WO2019011478A1

WO2019011478A1 - An insulating transport and storage container

Info

Publication number: WO2019011478A1
Application number: PCT/EP2018/025189
Authority: WO
Inventors: Richard Darren WOOD; Ross Malcolm BEECH; James Nathan JARVIS; Timothy ASTLEY-COOPER
Original assignee: Softbox Systems Limited
Priority date: 2017-07-10
Filing date: 2018-07-10
Publication date: 2019-01-17
Also published as: GB201711171D0; GB2566792A; GB2566792B; GB201711104D0; GB201811319D0

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 - 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. The present invention provides an improved shipper. In particular, the present invention relates to a system of thermo-panels that can be simply employed to provide a reusable shipper system.

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 and to a configuration of temperature control panels for use therein. More particularly, the present invention relates to storage containers that comprise a box or box-like container that can be handheld.

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] With respect to 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. The transportation of 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 field, 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] In order to provide an appropriate temperature profile for a particular duration, one or more phase change material containers may be employed. A container may utilize two or more different phase change materials. A modern packaging system can therefore, by careful selection of vacuum insulation panels and PCMs, create a compact, lightweight, high performance transport container / shipper. These packaging materials are expensive to manufacture and assemble, not only resulting in a relatively high retail price, but also requiring care when being placed within a container.

[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 built, (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 can 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 panel is 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.

L0015] Accordingly, a need continues to exist for a high quality, passively thermal controlled shipping container. 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. Th is 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

[0016] 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. The present invention also seeks to provide a system that is simple to pack and that the thermo-panels are less likely to be improperly selected and/or oriented.

Statement of Invention

[0017] In accordance with a general aspect of the invention, there is provided a thermally insulating shipper container for transporting/storing temperature sensitive materials.

[0018] Thus, in a first aspect, the present invention provides a shipper being a thermally insulated container, said shipper comprising : a primary carton having a base, a sidewall and at least one hinged lid member; a layer of insulation associated with the inside surfaces of the outer carton, to define a cuboid placement volume; at least one set of thermo-panels comprising insulating or phase change materials, wherein the thermo-panels are arranged to be placed within the placement volume, the thermo-panels comprising a generally rectangular shape, wherein the panels comprise first and second generally rectangular major surfaces having a length and a width, spaced apart in a parallel spaced apart fashion by a depth, with the major surfaces of corresponding area being separated by a circumferential edge along corresponding lengths and widths, the circumferential edge being generally orthogonal to the major surfaces, wherein, at least one major surface has, adjacent an edge and across its width, an elongate contoured abutment surface and at least along the edges about a width of the major surfaces, a contoured abutment surface complementary to the contoured surface of said major plane, wherein, upon positioning within the inner carton, each thermo-panel can provide at least one of an adjacent an edge contoured abutment surface and/or at least one edge complementary contoured abutment surface, whereby four such thermo-panels can be orthogonally arranged in a mutually abutting relationship whereby to define a cuboid load volume. Conveniently, the primary carton is further enclosed within an outer container, which can provide greater physical ruggedness to the shipper. Ideally the outer container is easily removable. The outer carton is conveniently disposable. In defining a regular cubic volume (all the lengths of the sides are the same length), then the invention provides the advantage, for such a configuration, that all the thermo-panels are of the same shape.

[0019] In accordance with a second aspect of the present invention, there is provided a shaped thermo-panel configured for use with the shipper, whereby the shipper can be packed in a simple yet secure fashion, whilst maintaining a secure arrangement of thermal control elements, without the need of separate sleeves to be placed around the individual thermal control elements, the components sealing with each other to prevent passage of air and thus minimize condensation issues.

[0020] Preferably, each said at least one major surface of the thermo-panels has two elongate contoured abutment surfaces each adjacent an edge across its width. This will facilitate packing by operatives, since the faces will not need to be inspected for a particular orientation. Preferably, each major surface of the thermo-panels is provided with at least one elongate contoured abutment surface adjacent an edge across its width.

[0021] Conveniently said contoured abutment surfaces of the one major surface of the thermo-panels are one of concave or convex, with the contoured surfaces being complementary with respect to each other. A resilient foam strip can be provided to assist in sealing of respective abutment features, to further restrict passage of air within the container, noting that a passage of air will occur due to temperature variations within each container, to varying degrees, dependent, in part on ambient conditions.

