WO2024102719A2

WO2024102719A2 - Passive thermally controlled shipping container and methods of in-place thermal conditioning, holistic evaluation of thermal integrity, repairing or replacing deficient components and loading

Info

Publication number: WO2024102719A2
Application number: PCT/US2023/078929
Authority: WO
Inventors: Sharp Ugwuocha; George Hays; Kai Goellner
Original assignee: Peli Biothermal Llc
Priority date: 2022-11-07
Filing date: 2023-11-07
Publication date: 2024-05-16

Abstract

A thermally-condition-in-place insulated passive thermally controlled shipping container (10) and methods of in-place thermal conditioning of the shipping container (10) using a separate chilling unit (500), holistic evaluation of thermal integrity of the shipping container (10) by comparing in-place thermal conditioning times t_Condition to establish a Δt and comparing the Δt to a threshold, value Δt_Thrshold repairing or replacing deficient components on the shipping container (10), and loading of the thermally conditioned shipping container (10)

Description

PASSIVE THERMALLY CONTROLLED SHIPPING CONTAINER AND

METHODS OF IN-PLACE THERMAL CONDITIONING, HOLISTIC EVALUATION OF THERMAL INTEGRITY, REPAIRING OR REPLACING DEFICIENT COMPONENTS AND LOADING

BACKGROUND

[0001] The shipment of temperature - sensitive goods is difficult when the shipping container itself is not independently temperature - controlled; i.e., does not have an independent power source for maintaining interior temperatures within close parameters.

[0002] Goods such as medical supplies, blood, and vaccines are often extremely temperature sensitive and need to be maintained within a given temperature range. Transport of such goods is particularly challenging. Such temperature sensitive goods are shipped to a variety of destinations where the ambient outside temperature varies from extreme cold to extreme heat.

[0003] One known solution is to use shipping containers with internal phase change material panels surrounded by exceptionally thick layers of insulation. However, the small ratio of payload chamber volume to container volume results in excessively complicated and expensive storage, handling and transport of the containers.

[0004] Another solution is to use shipping containers with internal phase change material panels surrounded by superior thermal insulation panels (i.e., vacuum insulation panels). A number of such shipping containers have been developed over the years including those disclosed and described in US Patents 7,500,593, 7,422,143, 7,257,963, 7,908,870, 7,950,246, 9,751,682, 8,424,335 and 10,766,685 the disclosures of which are hereby incorporated by reference.

[0005] One of the drawbacks associated with passive thermal controlled shipping containers that rely upon phase change material panels (PCM panels) to control the temperature of the payload chamber is the logistic complications and high labor costs associated with the thermal lifecycle of the PCM panels. Each PCM panel must be (i) constantly tracked and its thermal conditioned status monitored during thermal conditioning of the panel within a refrigeration/freezer unit, (ii) identified as a fully thermally conditioned panel and transported from the refrigeration/freezer unit to an assembly site for insertion into the container, (iii) removed from the container when thermally spent, and (iv) returned to a refrigeration/freezer unit for thermal conditioning. [0006] Hence, a substantial need exists for improving and simplifying the thermal lifecycle of PCM panels so as to simplify logistics and reduce labor costs associated with the thermal lifecycle of the PCM panels.

SUMMARY OF THE INVENTION

[0007] A. first aspect of the invention is a passive thermally controlled chill-in-place shipping container.

[0008] A second aspect of the invention is a chill-in-place system that includes a passive thermally controlled chill-in-place shipping container in accordance with the first aspect of tire invention and a powered forced-air chilling unit.

[0009] A. third aspect of the invention is a method of in-place thermal conditioning of the phase change material within a passive thermally controlled chill-in-place shipping container in accordance with the second aspect of the invention.

[0010] A fourth aspect of the invention is a method of loading a thermally conditioned, passive thermally controlled chill-in-place shipping container in accordance with tire first aspect of the invention.

[0011] A fifth aspect of the invention is a method of method of replacing the phase change material tanks on a passive thermally controlled shipping container in accordance with the first aspect of the invention.

[0012] A sixth aspect of the invention is a method of holistically evaluating the thermal integrity of a passive thermally controlled shipping container in accordance with the first aspect of the invention equipped with a plurality of temperature sensors.

[0013] A first embodiment of the first aspect of the invention includes (i) a container having walls defining an enclosed chamber wherein at least one of the walls comprises an access door defining an access opening into the chamber, (ii) thermal insulation lining the chamber to define a thermally insulated chamber, (iii) at least one phase change material tank lining the thermally insulated chamber to define a thermal controlled chamber, and (iv) a swing gate across the access opening and carrying at least one phase change material tank, the swing gate pivotable at least approximately 120° about at least one vertical axis as between a loading position providing unrestricted access to the thermal controlled chamber through the accesses opening, and a thermal conditioning position wherein the swing gate extends into the thermal controlled chamber. [0014] A second embodiment of the first aspect of the invention includes (i) a pallet, (ii) an outer frame secured to and positioned atop the pallet, (iii) walls releasably secured to the outer frame and defining an enclosed chamber wherein at least one of the walls comprises an access door defining an access opening into the chamber, (iii) an inner frame secured to and positioned atop the pallet within the chamber, (iv) a core layer of thermal insulation releasably secured to the inner or outer frame and defining a thermally insulated chamber with an entry' opening aligned with the access opening, and (v) phase change material tanks secured to the inner frame and positioned within the thermally insulated chamber so as to define a thermal controlled chamber.

[0015] A third embodiment of the first aspect of the invention includes (i) a base plate having thermally conductive structural elements, (ii) a receptacle having sidewalls and a top wall, the receptacle including thermally conductive components and thermally insulating components and defining a thermally insulated chamber, the receptacle secured atop the base plate at points of attachment, and (iii) a thermal isol ating standoff positioned between the base plate and the receptacle at the points of attachment, thereby thermally isolating the thermally conductive components of the base plate from the thermally conductive components of the receptacle.

[0016] A fourth embodiment of the first aspect of the invention includes (i) a container having walls defining an enclosed chamber wherein at least one of the walls comprises an access door having an interior surface and defining an access opening into the chamber, (ii) thermal insulation lining the chamber to define a thermally insulated chamber, (iii) at least one phase change material tank lining the thermally insulated chamber to define a thermal controlled chamber, (iv) at least one quick detach phase change material door panel, (v) a mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in athermal conditioning position inside the thermally controlled payload chamber with the access door open, and (vi) a mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in athermal attenuating positioning on the interior surface of the access door.

[0017] A particular embodiment of the second aspect of the in vention includes (i) a passive thermally controlled shipping container in accordance with the first aspect of the invention, and (ii) a powered forced-air chilling unit configured and arranged to sealingly dock with the passive thermally controlled shipping container over the access opening when the access door is pivoted into the open position, wherein the chilling unit is operable for cycling air from within the thermal controlled chamber through the chilling unit to cool the air to a temperature at or below the phase change temperature of the phase change material and then back into the thermal controlled chamber.

