WO2018197049A1

WO2018197049A1 - An insulating transport and storage container

Info

Publication number: WO2018197049A1
Application number: PCT/EP2018/025125
Authority: WO
Inventors: Richard Darren WOOD; Ross Malcolm BEECH; James Nathan JARVIS; Timothy ASTLEY-COOPER
Original assignee: Softbox Systems Limited
Priority date: 2017-04-24
Filing date: 2018-04-24
Publication date: 2018-11-01
Also published as: GB2563732A; GB201806692D0; GB201706482D0

Abstract

The present invention relates to the field of the transportation of goods and, in particular, to a box or box-like transport container - a shipper (50) -that can provide a high degree of thermal insulation. More particularly, the present invention relates to storage containers that comprise a box or box-like container that can be handheld. The present invention provides an improved shipper (50).

Description

AN INSULATING TRANSPORT AND STORAGE CONTAINER

Field of Invention

[0001] The present invention relates to the field of the transportation and storage of goods and, in particular, to a box or box-like transport container that can provide a high degree of thermal insulation. More particularly, the present invention relates to storage containers that comprise a box or box-like container that can be hand-held.

Background to the Invention

[0002] In the field of logistics, that is the field of movement and supply of produce and materials, there is a widespread requirement to protect a thermally sensitive load to ensure that certain types of produce and materials do not to pass through certain temperature thresholds. It is well known that, for example, vegetables when subject to extremes of temperature that they become flaccid, as the cell structure is broken down through the formation of icicles or through dehydration.

[0003] In essence, in any transport container with a thermally sensitive load, the rate at which heat passes through the packaging material of the transport container - the amount of heat that flows per unit time through a unit area with a temperature gradient per unit distance must not extend beyond a permitted temperature range for the product. Temperature control of thermally sensitive goods is particularly challenging when the thermally sensitive goods must be maintained within a narrow temperature range. Refrigeration units as used on certain trucks and containers require a source of electrical power or a fuel for a gas-powered air-conditioning / freezer unit and also require an atmosphere with which to exchange heat. Such refrigeration units not only occupy a volume, they cannot be used for small containers and individual boxes. Typical means for shipping temperature sensitive materials involves the use of an insulated box, with the necessary shipping and warning labels, along with some cooling agent. These cooling agents have typically been, for example, a frozen gel, dry ice, or water-based ice, placed within an insulator packing agent, such as cotton or, latterly, plastics materials such as expanded polystyrene foam, wherein heat is absorbed by such cooling agents.

[0004] It has become established in the transport of temperature controlled goods - also known as the cold chain shipper market - that it is necessary to utilise advanced packaging materials in order to provide a high level of thermal protection to temperature sensitive products in the construction of such shippers. In the transport of medicaments, product needs to be maintained within a particular temperature range to conform to tested product behaviour, irrespective of potential degradation; packaging may also need to absorb shock. Equally, in the case of materials that are to be tested by way of clinical diagnosis, etc., tests and products may be compromised if product is not maintained within a particular temperature range and packaging solutions will be custom designed for processing bulk loads of bio-substances and performing clinical trials. Temperature assurance packaging ensures the integrity of research materials when work is being performed upon volatile substances, biological cultures etcetera .

[0005] For example, in the transport of foodstuffs, keeping food items cold or hot in transit is critical to food safety and integrity - and common sense - but not always simple to ensure. In another filed, Clinical Research Organisations (CROs) may need to distribute small diagnostic kits / packages of high value that are thermally sensitive. Investigational Medicinal Products (IMPs) may need to be despatched to Investigator Sites that might be situated in remote regions and often incur extended shipping times due to geographical and customs clearance complications.

[0006] The advanced packaging materials have been developed over the years and referred to above comprise two categories of material : insulators and passive temperature maintenance materials. For example, Vacuum Insulation Panels (VIPs) have been developed which provide a very low thermal conductivity value (<5mW/m.K) which prevent heat flow into or out or the thermal package. Nonetheless, given that they effectively comprise a plastics bag that is filled with particles of low conductivity, which bags are evacuated and then sealed need to be protected from mishandling, to prevent the plastics bags from being ripped and cut, whereby to destroy the vacuum therewithin. Thermal maintenance materials such as phase change materials are frequently employed. A phase change material (PCM) is a substance with a high heat of fusion whereby upon melting and solidifying at a certain temperature, is capable of storing and releasing large amounts of energy. Heat can be absorbed or released when the material changes from solid to liquid and vice versa. PCMs are often referred to as latent heat storage materials. Phase Change Material (PCMs), typically comprising a substance having a freeze/thaw temperature that is selected to absorb/release energy whilst passing through a change in phase status endothermic/ exothermic reactions, thus creating a thermally stable temperature. [0007] A modern packaging system can therefore, by careful selection of vacuum insulation panels and PCMs, create a compact, lightweight, high performance transport container / shipper. However, it will be appreciated, these packaging materials are expensive to manufacture and assemble, resulting in a relatively high retail price.

