GB2553676A

GB2553676A - Modular thermally insulated transportation container

Info

Publication number: GB2553676A
Application number: GB1713730.8A
Authority: GB
Inventors: Robert Krzak Christopher; Roland Vann James
Original assignee: Tower Cold Chain Solutions Ltd
Current assignee: Tower Cold Chain Solutions Ltd
Priority date: 2013-09-26
Filing date: 2013-09-26
Publication date: 2018-03-14
Anticipated expiration: 2033-09-26
Also published as: WO2015044668A1; SG11201602285VA; GB2518645B; GB201317138D0; GB2518645A; EP3049340A1; GB201713730D0; GB2553676B

Abstract

A modular system for constructing thermally insulated transportation containers (1, figure 1a) for transporting temperature sensitive goods, said modular system enabling a variety of different sized thermally insulated containers to be constructed, said modular system including: a set of thermally insulated wall elements (5, 7, 9, figure 2b) that are configurable into a plurality of container sections (3, figure 2a); and a support frame 335 for fixing the container sections together to form at least part of a thermally insulated container structure, said support frame including a plurality of longitudinal support elements 359, a plurality of transverse support elements 361, and a plurality of vertical support elements 363, wherein the lengths of at least some of the support elements are adjustable, the arrangement being such that at least two of the height of the support frame, the width of the support frame and the length of the support frame are adjustable. A method for constructing a modular thermally insulated transportation container is also disclosed, where the support frame applies a compressive load to the container sections. Preferably the wall elements contain phase change materials (PCM).

Description

(54) Title ofthe Invention: Modular thermally insulated transportation container

Abstract Title: Thermally insulated transportation container and adjustable frame (57) A modular system for constructing thermally insulated transportation containers (1, figure 1a) for transporting temperature sensitive goods, said modular system enabling a variety of different sized thermally insulated containers to be constructed, said modular system including: a set of thermally insulated wall elements (5, 7, 9, figure 2b) that are configurable into a plurality of container sections (3, figure 2a); and a support frame 335 for fixing the container sections together to form at least part of a thermally insulated container structure, said support frame including a plurality of longitudinal support elements 359, a plurality of transverse support elements 361, and a plurality of vertical support elements 363, wherein the lengths of at least some of the support elements are adjustable, the arrangement being such that at least two of the height of the support frame, the width of the support frame and the length of the support frame are adjustable. A method for constructing a modular thermally insulated transportation container is also disclosed, where the support frame applies a compressive load to the container sections. Preferably the wall elements contain phase change materials (PCM).

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MODULAR THERMALLY INSULATED TRANSPORTATION CONTAINER

The present invention relates to a modular thermally insulated transportation container for transporting temperature sensitive items; a modular system for constructing thermally insulated transportation containers; and a method for constructing a thermally insulated container.

Thermally insulated containers are used to transport items that are sensitive to temperature and must therefore be maintained within predetermined temperature ranges throughout the journey, such as +2°C to +8°C and +15°C to +25°C, or close to a particular temperature such as -20°C. Such items include goods such as vaccines and drugs, biological samples, tissue cultures, chilled and frozen foods and many other products, some of which have extremely high financial value and are very sensitive to temperature changes. It is essential that such products are maintained within the appropriate temperature ranges during transportation.

Such goods are normally transported in thermally insulated containers and gel bags containing Phase Change Materials (hereafter referred to as PCMs) that have been cooled or heated to a predetermined temperature to provide additional heating or cooling as required. Heat energy flows into or out of the container, according to the difference between the ambient temperature and the internal temperature of the container. The temporal ambient temperature profile that will be experienced by the container cannot be predicted a priori, since containers may be moved from relatively cold countries to relatively hot countries and may be left standing for a significant period of time.

If the container is exposed to excessively high or low temperatures for extended periods, the internal temperature may go outside the required range, causing damage to the contents. The requirement to open a container on its journey increases the risk of payload theft. In current containers, the number and type of PCM packs employed is calculated according to the anticipated delivery time and the ambient temperature ranges likely to be experienced during transportation. However, as delivery can take longer than anticipated and the ambient temperatures may be much higher or lower than expected, the payload temperature may go outside the required range. During transportation, shocks, collisions or vibrations can cause the goods to move within the container, particularly those located at the side walls; these might then fall to a lower part of the container, increasing the risk of being heated/cooled to a temperature outside the predetermined safe range.

Thus it is desirable to provide a thermally insulated container that is arranged to maintain the temperature within the desired temperature range throughout the payload volume for the duration of the journey.

Thermally insulated containers are frequently transported by aircraft. Transportation aircraft can typically be classified into narrowed bodied, wide bodied and freighter variations. Usually the container is mounted onto a Unit Load Device (ULD) such as a pallet, which is then loaded onto the aircraft. There are several different types of standard pallet available, for example for use on the main and/or lower decks on aircraft, which include, but are not limited to, PMC, PAG, PKC (IATA references) and LD3, LD7, LD11 (ISO references).

When manufacturing thermally insulated containers, it is typical for manufacturers to take into account the pallet size and the dimensions of the aircraft when determining the dimensions of the container, for a given internal capacity required. This can lead to a large number of different sized and shaped containers being made, with each container requiring different manufacturing techniques, sized components and/or tooling. This leads to increased manufacturing costs.