[0018] A first embodiment of the third aspect of the invention includes the steps of (i) docking the forced-air chilling unit to the passive thermally controlled shipping container with the access doors of the container in the open position, (ii) actuating the forced-air chilling unit to (a) cycle air from within the thermal controlled chamber of the passi ve thermally controlled shipping container through the chilling unit and back into the thermal controlled chamber, and (b) cool the air cycled through the chilling unit, and (iii) continuing actuation of the docked chi lling unit until the phase change m aterial in the phase ch ange material tanks freezes.

[0019] A. second embodiment of the third aspect of the invention includes the steps of (i) obtaining a passi ve thermally controlled shipping container chill-in-place system, comprising (A) a shipping container, including (1) walls defining an enclosed chamber wherein at least one of the walls comprises an access door defining an access opening into the chamber, (2) a layer of therm al insulation lining th e walls to form an insulated ch am ber, (3) at least one phase change material tank containing a phase change material having a freeze point temperature of T_Freeze within the insulated chamber to form a passive thermal controlled ch am ber, and (4) at least one temperature sensor for sensing th e temperature of the phase change material within the at least one phase change material tank, (B) a forced-air chilling unit operable for generating a flow of chilled air at a temperature (T_Condition) below T_Freeze when actuated, and (C) a control unit in communication with both the at least one temperature sensor for periodically receiving temperatures sensed by the temperature sensor indi cative of the temperature of the phase ch ange material within the at least one phase change material tank, and the forced-air chilling unit for controlling actuation of the forced- air chilling unit, (ii) docking the forced-air chilling unit to the passive thermally controlled shipping container, (iii) actuating the docked forced-air chilling unit to (A) cycle air from within the thermal controlled chamber of the passive thermally controlled shipping container through the chilling imit and back into the thermal controlled chamber, and (B) cool the air cycled through the chilling unit to T_Condition, (iv) periodically communicating the temperature sensed by the at least one temperature sensor to the control unit while the forced-air chilling unit is actuated, and (v) automatically deactivating the chilling unit when a received temperature is at or below a previously determined threshold temperature (T_Threshold) that is between T_Condition and T_Freeze.

[0020] A particular embodiment of the fourth aspect of the invention includes the steps of (i) obtaining a passive thermally controlled shipping container in accordance with the first embodiment of the first aspect of the invention, (ii) with the phase change material tanks in the passive thermally controlled shipping container thermally conditioned, pivoting the access doors from the open position to the closed position and securing the access doors in the closed position to form a portable thermally conditioned unladen shipping container, (iii) transporting the portable thermally conditioned unladen shipping container to a loading site,

(iv) pivoting the access doors from the closed position to the open position, (v) loading a payload into the passive thermally controlled chamber through the access opening in the thermally conditioned unladen stripping container, and (vi) pivoting the access doors from the open position back into the closed position and securing the access doors in the closed position to form a transportable thermally conditioned loaded shipping container.

[0021] Another particular embodiment of the fourth aspect of the invention includes the steps of (i) obtaining a passive thermally controlled shipping container in accordance with the fourth embodiment of the first aspect of the in vention, (ii) with the at least one phase change material tank in the passive thermally controlled shipping container thermally conditioned, the at least one quick detach phase change material door panel thermally conditioned and in the thermal conditioning position within the passive thermally controlled shipping container, and the access door in the open position, repositioning the thermally conditioned at least one quick detach phase change material door panel from the thermal conditioning position inside the thermally controlled payload chamber to the secured thermal attenuating position on the interior surface of the access door, (iii) pi voting the access door from the open position to the closed position and securing the access door in the closed position to form a portable thermally conditioned unladen shipping container, (iv) transporting the portable thermally conditioned unladen shipping container to a loading site,

(v) pivoting the access door from the closed position to the open position at the loading site,

(vi) loading a payload into the passive thermally controlled chamber through the access opening in the thermally conditioned unladen shipping container, and (vii) pivoting the access door from the open position back into the closed position and securing the access door in the closed position to form a transportable thermally conditioned loaded shipping container. [0022] A first embodiment of the fifth aspect of the invention includes the steps of (i) obtaining a passive thermally controlled shipping container in accordance with the first embodiment of the first aspect of the invention, (ii) nondestructively detaching a wall and associated thermal insulation from the container from external the container to expose the phase change material tanks thereunder, (iii) nondestructively detaching at least one of the exposed phase change material tanks from external the container to create an empty space, (iv) attaching a replacement phase change material tank to the container in the empty space from external the container, and (v) reattaching the wall and associated thermal insulation to the container from external the container.

[0023] A second embodiment of the fifth aspect of the in vention includes the steps of (i) obtaining a passive thermally controlled shipping container in accordance with the second embodiment of the first aspect of the invention, (ii) nondestructively detaching a wall from the outer frame from external the container to expose the core layer of thermal insulation thereunder, (iii) nondestructively de taching the exposed core layer of thermal insul ation from the inner or outer frame from external the container to expose the phase change material tanks thereunder, (iv) nondestructively detaching at least one of the exposed phase change material tanks from the inner or outer frame from external the container to create an empty space, (v) attaching a replacement phase change material tanks to the inner frame in the empty space from external the container, (vi) reattaching the core layer of thermal insulation to the inner or outer frame from external the container, and (vii) reattaching the wall to the outer frame from external the container.

[0024] A particular embodiment of the sixth aspect of the invention includes the steps of (i) obtaining a passive thermally controlled shipping container in accordance with the first aspect of the invention equipped with a plurality of temperature sensors, with each temperature sensor operable, configured and arranged in association with a phase change material tank onboard the passive thermally controlled shipping container for sensing the temperature of the phase change material in the associated phase change material tank as between a temperature (T_Liquid) indicative of liquid phase change material in the associated phase change material tank and a temperature (T_Solid) indicative of frozen phase change material in the associated phase change material tank, (ii) thermally conditioning the passive thermally controlled shipping container through a thermal conditioning cycle by (A) docking a forced-air chilling unit to the passive thermally controlled shipping container with the phase change material in the onboard phase change material tanks in liquid phase at ambient temperature (e.g., between 15° and 30° C) and access doors in the open position, (B) actuating the docked forced-air chilling unit to cycle air into the thermal controlled chamber having a temperature (T_Condition) below T_Solid at start time (to), and (C) continuing actuation of the docked chilling unit for a time period (t_Condition) measured from to until each of the plurality of temperature sensors senses a temperature change ΔT of the phase change material from T_Liquid to T_Solid, (iii) recording the value of t_Condition, (iv) comparing t_Condition for a current thermal conditioning cycle with t_Condition for at least one previous thermal conditioning cycle for the same specific passive thermally controlled shipping container to establish a Δt between these two values, and (iv) pulling the specific passive thermally controlled shipping container from service when Δt exceeds a threshold value indicative of athermal integrity breach in the specific passive thermally controlled shipping container.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a perspective view of one embodiment of a passive thermally controlled shipping container in accordance with the invention with both halves of the vertically split access door pivoted into the open position and both halves of the vertically split swing gate pivoted into the thermal conditioning position.