[0022] It will be appreciated that for a given range of products, thermo-panels having the same dimensions can be employed, depending upon the need for passive heating/coolant requirements, noting that the thermo-panels can comprise only insulation having extremely low thermal conductivity values. Indeed, the thermo-panels are manufactured such that they are made from one or more of a vacuum insulation material (to form a so-called vacuum insulation (VI) panel), an insulator such as polystyrene, a container such as a moulded thermoplastics container for a phase change medium.

[0023] There are several computing programs available that can determine a likely temperature profile of a package given an expected route, mode of transport etc., whereby a phase change material selection is determined and upon installation, by appropriate use of coding etc., appropriate phase change materials can easily be positioned in order to simply provide a temperature- controlled shipper.

[0024] In addition to the basic concept in the provision of thermo-panels to define a cuboid load volume, one or two further thermo-panels can be operably arranged in specific mutually abutting relationship to define a cuboid load volume having all six faces of the cuboid being closed by thermo-panels. Conveniently, at least one major surface is provided with two abutment surfaces at either edge of the rectangular face of the thermo-panel, with a first panel being placed upon a base of the placement volume whereby to have said first and second abutment surfaces are upwardly directed, with a first set of two thermo-panels being placed orthogonally such that edges of said first set of thermo-panels face the base of the placement volume and the respective edge abutment surfaces of each major face of the thermo-panels face the edges of the first panel in an abutting relationship with a second set of two thermo-panels being placed orthogonally with respect to said first panel and to the first set of thermo-panels such that each lower edge of the first and second thermo-panels of the second set abut, respectively, the first and second upwardly directed abutment surfaces, whi lst the respective first and second abutment surfaces of the first and second thermo- panels of the second set abut the upstanding edges of the first set of two thermo- panels. A sixth panel can be disposed facing the first base panel. It has been found that by having the abutment surfaces so arranged within a placement volume of corresponding dimensions to the external dimensions of the panels can interlock simply; upon installation, using panels having identical first and second faces means that the panels cannot be incorrectly placed (i.e. the wrong way round).

[0025] Once the thermo-panels have been placed, the at least one hinged lid member of the outer carton and any separate layer of insulation associated with the top inside surface of the carton can be placed upon the cuboid load volume. In addition to the six thermo-panels, an additional thermo-panel could be provided on an inside lid, whereby to provide a versatile system, for example providing between one and seven phase-change materials in a system, whereby to cater for any particular thermal load. During development, it has been found that the placement of the interlocking thermo-panels has been intuitive, assisting a speed of packing of containers and reducing a chance of improper arrangement of thermo-panels, noting that the thermo-panels can be arranged with various arrangements of phase change materials to maintain a particular temperature profile over a period of transport and/or storage time for a product.

[0026] In accordance with a third aspect of the present invention, there is provided a kit tray for placement of goods within the cubic load volume, whereby the shipper can be packed in a simple yet secure fashion. The kit tray is provided as an inside container element, operable to enclose goods within the interior of the inner carton. The Kit tray is conveniently provided with apertured foldable lid members that can be provided with apertures which can assist in checking of any data loggers and temperature indicators and can also provide convenient means for securing with security seals indicators. The tray is shaped to fill the cubic volume - but it will be appreciated that multiple trays could be utilised, if, for example, two half height trays were provided. Notwithstanding there being a reduced likelihood of there being any condensation, relative to known systems, the trays in themselves will also further reduce any risk of condensation issues with respect to the load.

[0027] Conveniently, there is provided a load cover element for placement within the kit tray, which 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 space of the kit tray 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 . The cover is operably arranged to maintain goods within the tray in position.

[0028] 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 are 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.

[0029] A lid member of the primary carton can have a sleeve feature that can be operably associated with a thermo-panel, whereby to associate the thermo-panel with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper. 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. The present invention can provide a simple to manufacture, low-cost shipper for a wide variety of applications

[0030] In accordance with another aspect of the invention, there is provided a method of packing a product for shipment by shipper. 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.

[0031] 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. 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

[0032] 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 : - Figure 1 illustrates a first embodiment of the invention;

Figure 2 illustrates an outer container in accordance with one aspect of the invention;

Figures 3a, 3b, 3c and 3d show the first embodiment of the invention, respectively, in an exploded fashion, base and sidewall internal insulation panels for a shipper per Figure 3a, ready for despatch within an outer container per figure 2, and an alternative base member;

Figure 4a - 4d show, respectively, a perspective, edge and side views view, of a thermo-panel and a perspective view of a PCM container thermo-panel ;

Figure 5a - 5b show how a connected group of five thermo-panels are orthogonally arranged with respect to each other to define a load volume and how they can be placed within a shipper;

Figures 5c,d &e show alternative sizes of thermo-panels, operable to provide alternative cubic load volumes;

Figures 6a - 6d show how a first set of six thermo-panels can be arranged to define a closed load volume;

Figures 6a' - 6d' show how a second set of six thermo-panels can be arranged to define a closed load volume;

Figures 6a" - 6e" show the steps taken in a third method of arranging a set of six thermo-panels to define a closed load volume;

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

Figures 8a - 8c show a cluster, plan and perspective views of dual type thermo-panels in accordance with a further aspect of the invention; Figure 8d shows a further embodiment, wherein a rectangular cuboid load volume is realized;

Figures 9a - 9e relate to an inner, load carton and load restraint aspects in accordance with a further aspect of the invention; and,

Figure 10 is a graphical indication of relative performance of the present invention in different configurations.

Detailed description of the Preferred Embodiments

[0033] 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.

[0034] Referring now to Figure 1, there is shown a completed primary carton 10, being a rectangular cuboid box, with handles 11 being an outer carton having a base, a sidewall and at least one hinged lid 12 member in accordance with the invention. Figure 2 shows an external rugged box 20 showing optional apertures 21 placed such that optional handles 11 of primary carton 10 can be accessed when the carton 10 is placed within the external box 20. Figure 3a shows carton 10, within external box 20 in an exploded view, with temperature control panels - or thermo-panels 30 arranged about an interior load carton 31, conveniently provided with handles 32. Thermo-panels 30 are conveniently moulded plastics containers - conveniently blow-moulded HDPE - filled with a phase change material, whereby, in use, to provide temperature control to the load area within the interior load carton. Equally, the thermo-panels could be manufactured from solid materials with a high thermal capacity. The thermo-panels have, along one perimeter edge an aperture 34, covered in use by a cap which can be a plastics foil sealing member, of metal or other materials, the aperture 34 being spaced between two shoulder elements 34'. Insulating panels 33 - as are known - are shown in place within the primary carton 10. Thermo-panel 30' is shown oriented such that it can be placed within sleeve 35 upon an inside face 36 of lid 12 of carton 10. Figure 3b shows how insulating panels 33 are simply arranged within the carton (not shown). Figure 3c show a closed external box with a carton 10 having handles 11 extending from the carton 10 in a packed condition. Figure 3d shows a further variant, where a thermo-panel is integrally moulded with a base insulation surface 33". This provides the advantage that the base thermo-panel is correctly positioned, whereby subsequent thermo-panels can be simply placed in a vertical orientation about this base member. Careful attention to temperature conditioning will be necessary, given that the shape of the base will not correspond with the standard nature of the thermo-panels.

[0035] Figure 4a shows a basic thermo-panel 30 in accordance with the invention in perspective view, the thermo-panels comprising a generally rectangular shape, having first 41, and second 42 generally rectangular major surfaces. Details concerning PCM fill aperture 34 are shown in Figure 4d The major surfaces each have a length L and a width W, as indicated with reference to edge views of the width and length of the thermo-panels as shown in figures 4b and 4c, respectively. The major surfaces are spaced apart in a parallel spaced apart fashion by a depth D. The major surfaces are of a corresponding area and are separated by a circumferential edge 43, 44 along corresponding lengths and widths. The major surfaces have, adjacent each edge and across the width of the thermo-panel, an elongate contoured abutment surface 45. The thermo-panel 41 preferably possesses mirror symmetry along the three main (x, y, z) coordinates about a centre. This provides significant advantages when being placed within a carton by any person / machine performing a packing operation. As a basic system requirement, at least one major surface of the thermo-panels has an elongate contoured abutment surface adjacent each edge across its width - whereby to permit four thermo-panels to be arranged whereby to define a cuboid volume, if all four thermo-panels were to be arranged orthogonally with respect to each other with and edge feature of one thermo-panel abutting the single abutment surface on a major plane of the orthogonal panel to which it abuts.