Therefore it is desirable to simplify the manufacturing processes and construction of the thermally insulated containers, while still providing some variety for the size and shape of the thermally insulated containers in order to fit different sized pallets and aircraft.

Accordingly the present invention seeks to provide a modular thermally insulated transportation container for transporting temperature sensitive items; a modular system for constructing thermally insulated transportation containers; and a method for constructing a thermally insulated container that mitigates at least one of the aforementioned disadvantages, or at least provides an alternative configuration to known containers, systems and methods.

According to one aspect of the invention there is provided a thermally insulated container for transporting temperature sensitive goods. The container has a modular construction that includes a plurality of thermally insulated container sections. The container further includes means for fixing the container sections together to provide at least part of the thermally insulated container structure.

Advantageously at least some of the container sections can be tubular, and preferably each of the container sections is tubular.

Advantageously at least some of the container sections can include a plurality of thermally insulated wall elements, and preferably each of the container sections includes a plurality of thermally insulated wall elements.

Advantageously at least some of the container sections can include a first substantially Ushaped thermally insulated wall element, and preferably each of the container sections includes a first substantially U-shaped thermally insulated wall element.

Advantageously at least some of the container sections can include a second substantially Ushaped thermally insulated wall element, and preferably each of the container sections includes a second substantially U-shaped thermally insulated wall element. The first and second substantially U-shaped sections can be similar. Advantageously the first and second substantially U-shaped thermally insulated wall elements can be connected together to form a substantially tubular container section. In some embodiments, each container section consists of first and second substantially U-shaped thermally insulated wall elements only.

Advantageously at least some of the container sections can include at least one thermally insulated wall panel, and preferably each of the container sections includes at least one thermally insulated wall panel. Typically, at least some, and preferably each, container section includes at least one pair of thermally insulated wall panels.

Advantageously at least some of the container sections can include at least one thermally insulated wall panel interposed between the first and second substantially U-shaped thermally insulated wall elements. For example, the first and second substantially U-shaped thermally insulated wall elements can be connected together by a pair of thermally insulated wall panels to provide a tubular container section of increased size. Additional thermally insulated wall panels can be included to increase the size of the tubular container section further.

Advantageously at least some of the thermally insulated wall sections can include locating formations, such as a tongue and groove arrangement, for connecting the thermally insulated wall sections together.

Advantageously the structural support elements can be used to make several different 5 container sizes, including Euro; Double (length) Euro; EfS; Double (length) EfS; Freighter;

Double (length) Freighter. These six variations can be made in different heights to suit main deck loading on the aircraft, which give a further six container configurations.

Advantageously the means for fixing the container sections together can include a support frame.

Advantageously the support frame can be mounted externally of the container sections.

Advantageously the support frame can be arranged to apply a compressive load to at least some of the container sections. Advantageously the support frame is arranged to apply a compressive load to the container sections in at least one of the following directions: a longitudinal direction, a transverse direction and a vertical direction.

Advantageously the height of the support frame can be adjustable. The support frame includes means for adjusting the height of the support frame.

Advantageously the width of the support frame can be adjustable. The support frame includes means for adjusting the width of the support frame.

Advantageously the length of the support frame can be adjustable. The support frame includes 20 means for adjusting the length of the support frame.

Advantageously the support frame can be continuously adjustable.

Advantageously the support frame can include a plurality of longitudinal support elements. Advantageously the support frame can include a plurality of horizontal support elements. Advantageously the support frame can include a plurality of vertical support elements.

Advantageously at least some of the support elements are elongate. At least some, and preferably each, of the support elements are tubular, or include a tubular part.

Advantageously the length of at least one, and preferably each, of the longitudinal support elements is adjustable. In preferred embodiments the or each longitudinal support element is telescopically adjustable.

Advantageously the length of at least one, and preferably each, of the transverse support elements is adjustable. In preferred embodiments the or each transverse support element is telescopically adjustable.

Advantageously the length of at least one, and preferably each, of the vertical support elements is adjustable. In preferred embodiments the or each vertical support element is telescopically adjustable.

Advantageously at least one, and preferably each, of the longitudinal support elements includes a first part, which is preferably a tubular outer part, and a second part that is arranged to move with respect to the first part, said second part preferably being a first connecter member that is arranged to move axially within the tubular outer part a limited amount. Advantageously at least one, and preferably each, of the longitudinal support elements can include a second connector element that is arranged to move axially within the tubular outer part a limited amount. The first connector element is located towards one end of the longitudinal support element and the second connector element is located towards the other end. Adjusting the position of the first and/or second connector elements with respect to the first part adjusts the overall length of the longitudinal support element. By shortening the length of the longitudinal support elements, a compressive load is applied to the container sections in a longitudinal direction, that is, a direction that pushes the container sections together along the axis of the container sections.

The container can include at least one first threaded element that is arranged to adjust the position of the second part with respect to the first part. Advantageously the first threaded element is arranged to adjust the position of the first and second connector elements with respect to the first part.