[0008] To ameliorate a high price arising from the use of these shippers, products and business models have been developed to maximise value / minimise operating cost; being created that enable the reuse of the shipper, to reduce the 'price per turn' to a point where the high unit price is made cost effective. For this to operate the vendor of the shipper or the customer must facilitate the return of the packaging system, which requires additional transportation cost and management resource.

[0009] There are a number of use - reuse models, with the following operational modes being the most common : Closed loop return/refurbishment - where a customer is responsible for the use and subsequent return - being responsible for any necessary refurbishment and replacement of the shipper components; and, Vendor refurbishment - where a vendor will be sent the shipper after use and whom shall be responsible for any refurbishment and return to the customer for reuse.

[0010] There are advantages/disadvantages to both models, with the following factors being required to be taken into account: * Location (logistical accessibility) : return of a shipper may not be cost effective or even possible; * Apparent Degradation; a shipper construction may degrade over time due to the insulation assembly becoming less thermally efficient than when initially bu ilt. (e.g. physical gaps may develop where none should exist, allowing passage of air currents); * Non-Apparent Degradation (Qualification / documentation) : it will be appreciated that a shipper will have a known ex-works thermal capability. However, there will be little documentation to support reuse, given that 'Qualification Documents' are based on the level of performance achieved when the shipper is new (turns = 0), but there will be no documentation to confirm how a shipper will perform after, for example, ten or twenty turns. Any refurbishment process will be time consuming and possibly costly. If a vendor provides a refurbishment service then there will be additional inventory issues to consider, arising from re-work stations and associated tracking, all which will add to an overall cost of use.

[0011] Most vendors have tackled the challenge where shippers cannot be returned cost effectively by creating single use products, utilising similar packaging materials, but designed such that the shipper ca n be cost effectively used once, and then disposed of - colloquially known as 'ship and burn' - notwithstanding there being an increasing international requirement to use recyclable/compostable packaging .

[0012] Generally, however, a vendor will seek a cost engineered version of their reusable shipper, and market the product at a price point that is attractive to its customers. There are several examples of single use / reuse systems presently available from manufacturers such as Pell BioThermal, Sonoco Thermosafe and Intelsius with their respective single use products sold under their Chronos, Certis and Orca S brands and re-usable products sold under their Credo Cube, Chill Tech and Orca brands. These products, although addressing perceived needs suffer from one or more of, inter alia, cost, fragility mechanical damage, through mishandling and real-world shipping challenges.

[0013] In general the insulation assembly of vacuum insulation panel shipper comprises a "lid" vacuum insulation panel and a 'tub' that is built from five vacuum insulation panels constructed to form an open, five sided box. The construction methods used can create an assembly that is difficult to repair cost effectively, and as mentioned earlier, can become less thermally efficient over time. Due to the construction method used for the 'tub', if any one vacuum insulation panel becomes damaged and needs replacing it is costly in terms of materials and labour to replace. Equally, the vacuum insulation panels may be replaced by panels having PCMs, whereby to provide a passive temperature control system.

[0014] Additionally, irrespective of the manner of shipper, further considerations need to be taken into account:

* The phase change materials are often manufactured from thermoplastics such as high-density polyethylene (HDPE) and an unintended consequence of employing these plastic materials is the accumulation of condensate on the surface of the panel as they are conditioned to the correct temperature prior to packing into the shipper. Furthermore, tests have shown that even when residual moisture is wiped from the surface of the panel prior to packing into the shipper, the interior space within the shipper during shipment can frequently have a relative humidity of 100%, i.e. the air within the payload space of the shipper is saturated with water vapour - which can have a detrimental effect on any materials placed into the shipper, and it has been observed that customers pack their goods into plastic bags to prevent damage from this excess moisture. * In any shipper re-use scenario, the refurbishment process must ensure that the coolants are cleaned such that they can be shown to be suitable for reuse, this process often involves wiping down with isopropyl alcohol or treatment with ultra violet radiation, both of which require specialist processes and/or equipment. * Re-useable shippers also suffer from the loss of components at a receiving site, prior to return. Often the upper insulation panel and the upper coolant panel are separate components that must be removed from the shipper to gain access to a goods compartment, and can easily be misplaced as the shipper is repacked ready for return. The replacement of these components can be costly, not necessarily per unit cost, but by reason of an item having been misplaced and extra time being required to perform such a replacement.

* In the event that a transported good comprises a small package or a set of small items will result in that the payload space within the shipper is not fully utilised and the excess space is typically filled with dunnage bags - also known as airbags or inflatable bags - which are used to secure and stabilize cargo, being convenient and cost-effective cargo stabilization in container transport systems etc.. A detrimental effect of these filler materials is that some of the transported goods can sometimes be left within the shipper by the recipient as they did not 'find' all the materials shipped to them. These kits are often discovered during the refurbishment process, and the knock on effect is the need to provide an additional shipment of replacement kits to the investigator site.

