WO2017136547A1 - Conteneur d'expédition résistant aux températures élevées - Google Patents

Conteneur d'expédition résistant aux températures élevées Download PDF

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Publication number
WO2017136547A1
WO2017136547A1 PCT/US2017/016211 US2017016211W WO2017136547A1 WO 2017136547 A1 WO2017136547 A1 WO 2017136547A1 US 2017016211 W US2017016211 W US 2017016211W WO 2017136547 A1 WO2017136547 A1 WO 2017136547A1
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WO
WIPO (PCT)
Prior art keywords
container
pcl
payload
inner chamber
support matrix
Prior art date
Application number
PCT/US2017/016211
Other languages
English (en)
Inventor
Charles A. Howland
Jeremy Branson
Isaac Angres
Original Assignee
Warwick Mills, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US15/353,012 external-priority patent/US9890988B2/en
Application filed by Warwick Mills, Inc. filed Critical Warwick Mills, Inc.
Publication of WO2017136547A1 publication Critical patent/WO2017136547A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
    • B65D81/3802—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container in the form of a barrel or vat
    • B65D81/3804—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container in the form of a barrel or vat formed of foam material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/80—Packaging reuse or recycling, e.g. of multilayer packaging

Definitions

  • the invention relates to shipping and packaging containers, and more particularly, to containers for shipping temperature sensitive contents under conditions where exposure to high temperature is an anticipated possibility.
  • Lithium batteries can be dangerous under some conditions and can pose a safety hazard because they contain a flammable electrolyte and also because they are kept pressurized. Moreover lithium batteries contain oxidizers, which can significantly increase the difficulty of fire suppression.
  • UPS has started using fireproof cargo containers, and has ordered more than 1 ,800 fiber-reinforced shipping containers that are designed to withstand fires for up to four hours.
  • such containers may maintain their integrity in a fire, they do little to prevent a surrounding fire from heating lithium batteries contained therein and eventually causing them to explode.
  • phase-change packaging is packaging that surrounds contents with an unbroken barrier comprising an substance such as water that vaporizes when subj ected to heat, thereby
  • phase change packaging approaches that work well at less extreme temperatures fail when subj ected to temperatures greater than 1000 °F. This is because internal structural degradation caused by the very high temperatures tends to open up gaps or "windows" in the phase change shield that allow the external heat to penetrate and reach the inner contents. Even if the phase change substance is contained in compartments or "packs" of a gel or similar substance, and the packs are held in place by rigid walls that maintain their structure at high temperatures, the packs themselves can nevertheless shrink and sag as the water or other phase-changing substance is consumed, thereby opening up gaps or "windows” in the phase- change shield.
  • Some of these limitations can be avoided by filling a packing container with a mixture of vermiculite and water as a single-use packing material that completely surrounds and submerges the lithium batteries or other contents. When heated, the water in the vermiculite is vaporized, but the vermiculite continues to surround and cover the contents, allowing the vaporized water to flow throughout and permeate the vermiculite, so that "windows" are avoided and the contents remain protected until the water is fully exhausted.
  • such packaging requires added insulation, is not easy to use, is not reusable, and is not sufficiently robust or durable for certain applications.
  • a robust, durable, easy to use, reusable container is disclosed that is capable of protecting contents from surrounding high temperatures up to 1000 degrees Fahrenheit for a minimum of at least three and a half hours.
  • the container includes an outer shell, at least one layer of thermal insulation, and an inner chamber in which a payload is surrounded by a phase change liquid (“PCL") that is sequestered in a supporting matrix.
  • PCL phase change liquid
  • heat that flows to the inner chamber through the outer shell and layers of insulation heats both the matrix and the PCL, causing the PCL to flash to gas, thereby maintaining the temperature of the payload at the vaporization
  • the container includes features that allow the flashed PCL to escape when exposed to heat or fire, while preventing the PCL from evaporating during normal storage.
  • the supporting matrix maintains the positioning of the PCL as it is evaporated, so that the payload remains surrounded by PCL and the entering heat is not able to bypass the PCL and reach the payload until the PCL is entirely exhausted.
  • the outer shell and insulation layers comprise sewn layers of fiberglass, ceramic insulation, and/or cotton.
  • the PCL is a highly water absorbent semi-solid polymer gel
  • the support matrix is a fiber matrix that comprises temperature resistant fibers, such as para aramid fibers.
  • the PCL and fiber matrix are contained within a barrier film and provided as semi-solid "gel packs" that surround the payload. The fiber matrix causes the gel packs to maintain their shapes at temperatures up to 1000 °F. In some of these embodiments, even after all the PCL is lost to evaporation the para-aramid matrix continues to maintain the shapes of the gel packs, and is clearly visible as a sponge-like mass inside the gel packs.
  • the gel-packs are further supported by the internal structure of the container, and cover a large percentage (in embodiments more than 90%) of the interior surface of the thermal insulation layer(s).
  • the inner chamber is bounded by gel panels comprising gel packs sandwiched between stiffening panels.