Advantageously at least one, and preferably each, of the transverse support elements includes a first part, which is preferably a tubular outer part, and a second part that is arranged to move with respect to the first part, said second part preferably being a connecter member that is arranged to move axially within the tubular outer part a limited amount. Advantageously at least one, and preferably each, of the transverse support elements can include a second connector element that is arranged to move axially within the tubular outer part a limited amount. The first connector element is located towards one end of the transverse support element and the second connector element is located towards the other end. Adjusting the position of the first and/or second connector elements with respect to the first part adjusts the overall length of the transverse support element. By shortening the length of the transverse support elements, a compressive load is applied to the container sections in a transverse direction.

The container can include at least one second threaded element that is arranged to adjust the position of the second part with respect to the first part. Advantageously a second threaded element is arranged to adjust the position of the first connector element with respect to the first part. Advantageously another second threaded element is arranged to adjust the position of the second connector element with respect to the first part.

Advantageously at least one, and preferably each, of the vertical support elements includes a first part, which is preferably a tubular outer part, and a second part that is arranged to move with respect to the first part, said second part preferably being a connecter member that is arranged to move axially within the tubular outer part a limited amount. Advantageously at least one, and preferably each, of the vertical support elements can include a second connector element that is arranged to move axially within the tubular outer part a limited amount. The first connector element is located towards one end of the vertical support element and the second connector element is located towards the other end. Adjusting the position of the first and/or second connector elements with respect to the first part adjusts the overall length of the vertical support element. By shortening the length of the vertical support elements, a compressive load is applied to the container sections in a vertical direction. This acts to urge the structural wall elements within each section towards one another, thereby more tightly holding the individual sections together.

The container can include at least one third threaded element that is arranged to adjust the position of the second part with respect to the first part. Advantageously a third threaded element is arranged to adjust the position of the first connector element with respect to the first part. Advantageously another third threaded element is arranged to adjust the position of the second connector element with respect to the first part.

Advantageously each longitudinal support element can be connected to at least one of a transverse support element and a vertical support element. Advantageously the longitudinal support elements are connected to their respective transverse and/or vertical support element via the connector elements.

Advantageously each longitudinal support element can be connected to two transverse support elements. Advantageously the longitudinal support elements are connected to their respective transverse support elements via the connector elements.

Advantageously each longitudinal support element can be connected to two vertical support elements. Advantageously the longitudinal support elements are connected to their respective vertical support elements via the connector elements.

Advantageously each transverse support element can be connected to two vertical support elements. Advantageously the transverse support elements are connected to their respective vertical support elements via the connector elements.

Advantageously the support frame is at least partly separable in order to recover the thermally insulated wall elements for use in a new container.

The container can include a first closure member that is openable to provide access to the interior of the container. Preferably the first closure member comprises a first door. The first door is pivotally attached to the support frame. Advantageously the first door can be arranged to pivot about the hinge through an angle that is greater than 180 degrees, typically up to around 250 degrees.

The container can include a second closure member that is openable to provide access to the interior of the container. Preferably the second closure member comprises a second door. The second door is pivotally attached to the support frame. Advantageously the second closure member is arranged substantially opposite to the first closure member. Advantageously the second door can be arranged to pivot about the hinge through an angle that is greater than 180 degrees, typically up to around 250 degrees.

The container can include a set of PCM units for controlling the temperature within the container.

Advantageously some of the PCM units are mounted on each of the walls of the container. The PCM units are preferably mounted onto the walls via brackets. Advantageously substantially the entire inner surface of each wall is covered with PCM units to provide more even heating / cooling within the container.

Advantageously some of the PCM units are mounted on at least one of the first and second closure members. Advantageously substantially the entire inner surface of each closure member is covered with PCM units to provide more even heating / cooling within the container.

In preferred embodiments, at least one of the container walls and/or container closure members includes a plurality of layers of PCM units.

The set of PCM units can include a first PCM unit having a first PCM arranged to change phase at a first temperature and a second PCM unit having a second PCM arranged to change phase at a second temperature, wherein the first and second temperatures are different. For example, the first PCM can change phase at a temperature in the range -20°C to +5°C, and preferably at a temperature of around 0°C, and the second PCM changes phase at a temperature in the range +5°C to +20°C and preferably at a temperature of around +5°C. The first PCM can mostly comprise of water and the second PCM can mostly comprise of a wax.

Advantageously the PCM can change from a solid state to a liquid state at a temperature in one ofthe following ranges: +2°C to +8°C; -25°C to -15°C; +15°C to +25°C.

The container can include an external temperature sensor for measuring the ambient temperature outside of the container.

The container can include an internal temperature sensor for measuring the temperature in the payload volume.

The container can include a recording device for recording the temperature in the payload volume and / or the ambient temperature.

Advantageously the container is made from recyclable materials.

According to another aspect of the invention there is provided a modular system for constructing thermally insulated transportation containers for transporting temperature sensitive goods, said modular system enabling a variety of different sized thermally insulated containers to be constructed, (wherein each thermally insulated container constructed is sized and shaped for loading onto an aircraft Unit Load Device), said modular system including thermally insulated wall elements that are configurable into a plurality of container sections, and means for fixing the container sections together to form at least part of a thermally insulated container structure. The modular system enables transportation containers of any configuration described herein to be constructed.