[0026] Figure 2 is a front view of the passive thermally controlled shipping container depicted in Figure 1 , with both halves of the vertically split access door pivoted into the open position and both halves of the vertically split swing gate pivoted into the shipping position.

[0027] Figures 3A-D are schematic top views of a passive thermally controlled shipping container as depicted in Figure 1, depicting the various positions into which the swing gate and access door are pivoted through a trip cycle (i.e., thermal conditioning, loading, transport, unloading and return).

[0028] Figure 3 A depicts the passive thermal controlled shipping container with the access doors closed and the swing gates in the shipping position. These are the positions upon transport of an empty thermally conditioned container from a thermal conditioning site to a loading site, transport of a loaded thermally conditioned container from a loading site to a payload destination, and transport of an unloaded thermally-spent container from a payload destination back to the thermal conditioning site.

[0029] Figure 3B depicts the returned thermally-spent shipping container with the access doors open and the swing gates still in the shipping position. An alternate fully open position of the access doors is depicted by dashed lines. [0030] Figure 3C depicts the retured thermally-spent shipping container ready for thermal conditioning with the access doors fully open and the swing gates in the thermal conditioning position.

[0031] Figure 3D depicts the passive thermally conditioned shipping container ready for loading or unloading of a payload, with the access doors fully open and the swing gates in the loading/unloading position.

[0032] Figures 4A-G are construction stage sequence drawings of the passive thermally controlled shipping container depicted in Figure 1.

[0033] Figure 4A is a front perspective view of the platform/pallet component of the thermally controlled shipping container.

[0034] Figure 4B is a front perspective view of a stage one assembly, with the interior/inner frame mounted to the platform/pallet.

[0035] Figure 4C is a front perspective view of a stage two assembly with phase change material tanks mounted to the interior/inner frame over the wall openings.

[0036] Figure 4D is a front perspective view of a stage three assembly with the swing gate halves mounted to the interior/inner frame, and the exterior/outer frame mounted to the platform/pallet.

[0037] Figure 4E is a front perspective view of a stage four assembly with the access door halves mounted to the exterior/outer frame.

[0038] Figure 4F is a rear perspective view of a stage five assembly, with the interior/inner/core thermal insulation cartridges mounted to the interior/inner frame.

[0039] Figure 4G is a front perspective view of a stage six assembly, with the exterior/outer/shell thermal insulation cartridges and protective exoskeleton layers mounted to the exterior/outer frame, with one of the exteri or/outer/shell thermal insulation cartridges removed and two of the protective exoskeleton layers removed to facilitate viewing of the spatial relationship of the components.

[0040] Figure 5 A is a front view of one phase change material tank depicted in Figure

4C.

[0041] Figure 5B is a top view of one phase change material tank depicted in Figure

5A. [0042] Figure 6 A is a perspective view of the outward facing major surface of one interior/inner/core thermal insulation cartridge depicted in Figure 4F.

[0043] Figure 6B is a perspective view of the inward facing major surface of the interior/inner/core thermal insulation cartridge depicted in Figure 6A.

[0044] Figure 7 A is a perspective view of the outward facing major surface of one exterior/outer/shell thermal insulation cartridge depicted in Figure 4G.

[0045] Figure 7B is a perspective view of the inward facing major surface of the exterior/outer/shell thermal insulation cartridge depicted in Figure 7A.

[0046] Figure 8 is a perspective view of the container depicted in Figure 1 with phase change material door panels, one shown in the thermal conditioning position and one shown in the thermal attenuating position, substituted for the swing gates.

[0047] Figure 9 is an enlarged perspective view of an upper portion of the access door on the container depicted in Figure 8 showing a phase change material door panel in the process of being mounted to the access door into the thermal attenuating position.

[0048] Figure 10 is a perspective view of Figure 9 after the phase change material door panel lias been mounted to the access door in the thermal attenuating position.

[0049] Figure 11 is a greatly enlarged side view of the upper portion of the access door depicted in Figure 8 with mounted phase change material door panel.

[0050] Figure 12 is a greatly enlarged side view of the lower end of the phase change material door panel in the thermal conditioning position inside the payload chamber depicted in Figure 8.

[0051] Figure 13 is a perspective view of the passive thermally controlled shipping container depicted in Figure 1 docked with a forced air chilling unit.

[0052] Figure 14 is a cross-sectional schematic view of the docked passive thermally controlled shipping container and forced air chilling unit of Figure 13 taken along line 14-14, with a depiction of thermal conditioning air flow through the thermally controlled chamber.

[0053] Figure 15 is a perspective view of one embodiment of a corner thermal insulation cartridge. [0054] Figure 16 is a program flowchart for one embodiment of a control program for automatic cold thermal conditioning and cold thermal maintenance of the phase change material tanks in the passive thermally controlled shipping container depicted in Figure 8.

[0055] Figure 17 (broken into two sheets as Figs 17A and 17B due to size) is a program flowchart for one embodiment of a control program for holistic evaluation of thermal integrity of a passive thermally controlled chill-in place shipping container.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Definitions

[0056] As utilized herein, including the claims, the phrase “ground contact travel appliance” means a device which con tacts a support surface and facil itates travel of an item supported by the device across the support surface. Ground contact travel appliances include specifically but not exclusively, skids, wheels, casters, low friction glides and sliders, etc.

[0057] As utilized herein, including the claims, the term “thin ”, when used to describe a phase change material tank, means a thickness of less than 10 cm, wherein the thickness dimension is the linear dimension of a phase change material tank affixed in a passive thermally controlled shipping container which extends from the thermal controlled chamber to the exterior of the passive thermally controlled shipping container.

[0058] As utilized herein, including the claims, the phrase “thermal insulating” means a “k” value of less than 0.06 W/mK and a layer is a layer of thermal insulation when tiie layer is constructed of a material that is thermal insulating.

[0059] As utilized herein, including the claims, the phrase “thermally isolating standoff” means a structural component configured and arranged to hold something at a distance from a surface and having a “k” value of less than 1 W/mK.

[0060] As utilized herein, including the claims, the phrase “thermally conductive” means a “k” value of greater than 10 W/mK.

[0061] As utilized herein, including the claims, the phrase “thermally isolating” means spatially separating one thermally conductive component or surface from another thermally conductive component or surface to create a thermal break between the components and/or surfaces and thereby prevent a thermal bridge.