* Any data logging device used to monitor a shipment can also be misplaced and/or difficult to find when a shipment is received. This can delay the release of the goods. In addition, the location of such a monitor will change from one shipment to another, making the process of monitoring and retrieval variable from one shipment to the next.

J 015] Hence, a need continues to exist for a high quality, passively thermal controlled shipping container.

[0016] US2004231355 to Minnesota Thermal Science LLC teaches of an apparatus for shipping articles under controlled temperature conditions, having alternating enclosure walls for providing temperature insulation and for providing alternating reservoirs of phase change materials, wherein the respective phase change materials are different in each alternating reservoir. This is not straightforward to use. EP2512954 also to Minnesota Thermal Science LLC provides a cascading series of thermally insulated passive temperature control containers comprising a modular collection of components comprising at least: (a) three differently sized sleeves of thermal insulation including a smaller, a larger and an intermediate sized sleeve, and, accordingly, is also not straightforward to use.

Object of the Invention

[0017] The present invention seeks to provide a solution to the problems addressed above. The present invention seeks to provide a thermally stable container that can provide a simple passive arrangement for use with and without phase change materials can enable goods to reliably be maintained within a particular temperature range. The present invention also seeks to provide a temperature controlled shipper assembly, whereby goods can be maintained within an atmosphere having a predefined temperature range.

Statement of Invention

[0018] In accordance with a general aspect of the invention, there is provided a thermally insulating shipper container for transporting/storing temperature sensitive materials.

[0019] Thus, in a first aspect, the present invention provides a shipper being a thermally insulated container, said shipper comprising : An outer carton having a base, a sidewall and at least one hinged lid member; An inner carton having a base, a sidewall and at least one hinged lid member; At least one set of thermo- panels comprising insulating or phase change members; Wherein the inner carton is operably received within the outer carton; Wherein the thermo panels are arranged to be placed within the inner carton whereby to define a load volume.

[0020] Conveniently, there is provided a cover element operable to enclose goods within the interior of the inner carton. Conveniently, the cover element is made from a section of material, conveniently low density polyethylene or similar plastics material / cardboard corrugated material that is sized such that, in use, it provides a friction fit with the interior of the payload space whereby to enable secure positioning of the cover within the inner carton. The cover is shaped to generally correspond with an inside cross-section of the carton, although apertures located at opposite corners of the cover element, for example, can be provided to simplify removal.

[0021] Alternatively, the cover element is made from a section of material, conveniently low density polyethylene or similar plastics material / cardboard corrugated material and is provided with hook and loop fastening means whereby it can be attached with an inside wall of the carton, the inside wall of the inner carton having corresponding hook and loop fastening means, whereby to enable secure positioning of the cover within the inner carton. Similarly, mutually corresponding surface features as between a circumferential edge of the cover element and an inside circumferential wall surface of the carton can also be employed whereby to secure a relative position of the cover with respect to a containment volume.

[0022] The cover element can comprise two spaced apart generally rectilinear faces, with four edge faces, each edge face arranged perpendicularly with respect to each adjacent face. The cover element can provide a receptacle data logging/temperature monitoring whereby to enable at least one of temperature monitoring and tracking. Conveniently, the cover element is formed from a resilient material and can have predefined apertures or cut-out sections for the secure retention of data-logging equipment, GPS transponders, temperature sensors, humidity sensors and the like; by having the cover element formed from a resilient material, such equipment can be resiliently retained within such predefined apertures. The cover element can be provided with resilient members, which resilient members operably extend towards a load, whereby, upon placement of the cover within a payload volume, the cover acts to reduce or prevent movement of unsecured good within the payload volume. The resilient members are conveniently formed of compressible foam material or a re manufactured from compressible spring metallic, plastics members or balloon-like elements, whereby to provide a resilient tendency to extend downwardly, in a direction facing the opposing bottom face of the shipping container. Conveniently, temperature sensors are provided in distal portions of the resilient members and are operable associated with a temperature measurement device. Importantly, it will be realized that any monitors provided will necessarily be able to confirm the status of the goods within a container from within such a container. More than one cover element could be provided to provide a degree of separation between types of good within a container.

[0023] A lid member can have a tongue that can be operably associated with a thermo-panel, whereby to associate the thermo pack with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper. Alternatively, a lid member can have a sleeve feature that can be operably associated with a thermo-panel, whereby to associate the thermo pack with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper.

