US20220153505A1 - Cold chain barrier wall packaging system - Google Patents
Cold chain barrier wall packaging system Download PDFInfo
- Publication number
- US20220153505A1 US20220153505A1 US17/530,146 US202117530146A US2022153505A1 US 20220153505 A1 US20220153505 A1 US 20220153505A1 US 202117530146 A US202117530146 A US 202117530146A US 2022153505 A1 US2022153505 A1 US 2022153505A1
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- US
- United States
- Prior art keywords
- enclosure
- corrugated board
- packaging system
- cold chain
- interior surface
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 230000004888 barrier function Effects 0.000 title claims abstract description 59
- 238000004806 packaging method and process Methods 0.000 title claims abstract description 56
- 239000012782 phase change material Substances 0.000 claims abstract description 28
- 239000011800 void material Substances 0.000 claims abstract description 17
- 125000006850 spacer group Chemical group 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims description 72
- 239000011162 core material Substances 0.000 claims description 11
- 239000006260 foam Substances 0.000 claims description 11
- 239000011087 paperboard Substances 0.000 claims description 4
- 238000000034 method Methods 0.000 description 10
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 8
- 235000011089 carbon dioxide Nutrition 0.000 description 8
- 239000000825 pharmaceutical preparation Substances 0.000 description 6
- 229940127557 pharmaceutical product Drugs 0.000 description 6
- 239000003292 glue Substances 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 229960005486 vaccine Drugs 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 241000167854 Bourreria succulenta Species 0.000 description 1
- 229940022962 COVID-19 vaccine Drugs 0.000 description 1
- 235000013361 beverage Nutrition 0.000 description 1
- 239000011111 cardboard Substances 0.000 description 1
- 235000019693 cherries Nutrition 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000011094 fiberboard Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000011140 metalized polyester Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3825—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container
- B65D81/3834—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container the external tray being formed of different materials, e.g. laminated or foam filling between walls
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
- B65D5/0254—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body with end closures formed by inward folding of flaps and securing them by means of a tongue integral with one of the flaps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
- B65D5/22—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form held erect by extensions of one or more sides being doubled-over to enclose extensions of adjacent sides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
- B65D5/42—Details of containers or of foldable or erectable container blanks
- B65D5/56—Linings or internal coatings, e.g. pre-formed trays provided with a blow- or thermoformed layer
- B65D5/563—Laminated linings; Coatings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/18—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3825—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container
- B65D81/3827—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container the external tray being formed of foam material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3825—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container
- B65D81/383—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container with one or more containers located inside the external container the external tray being formed with double walls, i.e. hollow
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3848—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation semi-rigid container folded up from one or more blanks
- B65D81/3858—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation semi-rigid container folded up from one or more blanks formed of different materials, e.g. laminated or foam filling between walls
Definitions
- the subject invention is directed to product packaging, and more particularly, to a cold chain barrier wall packaging system for shipping and storing a payload such as pharmaceutical products at ultra-low temperatures.
- the subject invention is directed to a new and useful cold chain packaging system for shipping and storing a payload at ultra-low temperatures, such as, for example, pharmaceutical products.
- the packing system includes a first enclosure constructed from a corrugated board material for receiving a payload.
- the first enclosure has an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material.
- the packaging system includes a second enclosure constructed from a corrugated board material for receiving the first enclosure.
- the second enclosure has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material.
- the packaging system includes a third enclosure constructed from a corrugated board material for receiving the second enclosure.
- the third enclosure has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material.
- the packaging system includes a fourth enclosure constructed from a corrugated board material for receiving a phase change material, such as, for example, dry ice in a pelletized or granulated form.
- the fourth enclosure has an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material, and wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- the first enclosure is adapted and configured to create a moat between the exterior surface of the first enclosure and the interior surface of the second enclosure for receiving a phase change material
- the packaging system further includes a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between the exterior surface of the second enclosure and the interior surface of the third enclosure. The air gap mitigates heat transfer from the second enclosure.
- the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel that is supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.
- the first enclosure also includes integral support flanges extending outwardly from a bottom end thereof to center the first enclosure within the second enclosure and to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material.
- the top and bottom trays both have interior and exterior surfaces, wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.
- an interior surface of the top and bottom tray is lined with an insulating panel constructed from a foam core material.
- each of the plurality of spacer blocks is adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier or air gap between the exterior surface of the second enclosure and the interior surface of the third enclosure.
- the cold chain packaging system includes a first enclosure for receiving a payload, a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- the first enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material.
- the second enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material.
- the third enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material.
- the fourth enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material.
- the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.
- the first enclosure preferably includes integral support flanges that extend outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material.
- the top and bottom trays both have interior and exterior surfaces, wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.
- an interior surface of the top and bottom tray is lined with an insulating panel constructed from a foam core material, and each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
- the subject invention is also directed to a cold chain packaging system that includes a first corrugated paper board blank for constructing a first enclosure for receiving a payload, a second corrugated board blank for constructing a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third corrugated board blank third for constructing a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth corrugated board blank for constructing a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- the first corrugated board blank has an interior surface and an exterior surface, wherein at least the exterior surface of the first blank is lined with a radiant barrier material
- the second corrugated board blank has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second blank are lined with a radiant barrier material
- the third corrugated board blank has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third blank are lined with a radiant barrier material
- the fourth corrugated board blank has an interior surface and an exterior surface, wherein at least the interior surface of the fourth blank is lined with a radiant barrier material.