Construction

Base Shipping Container 10

[0062] A passive thermally controlled chill-in-place shipping container 10 having a payload chamber 19¹ accessible through an access door 240 and enclosed by an inner layer of phase change material tanks 110, also referenced as latent heat storage elements, and at least one layer of thermal insulation 120 and/or 220.

[0063] Referring to Figure 1, the shipping container 10 is preferably cuboidal with a cuboidal payload chamber 19¹. The payload chamber 19¹ preferably has a floor 12b sized and dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container 10.

Phase Change Thermal Control Tanks 140

[0064] Referring to Figures 4C, and 5A-B, the phase change material tanks 110 are preferably thin, elongated panels, filled with a phase change material having the desired phase change temperature, designed to extend from comer-post to corner-post of an inner frame 100 or an outer frame 200. Each phase change material tank 110 has a fill port 111 and an air vent port 112 which are sealed after the panel 110 has been filled with phase change material.

[0065] The phase change material tanks 110 are preferably vertically stacked across the sidewall openings 109s defined by the inner frame 100 and horizontally laid side-by-side across tire top opening 109t and bottom opening 109b defined by the inner frame 100. Gaskets 116 can be placed between adjacent phase change material tanks 110 to prevent the phase change material tanks 110 from rubbing against one another, and to control thermal convection from the walls 12 of the shipping container 10 past the phalanx of phase change material tanks 110 and directly into the payload chamber 19¹, creating “warm” zones within the payload chamber 19¹.

[0066] The phase change material tanks 110 are intended to be installed and thereafter thermally conditioned without removal from the thermally insulated chamber 19² (i.e., chilled-in-place). Hence, the inner layer of phase change material tanks 110 can be robustly secured to the inner frame 100.

[0067] In a preferred embodiment, the phase change material tanks 110 are constructed from metal or plastic and bolted to the comer-posts of an inner frame 100 from exterior the shipping container 10 using mounting brackets 115 extending from each end of each phase change material tanks 110, thereby providing secure attachment to the inner frame 100 but still accommodating individual detachment of each phase change material tank 110 from exterior the shipping container 10 for any necessary' repair or replacement.

[0068] Referring to Figure 4C and 13, temperature sensors 600 may be configured and arranged on one or more of the phase ch ange material tanks 110 for sensing and transmitting the temperature of the phase change material in the tank 110 for use in automatically controlling thermal conditioning of the phase change material and holistically evaluating the thermal integrity' of the shipping container 10. The temperature sensors 600 should be thermally insulated and shielded from any thermal influence by the thermally conditioning air emitted and circulated through the thermally controlled chamber 19³ by the chilling unit 500 as the typically significant temperature difference between the air emitted by the chilling unit 500 (Tcondition) and the actual temperature of the phase change material (T_PCM) will result in incorrect temperature readings. Preferably, a temperature sensor 600 is association with a phase change material tank lining each of the top 12t, and back and side walls 12s, and most preferably all walls 12.

Swing Gate 140

[0069] Referring to Figures 1, 2 and 3A-D, a swing gate 140 can extend across an entry' opening 108 into the payload chamber 19¹. The swing gate 140 can be a vertically split gate with each gate half 140¹ and 140² pivotable about respective vertical axis as disclosed below. Each gate half 140¹ and 140² is preferably supported by one or more ground travel appliances 145, such as a caster. Each swing gate half 140¹ and 140² should be pivotable at least approximately 120° and preferably at least approximately 180° about the vertical axis as between a loading position (depicted in Figure 3D) providing unrestricted access to the thermal controlled chamber 19³ through the accesses opening 208 and the entry opening 108, and a thermal conditioning position (depicted in Figure 3C) wherein the swing gate halves 140¹ and 140² extend into the thermal controlled chamber 19³.

[0070] The swing gate halves 140¹ and 140² each carry a set of phase change tanks 110 for positioning the sets of phase change tanks 110 as between (i) a shipping position (Figure 3 A) wherein the set of phase change tanks 110 are positioned across the accesses opening 208 so as to attenuate heat transfer through the access door 240, (ii) a thermal conditioning position (Figure 3C) wherein the set of phase change tanks 110 are positioned within the thermal controlled chamber 19³ for in-place thermal conditioning, and (iii) a loading/unloading position (Figure 3D) providing unrestricted access to the thermal controlled chamber 19³ through tire accesses opening 208.

[0071] Referring to Figures 2, 3A and 3C, pivoting of the swing gate halves 140¹ and 140² as between the shipping position (Figure 3A) and the thermal conditioning position (Figure 3C) occurs about a set of narrow vertical pivot axis 142¹p and 142²p. The first and second narrow vertical pivot axis 142¹p and 142²p are offset from the respective sidewall 12s of the shipping container 10 in order to provide an air flow gap between the phase change tanks 110 on the sidewalls 12s and the phase change tanks 110 on tire swing gate halves 140¹ an d 140² to facilitate th ermal condition ing heat exchange with both groups of phase change tanks 110.

[0072] Referring to Figures 2, 3A and 3D, pivoting of the swing gate halves 140¹ and 140² as between the shipping position (Figure 3A) and the loading/unloading position (Figure 3D) occurs about first and second wide vertical pivot axis 141¹p and 141²p. The wide vertical pivot axis 141³p and 141²p are proximate a respective sidewall 12s of the stripping container 10 in order to provide access to the full width of the payload chamber 19¹ during loading and unloading.

Quick Detach Phase Change Material Door Cartridge 155

[0073] Referring to Figures 8-12, in addition to or as an alternative to the swing gate 140, the access door 140 can be lined with one or more quick detach phase change material door panels 150. Each quick detach phase change material door panel 150 has one or more panels filled with phase change material. Each quick detach phase change material door panel 150 is configured and arranged for repeated releasable secure repositioning of the panel 150 as between (i) a thermal conditioning positioning inside the thermally controlled payload chamber 19³ with the access door 140 open, for thermal conditioning of the phase change material in the phase change material door panel 150 alongside the phase change material tanks 110 lining the thermally controlled payload chamber 19³ with the forced air chilling unit 500, and (ii) a thermal attenuating position on the interior first major surface 151 of the access door 240 after completion of thermal conditioning and prior to loading of a payload into the thermally controlled payload chamber 19³ for attenuating heat transfer into the thermally controlled payload chamber 19³ through the access door 140.

[0074] When in the thermal conditioning position inside the thermally controlled payload chamber 19³, the phase change material door panel(s) 150 is preferably restrained in a position offset from the phase change material tanks 110 lining the thermally controlled payload chamber 19³ so to prevent the phase change material door panel(s) 150 from covering the tanks 110, thereby allow chilling air blown into the thermally controlled payload chamber 19³ by the forced air chilling unit 500 to directly impinge upon and cool both sides of the phase change material door panel(s) 150 and the full exposed surface area of the tanks 110.

[0075] Mechanisms 160 and 170 are provided for (i) releasably and stably supporting tiie quick detach phase change material door panel(s) 150 in a thermal conditioning position inside the thermally controlled payload chamber 19³ with the access door 140 open, and (ii) releasably and stably supporting the quick detach phase change material door panel(s) 150 in athermal attenuating position on the interior surface 241 of the access door 140, respectively.

[0076] Handles (unnumbered) may be provided proximate each side of each phase change material door panel(s) 150, centered between the ends of the panel(s) 150, to facilitate handling of the panel(s) 150 as they are moved between the thermal conditioning position and the thermal attenuating position.

[0077] The thermal conditioning support mechanism 160 preferably supports all quick detach phase change material door panels 150 in a vertically standing orientation inside the thermally controlled payload chamber 19³ to eliminate the need to rotate the panel(s) 150 about a horizontal axis when the panel(s) 150 are transitioned from the thermal conditioning position inside the thermally controlled payload chamber 19³ to the thermal attenuating positioning on the interior surface 241 of the access door 240. [0078] Tire thermal conditioning support mechanism 160 also preferably supports all quick detach phase change material door panels 150 with an air flow gap 169 between the panel(s) 150 and the walls 12 of the container 10 so as to allow chilling air to flow between the panel(s) 150 and the walls 12 during thermal conditioning.

[0079] Referring to Figures 8 and 12, one suitable thermal conditioning support m echani sm 160 includes a pair of vertically x aligned longitudinally z extending support channels 161 in the container 10, and (ii) a pair of footings 162 on each panel 150, with each footing 162 configured and arranged for supportive engagement within a corresponding channel 161. The channels 161 and footings 162 are preferably configured and arranged for longitudinal z sl idable insertion and removal of the footings 162 into and out from the channels 161 from the access opening 208 into the container 10 when the access door 240 is open.

[0080] Referring to Figures 8-11, one suitable thermal attenuating support mechanism 170 includes a pair of vertically x aligned support brackets 171 on the interior surface 241 of the access door 240, and (ii) a pair of receivers 172 on each quick detach phase change material door panel 150, with each receiver 172 configured and arranged for engaging with a corresponding support bracket 171 so as to secure the panel 150 to the bracket 171 and thereby secure the panel 150 to the interior surface 241 of the access door 240.

[0081] Referring to Figures 9 and 10, the thermal attenuating support mechanism 170 preferably includes a locking mechanism 175, such as a locking hook, barrel bolt, etc. for (i) selective reception and release of a bracket 171 by a corresponding receiver 172 for mounting and dismounting of the phase change m ateri al door panel 150 in the thermal attenuating positioning on the interior surface 241 of the access door 240 when in an unlocked state, and (ii) securing the bracket 171 to the corresponding receiver 172 to stably fasten the phase change material door panel 150 in athermal attenuating positioning on the interior surface 241 of the access door 240 when in a locked state.

Thermally Insulating Walls 12

[0082] The phase change material tanks 110 are enclosed within thermally insulating walls 12 that include a top wall 12t, a bottom wall 12b and sidewalls 12s to define an enclosed thermally insulated and thermally controlled payload chamber 19¹. Each wall 12t, 12b and 12s can comprise (i) a single wall panel or a plurality of edge-to-edge arranged wall panels, and (ii) one or more separately attachable and detachable layers. [0083] Referring to Figure 4A, the bottom wall 12b can be comprised of a platform 20 having forklift openings 28 for accommodated lifting and transport of the shipping container 10 via a pallet jack or forklift. A layer of thermal insulation (not shown) is preferably provided atop the platform 20, with the thermal insulation protectively sandwiched between an inner structural layer and an outer structural layer (not shown).

Access Door 240

[0084] Referring to Figures 1, 2 and 3A-D, one of the side walls 12s comprises an access door 240. The access door 240 can be a vertically split door with each door half 240¹ and 240² pi votable about a respective vertical axis 240¹p and 240²p between an open position and a closed position. When the shipping container 10 is cuboidal each door half 240¹ and 240² is preferably pivotable approximately 180° and most preferably approximately 270° against a corresponding sidewall wall 12s of the shipping container 10. Automatic door holders 246 can be employed to hold the door halves 240¹ and 240² in the fully open position to prevent the door halves 240¹ and 240² from prematurely pivoting towards the closed position during thermal conditioning, loading and unloading of the shipping container 10. Suitable door holders include the various widely available commercial grade magnetic and mechanical door holders.

[0085] Access door position sensors (not depicted) can be provided for detecting the position of the access door halves 240¹ and 240² as between the open position and the closed position and generating at least one audibly and/or visually perceptible signal selected from a first signal when a corresponding access door half 240¹ and 240² is in the open position and a second signal when the corresponding access door half 240¹ and 240² is in the closed position. Tire first signal is preferably generated only when the corresponding access door half 240¹ and 240² is arrested in the fully open position by a door holder 246.

[0086] Referring to Figures 4A-G, a preferred embodiment of the passi ve thermally controlled chill-in-place shipping container 10 has top 12t and sidewall 12s walls comprised of separately attachable and detachable inner 12i and outer 12o layers.

[0087] Each of the inner walls 12i may be releasably secured directly to one another to form the shipping container 10, but are preferably releasably secured to an inner frame 100.

[0088] Each inner wall 12i covers a wall opening 109 defined by the inner frame 100 (e.g. , a top inner wall 12it covering a top wall opening 109t through the inner frame 100 and sidewall inner walls 12is covering sidewall openings 109s through the inner frame 100). The inner frame 100 can be constructed from any material capable of providing the necessary structural integrity, with metal such as aluminum generally preferred.

[0089] In similar fashion, each of the outer walls 12o may be releasably secured directly to one another to form the shipping container 10, but are preferably releasably secured to an outer frame 200.

[0090] Each outer wall 12o covers a wall opening 209 defined by the outer frame 200 (e.g., a top outer wall 12ot covering a top opening 209t through the outer frame 200 and sidewall outer wall 12os covering sidewall openings 209s through the outer frame 200). The outer frame 200 can be constructed from any material capable of providing the necessary structural integrity, with metal such as aluminum generally preferred.

Thermal Insulation Layers 120 and/or 220

[0091] Referring to Figures 4F and 4G, at least one layer of thermal insulation 120 and/or 220 define a therm ally insulated chamber 19². The layer of th ermal insulation 120 and/or 220 can be a component of the walls 12i and/or 12o respectively, such as a layer sandwiched between an inner structural layer and an outer structural layer (unnumbered).

[0092] Referring to Figures 4G, 6A-B and 7A-B, in a preferred embodiment, dual separately attachable and detachable inner and outer layers of thermal insulation 120 and 220 define the thermally insulated chamber 19², with an inner protective layer provided on the inner layer of thermal insulati on 120 and an outer protective layer provi ded on the outer layer of thermal insulation 220.