Advantageously the set of thermally insulated wall elements includes a substantially Ushaped element and a wall panel. Typically each container section includes first and second substantially U-shaped elements which are similar, and optionally can include at least one pair of wall panels interposed between the first and second substantially U-shaped elements.

Advantageously at least some of the thermally insulated wall sections include locating formations, such as a tongue and groove arrangement, for connecting the thermally insulated wall sections together.

Advantageously the means for fixing the container sections together includes a support frame.

The support frame can be arranged according to any configuration described herein.

According to another aspect of the invention there is provided a method for constructing a modular thermally insulated transportation container that is arranged for transporting temperature sensitive goods, including: constructing a plurality of container sections from a set of thermally insulated wall elements, and fixing said container sections together to form at least part of a thermally insulated container structure.

In preferred methods each container section is tubular.

Advantageously the method can include constructing a thermally insulated container according to any configuration described herein.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:

Figs, la to If are views of a thermally insulated container according to a first embodiment of the invention;

Fig. 2a is an isometric view of structural elements that define the thermally insulated walls of the container in Figures la to If;

Fig. 2b is an exploded view of the structural elements of Fig. 2a;

Fig. 3a is an isometric view of an outer frame used to hold the structural elements of Fig. 2a together, in a non-loaded condition;

Fig. 3b is an enlarged detail view, with partial cutaway section, of a frame corner joint highlighted in Figure 3a, in the non-loaded condition;

Fig. 3c is a plan view from above of Fig. 3b showing part of a longitudinal support element, a transverse support element and some hidden details of their respective adjustment mechanisms;

Fig. 3d is a side view of Fig. 3b showing part of a longitudinal support element, a vertical support element and some hidden details of their respective adjustment mechanisms;

Fig. 3e is a side view of Fig. 3b showing part of a longitudinal support element, a transverse support element a vertical support element and some hidden details of their respective adjustment mechanisms;

Fig. 4a is an isometric view of the outer frame used to hold the structural elements of Fig. 2a together, in loading (reduced size) condition;

Fig. 4b is an enlarged detail view, with partial cutaway section, of a frame corner joint highlighted in Figure 4a, in the loaded (reduced size) condition;

Fig. 4c is a plan view from above of Fig. 4b showing part of a longitudinal support element, a transverse support element and some hidden details of their respective adjustment mechanisms;

Fig. 4d is a side view of Fig. 4b showing part of a longitudinal support element, a vertical support element and some hidden details of their respective adjustment mechanisms;

Fig. 4e is a side view of Fig. 4b showing part of a longitudinal support element, a transverse support element a vertical support element and some hidden details of their respective adjustment mechanisms;

Figs. 5a to 5c are isometric views of the structural elements of the container in different configurations, which enable different sized containers to be constructed from that shown in Figures la to If;

Figures 6a to 6f are views of a thermally insulated container according to a second embodiment of the invention;

Figures 7a to 7f are views of a thermally insulated container according to a third embodiment of the invention;

Figure 8a shows an alternative frame arrangement that can be used in conjunction with the first, second and third embodiments, wherein the length and the height of the frame is adjustable, but the width is not; and

Figure 8b shows an enlarged view of a portion of the alternative frame of Figure 8a.

Thermally insulated containers according to the invention have a modular construction. The containers include a plurality of container sections, which are typically tubular, that are joined together in order to provide at least part of the thermally insulated container structure. A frame holds the tubular sections together. Furthermore each tubular section itself has a modular construction. Each tubular section includes at least upper and lower substantially Ushaped members (typically having a base/top member that is substantially orthogonal to its side walls) and, optionally at least one side wall panel. The container also includes at least one door for accessing the interior of the container, and preferably two doors arranged opposite to one another.

It will be appreciated from the following description that a number of different sized thermally insulated containers can be constructed from a relatively low number of basic components in order to enable the containers to be mounted onto particular aircraft pallets and aircraft, such as *4 PMC, ¹/2 LD11,¹/2 PAG, and Vi PMC pallets.

A thermally insulated container 1 according to a first embodiment of the invention is shown in Figs, la to 4d. The container 1 includes five tubular sections 3 that are arranged substantially co-axially to form part of the structure of the container 1. The tubular sections 3 each have a rectangular cross-section and therefore, when they are axially aligned, they form an upper wall 11, a base 12 and two side walls 13,15 of the container 1, and provide front and rear openings. Though of course, it will be appreciated by the skilled person that the tubular sections 3 can be aligned in a different orientation, for example vertically to provide four side walls, and upper and lower openings.

Each tubular section 3 is similar. Each tubular section 3 includes an upper U-shaped element 5, a lower U-shaped element 7 and four side panels 9. The side panels 9 are located between the upper and lower U-shaped elements 3,5 and provide the container with extended side walls.

The upper U-shaped elements 5,7 and the side panels 9 each include an outer shell made from a plastics material, to provide a substantially rigid outer shell. They are each manufactured by a roto-moulding process and are each filled with foam, and preferably high density foam, such as polyurethane foam, and are therefore thermally insulated.