  • the container is built as a flat, layered assembly that can be folded into a six-sided box shape and latched with the use of attached hardware. The design allows for the container to be opened and closed for use without unfolding it completely, or to be completely unfolded and stored flat to save space.
  • the payload is submerged within the PCL and supporting matrix, which fills the inner chamber.
  • the payload is surrounded by over-packaging that prevents direct contact between the payload and the PCL.
  • the overpackaging helps to maintain a separation between the payload and the inner chamber walls.
  • the PCL matrix is able to maintain the separation between the payload and the inner chamber walls, so that the over-packaging serves only to prevent direct contact between the payload and the PCL.
  • Embodiments of the present invention satisfy this DOT requirement with a design factor of 2 by providing approximately 10,000 kJ of phase change heat capacity, in combination with surrounding insulation that limits heat flux so that the PCL is not exhausted within 3.5 hours of exposure at 1000 °F, and in embodiments up to 7 hours of exposure at 1000 °F.
  • Some of these embodiments that use water as the PCL consume less thanl O grams of water per minute when exposed to an exterior temperature of 1000 °F, such that the inner chamber is maintained in a steam atmosphere at a temperature of approximately 212 °F.
  • Various of these embodiments that use water as the PCL consume less thanl O grams of water per minute when exposed to an exterior temperature of 1000 °F, such that the inner chamber is maintained in a steam atmosphere at a temperature of approximately 212 °F.
  • embodiments require only 4.5 kg of water to meet the US DOT criteria.
  • a first general aspect of the present invention is a high temperature resistant shipping container that includes an outer shell, at least one insulation layer contained within the outer shell, an inner chamber located within the insulation layer, a support matrix contained within the inner chamber, a phase change liquid (“PCL") saturating and supported by the support matrix within the inner chamber, and a payload area located within the inner chamber and surrounded by the PCL-saturated support matrix.
  • the outer shell comprises steel, cementitious board, fiberglass cloth combined with corrugated cardboard, and/or ceramic fiber cloth combined with corrugated cardboard.
  • the insulation layer can comprise at least one of vermiculite, a cellulosic fiber pulp combined with at least one of a boric acid stabilizer and a fire retardant, cellulose foam sponge material, and a foamed polymeric material.
  • the support matrix can include at least one of vermiculite, para aramid fiber pulp, meta aramid fiber pulp, polyvinyl alcohol foam sponge material, high expansion polyester foam sponge material, and open cell polyurethane foam sponge material.
  • the container can be configured to inhibit evaporation of the PCL at atmospheric pressure, while allowing vaporized PCL to escape from the container at pressures above atmospheric pressure.
  • the PCL can have a total weight of less than 4.5 kg.
  • the insulation layers can occupy a volume that is between 30% and 70% of a volume of the outer shell.
  • the inner chamber can occupy a volume that is between 30% and 70% of a volume of the outer shell.
  • the outer shell and insulation layers can have a combined thermal conductivity of not more than 1.15 W/mK at 1000 degrees Fahrenheit.
  • a volume filled by the PCL and support matrix can be sufficient to maintain the payload area at a temperature below 300 oF during an exposure of the container to a temperature of 1000 oF, said exposure lasting more than 3.5 hours.
  • the container can be foldable into a flat configuration.
  • the PCL and support matrix can include a plurality of gel packs filled with semi-solid PCL-filled polymer gel and packaged in a vapor barrier membrane.
  • the support matrix comprises heat-resistant fibers.
  • the gel packs are sandwiched between stiffening panels to form gel panels that surround the payload area.
  • the heat-resistant fibers can cause the gel packs to remain unchanged in shape as the PCL is evaporated therefrom.
  • the gel packs can have a slump less than 8" according to ASTM Standard C 143/C 143M Standard Test Method for Slump of Hydraulic-Cement Concrete.
  • the vapor barrier membrane can maintain the PCL in the semi-solid gel such that less than 1% per year by weight of the PCL is lost through the barrier membrane when the container is maintained at a temperature of 75 degrees Fahrenheit.
  • the semi-solid gel can be more than 90% PCL by weight.
  • the heat-resistant fibers can include para-aramid fibers.
  • the inner chamber can be filled by the PCL and support matrix
  • the payload area can be a volume of PCL and support matrix that is displaced when a payload is immersed within the PCL and support matrix.
  • a second general aspect of the present invention is a method for protecting a payload from external heat.
  • the method includes providing a container according to the first general aspect, wherein the inner chamber is filled by the PCL and support matrix, and the payload area is a volume of PCL and support matrix that is displaced when a payload is immersed within the PCL and support matrix.
  • the method further includes enclosing the payload with an over- package, immersing the payload and over-package within the PCL and support matrix, so that the payload is offset from all walls of the inner chamber and completely surrounded by the PCL and support matrix, and closing the container, the over-package being configured to prevent direct contact between the payload and the PCL.
  • the offset of the payload from all walls of the inner chamber is maintained by the over-package, while in other embodiments the offset of the payload from all walls of the inner chamber is maintained by the support matrix.