- the first corrugated board blank is configured to form a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs formed in the first blank.
- the first corrugated board blank includes integral support flanges that extend from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- the second corrugated board blank is configured to form a rectangular sleeve, and the system further includes a fifth corrugated board blank for constructing a top tray for securing a top portion of the second enclosure and a sixth corrugated board blank for constructing a bottom tray for securing a bottom portion of the second enclosure.
- the fifth and sixth corrugated board blanks both have interior and exterior surfaces, and wherein at least the exterior surfaces of the fifth and sixth blanks are lined with a radiant barrier material.
- the cold chain packaging system further includes an insulating panel constructed from a foam core material for lining an interior surface of each of the top and bottom trays.
- the subject invention is also directed to a method of assembling a cold chain packaging system that includes the steps of constructing a first enclosure from a corrugated board blank for receiving a payload, and constructing a second enclosure from a corrugated board blank for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material.
- the method further includes the steps of constructing a third enclosure from a corrugated board blank for receiving the second enclosure, constructing a fourth enclosure from a corrugated board blank for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- the method also includes the steps of constructing a top tray from a corrugated board blank for securing a top portion of the second enclosure and constructing a bottom tray from a corrugated board blank for securing a bottom portion of the second enclosure.
- the method further includes the steps of centering the first enclosure within the second enclosure, positioning the fourth enclosure above the first enclosure within the second enclosure, lining the top and bottom trays with a foam core insert, and then securing the top and bottom trays to the top and bottom portions of the second enclosure, respectively, by way of a friction fit.
- the method further includes the step of encapsulating the second enclosure within the third enclosure using a plurality of corner blocks to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure.
- the method also includes the steps of loading a payload into the first enclosure, storing a phase change material in the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure, and storing a phase change material in the fourth enclosure.
- the method can also include the steps of replenishing the phase change material in the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure after a period of time, and replenishing the phase change material in the fourth enclosure after a period of time.
- FIG. 1 is a fully exploded perspective view of the cold chain packaging system of the subject invention with all of the component parts thereof separated from one another for ease of illustration;
- FIG. 2 is another exploded perspective view of the cold chain packaging system of the subject invention in a partially assembled condition
- FIG. 3 is yet another exploded perspective view the cold chain packaging system of the subject invention in a more fully assembled condition
- FIG. 4 is a perspective view the cold chain packaging system of the subject invention in a fully assembled condition
- FIG. 5 is a plan view of a blank for forming the first enclosure of the cold chain packaging system of the subject invention, which receives the payload;
- FIG. 6 is a perspective view of the first enclosure in an open condition with the bottom panel separated from the enclosure;
- FIG. 7 is a plan view of a blank for forming the second enclosure of the cold chain packaging system of the subject invention, which receives the first enclosure;
- FIG. 8 is a perspective view of the second enclosure in an open condition
- FIG. 9 is a plan view of a blank for forming the fourth enclosure of the cold chain packaging system of the subject invention, which receives the phase change material and is positioned within the second enclosure above the first enclosure;
- FIG. 10 is a perspective view of the fourth enclosure in an open condition
- FIG. 11 is a plan view of a blank for forming the top and bottom trays of the cold chain packaging system of the subject invention, which secures the second enclosure;
- FIG. 12 is a perspective view of the insulating panel for lining the top and bottom trays
- FIG. 13 is an exploded perspective view of a tray with the insulating panel separated therefrom for ease of illustration;
- FIG. 14 is a perspective view of a tray with the insulating panel installed therein;
- FIG. 15 is a plan view of a blank for forming the third enclosure of the cold chain packaging system of the subject invention, which receives the second enclosures;
- FIG. 16 is a perspective view of the second enclosure in an open condition.
- FIG. 17 is a perspective view of one of the spaced blocks shown in FIG. 3 that is used to encapsulate the second enclosure within the third enclosure to create a void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
- FIGS. 1-4 the cold chain packaging system of the subject invention, which is designated generally by reference numeral 10 .
- Packaging system 10 is adapted and configured to shipping and storing a payload at ultra-low temperatures, such as, for example, pharmaceutical products.
- the packing system 10 includes a first or innermost enclosure 12 constructed from a corrugated board material for receiving a payload of a vaccine or other pharmaceutical product.
- An exemplary pharmaceutical payload might include several stacked trays of vials, with each tray holding up to 195 multiple dose vials.
- the first enclosure 12 has an interior surface 14 and an exterior surface 16 , wherein the exterior surface 14 of the first enclosure 12 is lined with a radiant barrier material, as best seen in FIG. 6 . It is envisioned however that both the interior and exterior surfaces 14 , 16 of the first enclosure 12 could be lined with the radiant barrier material.
- corrugated board for use in the packaging system 10 of the subject invention shall be understood to refer to and include corrugated packaging material that is made from corrugated containerboard, paperboard, cardboard, fiberboard or the like.
- a suitable “radiant barrier material” for use in the packaging system 10 of the subject invention is manufactured by WestRock and is marketed under the tradename InsulShieldTM system, which uses fiber-based corrugated board for strength and durability and added Met-PET (metalized polyester) laminated liners and inserts to provide steady temperature maintenance.