[0093] The inner and outer protective layers and can be selected from any material having sufficient structural integrity including wood panels, wood composite panels, plastic panels and plastic composite panels. A particularly suited lightweight yet structurally robust material is a plastic composite panel comprising a thermoplastic honeycomb core fused between pl asti c face sheets commerci ally available from a number of suppl iers including Composites GmbH & Co KG of Rottenbach, Germany under the brand MONOPAN, and Hangzhou Holycore Composite Materials Co. Ltd of Hangzhou, China under the brand HOLYPAN.

[0094] Vacuum insulation panels 122 and 222 are the preferred thermal insulation material due to their superior thermal resistance (i.e., low thermal k values). Wall Thermal Insulation Cartridges 125 and 225

[0095] Vacuum insulation panels are notorious for premature loss of insulating value. The panels are prone to loss of vacuum, often as a result of a breach through the enclosing membrane caused by normal wear and tear, which results in a substantial loss in thermal resistance. Hence, vacuum insulation panels require periodic inspection and replacement of spent panels (i.e., panels no longer under sufficient vacuum).

[0096] Referring to Figures 4F, 4G, 6A-B and 7A-B, the inner and outer walls 12i and 12o are each preferably formed of multiple independently removable inner and outer thermal insulation cartridges 125 and 225 respectively. These thermal insulation cartridges 125 and 225 permit quick and easy access to and replacement of spent vacuum insulation panels 122 and 222 respectively.

[0097] Each inner thermal insulation cartridge 125 has a layer of therm al in sulation 120, typically a plurality of edge-to-edge arranged inner vacuum insulation panels 122, surrounded by an inner peripheral frame 126. Each inner thermal insulation cartridge 125 can include a structural protective layer over the interior facing major surface of the inner vacuum insulation panels 122 for providing structural rigidity to the inner thermal insulation cartridge 125 and protecting the fragile inner vacuum insulation panels 122 from damaging contact with the inner frame 100 outer frame 200 or the phase change material tanks 110 during initial assembly, detachment and reassembly. Each inner thermal insulation cartridge 125 can further include a structural protective layer over the exterior facing major surface of the inner vacuum insulation panel 122 for providing further structural rigidity to the inner thermal insulation cartridge 125 and protecting the fragile inner vacuum insulation panels 122 from damaging contact with an outer thermal insulation cartridge 225 during initial assembly, detachment and reassembly of the outer thermal insulation cartridges 225, but this further structural protective layer tends to impede visual inspection and replacement of spent inner vacuum insulation panels 122 and is therefore generally disfavored.

[0098] In similar fashion, each outer thermal insulation cartridge 225 has a layer of thermal insulation 220, typically a plurality' of edge-to-edge arranged vacuum insulation panels 222, surrounded by an outer peripheral frame 226. Each outer thermal insulation cartridge 225 can include a structural protective layer over the exterior facing major surface of the outer vacuum insulation panels 222 for providing structural rigidity to the outer thermal insulation cartridge 225 and protecting the fragile outer vacuum insulation panels 222 from damaging contact by objects striking the exterior of the shipping container 10. Each outer thermal insulation cartridge 225 can further include a structural protective layer over the interior facing major surface of the outer vacuum insulation panels 222 for providing further structural rigidity to the outer thermal insulation cartridge 225 and protecting the fragile inner vacuum insulation panels 122 from damaging contact with an inner thermal insulation cartridge 125 or the outer frame 200 during initial assembly, detachment and reassembly of the outer thermal insulation cartridges 225, but this further structural protective layer tends to impede visual inspection and replacement of spen t outer vacuum insulation panels 222 and is therefore generally disfavored.

[0099] The inner thermal insulation cartridges 125 are releasably secured to the inner frame 100 and the outer thermal insulation cartridges 225 are releasably secured to the outer frame 200. Once detached from the frame 100 or 200, the inner and outer vacuum insulation panels 122 and 222 respectively, can be inspected, and spent or otherwise damaged panels 122 and 222 replaced.

Offset Wall Insulation Cartridge Seams 128 and 228

[0100] Referring to Figure 4G, each abutment of inner thermal insulation cartridges 125 and each abutment of outer thermal insulation cartridges 225 form a seam 128 and 228, respectively. These inner and outer seams 128 and 228 act as thermal bridges across their respective inner and outer thermal insulation layer 120 and 220, respectively. It is desired to offset these inner and outer seams 128 and 228 so as to force heat moving across these thermal bridges from exterior the shipping container 10 through both thermal insulation layers 120 and 220 to travel a tortuous serpentine path as opposed to a straight l inear path as would be provided by aligned inner and outer seams 128 and 228 in both the inner and outer thermal insulation layers 120 and 220. This can be conveniently accomplished by providing differently sized inner and outer thermal insulation cartridges 125 and 225. For example, as exemplified in Figure 4G, size the inner thermal insulation cartridges 125 so that four inner thermal insulation cartridges 125 span the length of a side wall opening 109s defined by the inner frame 100 and size the outer thermal insulation cartridges 225 so that three outer thermal insul ation cartridges 225 span the length of the corresponding sidewall opening 209s defined by the outer frame 200. Exoskeleton 230

[0101] Referring to Figures 1 and 9, an aesthetic and/or protective exoskeleton 230 may be provided over the outermost surface of each of the top wall 12t and sidewalls 12s of tire shipping container 10, including each access door half 240¹ and 240², comprised of a single planar sheet of material over each wall, such as a solid sheet of thermoplastic or a plastic composite panel comprising a thermoplastic honeycomb core fused between plastic face sheets.

Corner Thermal Insulation Cartridge 325

[0102] Referring to Figure 15, a corner thermal insulation cartridge 325 comprised of orthogonally positioned beveled edge to beveled edge or edge-to-face abutting vacuum insulation panels 322 retained within an L-shaped supporting sleeve 323, may be positioning at the comers of the walls 12 to reduce heat flow past the inner and outer thermal insulation layers 120 and/or 220 at the comers of the shipping container 10.

Thermal Isolating Standoffs 400

[0103] Referring to Figure 4F, a thermally isolating standoff 400 comprised of a thermally insulating material is positioned between the platform 20 and the inner frame 100 at each point of attachment for thermally isolating the thermally conductive components of the platform from the thermally conductive components of the inner frame 100. The thermally isolating standoff 400 can be a single integrated unit or multiple individual blocks. The thermally isolating standoffs 400 can be constructed from any thermally insulating material possessing suitable structural integrity, such as natural wood, manufactured wood, wood composites, natural rubber, synthetic rubber, and plastic.