The upper U-shaped element 5 includes an upper wall 5a and first and second sides 5b,5c. The first side 5b is located towards one end of the upper wall 5a and is arranged substantially perpendicular thereto. The second side 5c is located towards the other end of the upper wall 5a and is arranged substantially perpendicular thereto. The first and second sides 5b,5c are arranged substantially parallel to one another. The upper wall 5a defines a part of an upper wall 11 of the container. The first and second sides 5b,5c define part of side walls 13,15 of the container.

The first side 5b includes a first tongue and groove arrangement 17, which includes a central tongue 19 located at one end of the first side 5a. The second side 5c includes a second tongue and groove arrangement 21, which includes first and second lateral tongues 23,25, and a central cavity 27. The first tongue and groove arrangement 17 is complementary to the second tongue and groove arrangement 21.

The upper U-shaped element 5 includes front and rear lips 29,31 for supporting transverse members 33 in an external support frame 35. The front lip 29 on a first tubular section 3 forms a transverse recess with the rear lip 31 on an adjacent second tubular section 3.

The upper U-shaped element 5 includes comer recesses 37 for receiving longitudinal members 59 in the frame 35.

The upper U-shaped element 5 includes a central ridge 41, which provides a mounting for receiving central brackets 43,44 which are used to locate and support PCM units 42 in the interior of the container. The ridge 41 is arranged centrally on the internal face 45 and is arranged substantially parallel with the first and second sides 5b,5c. The upper U-shaped element 5 further includes lateral ridges 47,49, which provide mountings for receiving lateral brackets 51,53, which are used to locate and support PCM units in the interior of the container. Further brackets 48 are mounted on internal ridges 50 located on an inner face of the side panels 9.

The lower U-shaped element 7 is similarly arranged to the upper U-shaped element 5. The wall 7a defines part of the container base 12.

Each side panel 9 is substantially rectangular in plan. Each side panel 9 includes a first tongue and groove arrangement 55, which is located towards one end of the panel. The first tongue and groove arrangement 55 is arranged similarly to the first tongue and groove arrangement 17 on the upper U-shaped element 5. Each side panel 9 includes a second tongue and groove arrangement 57, which is located at an opposite end to the first tongue and groove arrangement 55. The second tongue and groove arrangement 57 is similarly arranged to the second tongue and groove arrangement 21 on the upper U-shaped element 5.

The side panels 9 are interposed between the upper and lower U-shaped elements 5,7 in order to adjust the height of the tubular sections 3.

In Figures la-If, the each tubular section 3 includes four side panels 9, with the upper Ushaped element 5 being spaced from the lower U-shaped element 7 by two panels 9 on each side. Each pair of panels 9 is connected by the complementary first and second tongue and groove arrangements 55,57. Each panel 9 in the pair is connected to one of the upper and lower U-shaped elements 5,7 via the complementary first and second groove arrangements

17,57;21,55. When the side panels 9 are connected to the upper and lower U-shaped elements 5,7, a tubular container wall section 3 is constructed, which is thermally insulated. However, it will be appreciated by the skilled person that while two panels 9 are provided on each side in Figures la-Id, that more or fewer panels 9 can be included in order to adjust the shape of the tubular section 3. It will be further appreciated that the side panels 9 are entirely optional and that the upper and lower U-shaped elements 5,7 can be connected together via the first and second tongue and groove arrangements 17,21 in order to construct a tubular section 3.

The container 1 includes a plurality of tubular sections 3. In Figures la-If, the container 1 includes five tubular sections 3. Optionally, the tubular sections 3 can include one or more alignment pin and recess pairs (not shown) for aligning the sections 3 with respect to one another.

The tubular sections 3 are fixed together by the external frame 35. The size of the external frame 35 is adjustable to apply a compressive load to the tubular sections 3, thereby fixing their positions relative to each other.

The frame 35 includes four horizontal longitudinal frame elements 59, four horizontal transverse frame elements 61, and four vertical frame elements 63. The frame elements 59,61,63 are arranged in a substantially cuboid space frame fashion (see Figures 3a and 4a). The frame 35 is fitted about the tubular sections such that the longitudinal support elements 59 sit in the comer recesses 37 of the tubular sections 3.

The frame 35 is arranged to apply a compressive load to the tubular sections 3, and as such includes mechanisms for adjusting the size of the frame in each of the longitudinal, transverse and vertical directions. Reducing the size of the frame applies a compressive load to the tubular sections 3. Increasing the size of the frame reduces / removes the compressive load, for example when it is desired to disassemble the container 1. Details of the way in which the frame elements 59, 61 and 63 are connected together and the mechanisms for tightening/releasing the frame are illustrated in Figures 3b to 4e.

Each of the frame elements 59,61,63 includes an outer section 59a,61a,63a of tubing, which is elongate and has a rectangular cross section. Preferably the tubing is made from aluminium, however other materials such as steel and / or plastics can be used.