- InsulShieldTM system which uses fiber-based corrugated board for strength and durability and added Met-PET (metalized polyester) laminated liners and inserts to provide steady temperature maintenance.
- the packaging system 10 further includes a second or intermediate enclosure 22 constructed from a corrugated board material for receiving the first enclosure 12 .
- the second enclosure 22 is designed to be sift resistant and it has an interior surface 24 and an exterior surface 26 , wherein the interior and exterior surfaces of the second enclosure 22 are both lined with a radiant barrier material, as best seen in FIG. 8 .
- the packaging system 10 includes a third or outermost enclosure 32 that is constructed from a corrugated board material for receiving the second enclosure 22 .
- the third enclosure 32 is also designed to be sift resistant and it has an interior surface 34 and an exterior surface 36 , wherein the interior and exterior surfaces of the third enclosure 32 are both lined with a radiant barrier material, as best seen in FIG. 16 .
- the packaging system 10 includes a fourth enclosure 42 constructed from a corrugated board material for receiving a phase change material, such as, for example, dry ice in a pelletized or granulated form. It is envisioned that the fourth enclosure 42 would be dimensioned and configured to store approximately 10 kg of pelletized or granulated dry ice.
- a phase change material such as, for example, dry ice in a pelletized or granulated form. It is envisioned that the fourth enclosure 42 would be dimensioned and configured to store approximately 10 kg of pelletized or granulated dry ice.
- the fourth enclosure 42 has an interior surface 44 and an exterior surface 46 , wherein the interior surface 44 of the fourth enclosure 42 is lined with a radiant barrier material, and wherein the fourth enclosure 42 is dimensioned and configured to be received within the second enclosure 22 positioned above the first enclosure 12 .
- the radiant barrier material on the interior surface 44 of the fourth enclosure serves to retard the rate at which the dry ice stored therein will sublimate.
- the first enclosure 12 is adapted and configured to create a moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 for receiving a phase change material, such as, for example, pelletized or granulated dry ice, as described in more detail below.
- the packaging system 10 further includes a plurality of plastic spacer blocks 50 for encapsulating the second enclosure 22 within the third enclosure 32 to create a void barrier or insulating air gap between the exterior surface 26 of the second enclosure 22 and the interior surface 34 of the third enclosure 32 .
- the void barrier or air gap functions to advantageously mitigate heat transfer from the second enclosure 22 to the ambient environment.
- the spaced blocks 50 could be constructed from a different structural material, such as a foam core material or the like.
- the first enclosure 12 is defined by a rectangular sleeve 13 having an integral top closure panel 15 and a separate bottom closure panel 17 .
- the bottom closure panel 17 is supported within the rectangular sleeve 13 by a plurality of inwardly projecting integral corner tabs 18 .
- the first enclosure 12 also includes a plurality of integral support flanges 19 that extend outwardly from a bottom end thereof to center the first enclosure 12 within the second enclosure 22 and to define the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 .
- the moat is deigned to receive a phase change material, such as, for example, pelletized or granulated dry ice.
- a phase change material such as, for example, pelletized or granulated dry ice.
- approximately 1 kg of pelletized dry ice can be stored in the moat, and in the cavity created within the first enclosure 12 beneath the separable bottom panel 17 .
- the radiant barrier material that delimits the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 serves to advantageously retard the rate at which the dry ice stored therein will sublimate.
- the second enclosure 22 is defined by a rectangular sleeve 23 that is secured between a top tray 60 constructed from a corrugated board material and a bottom tray 70 that is constructed from a corrugated board material.
- the top and bottom trays 60 , 70 both have interior and exterior surfaces, i.e., surfaces 62 , 64 and 72 , 74 , respectively.
- the exterior surfaces 64 , 74 of the top and bottom 60 , 70 trays are each lined with a radiant barrier material.
- the top and bottom trays 60 , 70 are preferably friction fit on to the upper and lower portion of the second enclosure 22 during assembly of the packaging system 10 and they serve to secure and seal the upper and lower end of the second enclosure 22 .
- an interior surfaces 62 , 72 of the top and bottom trays 60 , 70 are each lined with an insulating panel 80 constructed from a foam core material, such as for example, styrene or a similar material, as best seen in FIG. 14 .
- the foam core panels 80 lining the top and bottom trays 60 , 70 help to seal the upper and lower end portions of the second enclosure 22 and provide a cushion for impact and shock resistance during transit and storage.
- each of the plurality of spacer blocks 50 which are best seen in FIG. 17 , is adapted and configured to engage a respective corner of the top and bottom trays 60 , 70 to create the void barrier between the exterior surface 26 of the second enclosure 22 and the interior surface 34 of the third enclosure 32 to mitigate heat transfer from the second enclosure 22 .
- the first enclosure 12 is constructed from a first corrugated paper board blank 112 , wherein the exterior surface of the first blank 112 is lined with a radiant barrier material.
- the first blank 112 is of the style commonly referred to as a tuck top blank, which includes four primary side panels 11 a - 11 d that are configured to form the rectangular sleeve structure 13 of the first enclosure 12 , the integral top closure panel 15 and the separable bottom closure panel 17 .
- a glue flap 11 e extends outwardly from the side panel 11 d of blank 112 for constructing the rectangular sleeve 13 of the first enclosure 12 .
- a plurality of inwardly projecting integral corner tabs 18 a - 18 c are formed in the first blank 112 , between adjoining side panels to support the bottom closure panel 17 within the rectangular sleeve 13 .
- the first blank 112 further includes plurality of integral support flanges 19 a - 19 d that extend outwardly from a bottom end thereof to center the first enclosure 12 within the second enclosure 22 and to define the moat between the exterior surface 16 of the first enclosure 12 and the interior surface 24 of the second enclosure 22 .
- the second enclosure 22 is constructed from a second corrugated board blank 122 , wherein the interior and exterior surfaces of the second blank 122 are lined with a radiant barrier material.
- the second blank 122 is of the type commonly referred to as a CSSC blank, which includes four primary side panels 21 a - 21 d that are configured to form the rectangular sleeve structure 23 of the second enclosure 22 .
- a glue flap 21 e extends outwardly from the side panel 21 d of blank 122 for constructing the rectangular sleeve 23 of the second enclosure 22 .
- the fourth enclosure 42 is constructed from a fourth corrugated board blank 422 , wherein the interior surface of the fourth blank 422 is lined with a radiant barrier material.
- the fourth blank 422 is of the type commonly referred to as a 2-sided roll over with a cherry tuck top blank.
- top and bottom trays 60 and 70 are constructed from identical corrugated board blanks designated generally by reference numeral 522 , shown in FIG. 11 , wherein the exterior surfaces of these blanks 522 are lined with a radiant barrier material.
- the foam core insulating panel 80 for lining the interior surfaces of the top and bottom trays 60 and 70 is illustrated in FIGS. 12 and 13 .
- the third or outermost enclosure 32 is constructed from a third corrugated board blank 322 , wherein the interior and exterior surfaces of the third blank 322 are lined with a radiant barrier material.
- the third blank 322 is also of the type commonly referred to as a CSSC blank, which includes four primary side panels 31 a - 31 d that are configured to form the rectangular sleeve structure 33 of the third enclosure 32 .
- a glue flap 31 e extends outwardly from the side panel 31 d of blank 322 for constructing the rectangular sleeve 33 of the second enclosure 32 .
- the first enclosure 12 is constructed from the corrugated board blank 122
- the second enclosure 22 is constructed from the corrugated board blank 222
- third enclosure 32 is constructed from the corrugated board blank 322
- the fourth enclosure 42 is constructed from the corrugated board blank 422 .
- the top and bottom trays 60 and 70 are constructed from two corrugated board blank 522 .
- the first enclosure 12 is centered within the second enclosure 22
- the fourth enclosure 42 is positioned above the first enclosure 12 within the second enclosure 22
- the top and bottom trays 60 and 70 are both lined with foam core inserts 80
- the top and bottom trays 60 and 70 are secured to the top and bottom portions of the second enclosure 22 by a friction fit.
- the second enclosure 22 is encapsulated within the third enclosure 32 using a plurality of corner blocks 50 to create a void barrier between an exterior surface of the second enclosure 22 and an interior surface of the third enclosure 32 .
- the method also includes the steps of loading a payload into the first enclosure 12 , storing a phase change material in the moat between the exterior surface of the first enclosure 12 and the interior surface of the second enclosure 22 , and storing a phase change material in the fourth enclosure 42 .
- the method can also include the steps of replenishing the phase change material in the moat between the exterior surface of the first enclosure 12 and the interior surface of the second enclosure 22 after a period of time, and replenishing the phase change material in the fourth enclosure 42 after a period of time.
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Abstract
A cold chain packaging system is disclosed that includes a first enclosure for receiving a payload, a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
Description
- The subject invention is directed to product packaging, and more particularly, to a cold chain barrier wall packaging system for shipping and storing a payload such as pharmaceutical products at ultra-low temperatures.
- Cold chain logistics using specialized refrigeration, transportation and storage resources is commonly employed in the food and beverage industry to meet demands for product freshness and to reduce loss and waste during transit.
- The development of innovative cold chain solutions and distribution logistics to facilitate the supply and storage of pharmaceutical products such as vaccines is of increased importance. Indeed, some of the Covid-19 vaccines that are currently in large-scale clinical trials require ultra-cold storage and transport. At least one of these vaccines must be kept at or near minus 75 degrees Celsius during transport and while it is stored at an administration site or clinic for an extended period of time of up to 10 days or longer.
- Thus, there is a need in the art for a cold chain packaging solution for shipping and storing pharmaceutical products and similar payloads that can meet such stringent logistical requirements.
- The subject invention is directed to a new and useful cold chain packaging system for shipping and storing a payload at ultra-low temperatures, such as, for example, pharmaceutical products. The packing system includes a first enclosure constructed from a corrugated board material for receiving a payload. The first enclosure has an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material. The packaging system includes a second enclosure constructed from a corrugated board material for receiving the first enclosure.
- The second enclosure has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material. The packaging system includes a third enclosure constructed from a corrugated board material for receiving the second enclosure. The third enclosure has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material.
- The packaging system includes a fourth enclosure constructed from a corrugated board material for receiving a phase change material, such as, for example, dry ice in a pelletized or granulated form. The fourth enclosure has an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material, and wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- Preferably, the first enclosure is adapted and configured to create a moat between the exterior surface of the first enclosure and the interior surface of the second enclosure for receiving a phase change material, and the packaging system further includes a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between the exterior surface of the second enclosure and the interior surface of the third enclosure. The air gap mitigates heat transfer from the second enclosure.