Force Air Chilling Unit 500

[0104] Referring to Figures 13 and 14, the phase change material tanks 110 in the shipping container 10 are chilled-in-place by a forced air chilling unit 500 that docks with the open access opening 208 of the shipping container 10. Tire forced air chilling unit 500 has a condenser (unnumbered) for supplying cold fluid to the interior of a heat exchanger 506. A blower 505 pulls “warm” air into the unit from the thermally controlled chamber 19³ of the container through a central ly located forw ard facing intake vent 501. The “warm” air is pulled through the heat exchanger 506 to cool the air. A baffle 503 directs the cooled air to forward facing peripheral outflow vents 502 that discharge the cooled air along the inward facing surfaces of the phase change material tanks 110 on the top 12t, bottom 12b, and left and right sidewal ls 12s of the shipping container 10 towards the rear sidewall 12s of the shipping container 10, where the rear sidewall 12s redirects the air back towards the center of the thermally controlled chamber 19³ where it is once again pulled into the forced air chilling unit 500 through the intake vent 501.

[0105] Suitable forced air chilling units are available from a number of sources in clud ing Climatec Ltd of Watford, Engl and, United Kingdom, an d Green Cooling Ltd of Preston, England, United Kingdom.

[0106] The forced air chilling unit 500 should be mounted on wheels 507 to facilitate movement and docking.

[0107] Actuation of the forced air chilling unit 500 can be controlled by an onboard or remote control unit 700 that also communicates with sensors 600 sensing the temperature of the phase change material in a shipping con tainer 10 undergoing thermal conditioning for automatically controlling the thermal conditioning cycle.

Method of Thermally Conditioning the Shipping Container 10

[0108] The shipping container 10 may be thermally conditioned by (i) docking the forced-air chilling unit 500 to the shipping container 10 with the swing gate halves 140¹ and 140² in the conditioning position and the access door hal ves 240¹ and 240² in the open position as depicted in Figure 3C, (ii) actuating the forced-air chilling unit 500 to (A) cycle air from within the thermally controlled chamber 19³ of the shipping container 10 through the forced air chilling unit 500 and back into the thermally controlled chamber 19³, and (B) cooling the air as it cycles through the forced air chilling unit 500 to a temperature below the freeze temperature of the phase change material in the phase change material tanks 110, and (iii) continuing actuation of the docked forced air chilling unit 500 until the phase change material in the phase change material tanks 110 freezes.

Auto Control of Thermal Conditioning

[0109] Referring to Figures 4C, 13 and 16, the shipping container 10 can be equipped with a system for controlling thermal conditioning of tiie phase change material retained within the phase change material tanks 110. The thermal conditioning system includes at least one and preferably a plurality of temperature sensors 600, and a controller 700. The temperature sensor(s) 600 are placed in thermal communication with the phase change material retained within a plurality of the phase change material tanks 110, preferably scattered throughout the payload chamber 19¹ and including at least one on each of the walls 12 of the shipping con tainer 10, to periodically measure the temperature of the phase change material and transmit the measured temperature to the controller 700.

[0110] To thermally condition the phase change material retained within the phase change material tanks 110, the controller 700 periodically receives the transmitted measured temperature from the temperature sensor(s) throughout a thermal conditioning period, circulates chilled air throughout the payload chamber 19¹ when the measured temperature value T_n of at least one or preferably a plurality of the phase change material tanks 110 is above a first threshold temperature value T_Frozen, and discontinues the circulation of chilled air throughout the payload chamber 19¹ when the measured temperature value T_n of each or at least most of the phase change material tanks 110 is below a first threshol d temperature value T_Frozen, wherein tire first threshold temperature value T_Frozen is selected so that a measured temperature value T_n falling below the first threshold temperature value T_Frozen is indicative of completion of phase change transition of the phase change material retained within the phase change material tanks 110 from a liquid to a solid.

[0111] The controller 700 can discontinue circulation of chilled air throughout the payl oad chamber 19¹ by shutting off the blower 505 an d/or the condenser (not numbered) of the forced air chilling unit 500. Alternatively, instead of shutting off the blower 505 and/or the condenser (not numbered) of the forced air chilling unit 500 when the measured temperature value T_n is below a first threshold temperature value T_Frozen, the controller 700 can (i) reduce the flow of chilled air by slowing down the blower 505, and/or (ii) restrict the flow of chilled air by partially closing the intake and/or outflow vents 501 and 502, respectively, on the forced air chilling unit 500. The discontinued and/or restricted flow opti ons facilitate maintenance of the phase change material retained within the phase change material tanks 110 in the thermally conditioned frozen state while the shipping container 10 awaits commencement of transport.

Auto Control of Thermal Maintenance

[0112] Referring to Figure 16, the shipping container 10 can further be equipped with a system for maintaining the phase change material retained within the phase change material tanks 110 in a thermally conditioned frozen state while awaiting commencement of transport. As with the thermal conditioning system, the thermal maintenance system includes at least one and preferably a plurality of temperature sensore (not shown), and a controller (not shown). The temperature sensor(s) are placed in thermal communication with the phase change material retained within a plurality of the phase change material tanks 110, preferably scattered throughout the payload chamber 19¹ and including at least one on each of the walls 12 of the shipping container 10, to periodically measure the temperature of the frozen phase change material and transmit the measured temperature to the con troller.

[0113] To maintain the phase change material retained within the phase change material tanks 110 in a fully thermally conditioned frozen state, the controller periodically receives the transmitted measured temperature from the temperature sensor(s) throughout a thermal hold period, and restarts the circulation of chilled air throughout the payload chamber 19¹ when the measured temperature value T_n is above a second threshold temperature value T_Melt, wherein the second threshold temperature value T_Melt is selected so that a measured temperature value T_n falling above the second threshold temperature value T_Melt is indicative of commencement of a phase change transition of the phase change material retained within the phase change material tanks 110 from a solid to a liquid.

[0114] The controller can restart circulation of chilled air throughout the payload chamber 19¹ by turning the forced air chilling unit 500 back on. Alternatively, when the circul ation of chilled air throughout the payload chamber 19¹ was restricted rather than discontinued, the blower 505 can be returned to full operation and/or the intake and/or outflow vents 501 and 502 can be returned to full open.