Each transverse frame element 61 includes a first connector 65 located towards each end of the outer section 61a. Each first connector 65 includes a block of material (such as aluminium or a thermoplastics material) that is located within the outer section 61a. The position of each first connector 65 with respect to the outer section 61a is adjustable. Each first connector 65 is associated with a first threaded anchor 67 and a first bolt 69. The threaded anchor 67 includes an internal thread that is arranged to receive the bolt 69. The position of the first anchor 67 is fixed with respect to the outer section 61a. Tightening/loosening the first bolt 69 adjusts the position of the first connector 65 relative to the outer section 61a, as can be seen by comparing Figures 3c and 4c. By adjusting the first bolt 69, the width of the frame 35 is adjusted. When the width of the frame is reduced, a compressive load is applied to the container sections 3 in a transverse direction.

Each longitudinal frame element 59 includes a second connector 71 located towards each end of the outer section 59a. Each second connector 71 includes a block of material (such as aluminium or a thermoplastics material) located within the outer section 59a. The position of each second connector 71 with respect to the outer section 59a is adjustable. The first bolt 69 passes through the outer section 59a and the second connector 71 and is arranged to move within first slots 73 formed in the outer section 59. A threaded element 75 passes through the second connector 71 at a first end and runs the entire length of the outer section 59a passing through the second connector 71 at the opposite end of the outer section 59a. A nut 77 is located towards each end of the threaded element 75. Rotating the nut 77 adjusts the axial position of the second connector 71 with respect to the outer section 59a. Rotating the nut 77 clockwise effectively shortens the overall length of the longitudinal frame element 59, and hence the length of the frame 35, and rotating the nut 77 anti-clockwise effectively extends the overall length of the longitudinal frame element 59. When the length of the frame is reduced, a compressive load is applied to the container sections 3 in a longitudinal direction.

The longitudinal frame element 59 includes second slots 79. A bolt 81 extends through the second slots 79 and the second connectors 71 into a third connector 83 which is located within the outer section 63a of the vertical frame element 63. Each third connector 83 comprises a block material (such as aluminium or a thermoplastics material) that is arranged for limited axial movement with respect to the outer section 63a. Third and fourth bolts 85,89 pass through the first connector 65 into the third connector 83. The third and fourth bolts 85,89 extend through the third connector 83 and engage with second and third threaded anchors

91,93 respectively. By rotating the third and fourth bolts 85,89 the position of the third connector 83 with respect to the outer section 63a can be adjusted by a small amount, thereby effectively adjusting the height of the frame 35 by a small amount. When the height of the frame 35 is reduced, a compressive load is applied to the container sections 3 in a vertical direction. Thus the thermally insulated wall elements 5,7,9 in each individual section 3 are urged together, thereby ensuring that each individual section 3 retains its shape.

The second bolt 81 passes through the third connector 83. The third bolt 83 is arranged to move within the second slot 79 when the second connector 71 moves relative to the frame element 59. Thus each longitudinal frame element 59 is connected to its respective transverse frame elements 61 and vertical frame elements 63 by an adjustable arrangement, wherein the height, width and length of the frame are each adjustable by a small amount.

The overall effect of applying the external frame 35 to the tubular sections 3 is to provide a part of the container structure, which defines four walls of the container (upper, base, and two side walls).

Optionally, the transverse cross members 33 can be applied within the recesses formed by the front and rear lips 29,31 in order to further strengthen the container.

It will be appreciated from Figures 3 a and 4a that at two corners of the frame the longitudinal frame elements 59 extend a little beyond the adjacent vertical frame elements 63. A hinge 95, in the form of a cylindrical rod, is provided between pairs of adjacent frame elements 59. A thermally insulated door 97 is mounted at each open end of the container via one of the hinges 95. Each door 97 includes a roto-moulded outer shell that is filled with an insulating material, such as foam, and preferably a high density foam. Having doors 97 at each end of the container provides better access to the payload volume within the container and also enables PCM units 42 to be loaded into the container more easily.

The insulated container 1 is designed specifically for use in transporting goods that must be maintained at a temperature of between +2°C and +8°C such as, for example, vaccines, temperature sensitive therapies and medicines. Insulated containers for different temperatures will be generally similar in construction, but may be modified as described in more detail below to maintain the required temperatures. For example, for some applications the internal temperature must be maintained in the range +15°C to + 25°C whereas for other applications, the internal temperature must be maintained in the range -25°C to -15°C.

It can be seen from Figure le that the PCM units 42 are loaded into the container in a regular fashion via the receiving brackets 43,44,51,53 and further brackets. The PCM units 42 are sized such that substantially the whole area of the interior face of the container walls and doors are lined with PCM units 42 to provide maximum cooling duration. Furthermore, since the arrangement of the PCM units is highly regular this provides good thermal equilibration within the container 1.

Each PCM unit 42 comprises a hollow container made from a polymer such as polyethylene and is filled with a PCM. The PCM used is dependent on the temperature characteristics that the payload requires. Some units 42 may have a different PCM from other units 42, in order to provide the required cooling required. For example, in order to maintain the goods being transported at a temperature of between +2°C and +8°C: some units 42 may include a PCM that changes phase at around 0°C and other units 42 may include a PCM that changes phase at around +5°C. A PCM that changes phase at around 0°C can comprise filtered water, and may include two acticides: DB20, which is fast acting, and MBS, which is slower acting. A PCM that changes phase at around +5°C can comprise a paraffin wax (mostly n-tetradecane).