  • a third general aspect of the present invention is a high temperature resistant shipping container that includes an inner chamber containing a support matrix that supports and is saturated by a phase change liquid (“PCL") that includes at least one of water and ethylene glycol, a volume of the PCL being sufficient to maintain a payload within the inner chamber at a temperature below 300 oF during an exposure of the container to a temperature of 1000 °F, said exposure lasting more than 3.5 hours.
  • the support matrix includes at least one of expanded vermiculite, cellulosic pulp and fiber combined with at least one of boric acid stabilizer and a fire retardant, a foamed polymeric material, para aramid fiber pulp, and meta aramid fiber pulp.
  • the support matrix can include at least one of: polyvinyl alcohol foam sponge material, high expansion polyester foam sponge material, open cell polyurethane foam sponge material, and cellulose foam sponge material.
  • the PCL can be water having a total mass that is at least 600% of a mass of the support matrix.
  • a super absorbing polymer can be blended with the PCL.
  • a mass of the SAP is between 0.5% and 50% of a mass of the support matrix.
  • the SAP can be able to stabilize a quantity of water having a mass that is more than 100 times as large as a mass of the SAP.
  • a fourth general aspect of the present invention is a high temperature resistant shipping container containing a phase change liquid ("PCL") having a sufficient volume to maintain an inner payload at a temperature below 300 °F during an exposure of the container to a temperature of 1000 oF, said exposure lasting more than 3.5 hours.
  • PCL phase change liquid
  • the PCL is water.
  • the PCL can be supported by a porous matrix.
  • the support matrix is expanded
  • the PCL can be surrounded by a high temperature insulation layer.
  • the container can include an outer steel drum having a containment volume of 10 gallons and an inner steel drum having a containment volume of 5 gallons.
  • the container can include an outer steel drum having a containment volume of 30 gallons and an inner steel drum having a containment volume of 10 gallons.
  • the container can include an outer steel drum having a containment volume of 55 gallons and an inner steel drum having a containment volume of 20 gallons.
  • the PCL can have a total mass of not more than 2.5 kg.
  • Figure 1 is a perspective view of the exterior of an embodiment of the present invention
  • Figure 2 is a horizontal cross-sectional illustration of an embodiment of the present invention
  • Figure 3 is a cross-sectional illustration of a panel forming a side of an insulated sub-container according to the embodiment of Figure 2;
  • Figure 4 is a perspective view of a first embodiment of the present invention, shown fully unfolded
  • Figure 5 is a perspective view of a second embodiment of the present invention, shown fully unfolded
  • Figure 6 is a perspective view illustrating the composition of the lid flaps in an embodiment of the present invention.
  • Figure 7 is a top view of the embodiment of Figure 5, showing panel assembly placement
  • Figure 8 is a perspective, transparent view of a cylindrical embodiment of the present invention.
  • Figure 9 is a vertical cross sectional view of the cylindrical embodiment of Figure 8.
  • Figure 10 is a horizontal cross sectional view of the cylindrical embodiment of Figure 8.
  • Figure 1 1 is a block diagram showing the placement of gel packs during construction of the gel pack panels in an embodiment of the present invention
  • Figure 12 is a graph presenting four data sets that record the interior temperature of an embodiment of the present invention during a seven hour exposure of the container to 1000 degrees Fahrenheit, wherein the plotted curves represent different interior locations;
  • Figure 13 is a table of results from multiple independent thermal tests performed on embodiments of the present invention.
  • Figure 14 is an exploded view of a closure hardware system in an embodiment of the present invention.
  • Figure 15 is a perspective view of the closure post of the closure hardware of Figure 14;
  • Figure 16 is a cross sectional view of a satchel embodiment of the present invention.
  • Figure 17 is a cross sectional view of the satchel embodiment of Figure 16 shown during the loading process
  • Figure 18 is a perspective view of the satchel embodiment of Figure 16 shown in a closed configuration.
  • Figure 19 is a cross-sectional diagram of an embodiment of the present invention.
  • a robust, durable, easy to use, reusable container is disclosed that is capable of protecting contents from surrounding high temperatures up to 1000 degrees Fahrenheit for a minimum of at least three and a half hours.
  • the container includes an outer shell, at least one layer of thermal insulation, and an inner chamber in which a payload is surrounded by a phase change liquid (“PCL") that is sequestered in a supporting matrix.
  • PCL phase change liquid
  • heat that flows to the inner chamber through the outer shell and layers of insulation heats both the matrix and the PCL, causing the PCL to flash to gas, thereby maintaining the temperature of the payload at the vaporization
  • the container includes features that allow the flashed PCL to escape when exposed to heat or fire, while preventing the PCL from evaporating during normal storage.
  • the supporting matrix maintains the positioning of the PCL as it is evaporated, so that the payload remains surrounded by PCL and the entering heat is not able to bypass the PCL and reach the payload until the PCL is entirely exhausted.
  • the container is durable enough to survive normal shipping and handling, and is able to pass the following tests and still be functional at the service temperature:
  • the outer shell is capable of maintaining containment of the system even after extended exposure to high temperatures up to 1000 °F.
  • Materials used in various embodiments include:
  • the invention provides at least one insulating layer just inside of the outer shell that moderates the heat flux into the inner chamber.