[0024] Conveniently, the inner carton has one or more apertures in its walls to enable one or more handles to be attached thereto. This provides handles to enable the shipper to be handled securely. [0025] The present invention can provide a simple to manufacture, low-cost shipper for a wide variety of applications

[0026] Notwithstanding the problems encountered by known systems which employ phase change materials for short-term use, it will be realised the present invention will also benefit in terms of duration of temperature control the use of phase change material temperature control packs that include one or more phase change materials, are contained in sealed containers can be provided to further increase a period of time within which temperature stability can be achieved. The sealed containers for phase change materials can be provided by one of a plastics bag, a blister pack, a sheet cellulose package, a sealed polymer enclosure. The temperature control packs can be configured to provide a defined thermally stable atmosphere within the payload volume for a number of days as is typical for international travel, for example. The phase change material could also be arranged to be installed in cut-outs defined with the walls of the container, or between layers of corrugated material .

[0027] In accordance with another aspect of the invention, there is provided a method of packing a product for shipment by shipper.

[0028] The method may be supplemented by the provision of a temperature control pack with, for example, a phase change material whereby to enable a longer duration of temperature control, with regard to the size of the container, and expected ambient conditions.

[0029] The present invention can thus provide a simple to use, easy to handle box or box-like container solution that provides a collapsible container of high thermal and mechanical insulation. Importantly, in a simple, multi-use scenario, an easy to assemble container can readily be provided. Also importantly, a substantial benefit, in a cellulose embodiment, is that the product is readily identifiable as a "green product", being made from natural resources and is readily decomposable. Notwithstanding this, when phase change materials are provided, the period of time in which temperature is maintained within a particular range is substantially increased. Certain thermally labile goods, such as medical supplies, blood, and vaccines, are often extremely temperature sensitive and need to be maintained within a tight temperature range to avoid deactivation, decomposition or spoilage. Transport of such thermally labile materials is particularly challenging. Such temperature sensitive goods are shipped to a wide variety of destinations, where the ambient temperature may vary from extreme cold in the frozen tundra of Alaska, to extreme heat in the desert southwest of the United States. Brief Description of the Figures

[0030] For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein : -

Figures la, lb illustrate first and second embodiments of the invention;

Figure 2a illustrates a blank for a sleeve in accordance with one aspect of the invention;

Figures 2b -2d illustrate methods of packing and arranging a sleeve per Figure 2a;

Figure 3a illustrates a blank for a second sleeve in accordance with one aspect of the invention;

Figures 3b - 3d illustrate methods of packing and arranging a sleeve per Figure 3a;

Figures 4a - 4d exemplify stages in the manufacture of the invention as shown in figure la;

Figures 5a - 5f exemplify features of the invention as shown in figure l b;

Figures 6a - 6c show how a thermo-panel in accordance with the invention is arranged;

Figures 7a, 7b show how thermo-panels can be arranged as they are inserted within a shipper;

Figures 8a, b and 9a, b compare the attachment and operation of thermo-panels with respect to the systems as shown in figures la & lb;

Figures 10a - 10c relate to a cover element in accordance with a further aspect of the invention;

Figure 11 details an alternative sleeve for a thermo-panel;

Figures 12a and 12b show a section through the internal sidewalls of a shipper in differing states of packaging ; and

Figure 13 shows an example of a variant cover plate.

Detailed description of the Preferred Embodiments

[0031] There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

[0032] Referring now to Figure la & lb, there are shown two variants of a shipper in accordance with the present invention ; with specific reference to Figure 1, there is shown :

In aspect "i": side thermo-panels Hi - l liv, base thermo-panel l lv and insert lid l lvi, the thermo-panels l li-vi being one of vacuum insulation panels or phase change media panels. Insert lid l lvi further comprises an electronic device l lvii such as a temperature logger and/or GPS locator (or equivalent) and/or transponder located within an aperture/cut out l lviii defined in thermo- panel l lvi.

In aspect "ii" the thermo-panels Hi - l liv are encased within a contiguous sleeve 12i; thermo-panel l lv is separately encased by an individual sleeve 12v.

In aspect "Mi" there is shown an internal box 13 i comprising a five-sided unit 13M hingedly attached with respect to a two part lid comprising a peripheral element 13iii and an central element 13iv, each of the peripheral and central elements being hinged about the same hinge axis 13v, although the central element could be hinged with respect to the peripheral element about a separate hinge axis. First and second handles 13vi are attached through apertures 13vii provided in oppositely facing sides of the internal box, which handles are arranged to protrude through corresponding apertures 13viii in an outer box 13ix located through slit aperture 13viii.

[0033] The thermo panel assembly of the sides and base of the container as indicated in aspect ii, above, is completed by reason of thermo-panel 12vi together with thermo-panel l lix within sleeve 12ix, attached to central element of the lid of inner box 13M by means of central element 13iv of the two part lid. It can also be clearly seen that thermo-panel element 12vi is attachable with respect to peripheral lid element 13iii by means of attachment means such as releasable adhesive element or hook and loop fastening means 13x. As will be appreciated, once the lid is closed the thermo-panels l lix and 12vi are brought such that they close the inner box 13 i completely and, additionally, assist in temperature maintenance by use of thermo-panels l lix and 12vi.

[0034] Figure lb shows a substantially similar arrangement to Figure la save for the arrangement of such thermo-panels l lix and 12vi, as shall be discussed below; the provision of a temperature logger and/or GPS locator (or equivalent) and/or transponder located within an aperture/cut out l lviii defined in thermo- panel l lvi is possible, but is not shown for simplicity. The significant difference is that in aspect iii, the inside portion of the lid of inner container is provided with a thermo-panel l lix being retained within a sleeve 14i, which sleeve is provided with a retaining hoop 14M, conveniently fabricated from paper or card, which is attached to the sleeve. It is also possible that such hoop or retaining ring could be manufactured from the sleeve 14i. The outer container 13ix is conveniently constructed from a corrugated board material and is arranged such that it can be replaced after each use, with the use of a tear-off strip, for example, to assist the removal of the carton. The shipping container may have an outside shell made from any material possessing sufficient structural integrity, such as corrugated cardboard, corrugated plastics, or the like. As discussed above, outer box has die-cut sections 13viii to allow the side handles 13vi of the vacuum insulation panel assembly to protrude through and allow ease of handling.

[0035] Turning now to Figure 2a, there is shown a sheet material blank, conveniently cut by die cutting means, as is well known, to provide a sleeve 20 which is folded along parallel spaced and orthogonal creased lines 21i and edge fold lines 21ii can be assembled to define three pockets 22i, ii, iii per Figure 2b, whereby to enable placement of three thermo-panels l liv, v, vi and provide an assembly 22iv having a generally 90° 'C'-shaped sleeve, as shown in Figure 2c. The vacuum insulation panel assembly is constructed from two Έ' sections, each comprising a die-cut vacuum insulation panel carrier 22iv and three insulation panels l lii. The thermo-panels, when used as insulation panels can utilise materials such as vacuum insulation panels, or any other insulation materials, such as extruded polystyrene or polyurethane. The die-cut vacuum insulation panel carrier can be constructed from corrugated materials such as cardboard or so-called "Correx" (corrugated-extruded polypropylene). Indeed, the sheet material can be selected from any material providing the necessary structural integrity, including specifically but not exclusively, plastics such as polyethylene, polypropylene and polyurethane; cellulosic materials such as cardboard and cardstock; and metals such as steel or aluminium. Plastics are generally preferred as the most cost efficient and lightest weight option for insulation panels. However, when the thermo-panels comprise PCM panels, due to a difference in temperature (generally reduced with respect to an ambient atmosphere) then moisture will condense from the atmosphere and it has been found that the sleeve is preferably manufactured from cardboard / corrugated paper board whereby the board provides a layer for condensate that occurs during PCM conditioning to be absorbed into, thus creating a drier interior environment inside the shipper. Typically, the sleeve is sized such that it is a friction fit onto the bottle - whereby tolerances can easily be known and catered for, the sleeve also providing a protective layer to the PCM panel and also enables a refurbishment of PCM components to be easily accomplished; basically all paper / card product is removed and recycled and the PCM panel cleaned for re-use.

[0036] As can be seen with reference to Figure 2d, two such assemblies 22iv can be arranged to provide a generally rectilinear box arrangement, suitable for enclosure by way of the internal and outer boxes 13 i, 13ix, as shown above. In detail, it will be seen that with respect to each pocket, there is provided an aperture 22v. This aperture - conveniently a simple circular aperture can be used to assess the integrity - or otherwise of the thermo-panel within. In the event that the thermo-panel within is a vacuum insulation panel, then a lack of vacuum can easily be determined by visual inspection. Equally, in the event that the thermo-panel is a phase control material, then spillage - or otherwise - can also easily be determined. In the event that the thermo-panels are PCM panels and they need to be conditioned at a particular temperature, in a refrigerator, as is known, then the provision of three such panels within a foldable sleeve can assist in enabling conditioning for three PCM panels and the sleeve, when folded to correspond with the orientation required for use, enables placement within a shipper.

[0037] Figure 3a, shows a similar paper or card blank, to provide a sleeve 30 which is folded along parallel spaced and orthogonal creased lines 31 i and edge fold lines 31 i i can be assembled to define four pockets 32i, ii, iii, iv in which are placed four corresponding thermo-panels 11 iv, v, vi, vii and provide an assembly 33i having a generally rectilinear ring shaped sleeve, as shown in Figure 3b, which sleeve 30 is closed by separate upper and lower thermo-panels 33ii, 33iii, also enclosed in individual sleeves. As can be seen with reference to Figure 3d, a box is provided using the sleeve 30 and upper and lower term-panels, 33M, iii, suitable for enclosure by way of an outer box. It will be appreciated that the lid and handles of internal container 13 i are not shown, as discussed above, and as indicated with reference to Figure 3d.

[0038] Figure 4a shows a completed carton 40, being a rectangular cuboid box, with handles 13vi as discussed previously. Figure 4b shows how internal box 13M can be placed within external box 13ix. Figure 4c shows a variant with respect aspect iii of Figure la in that a further thermo-panel l lix is not indicated, with Figure 4d showing how handles 13vi are associated with the internal box 13 i . The outer carton 40 is conveniently manufactured from a wood-fibre cardboard material and whilst there are many types of treatment that can be applied to cardboard materials to make them more durable, it is possible that certain embodiments are made from extruded plastics corrugated material, whilst more durable plastics outer containers can be employed, including fibreglass and more durable plastics, when a rugged container is required.

Figure 5a shows how the embodiment of Figure 1 can be extended to provide a shipper 50 with further thermo-panels 51 i - v, whereby, in addition to thermo- panel l lix, there is provided thermo-panels on the other five sides of the inside of the internal box. Figures 5b - 5f detail how, in one embodiment, a lid flap 51 i of the box 13ix can be employed to securely locate in a sliding fit fashion with an elongate aperture / internal edge member of lid 13 iii / 13iv. Specifically, with reference to Figure 5d (being a close-up of Figure 5c in relation to the connection system), it can be seen that a proximal edge of the lid flap 51 i is provided with a depending element 51M that is hingedly associated with lid 51 i about hinge 51iii such that it engages with the aforementioned . Note that the lid is Figure 5d is shown in the closed position and the lid element 51 i is at a maximum extent of bend whereby a gap 54 exists between a distal edge of panel 13iii relative to a hinge axis 15v thereof and the inside edge of lid 13iii. In contrast, with respect to Figure 5f, there is no gap, with the respective edges in resting contact with respect to each other as this particular arrangement is arranged to close the lid automatically - although it will be appreciated that the system does not need to operate in this fashion. It will be appreciated that by arranging the container thus, the thermo-panel 12vi is raised upon opening of the external box. It has been found that not only does this simplify the opening operation, it means that there is no separable element - and therefore there is no element of the container system that can be potentially lost - that is required to be present when it is desired to close the shipper when require. It can easily be envisaged that such losses have not been uncommon and that there is a significant benefit in having an arrangement wherein any thermo-panels are integrally associated with a container, whereby to prevent loss, misplacement or otherwise. Figure 5e shows how the depending element 51ii can be inserted into such an aperture perpendicular to the hinge axis of the lid.

[0039] Conveniently, a PCM panel is made up of two parts, the PCM container - typically being a type of bottle given that PCMs are generally employed such that they are liquid at a typical ambient temperature at a time of manufacture and, in any event the nature of a PCM means that the container needs to be capable of accommodating the PCM product as a liquid since it will change its phase during use. Typically, the PCM product will be retained by some type of thermoform plastic such as HDPE and is treated to prevent migration of the PCM though the wall of the bottle. Figure 6a shows how a PCM thermo-panel 61 i can be inserted into a sleeve l lx, to provide a complete sleeve/PCM combination as shown in Figure 6b. Figure 6c shows the other side of the sleeve l lx and indicates a pull tab 61ii operable to break the sleeve, for recycling, disposal or otherwise after each use, which can therefore be easily and simply accomplished. Additionally, when the shipper is received by a recipient e.g. such as a dock hand / clinical investigator etc. the process to unpack the shipper is greatly simplified as they do need to physically remove the vacuum insulation panel and PCM Coolant from the shipper, reducing the likelihood of it being lost. The PCM panel can be easily fitted with a new slide-on PCM sleeve to be readily prepared for reuse. This negates the need for isopropyl alcohol / ultra violet cleaning.

[0040] Figure 7a shows how a shipper can be assembled with a full complement of thermo-panels and shows PCM thermo-panels 71i arranged in suspended relation with respect to an opened package comprising an internal and external shipper 13ii, 13ix in accordance with the invention. Figure 7b shows the thermo- panels 71i in a spaced-apart fashion, generally indicating a payload volume 71ii thereby defined.

[0041] Figures 8a - 9b compare the modes of operation of two embodiments of the invention as shown with reference to Figures la and lb when the PCM components form a payload volume 7ii when assembled . Specifically, Figure 8a shows how, when a box in accordance with the invention in accordance with the system in accordance with Figure la, can have a thermo-panel sleeve l lix slidingly engaged with central element 13iv of the two part lid (akin to an inner tongue). The central element or tongue is designed to have the open end of the thermo-panel sleeve l lix slid over the end creating a hinged upper thermo-panel assembly. When the shipper is received by, for example by a clinical investigator, the process to unpack the shipper is greatly simplified as the investigator does not need to physically remove the thermo-panel be it a vacuum insulation panel and/or a PCM panel from the shipper, reducing the likelihood of it being lost. Figure 8b shows how the thermo-panel l lix can lie on top of the upper aperture of the payload volume, irrespective of the position of the open position of the lid of the outer carton 13ix, whereby the lid 13xi and any thermo-panel 12vi can be moved independently thereof. [0042] Figure 9a shows how, in an alternative configuration, per Figure lb, a thermo-panel l lx can be slidingly engaged with respect to an inside of lid 12vi - the lid operating as a unitary element. Figure 9b shows the lid in an open position, with thermo-panel in position, whereby to provide full access to the interior of the shipper 13ix.

[0043] Figures 10a - 10c relate to a still further aspect of the invention wherein there is provided a piston-like cover element 91, operable to be enclose goods within the interior of the shipper 13ix. The cover element 91 is made from a section of material, conveniently low density polyethylene or similar plastics material / cardboard corrugated material that, in use, provides a friction fit with the interior of the payload space. The cover element 91 has two spaced apart rectilinear faces 91i, 91M, with four edge faces, each face 91iii arranged perpendicularly with respect to each adjacent face 91iii and performs two functions. Firstly, it retains product in position; in this case with respect to its friction fit slide axis, without a need to add dunnage material; that is to say that the cover operates in a fashion akin to a piston within a cylinder in an internal combustion engine - except that the piston is conveniently static, once positioned. To enable a simple friction fit positioning of the cover within the internal volume of the shipper, then the cover can be manufactured such that it has a compressible/resilient edge feature, which edge serves to grip with the internal sides of the internal volume. Secondly it provides a convenient receptacle for data logging/temperature monitoring etc., as discussed above, enabling / assisting tracking, generally. In the event that the panel 91 provides support for a temperature monitor 91v, then, by being maintained in a central place, a greater consistency between readings can be assured, noting that further temperature sensors may also be provided.

[0044] With reference to Figures 10b & 10c, there is shown in a cross-sectional view of the assembled shipper, respectively with panel 91 in its uppermost position to create a maximum payload space and with panel locked in the lowermost position to create a minimum payload space, with - in this embodiment - laterally extending projections (not detailed) that engage with indented features present on inside wall faces associated with the vacuum panels.

[0045] Alternative methods of maintaining position can be provided by other techniques. For example, hook and loop fasteners could be employed. For example and with reference to Figure 11, the sleeve l lx for a thermo-panel to be employed to define the working volume of the shipper, could be placed such that the removable strip HON for separation and removal after first use is also supplemented by a strip of the hooks or loops of a hook and loop fastener system - where the four edge faces 91iii of the panel 91 are also provided with complementary loops or hooks of the hook and loop fastener system whereby to securely retain the panel 91 when in position. To assist in positioning, one of or both of the complementary hook and loop features could be covered by a removable paper / plastics sheet operable as a two dimensional sheath, whereby the panel 91 can be inserted in position and then the sheath sheets are removed whereby to allow the sheath to be removed and the hook and loop fasteners to engage and prevent relative movement as between the panel 91 and the internal sidewalls of the shipper. Equally, complementary surface features as between a circumferential edge of the cover element and an inside circumferential wall surface of the carton can also be provided, whereby a resilient cover element can be compressed to permit movement in and out of the containment volume until the cover element can comfortably retain product within the volume, the surface features of the circumferential edge ensuring that the cover element does not move, whilst enabling simple retention and removal of the data logger. It may be appropriate to have two or three layers of material whereby there can be no chance of the data logger from becoming dislodged, for example, if the two or three layers of resilient/elastic material were so arranged that a data logger be inserted from a circumferential side portion, whereby security of data is effectively guaranteed. In a further example, a friction fit cover element could be provided within, for example, a cardboard sleeve, with a resilient expanded plastics material slidingly received within the sleeve It will also be appreciated that the data logger until employed whereby to secure a relative position of the cover with respect to a containment volume.

[0046] Referring now to Figures 12a and 12b, a section through the internal sidewalls of the shipper is shown prior to positioning of a panel and after positioning of the cover panel 91. In Figure 12a, the panel 91 is at the top of the container space of the shipper, with a load 120iii positioned at the bottom thereof. On the underside of the panel 91 are resilient members 120i formed of compressible material - for example being manufactured from compressible plastics foam, conical members having a spiral spring metallic or plastics member, etc. within such members, whereby there can be provided lateral (X-Y) stability in addition to the up-down (Z) stability of the opposing top and bottom faces of the shipping container. For the benefit of example, and as shown in Figure 12b only load element 120iii is present. As can be seen, two of the resilient members 120M are shown in a compressed fashion, abutting an upper surface of the load element 120 Mi. It will be appreciated, that there could be many more elements - other than just four elements across the inside surface of the panel 91 - moreover the length could vary, depending upon the size, shape and nature of the goods to be carried. In a still further embodiment, temperature sensors associated with the datalogger can be associated with the distal regions of the resilient elements, whereby to enable a temperature of contact of the product to be sought as well as a temperature of the distal portions of the load area, in the event of a load per Figure 12b.

[0047] Figure 13 shows an alternative cover element 91, which has apertures 14i, 14ii & 14iii arranged purely for example. Devices of a corresponding size - or approximate size can be resiliently retained within the apertures, which preferably depend only partly through the cover element. The various sizes and shapes of apertures allow for the retention of various types of data-loggers; the sensors for which may be separate yet still be secured . A plastics material such as expanded polyethylene can be readily employed. Along edge of the panel 91, a hook and loop face is indicated 14iv although by using materials such as low density expanded polyethylene, by making the dimensions of the cover larger than the inside dimensions of the container, the panel can resiliently be retained, with various materials employed to provide friction, high friction or grit embedded paints, for example. It will be appreciated that further materials can be contemplated; a telescopic element could also be envisaged through the use of sliding walls of gradually reducing dimensions. Equally the cover element could be arranged in a concertina-like fashion.

[0048] The shipper in accordance with the invention can be assembled and disassembled by hand without the need for any tools. Thermo-panels of insulation and/or phase change material can be easily assembled and arranged into position, with a reduced likelihood of components being lost. Methods of use can be simplified and, overall, costs can be reduced, with improving operational success arsing therefrom. Upon delivery of the thermally labile payload (not shown) the empty shipper can be disassembled with the spent PCM panels removed from their associated sleeves and placed in an appropriate thermal conditioning unit (not shown) for thermal reconditioning.

Claims

CLAIMS :

1. A shipper being a thermally insulated container, said shipper comprising :

An outer carton having a base, a sidewall and at least one hinged lid member; An inner carton having a base, a sidewall and at least one hinged lid member;

At least one set of thermo-panels comprising insulating or phase change members;

Wherein the inner carton is operably received within the outer carton;

Wherein the thermo-panels are arranged to be placed within the inner carton whereby to define a load volume.

2. A shipper according to claim 1 wherein there is provided a cover element operable to enclose goods within the interior of the inner carton.

3. A shipper according to claim 2, wherein the cover element is made from a section of material, conveniently low density polyethylene or similar plastics material / cardboard corrugated material that is sized such that, in use, it provides a friction fit with the interior of the payload space whereby to enable secure positioning of the cover within the inner carton.

4. A shipper according to claim 2, wherein the cover element is made from a section of material, conveniently low density polyethylene or similar plastics material / cardboard corrugated material and is provided with hook and loop fastening means whereby it can be attached with an inside wall of the carton, the inside wall of the inner carton having corresponding hook and loop fastening means, whereby to enable secure positioning of the cover within the inner carton.

5. A shipper according to any one of claims 2 - 4, wherein the cover element comprises two spaced apart generally rectilinear faces, with four edge faces, each edge face arranged perpendicularly with respect to each adjacent face.

6. A shipper according to any one of claims 2 - 5, wherein the cover element provides a receptacle data logging/temperature monitoring whereby to enable at least one of temperature monitoring and tracking.

7. A shipper according to any one of claim 6, wherein the cover element comprises two major faces and circumferential side faces; and the cover element comprises layers/sheets of material; wherein the datalogger can be inserted via a circumferential side face.

8. A shipper according to any one of claims 2 - 7, wherein the cover element is provided with resilient members, which resilient members operably extend towards a load, whereby, upon placement of the cover within a payload volume, the cover acts to reduce or prevent movement of unsecured good within the payload volume.

9. A shipper according to claim 8, wherein the resilient members are formed of compressible foam material or are manufactured from compressible spring metallic or plastics members, whereby to provide a resilient tendency to extend downwardly, in a direction facing the opposing bottom face of the shipping container.

10. A shipper according to any one of claim 8 or 9, wherein the resilient members are arranged in rows across the underside of the cover element.

11. A shipper according to any one of claims 8 - 10, wherein temperature sensors are provided in distal portions of the resilient members and are operable associated with a temperature measurement device.

12. A shipper according to any one of claims 1 - 11, wherein the thermo-panels are arranged to be received within sleeves.

13. A shipper according to any one of claims 1 - 12, wherein one set of thermo- panels comprise insulating material.

14. A shipper according to any one of claims 1 - 12, wherein one set of thermo- panels comprise phase change material;

15. A shipper according to any one of claims 1 - 14, wherein a lid member has a tongue that can be operably associated with a thermo-panel, whereby to associate the thermo pack with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper.

16. A shipper according to any one of claims 1 - 14, wherein a lid member has a sleeve feature that can be operably associated with a thermo-panel, whereby to associate the thermo pack with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper.

17. A shipper according to any one of claims 1 - 16, wherein the inner carton has one or more apertures in its walls to enable one or more handles to be attached thereto.

18. A shipper according to claim 17, wherein the outer carton has one or more apertures to enable a handle from the inner carton to extend therethrough.

19. A shipper according to any one of claims 1 - 18, wherein the outer carton is manufactured from at least one of cardboard, corrugated extruded plastics, resin- impregnated fibre and moulded plastics.