An advantage of the invention is that for each of the temperature ranges +2°C to +8°C; -25°C to -15°C; +15°C to +25°C it is only necessary to have one set of PCM panels (one different set for each temperature range) for any destination, that is regardless as to whether the container is being sent to a relatively hot country or a relatively cold country. This is because of the thermal stability achieved by the invention.

In use, prior to loading the insulated container 1, each of the PCM units is conditioned by cooling (or heating) to predetermined temperatures. For example, any units 42 including a

PCM that changes phase at 0°C are typically cooled to a temperature of around -20°C and units 42 containing a PCM that changes phase at +5 °C are cooled to a temperature of around +6 °C. The units 42 are then loaded into the insulated container 1 to provide a substantially cuboid payload volume. At this stage the goods are loaded into the payload volume and can be surrounded by a packing material such as bubble wrap to ensure that the goods do not move during transit. If used, it is preferable that the packing material has also been conditioned to reduce its temperature prior to use.

It will be appreciated that when the container construction is completed, that it can be mounted on an appropriate aircraft pallet (see for example Figures la, lb, lc, le and If). The inventors have found that the width W of the container should be around 1550mm to enable the modular construction to be used on the following pallets: *4 BMC, Vi LD11, Vi PAG and Vi PMC. This corresponds to the length of the top/bottom walls 5a,7a of the upper and lower U-shaped elements.

The insulated container 1 has a modular construction that has a relatively small number of structural elements that can be constructed together to form the walls 3,5,7,9 of the container 1; and a frame 11, which is arranged to hold the structural elements together. The structural elements can be fitted together in different configurations, as can be seen in the Figures in order to produce differently sized containers 1,101,201, with the frame 135,135,235 being sized according to the size of the container (as will be apparent from the description below and from a comparison of Figs, la to If with Figs. 5a to 7f).

It will be appreciated from Figures 5a to 5c that different configurations of the tubular sections 3; 103; 303 are achievable by providing a greater or lesser number of side wall panels 9; 109.

For example, Figures 6a to 6f show a second embodiment of the invention which provides a container 101, which is made up of three tubular sections 103, a frame 135 and two doors 197. Each tubular section 103 includes upper and lower U-shaped elements 105,107 and one pair of wall panels 109 interposed therebetween. It will be apparent from the drawings that the second embodiment is constructed from the same basic elements as the first embodiment. It will also be appreciated that the size of the support frame 135 is smaller than in the first embodiment.

A third embodiment is shown in Figures 7a to 7e. This embodiment provides a container 203, which includes two tubular sections 203, a frame 235 and two doors 297. Each tubular section

203 includes upper and lower U-shaped elements 205,207 but does not include any wall panels. It will be apparent from the drawings that the third embodiment is constructed from the same basic elements as the first embodiment. It will also be appreciated that the size of the support frame 235 is smaller than in the first embodiment.

Various modifications of the invention are possible that fall within the scope of the current invention, some examples of which are discussed below.

While the support frame is shown in the Figures as having adjustability at each comer, it is envisaged that in some embodiments at least some of the comer joints will be non-adjustable, for example can be welded together. Adjustability at each corner is desirable because the manufacturing tolerances for roto-moulded products are relatively high. However, if the thermally insulated wall elements are manufactured by a different process, or the tolerances of the roto-moulding process improves, a simplified frame stmcture can be used. For example, it may only be necessary to apply a compressive load in any subset of the following directions: longitudinal, transverse and vertical, for example in just one of those directions (e.g. longitudinal only), or just two of those directions (e.g. longitudinal and vertical), and therefore the required adjustability at the corners can be set accordingly.

Figures 8a and 8b show an alternative frame arrangement 335 that can be used in conjunction with the first, second and third embodiments, wherein the length and the height of the frame 335 is adjustable, but the width is not. In this alternative frame 335, the longitudinal elements 359 are joined fixed to the vertical elements 363, and the vertical elements 363 are fixed to the transverse elements 361. The length of each transverse element 361 is fixed. The length of each longitudinal element 359 is adjustable. The length of each vertical element 363 is adjustable. Each longitudinal element includes first and second outer tubular parts 359a,359b and an inner part 359c, which is fixed to the first outer tubular part 359a, such that a portion of the inner part 359c protrudes from one end of the first inner part 359a. The second tubular part 359b is arranged to slide over the protruding portion of the inner part 359c. Thus the length is adjustable by adjusting the position of second tubular outer part 359b with respect to the first tubular outer part 359a. The relative positions of the first and second parts 359b,359c are fixed by screw elements 360.

The vertical supports 363 are adjustable in a similar fashion to the longitudinal supports 359.

Thus the adjustability has moved away from the corners.

Different types of PCM may be used to meet required temperature ranges. The invention is not to be considered as limited to just the ranges mentioned in the examples.

Optionally, the container can include at least one of an external temperature sensor mounted on the outside of the casing container, and an internal temperature sensor mounted inside the payload volume. These are connected to a single or multi-channel data logger that is provided to maintain a record of the payload temperature during the entire transit time. The temperature log may be kept in visual or electronic form, and in the latter case facilities may be provided for downloading the information to a computer. The data logger can also be arranged to record events such as the insulated container being opened or tampered with.