  • the outer face of this insulating layer will be exposed to very high temperatures. Accordingly, so as to avoid any combustion, this layer must be inert at 1000 °F. This high temperature requirement limits the material family of the insulating layers to inorganic materials.
  • Embodiments include one or more of:
  • the outer insulation layers represent from 30% to 70%) of the total volume of the system.
  • Embodiments that include higher performance materials in the insulation layer(s) are able to moderate the heat flux while occupying a lower percentage of the system volume.
  • the inner chamber contains the PCL, which must be prevented from flowing or wicking into the high temperature insulating layer(s). Therefore, the inner chamber walls must provide a barrier to movement and evaporation of the PCL. Furthermore, when exposed to heat flow, the flashing of the PCL into gas must be managed by the inner chamber walls. In embodiments, the vaporized PCL is wicked away from the inner chamber by the inner chamber walls.
  • the inner chamber walls must provide resistance to leakage of liquid PCL and resistance to PCL vapor at its boiling point, while retaining its tensile properties even when the external temperature is maintained at 1000 °F for up to 3.5 hours.
  • the inner chamber is separable from the container and is vapor competent.
  • the inner chamber walls are fabricated from rigid steel, aluminum, and/or fiber reinforced polymer.
  • This family of embodiments provides for enhanced mechanical integrity of the payload, and can sustain more shock and vibration than some other embodiments.
  • Some of these embodiments include close fitting caps or lids with mechanical fasteners that provide excellent separable closure options.
  • the inner chamber walls are fabricated from flexible materials, such as metallic foils and/or reinforced and/or unreinforced polymer films. Bonded and heat-sealed closures and rolled and clamped closures are also part of this family of embodiments.
  • Materials used in the fabrication of the inner chamber walls in various embodiments include:
  • PCL' s phase change liquids
  • water has a very large advantage over many other materials in this regard, due to its remarkably high heat of vaporization.
  • PCL vapor escapes from the containment during heat exposure, the PCL vapor must not be flammable.
  • a number of inert organic materials that would meet the heat of vaporization requirement for a PCL do not meet this vapor combustion requirement. Water and steam do not contribute to combustion, and have a high heat of vaporization.
  • Expanded or exfoliated vermiculite is used in some embodiments of the invention as the matrix that supports the PCL in the inner chamber, because if its low density of 4- 10 lb/ft3 and its fine cell structure. This material also has good water holding and stabilization properties, and because of its good insulation properties the heat flux is well controlled.
  • the PCL matrix material is cellulose pulp combined with a boric acid stabilizer and/or fire retardants.
  • the moisture transport for this material is very good, and the density and insulation is acceptable. Closely related embodiments use para or meta aramid pulp. In these embodiments, no added fire retardant or stabilizer is required.
  • the PCL matrix and stabilizing materials include at least one of:
  • the ratio of inner chamber volume to system volume ranges from 30% up to 70%, and the ratio of PCL mass to support matrix mass ranges from 50% to 600%. Generally, lower density matrix materials support higher PCL mass.
  • the PCL material is augmented with one or more super absorbing polymers ("SAP' s").
  • SAP material is dispersed in the PCL matrix, forming a polymer gel and helping to stabilize the PCL.
  • the SAP improves the evenness of the distribution of the PCL in the inner chamber volume.
  • the semi-solid gel is a mixture that has limited flow up to at least 200 degrees Fahrenheit and three atmospheres of pressure, and for which the contained water is not released under normal pressures or through freeze/thaw cycles.
  • the gel mix recipe in various embodiments is based on the weight of the water, with the SAP in some embodiments being as low as 0.5% of the water weight and the fiber content being as low as 3% of the water weight.
  • the semi-solid gel does not flow, is easily shaped, holds the shape in which it is formed, and has a viscosity of greater than 2000 cps.
  • the gel has a slump less than 8" according to ASTM Standard C 143/C 143M Standard Test Method for Slump of Hydraulic-Cement Concrete.
  • the terms "super absorbent polymer" and " SAP" refer to
  • sodium polyacrylate SAP is used together with water as the PCL.
  • An advantage of this system is that the sodium polyacrylate can hold 250 times its dry mass in water. This reduces the mass of the PCL matrix material that is required to hold the water in place.
  • the total mass of SAP in some of these sodium polyacrylate embodiments is less than 100 grams distributed throughout the inner volume.
  • embodiments include semi-solid gel packs that comprise a highly water absorbent semi-solid polymer gel mixed with a matrix of temperature resistant fibers, such as para aramid fibers, and contained within a barrier film.
  • the gel packs are assembled between stiffening panels to form stiffened gel-panels.
  • the container 100 includes:
  • an outer shell cover fabric 201 which can be a layer of uncoated or coated fiberglass, ceramic fiber, para aramid, meta aramid, phenolic, PTFE, or a blend thereof, where the fabric coating (if included) can be neoprene, silicone, acrylic, urethane, or blends thereof;
  • outer 207 and inner 204 insulation layers which can be ceramic
  • stiffening panels 203 which can be coated or uncoated fiberglass
  • a layer of gel packs 205 sandwiched between the stiffening panels 203 comprising gel contained 203 within a barrier film 303, which can be metalized PET, PET, PCTFE, nylon, polypropylene, or HDPE; and
  • an inner fabric layer 202 which can be fiberglass, non-woven, or
  • the gel packs contain a highly water absorbent gel mixed with a matrix of temperature resistant fibers.