[0036] It will be appreciated that the mutual contoured abutment surfaces of the thermo-panels can take many forms, but can simply be formed as being concave or convex. For stock control, re-ordering and general acceptance of a shipping system can be provided where all the thermo-panels have the same dimensions. The thermo-panels are manufactured such that they are made from one or more of a vacuum insulation material (to form a so-called vacuum insulation panel (VIP)), an insulator such as polystyrene; in the alternative they can comprise a container for a phase change medium, using suitably treated blow-moulded plastics. Conveniently, a 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 - and volume - during use. Typically, the PCM product will be retained by some type of thermoform plastic such as HDPE which has been treated to prevent migration of the PCM though the wall of the bottle. Thermo-panel 30 shown in Figure 4d is one which has a necked aperture 46, which is shaped to receive a phase change material as a liquid. The dimensions of the neck are 13mm (outside diameter), being a diameter commonly used in phase change mixture dispensing machines - noting that the amounts of phase change material must be precisely known, whereby to enable the temperature characteristics to be readily calculated. It will be appreciated that either side of the neck, there is a discontinuity 47, being dimensioned to enable accurate filling by means of a nozzle delivery system. A number of dimples - referred to as "standoffs" 48 are provided, where the material of the separate sides of the major faces are brought together, whereby to provide structural integrity, to prevent the thermo-panel from warping or otherwise losing its shape, given that the volume of a phase change material can change with temperature.

[0037] With reference to Figure 5a - which shows an open-box arrangement of five thermo-panels 50, connected by the use of an optional banding device, which could comprise tension bands fitted under tension or elastics bands 51, to minimize voids between the mutually contacting areas.. Figure 5b shows how the arrangement can be placed within the placement area 58. It has been found that such bands are not necessary when one can fit the thermo-panels in a placement area defined by a carton 10 or insulating panels 33 within a carton 10, the sidewalls of the carton 10 or insulating panels 33 urging the thermo-panels together in an abutting relationship. Notwithstanding this, it will be helpful to understand that thermo-panel 52- which is arranged such that a major face is directed towards a base surface - is gripped along the contoured abutment surface 44 of its long edges by means of corresponding abutment surfaces 45 of inwardly directed major surfaces of thermo-panels 53 & 54. The circumferential edges of the thermo-panel (noting that details relating to filling apertures are not shown) have a contoured abutment surface complementary to the contoured surfaces of said major planes, wherein, upon positioning within the inner carton, each thermo-panel can provide at least one of an adjacent an edge contoured abutment surface and/or at least one edge complementary contoured abutment surface, whereby four such thermo-panels can be orthogonally arranged in a mutually abutting relationship whereby to define a cuboid load volume 57. The contoured abutment surfaces of mating components are conveniently of corresponding concave - convex profile, with an axis in correspondence with an axis of the length of the contoured surface. It will be appreciated that each set of panels as shown will all define a particular volume. Figures 5c, 5d & 5e show three sizes of container 59 in accordance with the present invention, to define, respectively, load volumes of 5 litres, 12 litres and 24 litres, as determined by the dimensions of the central square region 59 being, respectively, 172mm x 172mm, 235mm x 235mm and 327mm x 327mm. The other dimension of height corresponds to the width plus twice the thickness of the containers, so that they can be placed together and define a load volume.

[0038] Figures 6a - 6d and 6a' - 6d' show how two sets of six thermo-panels 30 shaped in accordance with the present invention can be packed and configured to define a closed cuboid load volume 67 having all six faces of the cuboid being closed by thermo-panels. Whilst, there are slight differences in the assembly procedure, the resultant product is the same. Most importantly, it enables personnel to pack the products in a fashion that is most amenable to such individual personnel.

[0039] Figure 6a shows a first thermo-panel 61 arranged with the major planes 41 in a generally horizontal orientation upon a placement area (not shown); Thermo-panels 62 & 63 are arranged orthogonally with respect to thermo panel 61, such that they are vertically arranged, having a lower narrow side edge 43 in contact with the base support surface, with an inside contoured abutment surface 45 in contact with a long side edge contoured abutment surface 44 of thermo- panel 61, per Figure 6b. By having the contours of the respective adjacent separate elements being substantially in correspondence, the contact areas are in close contact with each other, whereby to substantially prevent gaseous exchange, assisting in the maintenance of a constant temperature within the carton. Figure 6c shows the positioning of thermo-panels 64 & 65, such that their respective lower long side edge contours 44 are in mutual contact with the upwardly directed mating surfaces 45 of base thermo-panel 61, with the corresponding inwardly directed surface 45 of the inside faces of the thermo- panels 64, 65 bearing against the long mating edges 44 of thermo-panels 62 & 63. Figure 6d shows how the sixth thermo-panel 66 can be resiliently clipped in a contact with the upstanding side wall thermo-panels 62 - 65, with mutually cooperating mating surfaces of the thermo-panels. Thermo-panel 66 can now be said to be in a parallel spaced-apart relationship with the base thermo-panel 61, whereby to close the cuboid load volume.

[0040] Figure 6a' shows a first thermo-panel 61 arranged with the major planes 41 in a generally horizontal orientation upon a placement are (not shown) ; Thermo-panels 64 & 65 are orthogonal to the thermo-panel 61 and are parallel spaced apart in correspondence with the length of the thermo-panels such that their lower edges 44 present an abutment surface to the respective upwardly directed abutment surfaces 45 of thermo-panel 61, as shown in Figure 6b'. In figure 6c', a further set of two thermo-panels 62, 63 extend vertically, but orthogonal in orientation with respect to thermo-panels 64, 65 such that the narrow edges 43 of the thermo-panels, 64, 65 present themselves toward the placement area (not referenced), with a lower inward abutment surface 45 of each thermo-panel 62, 63 facing respective edges 44 of thermo-panel 61, with the edges 44 of the panels 62, 63 abutting respective abutment portions 45 of thermo-panels 64, 65. It will be appreciated that when bands are employed or the panels are placed within a box or carton with restricted movement for the panels, then the panels clip together and, importantly, the vertically oriented panels remain upright (with respect to the base) preventing the panels from falling into the load volume, which would otherwise delay a packing process or require the use of special tools or be a two-operator process. A sixth panel, thermo-panel 66 can be resiliently disposed facing the first base panel, the respective edge engagement portions coupling with respect to each other, being a similar procedure with respect to Figure 6d .

[0041] Figure 6a" shows a still further arrangement, wherein the base thermo- panel 61" is integral with a base placement area / insulation panel associated with an insulation panel 33" (see Figure 3d). In a method of assembly, a first thermo-panel 64 is placed such that a length edge mating surface feature 44 is received by a narrow mating surface 45 of the base thermo-panel, per Figure 6a". In Figure 6b", thermo-panel 63 is positioned such that a ling edge surface feature 44 is received by a major surface feature 45 of panel 64: a sower short edge surface feature of panel 63 abuts a side edge feature 44 of integral element 61". In Figure 6c", a thermo-panel 62, facing opposite thermo-panel 63, is positioned such that a long edge surface feature 44 is received by a second major surface feature 45 of panel 64: a lower short edge surface feature of panel 62 abuts the other side edge feature 44 of integral element 61". In Figure 6d", a thermo-panel 65, facing opposite thermo-panel 64, is positioned such that a long edge surface feature 44 is received by upwardly directed second short surface feature 45 of panel 61", with the first and second major surface features 45 being received by the upstanding long edges of panels 62 and 63. Figure 6e" shows how a five-panel payload volume is formed. It will be appreciated that this is effectively functionally indistinguishable from the similar enclosures formed in Figures 6c and 6c' (after full insertion of the pairs of thermo-panels, respectively 64 & 65 and 62 & 63).

[0042] Figures 7a - h shows how the embodiments discussed above can be arranged to provide a shipper 70. Referring to Figure 7a, a shipper with an external ruggedized carton 20 surrounds a primary carton 10 having a lid, with simple insulating panels 33 placed upon a base (not shown) of the primary carton and surrounding the walls of the primary carton. A base thermo-panel 61 is placed in a first stage of the packing assembly. The base thermo-panel could be configured - if, for example, as an insulator - such that it is integral with the base insulation member 33'. This provides benefits in that the base feature is the same shape as a separate thermo-panel placed upon the base, but with the advantage of always being in the correct position, whereby to facil itate packing of the dimples 48 of the thermo-panels about the load volume. In the alternative, a location spigot could be provided to ensure location, whereby to ensure association with a dimple 48. Figures 5b, c detail placement of thermo-panels 43-46 about a load volume defined by such thermo-panels, as discussed in relation to Figures 6b, 6b', 6c & 6c' above.

[0043] Figure 7d shows another useful feature of the present invention in that an inner load tray - or "kit tray" - which is operable to retain the transported kit/good. The kit tray is provided with a data-tracker 73 and data-tracker support / load restraint element 74 is provided - as shall be discussed in more detail in relation to Figure 9. Figure 7f shows how the thermo-panel 66 is put in place, which together with thermo-panel 34 - which is placed within a sleeve 75 positioned on an inside surface of lid 12, ready for closure of external rugged container 20. The kit tray 72 and the sleeve 75 on the inside of the lid are conveniently fabricated 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 75 is sized such that it is a friction fit onto the thermo-panel - 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.

[0044] Figure 7g shows the lid 12 in an open position, with thermo-panel 66 in position, whereby to provide full access to the interior of the shipper 70. Documentation papers relating to samples, medication, etc. are conveniently placed within the primary carton, prior to sealing. Figure 7h shows the shipper with the lid 12 in a position ready for the lid element of the outer carton 20 to be sealed. Although not shown, a rip-cord packing tape can be provided with the external carton 20, whereby to assist opening of the carton, which can be beneficial, especially with respect to a frequently time-sensitive payload. Importantly, when the shipper is received by, for example, a clinical investigator, the process to unpack the shipper is greatly simplified. Furthermore, upon opening of the lid 12, as the investigator does not need to physically remove the thermo-panel 34 be it a vacuum insulation panel and/or a PCM panel from the shipper, reducing the likelihood of it being lost - noting that it is intended that items such as the phase change materials are recycled, whilst cartons, especially outer, rugged cartons are replaced, given that the integrity of the outer cartons can be compromised and total replacement can provide integrity to the shipment process.

[0045] Figures 8a - 8c detail another aspect of the present invention, wherein - per Figure 8a - a thermo-panel arrangement 80 is shown wherein all thermo- panels 81comprise interlocking first 82 and second 83 components, which components conveniently provide two distinct types of phase change media. In the alternative, one of the components can comprise an insulator body. This can enable, with a choice of phase change materials, a precise temperature profile for a particular class of temperature sensitive good. Figure 8d shows a further embodiment, wherein a rectangular cuboid load volume is defined by two sets of three PCM container panels, namely top and bottom panels 84 (only the bottom panel is shown in this figure), first set of side panels 85 and second set of side panels 86. The skilled man will realise that the panels that overlap - such as 86 need to be dimensioned such that they are of the length of the panel 84 plus twice the width of the respective end panels 84 and the skilled man will realise that many variations are possible. [0046] Figures 9a - 9e relate to a still further aspect of the invention wherein there is provided a load tray or container 90 which is provided with a kit lock / resilient cover member 74 - somewhat akin to a piston-like element within the tray in that it can be placed at any point within the tray 90 from the top - and towards an inside base 94 of the tray 90, whereby to constrain movement of goods between an underside 93 of the kit lock 74 and the base 94. The kit lock 74 is made from a section of material, conveniently low density polyethylene foam or similar plastics material / cardboard corrugated material that, in use, provides a friction fit with the interior of the payload space. The cover element 74 has two spaced apart rectilinear faces 92, 93, with four edge faces, each face 95 arranged perpendicularly with respect to each adjacent face 95 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 kit lock cover operates to maintain a static position, once placed . Alternative methods of maintaining position can be provided by other techniques. For example, hook and loop fasteners could be employed. 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 97 for data logging/temperature monitoring equipment 98 etc., as discussed above and with particular reference to Figure 9c, enabling / assisting tracking, generally. Specifically the kit lock is shaped to receive a data logging device such that it provides a secure physical location for the logger, permits convenient placement by personnel responsible for packing the temperature controlled goods and allows convenient reading of any display and/or retrieval by personnel acting for the recipient. In the event that the kit lock 74 provides support for a temperature monitor, 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. Figure 9c is an alternative kit lock 74, which has apertures 97, 97i & 97ii 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. Along edge of the panel 95, a hook and loop face could be provided, although using materials such as expanded polyethylene, by making the dimensions of the cover larger than the inside dimensions of the container, the kit lock 74 can simply be resiliently retained.

[0047] Referring now to Figures 9d and 9e, a section through the internal sidewalls of the tray is shown prior to positioning of the panel and after positioning of the panel. In Figure 9d, the kit lock panel 74 is at the top of the tray of the shipper, with a load 99 positioned at the bottom thereof. On the underside of the kit lock panel 74 are resilient members 91 formed of compressible material - for example being manufactured from compressible plastics foam, conical members having a spiral spring metallic or plastics member, etc. within whereby there is a tendency to extend downwardly, in a direction facing the opposing bottom face of the shipping container. For the benefit of example, and as shown in Figure 12b only load element 99 is present. As can be seen, two of the resilient members 91 are shown in a compressed fashion, abutting an upper surface of the load element 99. It will be appreciated, that there could be many more elements - other than just four elements across the inside surface of the kit lock panel 74 - 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 data logger 98 are 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 9e.

[0048] The shipper in accordance with the invention can be packed with differing numbers and different types of phase change materials to provide specific thermal stability to a temperature sensitive product. Figure 10 shows a thermal cycle result for an intensive thermal cycling test - under International Safe Transit Association 7D Hot testing rules. Under such a procedure, a development test to evaluate the effects of external exposures of individual packaged product is provided. Such tests are employed for individual or comparative performance analysis of standard or insulated transport packages against normally encountered conditions. This test, specifically, provides a standardized extreme thermal cycle test under where temperature is varied between 22.5 °C and 35°C over a period of days. It can be seen that with the use of seven conditioned thermo-panels filled with a phase change medium, a product volume of a shipper in accordance with the present invention can be maintained within a 2 - 8 °C thermal widow - which is a standard window - for one hundred and fifteen hours; with the use of six conditioned thermo-panels , the period is ninety-nine hours; with the use of five conditioned thermo-panels the period is 68 hours; whilst with the use of four conditioned thermo-panels the period is sixty-seven hours.

[0049] 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 :

a primary carton having a base, a sidewall and at least one hinged lid member; a layer of insulation being associated with the inside surfaces of the primary carton, to define a cuboid placement volume;

at least one set of thermo-panels comprising insulating or phase change materials;

wherein the thermo-panels are arranged to be placed within the placement volume, the thermo-panels comprising a generally rectangular shape, wherein the panels comprise first and second generally rectangular major surfaces having a length and a width, spaced apart in a parallel spaced apart fashion by a depth, with the major surfaces of corresponding area being separated by a circumferential edge along corresponding lengths and widths, wherein, at least one major surface has, adjacent an edge and across its width, an elongate contoured abutment surface and at least along the edges about a width of the major surfaces, a contoured abutment surface complementary to the contoured surface of said major plane, wherein, upon positioning within the cuboid placement volume, each thermo-panel can provide at least one of an adjacent en- edge contoured abutment surface and/or at least one edge complementary contoured abutment surface, whereby four such thermo-panels can be orthogonally arranged in a mutually abutting relationship whereby to define a cuboid load volume.

2. A shipper according to claim 1, wherein said at least one major surface of the thermo-panels has an elongate contoured abutment surface adjacent each edge across its width.

3. A shipper according to claim 1 or 2, wherein each major surface of the thermo- panels has at least one elongate contoured abutment surface adjacent an edge across its width.

4. A shipper according to any one of claims 1 - 3, wherein said contoured abutment surfaces of the one major surface of the thermo-panels are one of concave or convex.

5. A shipper according to any one of claims 1 - 4, wherein all the thermo-panels have the same dimensions.

6. A shipper according to any one of claims 1 - 5, wherein the thermo-panels can comprise one or more of: a vacuum insulation material such as a vacuum insulation panel (VIP), an insulator such as polystyrene, a container for a phase change medium.

7. A shipper according to claim 2, wherein there is a further thermo-panel operably arranged in specific mutually abutting relationship to define a cuboid load volume having five faces of the cuboid being closed by thermo-panels.

8. A shipper according to claim 2, wherein there are two further thermo-panels operably arranged in specific mutually abutting relationship to define a cuboid load volume having all six faces of the cuboid being closed by thermo-panels.

9. A shipper according to claim 7, wherein a first thermo-panel is operably placed upon a base of the placement volume whereby to have first and second abutment surfaces thereof upwardly directed, with a first set of two thermo-panels being placed orthogonally such that edges of said first set of thermo-panels face the base of the placement volume and the respective edge abutment surfaces of each major face of the thermo-panels face the edges of the first panel in an abutting relationship with a second set of two thermo-panels being placed orthogonally with respect to said first panel and to the first set of thermo-panels such that each lower edge of the first and second thermo-panels of the second set abut, respectively, the first and second upwardly directed abutment surfaces, whilst the respective first and second abutment surfaces of the first and second thermo- panels of the second set abut the upstanding edges of the first set of two thermo- panels.

10. A shipper according to claim 9, wherein a sixth thermo-panel can be disposed facing the first base panel.

11. A shipper according to any one of claims 1 - 10, wherein there is a further thermo-panel operably arranged in a parallel spaced relation to one face of the thermo-panels operably defining a cuboid load volume.

12. A shipper according to any one of claims 1 - 13, wherein a lid member has a sleeve feature that can be operably associated with a thermo-panel, whereby to associate the thermo-panel with the lid, reducing a likelihood of disassociating the lid thermo-panel from the shipper.

13. A shipper according to any one of claims 1 - 12, wherein the primary carton has one or more apertures in its walls to enable one or more handles to be attached thereto.

14. A shipper according to any one of claims 1 - 13, wherein there is provided a further, outer carton, which provides physical protection to the primary carton.

15. A shipper according to claim 14, wherein the outer carton, which provides physical protection to the primary carton.

16. A shipper according to claim 15, wherein the outer carton is disposable.

17. A shipper according to any one of claims 1 - 16, wherein there is provided a kit tray operable to fill the cuboid load volume, the kit tray being provided with a load restraint device/cover element.

18. A shipper according to claim 17, wherein the kit tray comprises a five-sided cubic tray.

19. A shipper according to claim 17 or 18, wherein the kit tray further comprises a load restraint device/cover element operable to prevent loose movement of product placed within the tray.

20. A shipper according to any one of claims 17 - 19, wherein the kit tray further comprises a load restraint device/cover element operable to prevent/reduce movement of product placed within the tray.

21. A shipper according to claim 20, wherein the load restraint device/cover element comprises a section of material 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.

22. A shipper according to claim 20, wherein the load restraint device/cover element comprises a section of material 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.

23. A shipper according to any one of claims 17 - 22, 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.

24. A shipper according to any one of claims 17 - 23, wherein the cover element provides a receptacle data logging/temperature monitoring whereby to enable at least one of temperature monitoring and tracking.

25. A shipper according to any one of claims 17 - 24, 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.

26. A shipper according to claim 25, 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.

27. A shipper according to any one of claim 25 or 26, wherein the resilient members are arranged in rows across the underside of the cover element.

28. A shipper according to any one of claims 17 - 27, wherein the kit tray is provided with a lid in the form of two apertured wings, upstanding from the walls of the kit tray.

29. A shipper according to claim 28, wherein the two wings of the kit tray can be sealed together to confirm integrity of product and to enable visual inspection of any sensor device within the kit tray.

30. A thermo-panel configured for use in any one or more of claims 1 - 29.

31. A kit tray for use in any one or more of claims 17 - 29.