Claims

1. A modular system for constructing thermally insulated transportation containers for transporting temperature sensitive goods, said modular system enabling a variety of different sized thermally insulated containers to be constructed, said modular system including: a set of thermally insulated wall elements that are configurable into a plurality of container sections; and a support frame for fixing the container sections together to form at least part of a thermally insulated container structure, said support frame including a plurality of longitudinal support elements, a plurality of transverse support elements, and a plurality of vertical support elements, wherein the lengths of at least some of the support elements are adjustable, the arrangement being such that at least two of the height of the support frame, the width of the support frame and the length of the support frame are adjustable.

2. A modular system according to claim 1, wherein the set of thermally insulated wall elements includes a first substantially U-shaped element.

3. A modular system according to claim 1 or 2, wherein the set of thermally insulated wall elements includes a second substantially U-shaped element.

4. A modular system according to claim 3, wherein at least one of the container sections includes first and second thermally insulated substantially U-shaped elements.

5. A modular system according to claim 4, wherein the or each container section having first and second thermally insulated substantially U-shaped elements, includes a pair of thermally insulated wall panels disposed between the first and second substantially U-shaped elements.

6. A modular system according to any one of the preceding claims, wherein the support frame is mounted externally of the container sections.

7. A modular system according to any one of the preceding claims, wherein the support frame is arranged to apply a compressive load to at least some of the container sections.

8. A modular system according to any one of the preceding claims, wherein the arrangement of the support frame is such that each of the height of the support frame, the width of the support frame and the length of the support frame is adjustable.

9. A modular system according to any one of the preceding claims, wherein each of the longitudinal support elements is telescopically adjustable.

10. A modular system according to any one of the preceding claims, wherein each of the transverse support elements is telescopically adjustable.

11. A modular system according to any one of the preceding claims, wherein each of the vertical support elements is telescopically adjustable.

12. A modular system according to any one of the preceding claims, wherein the support frame is continuously adjustable in at least one of the longitudinal, transverse and vertical directions.

13. A modular system according to any one of the preceding claims, longitudinal support element is connected to two transverse support elements.

14. A modular system according to any one of the preceding claims, longitudinal support element is connected to two vertical support elements.

A modular system according to any one of the preceding claims, transverse support element is connected to two vertical support elements.

wherein each wherein each wherein each

16. A modular system according to any one of the preceding claims, including a first closure member that is openable to provide access to the interior of the container.

17. A modular system according to any one of the preceding claims, including a second closure member that is openable to provide access to the interior of the container.

18. A modular system according to any one of the preceding claims, including a set of PCM units for controlling the temperature within the container.

19. A modular system according to claim 18, wherein PCM units are mounted on each of the walls of the container.

20. A modular system according to claim 19 or 20, when dependent on claims 16 or 17, wherein PCM units are mounted on at least one of the first and second closure members.

21. A modular system according to claim 19 or 20, wherein at least one of the container walls and/or container closure members includes a plurality of layers of PCM units.

22. A modular system according to any one of claims 18 to 21, wherein the set of PCM units includes a first PCM unit having a first PCM arranged to change phase at a first temperature and a second PCM unit having a second PCM arranged to change phase at a second temperature, wherein the first and second temperatures are different.

23. A modular system according to claim 22, wherein the first PCM changes phase at a temperature in the range -20°C to +5°C, and preferably at a temperature of around 0°C, and the second PCM changes phase at a temperature in the range +5 °C to +20°C and preferably at a temperature of around +5°C.

24. A modular system according to claim 22 or 23, wherein the first PCM mostly comprises of water and the second PCM mostly comprises of a wax.

25. A modular system according to any one of claims 18 to 24, wherein the PCM changes from a solid state to a liquid state at a temperature in one of the following ranges: +2°C to +8°C; -25°C to -15°C; +15°C to +25°C.

26. A modular system according to any one of the preceding claims, wherein the support frame is at least partly separable in order to recover the thermally insulated wall elements for use in a new container.

27. A modular system according to any one of the preceding claims, including an external temperature sensor for measuring the ambient temperature outside of the container.

28. A modular system according to any one of the preceding claims, including an internal temperature sensor for measuring the temperature in the payload volume.

29. A modular system according to any one of the preceding claims, including a recording device for recording the temperature in the payload volume and / or the ambient temperature.

30. A method for constructing a modular thermally insulated transportation container that is arranged for transporting temperature sensitive goods, including: constructing a plurality of container sections from a set of thermally insulated wall elements; fixing said container sections together with an external support frame having a plurality of longitudinal support elements, a plurality of transverse support elements, and a plurality of vertical support elements to form at least part of a thermally insulated container structure; and adjusting the lengths of at least some of the support elements such that at least two of the height of the support frame, the width of the support frame and the length of the support frame are adjusted.

31. A method according to claim 30, including reducing the size of the support frame to apply a compressive load to the container sections.

32. A method according to claim 30, including telescopically adjusting at least two of: the plurality of longitudinal support elements; the plurality of transverse support elements; and the plurality of vertical support elements.

33. A method according to any one of claims 30 to 32, wherein the container is constructed and arranged according to any one of claims 1 to 29.

Intellectual

Property

Office

GB1713730.8

1-33

Application No: Claims searched: