110 wherein the couplings are quick-disconnect couplings.

116. The passive thermally controlled shipping container of claim 113 wherein the couplings are quick-disconnect couplings.

117. The passive thermally controlled shipping container of claim 99 further comprising a plurality of heat exchange fins extending radially from each tube into the sealed volume of the shell surrounding the tube.

118. The passive thermally controlled shipping container of claim 117 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

119. The passive thermally controlled shipping container of claim 117 wherein the tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

120. The passive thermally controlled shipping container of claim 118 wherein the ribs are branching ribs.

121. The passive thermally controlled shipping container of claim 120 wherein the heat exchange fins are symmetrical.

122. The passive thermally controlled shipping container of claim 120 wherein the heat exchange fins are asymmetrical.

123. The passive thermally controlled shipping container of claim 120 wherein the heat exchange fins are vertically asymmetrical.

124. The passive thermally controlled shipping container of claim 120 wherein the heat exchange fins are horizontally asymmetrical.

125. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 110, comprising the steps of:

(a) connecting a first outlet line and a first return line of a chiller to the first entry coupling and the first return coupling on the container respectively,

(b) connecting a second outlet line and a second return line of a chiller selected from the same chiller and a different chiller, to the second entry coupling and the second return coupling on the container respectively, and

41 (c) cycling chilled coolant from the one or more chillers through the tubes of the first set and the second set of phase change thermal control panels.

126. The method of thermally conditioning a passive thermally controlled shipping container of claim 125 wherein the chiller is a portable chiller and chilled coolant is cycled through the tubes of each of the first set and the second set of phase change thermal control panels for a sufficient duration to solidify the entire supply of phase change material retained within the shells of the respective set of phase change thermal control panels.

127. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 114, comprising the steps of:

(a) connecting an outlet line and a return line of a chiller to the single entry coupling and the single return coupling on the container respectively, and

(b) setting the valve to one of the three settings.

128. The method of thermally conditioning a passive thermally controlled shipping container of claim 127 wherein (i) the value is set to the first setting and chilled coolant is cycled through the tubes of the first and second sets of phase change thermal control panels for a sufficient duration to solidify the entire supply of phase change material retained within the shells of both the first and second sets of phase change thermal control panels.

129. The method of thermally conditioning a passive thermally controlled shipping container of claim 127 wherein (i) the value is set to the second setting and chilled coolant is cycled through the tubes of only the first set of phase change thermal control panels for a sufficient duration to solidify the entire supply of phase change material retained within the shell of the first set of phase change thermal control panels.

130. A passive thermally insulated shipping container, comprising:

(a) a frame defining wall openings, and

(b) wall panels releasably secured to the frame over each wall opening defining an enclosed thermally insulated chamber, wherein (i) at least one of the wall panels is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the container, (ii) at least one of the wall panels is a quick repair wall panel comprising (A) an inner structural layer and an outer structural layer defining a void volume gap therebetween having at least one open edge, and (B) a layer of thermal insulation positioned within the void volume gap wherein the thermal insulation layer is fixed in position within the void volume gap when the at least one quick repair wall panel is secured to the frame, and removable

42 from the void volume gap through the open edge between the layers when the at least one quick repair wall panel is detached from the frame.

131. The passive thermally insulated shipping container of claim 130 further comprising at least one phase change thermal control panel lining the thermally insulated chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having a shell and a tube with (i) the shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tubeside outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

132. The passive thermally insulated shipping container of claim 130 wherein the frame is metal.

133. The passive thermally insulated shipping container of claim 130 wherein the frame is cuboidal with a bottom opening, four sidewall openings and a top opening.

134. The passive thermally insulated shipping container of claim 130 wherein a single wall panel covers each wall opening.

135. The passive thermally insulated shipping container of claim 130 wherein a plurality of edge-to-edge arranged wall panels cover at least one of the wall openings.

136. The passive thermally insulated shipping container of claim 130 wherein a plurality of edge-to-edge arranged wall panels cover at least two of the wall openings.

137. The passive thermally insulated shipping container of claim 130 wherein the at least one quick repair wall panel is releasably secured to the frame over a sidewall opening.

138. The passive thermally insulated shipping container of claim 130 wherein at least two wall panels over different sidewall openings are quick repair wall panels.

139. The passive thermally insulated shipping container of claim 130 wherein at least three wall panels over different sidewall openings are quick repair wall panels.

140. The passive thermally insulated shipping container of claim 130 wherein at least three wall panels over different sidewall openings and the wall panel over the top opening are quick repair wall panels.

141. The passive thermally insulated shipping container of claim 130 wherein the layer of thermal insulation within each quick repair wall panel is at least one vacuum insulation panel.

142. The passive thermally insulated shipping container of claim 130 wherein the layer of thermal insulation within each quick repair wall panel comprises one or more insulation

43 cartridges, each cartridge comprising a plurality of vacuum insulation panels secured together in-edge-to-edge arrangement and insertable into and removable from the void volume gap as a single unit.

143. The passive thermally insulated shipping container of claim 142 wherein each insulation cartridge includes a frame around a periphery of the plurality of vacuum insulation panels, and the frame includes at least one grippable element configured and arranged to be accessible when the insulation cartridge is retained within the void volume gap for facilitating gripping and removal of the insulation cartridge from the void volume gap.

144. The passive thermally insulated shipping container of claim 130 wherein the layer of thermal insulation in each quick repair wall panel is insertable into and removable from the void volume gap without a tool once the quick repair wall panel is detached from the frame.

145. The passive thermally insulated shipping container of claim 130 wherein the container defines a thermal insulated payload chamber operable for receiving a payload, and the thermal insulated payload chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

146. The passive thermally controlled shipping container of claim 130 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

147. The passive thermally insulated shipping container of claim 130 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

148. The passive thermally insulated shipping container of claim 147 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

149. The passive thermally controlled shipping container of claim 148 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

150. The passive thermally insulated shipping container of claim 131 further comprising an entry coupling and a return coupling in fluid communication with the tube-side inlet and the

44 tube-side outlet respectively, wherein the couplings are accessible from exterior the container for cycling coolant from a source of chilled coolant through the tube.

151. The passive thermally insulated shipping container of claim 150] wherein the couplings are quick-disconnect couplings.

152. The passive thermally insulated shipping container of claim 131 further comprising a plurality of heat exchange fins extending radially from the tube into the sealed volume of the shell.

153. The passive thermally insulated shipping container of claim 152 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

154. The passive thermally insulated shipping container of claim 152 wherein the tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

155. The passive thermally insulated shipping container of claim 153 wherein at least some of the ribs are branching ribs.

156. The passive thermally insulated shipping container of claim 155 wherein the heat exchange fins are symmetrical.

157. The passive thermally insulated shipping container of claim 155 wherein the heat exchange fins are asymmetrical.

158. The passive thermally insulated shipping container of claim 155 wherein the heat exchange fins are vertically asymmetrical.

159. The passive thermally insulated shipping container of claim 155 wherein the heat exchange fins are horizontally asymmetrical.

160. A method of replacing thermal insulation in a passive thermally controlled shipping container in accordance with claim 142, comprising the steps of:

(a) detaching a quick repair wall panel from the frame,

(b) pulling the insulation cartridge out from the void volume gap between the inner structural layer and the outer structural layer of the detached wall panel through the open edge,

(c) inserting a new insulation cartridge into the void volume gap between the inner structural layer and the outer structural layer of the detached wall panel through the open edge, and

(d) reattaching the detached wall panel to the frame.

161. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 150, comprising the steps of:

45 (a) connecting an outlet line and a return line of a chiller to the entry coupling and the return coupling on the container respectively, and

162. The method of thermally conditioning a passive thermally controlled shipping container of claim 161 wherein the chiller is a portable chiller and chilled coolant is cycled through the tube of the phase change thermal control panel for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

163. A passive thermally controlled shipping container, comprising:

(a) a hollow core frame defining wall openings,

(b) wall panels releasably secured to the frame over each wall opening defining an enclosed chamber wherein at least one of the wall panels is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the chamber,

(c) at least one phase change thermal control panel lining the chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having a shell and a tube with (i) the shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(d) a coolant entry coupling and a coolant return coupling accessible from exterior the container,

(e) a first length of conduit extending within the hollow core frame placing the coolant entry coupling in fluid communication with the tube-side inlet, and a second length of conduit extending within the hollow core frame placing the tube-side outlet in fluid communication with the coolant return coupling, and

(f) a disconnect coupling proximate each of the tube-side inlet and tube-side outlet for disconnecting the tube from the first and second lengths of conduit.

164. The passive thermally controlled shipping container of claim 163 wherein the frame is cuboidal.

46

165. The passive thermally controlled shipping container of claim 163 wherein the thermal controlled chamber is cuboidal.

166. The passive thermally controlled shipping container of claim 163 wherein the thermal controlled chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

167. The passive thermally controlled shipping container of claim 163 further comprising a sensor for detecting the position of the access door as between the open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is in the open position and a second signal when the door is in the closed position.

168. The passive thermally controlled shipping container of claim 163 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between the closed position and the open position.

169. The passive thermally controlled shipping container of claim 168 wherein pivoting of each half of the access door is automatically releasably arrested when pivoted approximately 270° into a fully open position.

170. The passive thermally controlled shipping container of claim 169 further comprising a sensor for detecting the position of the access door as between arrested in the fully open position and the closed position and generating at least one perceptible signal selected from a first signal when the door is arrested in the fully open position and a second signal when the door is in the closed position.

171. The passive thermally controlled shipping container of claim 163 further comprising a plurality of heat exchange fins extending radially from the tube into the sealed volume of the shell.

172. The passive thermally controlled shipping container of claim 171 wherein the heat exchange fins are a plurality of circumferentially spaced and axially elongated ribs.

173. The passive thermally controlled shipping container of claim 171 wherein the tube and associated heat exchange fins have a cross-section capable of unitary one-piece extrusion.

174. The passive thermally controlled shipping container of claim 172 wherein at least some of the ribs are branching ribs.

175. The passive thermally controlled shipping container of claim 174 wherein the heat exchange fins are symmetrical.

176. The passive thermally controlled shipping container of claim 174 wherein the heat exchange fins are asymmetrical.

47

177. The passive thermally controlled shipping container of claim 174wherein the heat exchange fins are vertically asymmetrical.

178. The passive thermally controlled shipping container of claim 174 wherein the heat exchange fins are horizontally asymmetrical.

179. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 163, comprising the steps of:

180. The method of thermally conditioning a passive thermally controlled shipping container of claim 179 wherein the chiller is a portable chiller and chilled coolant is cycled through the tube of the phase change thermal control panel for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

181. A passive thermally controlled shipping container, comprising:

(a) a hollow core frame defining wall openings,

(b) wall panels releasably secured to the frame over each wall opening defining an enclosed thermally insulated chamber, wherein (i) at least one of the wall panels is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the container, and (ii) a majority of the wall panels comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer,

(c) a phase change thermal control panel secured to the inner structural layer of one of the wall panels, the phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(d) an entry coupling and a return coupling accessible from exterior the container,

48 (e) a first length of conduit extending within the hollow core frame placing the coolant entry coupling in fluid communication with the tube-side inlet, and a second length of conduit extending within the hollow core frame placing the tube-side outlet in fluid communication with the coolant return coupling, whereby thermally conditioning coolant from a source of chilled coolant connected to the couplings can be cycled through the tube for thermally conditioning the supply of phase change material retained within the shell, and

(f) an in-line disconnect coupling proximate each of the tube-side inlet and tubeside outlet for disconnecting the tube from the first and second lengths of conduit for facilitating installation, removal and replacement of the phase change thermal control panel.

182. The passive thermally controlled shipping container of claim 181 wherein the thermal insulation is vacuum insulation panels.

183. A method of thermally conditioning a passive thermally controlled shipping container in accordance with claim 172, comprising the steps of:

(b) cycling chilled coolant from the chiller through the tubes of the phase change thermal control panel.

184. The method of thermally conditioning a passive thermally controlled shipping container of claim 183 wherein the chiller is a portable chiller and chilled coolant is cycled through the tube of the phase change thermal control panel for a sufficient duration to solidify the entire supply of phase change material retained within the shell.

185. A passive thermally controlled shipping container, comprising:

(b) thermal insulation lining the chamber to define a thermally insulated chamber,

(c) a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side

49 inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(d) at least one temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and

(e) a controller operable for periodically receiving the transmitted measured temperature throughout a thermal conditioning period and discontinuing flow of chilled coolant through the tube when the measured temperature is below a threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid. A passive thermally controlled shipping container, comprising:

(c) a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(d) a plurality of temperature sensors effective for measuring and transmitting the temperature of spatially separated zones of the phase change material retained within the sealed volume, and

(e) a controller operable for periodically receiving the transmitted measured temperatures from the plurality of temperature sensors throughout a thermal conditioning period and discontinuing flow of chilled coolant through the tube when the difference between the measured temperature from at least two of the sensors is below a threshold value indicative of completion of phase

50 change transition of the phase change material retained within the sealed volume from a liquid to a solid.

A passive thermally controlled shipping container, comprising:

(d) a temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and

(e) a controller operable for periodically receiving the transmitted measured temperature throughout a thermal conditioning and thermally conditioned maintenance period for (i) actuating flow of chilled coolant through the tube when the measured temperature is above a second threshold value indicative of commencement of phase change transition of the phase change material retained within the sealed volume from a solid to a liquid, and (ii) discontinuing flow of chilled coolant through the tube when the measured temperature is below a first threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid.

A passive thermally controlled shipping container, comprising:

(c) a phase change thermal control panel having a shell and a tube lining the thermally insulated chamber to define a thermal controlled chamber, the phase

51 change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(d) a flow control valve for governing flow of coolant through the tube,

(e) a temperature sensor effective for measuring and transmitting the temperature of the phase change material retained within the sealed volume, and

(f) a controller in communication with the flow control valve and the temperature sensor for periodically receiving the transmitted measured temperature throughout a thermal conditioning and thermally conditioned maintenance period and instructing the flow control valve to regulating flow of coolant as between (i) a first high flow rate of chilled coolant through the tube when the measured temperature is above a first threshold value indicative of commencement of phase change transition of the phase change material retained within the sealed volume from a solid to a liquid, and (ii) a second low or zero flow rate of chilled coolant through the tube when the measured temperature is below a second threshold value indicative of completion of phase change transition of the phase change material retained within the sealed volume from a liquid to a solid.

A passive thermally insulated shipping container, comprising:

(a) a container having a top, bottom and sidewalls defining an enclosed chamber with a floor wherein each sidewall has an inner surface facing the enclosed chamber and an outer exterior surface and the one of the sidewalls comprises an access door,

(c) openings below the floor of the container configured and arranged to accommodate insertion of forklift forks for lifting and transporting the container, and

(d) a protective layer of an aromatic polyamide fiber sheet covering at least a portion of the exterior surface of at least two of the sidewalls.

52

190. The passive thermally insulted shipping container of claim 189 further comprising at least one phase change thermal control panel lining the thermally insulated chamber to define a thermal controlled chamber, the phase change thermal control panel comprising a shell and tube heat exchanger having a shell and a tube with (i) the shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube-side coolant flow path through the shell from a tube-side inlet to a tubeside outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume.

191. The passive thermally insulated shipping container of claim 189 wherein the thermal insulation is vacuum insulation panels.

192. The passive thermally insulated shipping container of claim 189 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a portion of the exterior surface of at least three of the sidewalls.

193. The passive thermally insulated shipping container of claim 189 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a portion of the exterior surface of all sidewalls.

194. The passive thermally insulated shipping container of claim 189 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of the at least two sidewalls.

195. The passive thermally insulated shipping container of claim 189 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of at least three of the sidewalls.

196. The passive thermally insulated shipping container of claim 189 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of all sidewalls.

197. A passive thermally controlled shipping container, comprising:

(a) wall panels arranged to form a bottom, sidewalls and a top defining an enclosed thermally insulated chamber, wherein (i) at least one of the sidewalls is hinged to provide an access door operable for pivoting between a closed position and an open position for loading and unloading a payload into the container, and (ii) the wall panels comprising the sidewalls and top each comprise thermal insulation sandwiched between an inner structural layer and an outer structural layer,

53 (b) a phase change thermal control panel secured to the inner structural layer of one of the wall panels selected from the wall panels forming the sidewalls and the top, the phase change thermal control panel comprising a shell and tube heat exchanger having (i) a shell defining a sealed volume containing a supply of phase change material, and (ii) at least one tube in heat exchange communication with the supply of phase change material retained within the sealed volume and defining a tube- side coolant flow path through the shell from a tube-side inlet to a tube-side outlet operable for allowing flow of coolant through the tube to effect thermal cooling of the phase change material retained within the sealed volume,

(c) openings below the floor of the container configured and arranged to accommodate a pair of forks on a forklift for lifting and transporting the container, and

(d) a protective layer of an aromatic polyamide fiber sheet covering at least a portion of an exterior surface of at least two of the sidewalls.

198. The passive thermally insulated shipping container of claim 197 wherein the thermal insulation is vacuum insulation panels.

199. The passive thermally insulated shipping container of claim 197 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a portion of the exterior surface of at least three of the sidewalls.

200. The passive thermally insulated shipping container of claim 197 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a portion of the exterior surface of all sidewalls.

201. The passive thermally insulated shipping container of claim 197 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of the at least two sidewalls.

202. The passive thermally insulated shipping container of claim 197 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of at least three of the sidewalls.

203. The passive thermally insulated shipping container of claim 197 wherein a protective layer of an aromatic polyamide fiber sheet covers at least a bottom third of the exterior surface of all sidewalls.

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