  • the gel packs 205 are able to maintain their structure within the gel panels at temperatures up to 1000 °F because the gel is thickened by the matrix of temperature resistant fibers.
  • the gel-packs 205 cover a large percentage (in embodiments more than 90%) of the interior surface of the container. Also included in various
  • embodiments are insulation layers 204, 207, inner 202 and outer 201 cover fabric layers, and a closing mechanism including an upper lid flap 102, a lid 103, a lower lid flap 104, and closure hardware 101.
  • the gel packs 205 are constructed by bonding two pieces of barrier film 303 around a portioned amount of semi-solid gel 302 mixed with a matrix of high temperature fibers.
  • the preformed gel packs 205 are attached by an adhesive to a "stiffening panel" 203, which in embodiments is a panel of corrugated cardboard 203, and arranged such that there is a continuous, uniform layer of gel 302 across substantially the whole surface of the stiffening panel 203.
  • a second stiffening panel 203 is then attached in some of these embodiments to the upper surface of the gel packs using an adhesive, thereby forming a gel panel that is a "sandwich" of gel packs 205 with stiffening panels 203 on each side.
  • the outer shell 201 , closure hardware 101 , and insulation 204, 207 are able to maintain their structural integrity at service temperatures up to at least 1000 °F.
  • the inner liner 202, stiffening panels 203, and barrier film 303 are protected by the gel packs 205, and are not required to withstand these high temperatures.
  • the outer shell 201 is made from a material that will maintain its basic structure after exposure to the high temperatures, and is also durable enough to withstand the rigors of repeated handling and cycles of loading and unloading.
  • the outer shell 201 is made from woven fiberglass, and in other embodiments the outer shell 201 is made from woven aramid cloth.
  • Embodiments include a coating (not shown) applied to the outer shell fabric layer 201 that simplifies material processing by reducing fraying, increasing the fabric' s durability, and providing a small amount of shape to the final result. Since the coating plays no part in the temperature resistance, coatings such as neoprene and silicone with low service temperatures can be used.
  • the insulation layers 204, 207 must be robust enough to withstand the handling involved in normal packing and shipping procedures, capable of functioning at the high service temperatures, and applied in a thicknesses that is sufficient to mitigate water loss from the gel 302 for a desired minimum time at a specified maximum temperature.
  • ceramic wool felt is used as the insulation layers 204, 207.
  • the stiffening panels 203 play a critical role in helping to keep the gel packs 205 in their correct locations during the lifespan of the container 100, and as such need to be constructed out of a material that will retain its integrity during handling and shipping. Because they are placed on the interior side of the insulation layers, the stiffening panels 203 will not be exposed to the full service temperature of the container 100, but must nevertheless be resistant to temperatures that are elevated above ambient. In embodiments, the stiffening panels comprise coated fiberglass laminate and/or corrugated cellulose cardboard sheets. The mechanism used to attach the gel packs 205 to the stiffening panels 203 will depend on the materials selected, but must be sufficient to secure the gel packs 205 in position during transit.
  • the inner liner fabric 202 serves to keep the panel assembly (insulation layers 204, 207, stiffening panels 203, and gel packs 205) together, and provides a smooth interior surface for the inner chamber 206 of the container 100.
  • a critical characteristic for this liner material 202 is abrasion resistance, as the package will be loaded and unloaded multiple times over the container lifespan.
  • the barrier film 303 has a water vapor transmission rate that is low enough to ensure that the PCL content in the gel 302 remains adequate throughout the service life of the container 100.
  • the container 100 comprises five primary subassemblies, including upper and lower lid flaps 403, top 103 and bottom lids 404, side panels 402 and an outer shell assembly 405.
  • Construction of this example begins with the outer shell 405, which is a single layer of 0.20" thick fiberglass 201 coated with a neoprene based coating at a rate of 0.5oz/yard.
  • the neoprene coating makes the fiberglass easier to handle and cut, and also provides abrasion resistance.
  • the outer shell 405 is laid out with the coating side down and a 1 ⁇ 2" hem is sewn around the entire piece.
  • a layer 207 of insulation which is a 1/4" thick 8 lb/ft2 alkaline earth silicate (AES) blanket.
  • AES alkaline earth silicate
  • a single layer of lightweight cotton 202 is laid over the insulation 207, and the assembly is sewn together with a 1" hem on the two long sides and one of the short sides.
  • the last side 406 will become the location for the closure hardware 101 and so it is hemmed at 4 1 ⁇ 2".
  • the side panels 402, 403 of the container consist of 3 layers of 1 ⁇ 2" AES insulation 204 and a gel panel 300 covered with a single layer of cotton 202 and sewn onto the outer shell 405 in a layout that facilitates the folding of the container 100 into a rectangular shape.
  • gel panels 300 are constructed by arranging 5"xl l" and 5"x5" gel packs 205 filled with a semi-solid gel 302 and using hot melt adhesive to secure the gel packs 205 to stiffening panels 203 that are sheets of 200 pound, single layer corrugated cardboard 203. Once all of the gel packs 205 are attached to the cardboard sheet 203, a second sheet of cardboard 203 is adhered on top, forming a sandwich 300 gel panel .
  • the gel packs 205 are constructed by bonding 2 layers of heat-sealable metallized PET film 303 to form a pouch containing the semi-solid gel 302.
  • the semi-solid gel 302 is comprised of purified water and SAP, and is mixed with de- agglomerated aramid fibers as the support matrix.
  • Upper 403 and lower lid flaps 407 are assembled in a similar fashion.
  • the neoprene coated fiberglass 201 is laid out with coating side down and a 1 ⁇ 2" hem is sewn around the edge.
  • a single layer of 1 ⁇ 4" AES insulation 207 quilted between 2 layers of cotton fabric 202 is laid on top, and the assembly is sewn together with a 2" hem on the top, 4 1 ⁇ 2" hems on the ends, and a 1" hem on the bottom, in that order.
  • the upper lid flaps 403 are constructed in the same way as the lower lid flaps 407, with the addition of a small spacer 602 added to square up the container and allow for better sealing.
  • the spacer is a smaller version of the lid flap, built with a layer of fiberglass and layer of insulation, and covered with a layer of cotton.
  • This spacer 602 is placed between the fiberglass 601 and the quilted insulation layer 603 on the upper lid flap 403, and is located such that it is centered on the top edge after the lid flap 403 is fully hemmed.
  • the lid panels 401 , 404 are built in the same fashion as the side panels 402, 403 , with the exception that there is only one gel panel 300 per lid panel 401 ,
  • the neoprene coated fiberglass 201 for the lid is laid out coating side down. Three of the four sides are then hemmed at 1 ⁇ 2", with the fourth edge left unhemmed for attaching the lid to the outer shell. Three layers of AES insulation 204, 207 are stacked on the fiberglass 201 , with a gel panel 300 on top. This is covered with a single layer of cotton 202, and the assembly is hemmed at two and seven-eighths inches on the three previously hemmed sides.
  • Lid flaps 403, 407 are attached to the hemmed sides of the lid panels 401 , 404 and allowed to extend beyond the lid panels 401 , 404, forming the closure flaps 102.
  • the lid assemblies are then attached to the outer shell assembly
  • FIG. 7 A simplified top view of the embodiment described in this example is shown in Figure 7.
  • Figure 1 1 is a block diagram that illustrates the placement of gel packs during construction of the gel panels 300 in the embodiment of this example.
  • nylon webbing straps (not shown) are attached to allow for easy handling.
  • Figure 13 is a table of results from multiple independent thermal tests performed on the embodiment of example 1.
  • Closure hardware 101 is attached to the ends of the outer shell 405 and the edges of the lid flaps 403, 407 to allow for complete closure of the container 100.
  • the closure hardware 101 comprises quarter turn "common sense" fasteners.
  • Figure 14 is an exploded view of a closure hardware system 101 in an embodiment, where the closure hardware includes an eyelet 1401 , a post 1402, a washer 1403, and a clinch plate 1404.
  • Figure 15 is a close-up perspective view of the post 1402 of Figure 14.
  • Example 2 includes three main subassemblies: the outer shell assembly 805, the upper lid assembly 802, and the lower lid assembly 804.
  • Construction of the outer shell assembly 805 begins with a single outer shell layer of 0.20" thick uncoated fiberglass that is cut into a rectangular shape and hemmed at 1 ⁇ 2" on the long sides and at 4" on the short sides. Three layers of 1 ⁇ 2" insulation 204 and a panel 300 of gel packs 205 are stacked on top of the outer shell 805 and covered with another layer of fiberglass, which is then sewn onto the outer shell.
  • Lid flaps 801 , 803 are assembled in a similar fashion.
  • a fiberglass sheet is laid out and a 1 ⁇ 2" hem is sewn around the edge.
  • a single layer of 1 ⁇ 4" AES insulation quilted between 2 layers of cotton fabric is laid on top, and the assembly is sewn together with 1" hems on the top, the ends, and then the bottom, in that order.
  • Construction of the lid assemblies 802, 804 begins in the same manner. A circular sheet of fiberglass is hemmed, a single layer of insulation is placed on top, and then the cover fabric is sewn on top. After that, three layers of insulation and a gel panel 300 are centered on the lid, with the gel panel 300 on top. The cover fabric is pre-formed into a circular box-shape and is fit over the
  • lid flaps 801 , 803 are attached to the edges of the lids 802, 804 and the ends of the flaps 801 , 803 are sewn together to form sleeves that extend upward and downwards from the lids 802, 804.
  • Closure hardware 101 is attached to the ends of the outer shell in such a way that the shell can be formed into a cylinder, with the fiberglass on the outside and with open ends.
  • the lid assemblies are then sleeved over the ends of the outer shell, and the insulation assemblies are fit into the ends.
  • Figures 9 and 10 present vertical and horizontal cross sections, respectfully, of this embodiment.
  • construction of this example begins as with the other two examples by laying out the outer shell 201 , hemming the edge at 1 ⁇ 2", stacking a layer of insulation 204 and cover fabric, hemming again, stacking layers of insulation 204 and a gel panel 300, and then sewing a cover fabric over it all.
  • the insulation 204 and gel panel 300 are two-thirds of the size of the outer shell 201 , and are stacked off center on the outer shell 201 , so as to leave a section of outer shell 201 that will serve as a closure flap 1803.
  • final assembly is achieved by folding the outer shell assembly in half, so that it encloses a payload space 1700, after which the side panels are inserted and the entire mass is sewn together so that the ends of the insulation/gel panel are even and that the closure flap is able to cover the open side.
  • the side panels are constructed by encapsulating the layers of insulation in cover fabric.
  • straps 1801 made from folded and hemmed outer shell fabric of sufficient length to encircle the container are attached to the closure flap and appropriate hardware is included to facilitate the securing of the straps.
  • the entire inner chamber is filled with the PCL and supporting matrix, and the payload is immersed in this mixture.
  • Figure 19 presents a cross-sectional diagram of an embodiment 1900 of this general aspect of the present invention.
  • the outer shell includes outer walls 1902 and an outer closure 1904.
  • Materials used in the outer shell in various embodiments include:
  • a low density insulating layer 1906 is provided that moderates the heat flux into the PCL- containing inner chamber volume 1914.
  • the insulating layer includes one or more of:
  • the outer insulation layer 1906 represents from 30-70% of the total volume of the system. Embodiments that include higher performance materials in the insulation layer are able to moderate the heat flux while occupying a lower percentage of the system volume.
  • the inner chamber 1914 in the embodiment of Figure 19 contains the PCL and supporting matrix.
  • the inner chamber 1914 also contains the payload 1908, which is immersed in the PCL and supporting matrix and is enclosed within over-packaging 1916 so as to prevent the payload from coming into direct contact with the PCL.
  • the PCL must be prevented from flowing or wicking into the outer, high temperature insulating layer 1906. Therefore, the inner chamber walls 1910, 1912 must provide a barrier to movement and evaporation of the PCL. Furthermore, when exposed to heat flow, the flashing of the PCL into gas must be managed by the inner chamber walls 1910, 1912. In embodiments, the vaporized PCL is wicked away from the inner chamber 1914 by the surrounding wall 1910, 1912.
  • the inner chamber walls 1910, 1912 must provide resistance to leakage of liquid PCL and resistance to PCL vapor at its boiling point, while retaining its tensile properties even when the external temperature is maintained at 1000 °F for up to 3.5 hours.
  • the inner chamber 1914 is separable from the outer chamber 1906 and vapor competent.
  • the walls 1910, 1912 of the inner chamber are fabricated from a rigid material, such as steel, aluminum, and/or fiber reinforced polymer.
  • the inner chamber walls 1910, 1912 are fabricated from one or more flexible materials, such as metallic foils and/or reinforced and/or unreinforced polymer films, bonded and heat-sealed closures, and rolled and clamped closures.
  • Embodiments of this general aspect of the invention include any of the various phase change liquids ("PCL' s") discussed above, including water and/or ethylene glycol.
  • PCL' s phase change liquids
  • Expanded or exfoliated vermiculite is used in some embodiments of the invention as the support matrix that contains the PCL in the inner chamber 1914, because of its low density of 4- 10 lb/ft3 and its fine cell structure. This material also has good water holding and stabilization properties, and because of its good insulation properties the heat flux is well controlled.
  • the PCL matrix material is cellulose pulp combined with a boric acid stabilizer and/or fire retardants.
  • the moisture transport for this material is very good, and the density and insulation is acceptable.
  • Similar embodiments use para or meta aramid pulp, which do not require an added fire retardant or stabilizer is required.
  • a primary requirement for these embodiments is that there is adequate over-packaging 1916 to make sure that the normal settling of pulp does not leave a void at the top of the payload volume 1908.
  • the ratio of inner chamber volume to system volume ranges from 30% up to 70%, and the ratio of PCL mass to support matrix mass ranges from 50% to 600%. Generally, lower density matrix materials support higher PCL mass.
  • the PCL material in some embodiments of this general aspect of the invention is augmented with one or more super absorbing polymers ("SAP' s").
  • SAP material is dispersed in the PCL matrix and helps to stabilize the PCL. The SAP improves the evenness of the distribution of the PCL in the inner chamber volume.
  • Sodium polyacrylate SAP is used in some embodiments together with water as the PCL.
  • the advantage of this system is that the sodium polyacrylate can hold 250 times its dry mass in water. This reduces the mass of the PCL matrix material that is required to hold the water in place.
  • the total mass of SAP in some of these sodium polyacrylate embodiments is less than 100 grams distributed throughout the inner volume.
  • the PCL matrix and stabilizing materials include at least one of:
  • the payload 1908 is contained in embodiments within over- packaging 1916 so that the payload is not exposed directly to the PCL.
  • the payload must also not be placed too close to the walls 1910, 1912 of the inner chamber 1914, since the moderation in payload temperatures that is achieved by the PCL vaporization is most effective in the center of the inner chamber. "Hot spots" can occur in the outer 1 -3 inches of the inner chamber, where the PCL can become exhausted locally as the heat exposure time is extended because the wicking flow of vaporized PCL away from the inner chamber 1914 does not always maintain a completely uniform PCL distribution within the inner chamber 1914.
  • the payload is kept away from these potential boundary layer hotspots by a payload buffer, or over-packaging 1916, which keeps the payload 1918 away from the potentially hotter, outer boundary zone of the inner chamber 1914.
  • the over-packaging 1916 is fabricated using one or more of:
  • the PCL matrix support if the PCL matrix support has sufficient stability and crush resistance, and does not flow, the PCL matrix itself can be used to keep the payload 1918 separated from the walls 1910, 1912 of the inner chamber 1914.
  • PCL matrix materials such as vermiculite can provide this level of stability, thereby avoiding a need for the over-packaging 1916 to maintain this physical separation.
  • the payload packaging i.e. over- packaging 1916
  • the over-packaging 1918 is fabricated from materials that include one or more of:
  • the goal of this invention is to provide a maximum payload volume with a minimum of shipping material volume and weight.
  • the ratio of the payload volume to the total system volume is between 10% and 20%.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Packages (AREA)

Abstract

L'invention concerne un conteneur d'expédition robuste, durable, facile à utiliser et réutilisable, lequel conteneur peut protéger une charge utile vis-à-vis de températures environnantes élevées jusqu'à 1000 degrés Fahrenheit pendant un minimum d'au moins trois heures et demie. Le conteneur comprend une enveloppe externe, au moins une couche d'isolation et une chambre interne dans laquelle la charge utile est entourée par un liquide à changement de phase (PCL) séquestré dans une matrice de support qui maintient le liquide à changement de phase sous une forme et en un emplacement fixes. Le PCL peut être mélangé à un polymère super-absorbant pour former un gel. Le PCL qui s'évapore peut être peut être absorbé par un effet de mèche par les parois de la chambre interne. Dans un premier aspect général, la zone de charge utile est entourée par des panneaux de gel comprenant des paquets de gel pris en sandwich entre des panneaux de raidissement. Dans un second aspect général, la chambre interne est remplie par le liquide à changement de phase et la matrice de support, et la charge utile est renfermée dans un sur-emballage et submergée dans le PCL et la matrice.
PCT/US2017/016211 2016-02-05 2017-02-02 Conteneur d'expédition résistant aux températures élevées WO2017136547A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US201662291624P 2016-02-05 2016-02-05
US62/291,624 2016-02-05
US201662328211P 2016-04-27 2016-04-27
US62/328,211 2016-04-27
US15/353,012 2016-11-16
US15/353,012 US9890988B2 (en) 2016-04-27 2016-11-16 High temperature resistant shipping container

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WO2017136547A1 true WO2017136547A1 (fr) 2017-08-10

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108126233A (zh) * 2017-12-28 2018-06-08 广州润虹医药科技股份有限公司 一种高膨胀率压缩海绵
CN108609279A (zh) * 2018-04-19 2018-10-02 中国民用航空总局第二研究所 一种锂电池及含锂电池电子设备的应急或预防处置袋

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US20020017590A1 (en) * 1998-11-16 2002-02-14 Fay Ralph Michael Burn through resistant systems for transportation, especially aircraft
US20060188672A1 (en) * 2005-02-18 2006-08-24 Brower Keith R Thermal filtering insulation system
US20120067762A1 (en) * 2010-09-22 2012-03-22 Illinois Tool Works Inc. Container Assembly and Methods for Making and Using Same
WO2014088742A1 (fr) * 2012-12-03 2014-06-12 E. I. Du Pont De Nemours And Company Feuille composite et conteneur de fret la comprenant
WO2016012768A1 (fr) * 2014-07-21 2016-01-28 Goodwin Plc Contenant résistant au feu

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020017590A1 (en) * 1998-11-16 2002-02-14 Fay Ralph Michael Burn through resistant systems for transportation, especially aircraft
US20060188672A1 (en) * 2005-02-18 2006-08-24 Brower Keith R Thermal filtering insulation system
US20120067762A1 (en) * 2010-09-22 2012-03-22 Illinois Tool Works Inc. Container Assembly and Methods for Making and Using Same
WO2014088742A1 (fr) * 2012-12-03 2014-06-12 E. I. Du Pont De Nemours And Company Feuille composite et conteneur de fret la comprenant
WO2016012768A1 (fr) * 2014-07-21 2016-01-28 Goodwin Plc Contenant résistant au feu

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108126233A (zh) * 2017-12-28 2018-06-08 广州润虹医药科技股份有限公司 一种高膨胀率压缩海绵
CN108609279A (zh) * 2018-04-19 2018-10-02 中国民用航空总局第二研究所 一种锂电池及含锂电池电子设备的应急或预防处置袋

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