- The first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel that is supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs. The first enclosure also includes integral support flanges extending outwardly from a bottom end thereof to center the first enclosure within the second enclosure and to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- The second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material. The top and bottom trays both have interior and exterior surfaces, wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material. In addition, an interior surface of the top and bottom tray is lined with an insulating panel constructed from a foam core material. Preferably, each of the plurality of spacer blocks is adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier or air gap between the exterior surface of the second enclosure and the interior surface of the third enclosure.
- In another embodiment of the subject invention, the cold chain packaging system includes a first enclosure for receiving a payload, a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- The first enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material. The second enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material. The third enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material. The fourth enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material.
- Preferably, the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs. The first enclosure preferably includes integral support flanges that extend outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- Preferably, the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material. The top and bottom trays both have interior and exterior surfaces, wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.
- Preferably, an interior surface of the top and bottom tray is lined with an insulating panel constructed from a foam core material, and each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
- The subject invention is also directed to a cold chain packaging system that includes a first corrugated paper board blank for constructing a first enclosure for receiving a payload, a second corrugated board blank for constructing a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material, a third corrugated board blank third for constructing a third enclosure for receiving the second enclosure, a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier or air gap between an exterior surface of the second enclosure and an interior surface of the third enclosure, and a fourth corrugated board blank for constructing a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
- Preferably, the first corrugated board blank has an interior surface and an exterior surface, wherein at least the exterior surface of the first blank is lined with a radiant barrier material, the second corrugated board blank has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second blank are lined with a radiant barrier material, the third corrugated board blank has an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third blank are lined with a radiant barrier material, and the fourth corrugated board blank has an interior surface and an exterior surface, wherein at least the interior surface of the fourth blank is lined with a radiant barrier material.
- The first corrugated board blank is configured to form a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs formed in the first blank. The first corrugated board blank includes integral support flanges that extend from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
- The second corrugated board blank is configured to form a rectangular sleeve, and the system further includes a fifth corrugated board blank for constructing a top tray for securing a top portion of the second enclosure and a sixth corrugated board blank for constructing a bottom tray for securing a bottom portion of the second enclosure. The fifth and sixth corrugated board blanks both have interior and exterior surfaces, and wherein at least the exterior surfaces of the fifth and sixth blanks are lined with a radiant barrier material. The cold chain packaging system further includes an insulating panel constructed from a foam core material for lining an interior surface of each of the top and bottom trays.
- The subject invention is also directed to a method of assembling a cold chain packaging system that includes the steps of constructing a first enclosure from a corrugated board blank for receiving a payload, and constructing a second enclosure from a corrugated board blank for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material.
- The method further includes the steps of constructing a third enclosure from a corrugated board blank for receiving the second enclosure, constructing a fourth enclosure from a corrugated board blank for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure. The method also includes the steps of constructing a top tray from a corrugated board blank for securing a top portion of the second enclosure and constructing a bottom tray from a corrugated board blank for securing a bottom portion of the second enclosure.
- The method further includes the steps of centering the first enclosure within the second enclosure, positioning the fourth enclosure above the first enclosure within the second enclosure, lining the top and bottom trays with a foam core insert, and then securing the top and bottom trays to the top and bottom portions of the second enclosure, respectively, by way of a friction fit. The method further includes the step of encapsulating the second enclosure within the third enclosure using a plurality of corner blocks to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure.
- The method also includes the steps of loading a payload into the first enclosure, storing a phase change material in the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure, and storing a phase change material in the fourth enclosure. The method can also include the steps of replenishing the phase change material in the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure after a period of time, and replenishing the phase change material in the fourth enclosure after a period of time.
- These and other features of the cold chain packaging system of the subject invention as well as the method of assembling and using the system will become more readily apparent to those having ordinary skill in the art to which the subject invention appertains from the detailed description of the preferred embodiments taken in conjunction with the following brief description of the drawings.
- So that those having ordinary skill in the art will readily understand how to make, assemble and use the cold chain packaging system subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to the figures wherein:
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FIG. 1 is a fully exploded perspective view of the cold chain packaging system of the subject invention with all of the component parts thereof separated from one another for ease of illustration; -
FIG. 2 is another exploded perspective view of the cold chain packaging system of the subject invention in a partially assembled condition; -
FIG. 3 is yet another exploded perspective view the cold chain packaging system of the subject invention in a more fully assembled condition; -
FIG. 4 is a perspective view the cold chain packaging system of the subject invention in a fully assembled condition; -
FIG. 5 is a plan view of a blank for forming the first enclosure of the cold chain packaging system of the subject invention, which receives the payload; -
FIG. 6 is a perspective view of the first enclosure in an open condition with the bottom panel separated from the enclosure; -
FIG. 7 is a plan view of a blank for forming the second enclosure of the cold chain packaging system of the subject invention, which receives the first enclosure; -
FIG. 8 is a perspective view of the second enclosure in an open condition; -
FIG. 9 is a plan view of a blank for forming the fourth enclosure of the cold chain packaging system of the subject invention, which receives the phase change material and is positioned within the second enclosure above the first enclosure; -
FIG. 10 is a perspective view of the fourth enclosure in an open condition; -
FIG. 11 is a plan view of a blank for forming the top and bottom trays of the cold chain packaging system of the subject invention, which secures the second enclosure; -
FIG. 12 is a perspective view of the insulating panel for lining the top and bottom trays; -
FIG. 13 is an exploded perspective view of a tray with the insulating panel separated therefrom for ease of illustration; -
FIG. 14 is a perspective view of a tray with the insulating panel installed therein; -
FIG. 15 is a plan view of a blank for forming the third enclosure of the cold chain packaging system of the subject invention, which receives the second enclosures; -
FIG. 16 is a perspective view of the second enclosure in an open condition; and -
FIG. 17 is a perspective view of one of the spaced blocks shown inFIG. 3 that is used to encapsulate the second enclosure within the third enclosure to create a void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure. - Referring now to the drawings wherein like reference numerals identify similar structural features or elements of the subject invention, there is illustrated in
FIGS. 1-4 , the cold chain packaging system of the subject invention, which is designated generally byreference numeral 10.Packaging system 10 is adapted and configured to shipping and storing a payload at ultra-low temperatures, such as, for example, pharmaceutical products. - The
packing system 10 includes a first orinnermost enclosure 12 constructed from a corrugated board material for receiving a payload of a vaccine or other pharmaceutical product. An exemplary pharmaceutical payload might include several stacked trays of vials, with each tray holding up to 195 multiple dose vials. Thefirst enclosure 12 has aninterior surface 14 and anexterior surface 16, wherein theexterior surface 14 of thefirst enclosure 12 is lined with a radiant barrier material, as best seen inFIG. 6 . It is envisioned however that both the interior andexterior surfaces first enclosure 12 could be lined with the radiant barrier material. - A used herein, the term “corrugated board” for use in the
packaging system 10 of the subject invention shall be understood to refer to and include corrugated packaging material that is made from corrugated containerboard, paperboard, cardboard, fiberboard or the like. As used herein, a suitable “radiant barrier material” for use in thepackaging system 10 of the subject invention is manufactured by WestRock and is marketed under the tradename InsulShield™ system, which uses fiber-based corrugated board for strength and durability and added Met-PET (metalized polyester) laminated liners and inserts to provide steady temperature maintenance. - The
packaging system 10 further includes a second orintermediate enclosure 22 constructed from a corrugated board material for receiving thefirst enclosure 12. Thesecond enclosure 22 is designed to be sift resistant and it has aninterior surface 24 and anexterior surface 26, wherein the interior and exterior surfaces of thesecond enclosure 22 are both lined with a radiant barrier material, as best seen inFIG. 8 . Thepackaging system 10 includes a third oroutermost enclosure 32 that is constructed from a corrugated board material for receiving thesecond enclosure 22. Thethird enclosure 32 is also designed to be sift resistant and it has aninterior surface 34 and anexterior surface 36, wherein the interior and exterior surfaces of thethird enclosure 32 are both lined with a radiant barrier material, as best seen inFIG. 16 . - The
packaging system 10 includes afourth enclosure 42 constructed from a corrugated board material for receiving a phase change material, such as, for example, dry ice in a pelletized or granulated form. It is envisioned that thefourth enclosure 42 would be dimensioned and configured to store approximately 10 kg of pelletized or granulated dry ice. - As best seen in
FIG. 10 , thefourth enclosure 42 has aninterior surface 44 and anexterior surface 46, wherein theinterior surface 44 of thefourth enclosure 42 is lined with a radiant barrier material, and wherein thefourth enclosure 42 is dimensioned and configured to be received within thesecond enclosure 22 positioned above thefirst enclosure 12. The radiant barrier material on theinterior surface 44 of the fourth enclosure serves to retard the rate at which the dry ice stored therein will sublimate. - Preferably, the
first enclosure 12 is adapted and configured to create a moat between theexterior surface 16 of thefirst enclosure 12 and theinterior surface 24 of thesecond enclosure 22 for receiving a phase change material, such as, for example, pelletized or granulated dry ice, as described in more detail below. Thepackaging system 10 further includes a plurality of plastic spacer blocks 50 for encapsulating thesecond enclosure 22 within thethird enclosure 32 to create a void barrier or insulating air gap between theexterior surface 26 of thesecond enclosure 22 and theinterior surface 34 of thethird enclosure 32. The void barrier or air gap functions to advantageously mitigate heat transfer from thesecond enclosure 22 to the ambient environment. It is envisioned that the spacedblocks 50 could be constructed from a different structural material, such as a foam core material or the like. - As best seen in
FIG. 6 , thefirst enclosure 12 is defined by arectangular sleeve 13 having an integraltop closure panel 15 and a separatebottom closure panel 17. Thebottom closure panel 17 is supported within therectangular sleeve 13 by a plurality of inwardly projectingintegral corner tabs 18. Thefirst enclosure 12 also includes a plurality ofintegral support flanges 19 that extend outwardly from a bottom end thereof to center thefirst enclosure 12 within thesecond enclosure 22 and to define the moat between theexterior surface 16 of thefirst enclosure 12 and theinterior surface 24 of thesecond enclosure 22. - As noted above, the moat is deigned to receive a phase change material, such as, for example, pelletized or granulated dry ice. In this regard, approximately 1 kg of pelletized dry ice can be stored in the moat, and in the cavity created within the
first enclosure 12 beneath theseparable bottom panel 17. The radiant barrier material that delimits the moat between theexterior surface 16 of thefirst enclosure 12 and theinterior surface 24 of thesecond enclosure 22 serves to advantageously retard the rate at which the dry ice stored therein will sublimate. - As best seen in
FIG. 13 , thesecond enclosure 22 is defined by arectangular sleeve 23 that is secured between atop tray 60 constructed from a corrugated board material and abottom tray 70 that is constructed from a corrugated board material. The top andbottom trays bottom trays second enclosure 22 during assembly of thepackaging system 10 and they serve to secure and seal the upper and lower end of thesecond enclosure 22. - In addition, an interior surfaces 62, 72 of the top and
bottom trays panel 80 constructed from a foam core material, such as for example, styrene or a similar material, as best seen inFIG. 14 . Thefoam core panels 80 lining the top andbottom trays second enclosure 22 and provide a cushion for impact and shock resistance during transit and storage. - Preferably, each of the plurality of spacer blocks 50, which are best seen in
FIG. 17 , is adapted and configured to engage a respective corner of the top andbottom trays exterior surface 26 of thesecond enclosure 22 and theinterior surface 34 of thethird enclosure 32 to mitigate heat transfer from thesecond enclosure 22. - Referring now to
FIGS. 5 and 6 , thefirst enclosure 12 is constructed from a first corrugatedpaper board blank 112, wherein the exterior surface of the first blank 112 is lined with a radiant barrier material. The first blank 112 is of the style commonly referred to as a tuck top blank, which includes four primary side panels 11 a-11 d that are configured to form therectangular sleeve structure 13 of thefirst enclosure 12, the integraltop closure panel 15 and the separablebottom closure panel 17. Aglue flap 11 e extends outwardly from the side panel 11 d of blank 112 for constructing therectangular sleeve 13 of thefirst enclosure 12. - A plurality of inwardly projecting
integral corner tabs 18 a-18 c are formed in the first blank 112, between adjoining side panels to support thebottom closure panel 17 within therectangular sleeve 13. The first blank 112 further includes plurality ofintegral support flanges 19 a-19 d that extend outwardly from a bottom end thereof to center thefirst enclosure 12 within thesecond enclosure 22 and to define the moat between theexterior surface 16 of thefirst enclosure 12 and theinterior surface 24 of thesecond enclosure 22. - Referring to
FIGS. 7 and 8 , thesecond enclosure 22 is constructed from a secondcorrugated board blank 122, wherein the interior and exterior surfaces of the second blank 122 are lined with a radiant barrier material. The second blank 122 is of the type commonly referred to as a CSSC blank, which includes four primary side panels 21 a-21 d that are configured to form therectangular sleeve structure 23 of thesecond enclosure 22. Aglue flap 21 e extends outwardly from theside panel 21 d of blank 122 for constructing therectangular sleeve 23 of thesecond enclosure 22. - Referring to
FIGS. 9 and 10 , thefourth enclosure 42 is constructed from a fourthcorrugated board blank 422, wherein the interior surface of the fourth blank 422 is lined with a radiant barrier material. The fourth blank 422 is of the type commonly referred to as a 2-sided roll over with a cherry tuck top blank. - Referring to
FIGS. 11-14 , the top andbottom trays reference numeral 522, shown inFIG. 11 , wherein the exterior surfaces of theseblanks 522 are lined with a radiant barrier material. The foamcore insulating panel 80 for lining the interior surfaces of the top andbottom trays FIGS. 12 and 13 . - Referring now to
FIGS. 15 and 16 , the third oroutermost enclosure 32 is constructed from a thirdcorrugated board blank 322, wherein the interior and exterior surfaces of the third blank 322 are lined with a radiant barrier material. The third blank 322 is also of the type commonly referred to as a CSSC blank, which includes four primary side panels 31 a-31 d that are configured to form the rectangular sleeve structure 33 of thethird enclosure 32. Aglue flap 31 e extends outwardly from the side panel 31 d of blank 322 for constructing the rectangular sleeve 33 of thesecond enclosure 32. - To assemble cold
chain packaging system 10 of the subject invention, thefirst enclosure 12 is constructed from thecorrugated board blank 122, thesecond enclosure 22 is constructed from the corrugated board blank 222,third enclosure 32 is constructed from thecorrugated board blank 322 and thefourth enclosure 42 is constructed from thecorrugated board blank 422. Then the top andbottom trays corrugated board blank 522. - Thereafter, the
first enclosure 12 is centered within thesecond enclosure 22, thefourth enclosure 42 is positioned above thefirst enclosure 12 within thesecond enclosure 22, the top andbottom trays bottom trays second enclosure 22 by a friction fit. At such a time, thesecond enclosure 22 is encapsulated within thethird enclosure 32 using a plurality of corner blocks 50 to create a void barrier between an exterior surface of thesecond enclosure 22 and an interior surface of thethird enclosure 32. - The method also includes the steps of loading a payload into the
first enclosure 12, storing a phase change material in the moat between the exterior surface of thefirst enclosure 12 and the interior surface of thesecond enclosure 22, and storing a phase change material in thefourth enclosure 42. The method can also include the steps of replenishing the phase change material in the moat between the exterior surface of thefirst enclosure 12 and the interior surface of thesecond enclosure 22 after a period of time, and replenishing the phase change material in thefourth enclosure 42 after a period of time. - While the cold chain packaging system of the subject disclosure has been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.
Claims (21)
1. A cold chain packaging system comprising:
a) a first enclosure constructed from a corrugated board material for receiving a payload, the first enclosure having an interior surface and an exterior surface, wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material;
b) a second enclosure constructed from a corrugated board material for receiving the first enclosure, the second enclosure having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material;
c) a third enclosure constructed from a corrugated board material for receiving the second enclosure, the third enclosure having an interior surface and an exterior surface, wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material; and
d) a fourth enclosure constructed from a corrugated board material for receiving a phase change material, the fourth enclosure having an interior surface and an exterior surface, wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material, and wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
2. The cold chain packaging system as recited in claim 1 , wherein the first enclosure is adapted and configured to create a moat between the exterior surface of the first enclosure and the interior surface of the second enclosure for receiving a phase change material.
3. The cold chain packaging system as recited in claim 1 , further comprising a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
4. The cold chain packaging system as recited in claim 2 , wherein the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.
5. The cold chain packaging system as recited in claim 4 , wherein the first enclosure comprises integral support flanges extending outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
6. The cold chain packaging system as recited in claim 3 , wherein the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material, wherein the top and bottom trays both have interior and exterior surfaces, and wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.
7. The cold chain packaging system as recited in claim 6 , wherein the interior surfaces of the top and bottom trays are lined with an insulating panel constructed from a foam core material.
8. The cold chain packaging system as recited in claim 6 , wherein each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
9. A cold chain packaging system comprising:
a) a first enclosure for receiving a payload;
b) a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material;
c) a third enclosure for receiving the second enclosure;
d) a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure; and
e) a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
10. The cold chain packaging system as recited in claim 9 , wherein the first enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least the exterior surface of the first enclosure is lined with a radiant barrier material.
11. The cold chain packaging system as recited in claim 9 , wherein the second enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of the second enclosure are lined with a radiant barrier material.
12. The cold chain packaging system as recited in claim 9 , wherein the third enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of the third enclosure are lined with a radiant barrier material.
13. The cold chain packaging system as recited in claim 9 , wherein the fourth enclosure is constructed from a corrugated board material having an interior surface and an exterior surface, and wherein at least the interior surface of the fourth enclosure is lined with a radiant barrier material.
14. The cold chain packaging system as recited in claim 9 , wherein the first enclosure is defined by a rectangular sleeve having an integral top closure panel and a separate bottom closure panel supported within the rectangular sleeve by a plurality of inwardly projecting integral corner tabs.
15. The cold chain packaging system as recited in claim 14 , wherein the first enclosure comprises integral support flanges extending outwardly from a bottom end thereof to define the moat between the exterior surface of the first enclosure and the interior surface of the second enclosure.
16. The cold chain packaging system as recited in claim 15 , wherein the second enclosure is defined by a rectangular sleeve that is secured between a top tray constructed from a corrugated board material and a bottom tray constructed from a corrugated board material, wherein the top and bottom trays both have interior and exterior surfaces, and wherein at least the exterior surfaces of the top and bottom trays are lined with a radiant barrier material.
17. The cold chain packaging system as recited in claim 16 , wherein
the interior surface of the top and bottom trays is lined with an insulating panel constructed from a foam core material.
18. The cold chain packaging system as recited in claim 16 , wherein each of the plurality of spacer blocks are adapted and configured to engage a respective corner of the top and bottom trays to create the void barrier between the exterior surface of the second enclosure and the interior surface of the third enclosure.
19. A cold chain packaging system comprising:
a) a first corrugated paper board blank for constructing a first enclosure for receiving a payload;
b) a second corrugated board blank for constructing a second enclosure for receiving the first enclosure, wherein the first enclosure is adapted and configured to create a moat between an exterior surface of the first enclosure and an interior surface of the second enclosure for receiving a phase change material;
c) a third corrugated board blank for constructing a third enclosure for receiving the second enclosure;
d) a plurality of spacer blocks for encapsulating the second enclosure within the third enclosure to create a void barrier between an exterior surface of the second enclosure and an interior surface of the third enclosure; and
e) a fourth corrugated board blank for constructing a fourth enclosure for receiving a phase change material, wherein the fourth enclosure is dimensioned and configured to be received within the second enclosure positioned above the first enclosure.
20. The cold chain packaging system as recited in claim 19 , wherein each of the first corrugated board blank, the second corrugated board blank, the third corrugated board blank, and the fourth corrugated board blank has an interior surface and an exterior surface, and wherein at least one of the interior and exterior surfaces of at least one of the first corrugated board blank, the second corrugated board blank, the third corrugated board blank, and the fourth corrugated board blank is lined with a radiant barrier material.
21-38. (canceled)
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US17/530,146 US20220153505A1 (en) | 2020-11-18 | 2021-11-18 | Cold chain barrier wall packaging system |
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US202063115238P | 2020-11-18 | 2020-11-18 | |
US17/530,146 US20220153505A1 (en) | 2020-11-18 | 2021-11-18 | Cold chain barrier wall packaging system |
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