Method of Loading the Thermally Conditioned Shipping Container 10

[0115] When the shipping container 10 includes swing gates 140, the container 10 may be loaded after the phase change material in the phase change material tanks 110 have been thermally conditioned by (i) pivoting the swing gate hal ves 140¹ and 140² from the conditioning position as depicted in Figure 3C to the shipping position as depicted in Figure 3A and securing the sw'ing gate halves 140¹ and 140² in this shipping position, (ii) pivoting the access door halves 240¹ and 240² from the open position as depicted in Figure 3C to the closed position as depicted in Figure 3 A and securing the access door halves 240¹ and 240² in this closed position to form a portable thermally conditioned unladen shipping container 10, (iii) transporting the portable thermally conditioned unladen shipping container 10 to a loading site, typically a manufacturing facility where the thermally labile payload is manufactured, (iv) pivoting the access door halves 240¹ and 240² from the closed position as depicted in Figure 3 A to the open position as depicted in Figure 3D, (v) pivoting the swing gate halves 140¹ and 140² from the shipping position as depicted in Figure 3A to the loading position as depicted in Figure 3D, (vi) loading a payload (not shown) into the payload chamber 19¹ through the access opening 208 in the thermally conditioned unladen shipping container 10, (vii) pivoting the swing gate halves 140¹ and 140² from the loading position as depicted in Figure 3D back into the shipping position as depicted in Figure 3A and securing tiie swing gate halves 140¹ and 140² in this shipping position, and (viii) pivoting the access door halves 240¹ and 240² from the open position as depicted in Figure 3D back into the closed position as depicted in Figure 3A and securing the access door hal ves 240¹ and 240² in this closed position to form a transportable thermally conditioned loaded shipping container 10.

[0116] When the shipping container 10 includes one or more quick detach phase change material door panel 150 instead of swing gates 140, the con tainer 10 may be loaded, after the phase change material tanks 110 in the passive thermally controlled shipping container 10 have been thermally conditioned in-place and the phase change material door panel(s) 150 has been thermally conditioned while in the thermal conditioning position within the passive thermally controlled shipping container 10, by (i) repositioning the thermally conditioned phase change material door panel(s) 150 from the thermal conditioning position inside the thermally controlled payload chamber 19³ to the secured thermal attenuating position on the interior surface 241 of the access door 240 with the access door 240 open, (ii) pivoting the access door 240 from the open position to the closed position and securing the access door 240 in the closed position to fonn a portable thermally conditioned unladen shipping container 10, (iii) transporting the portable thermally conditioned unladen shipping container 10 to a loading site, (iv) pivoting the access door 240 from the closed position to the open position at the loading site, (v) loading a payload into the passive thermally controlled chamber 19³ through the access opening 208 in the thermally conditioned unladen shipping container 10, and (vi) pivoting the access door 240 from the open position back in to tiie closed position and securing the access door 240 in the closed position to form a transportable thermally conditioned loaded shipping container 10.

Method of Replacing Phase Change Material Tanks 110

[0117] In general terms, a damaged or otherwise exhausted phase change material tank 110 along the top wall 12t or one of the sidewall 12s can be replaced by (i) nondestructively detaching the top wall 12t or sidewall 12s covering the phase change material tank 110 to be replaced from external the shipping container 10, to expose the phase change material tank 110 thereunder, (ii) nondestructively detaching the exposed phase change material tank 110 to be replaced from external the shipping container 10 to create an empty space, (iii) attaching a fresh phase change material tank 110 to the shipping container 10 in the empty space from external the shipping container 10, and (iv) reattaching the detached wall 12.

[0118] Replacing a damaged or otherwise exhausted phase change material tank 110 located along the bottom wall 12b of the shipping contai ner 10 does not require detachment of the bottom wall 12b, but does require removal of the protective flooring covering the phase change material tanks 110, and will require de tachment of the phase change material tank 110 to be replaced and attachment of the fresh phase change material tank 110 from within the thermally controlled chamber 19³.

[0119] The phase change material tanks 110 on the swing gate halves 140¹ and 140² are fully exposed. Hence, replacing a damaged or otherwise exhausted phase change material tank 110 on one of the swing gate halves 140* and 140² merely requires pivoting of the swing gate half 140¹ or 140² into either the shipping position or the loading posi tion so that the phase change material tank 110 can be accessed from outside the shipping container 10.

[0120] The method can also be employed to retrofit a shipping container 10 with phase change material tanks 110 containing a phase change material having a different freeze/melt temperature by repeating the steps set forth above for all phase change material tanks 110 along all walls 12.

[0121] In more specific terms relative to a shipping container 10 constructed with inner and outer frames 100 and 200, bearing inner walls 12i and outer walls 12o respectively, a damaged or otherwise exhausted phase change material tank 110 along the top wall 12t or one of the sidewall 12s can be replaced by (i) nondestructively detaching an outer wall 12o from the outer frame 200 from external the shipping container 10 to expose the inner wall 12i, (ii) nondestructively detaching the exposed inner wall 12i from the inner frame 100 or the outer frame 200 from external the shipping container 10 to expose the phase change material tanks 110 thereunder, (iii) nondestructively detaching the exposed phase change material tank 110 to be replaced from the inner frame 100 from external the shipping container 10 to create an empty space, (iv) attaching a replacement phase change material tank 110 to the inner frame 100 in the empty space from external the shipping container 10, (v) reattaching the inner wall 12i to the inner frame 100 or the outer frame 200 from external the shipping container 10, and (vi) reattaching the outer wall 12o to the outer frame 200 from external the shipping container 10.

Method of Replacing a Vacuum Insulation Panel 122 and 222

[0122] Referring to Figures 4F and 4G, the vacuum insulation panels 122 and 222 in each of the inner thermal insulation layer 120 and outer thermal insulation layer 220, respectively, can be inspected by detaching the outer thermal insulation cartridges 225 from the outer frame 200.

[0123] When inspection reveals that an inner vacuum insulation panel 122 is excessively worn, damaged or spent, the inner vacuum insulation panel 122 can be quickly replaced from outside the shipping container 10 by (i) detaching any outer thermal insulation cartridges 225 overlapping the inner thermal insulation cartridge 125 with the spent inner vacuum insulation panel 122, (ii) detaching the inner thermal insulation cartridge 125 with the spent inner vacuum insulation panel 122 from the inner frame 100 or the outer frame 200, (iii) replacing the detached inner thermal insulation cartridge 125 with a fresh inner thermal insulation cartridge 125, (iv) attaching the fresh inner thermal insulation cartridge 125 to the inner frame 100 or the outer frame 200, and (v) reattaching the detached outer thermal insulation cartridges 225.

[0124] In similar fashion, when inspection reveals that an outer vacuum insulation panel 222 is excessively worn, damaged or spent, the outer vacuum insulation panel 222 can be quickly replaced from outside the shipping container 10 by (i) detaching the outer insulation cartridge 225 with the spent outer vacuum insulation panel 222 from the outer frame 200, (ii) replacing the detached outer thermal insulation cartridge 225 with a fresh outer thermal insulation cartridge 225, and (iii) attaching the fresh outer thermal insulation cartridge 225 to the outer frame 200.

Method of Holistic Evaluation of Thermal Integrity of Shipping Container 18

[0125] Referring to Figure 17, the holistic thermal integrity of a passive thermally controlled shipping container 10 can be performed when the shipping container 10 is equipped with a plurality of temperature sensors 600 for sensing the temperature of the phase change material T_PCM in an associated phase change material tank 110 onboard the shipping container 10 as between a temperature (T_Liquid) indicative of liquid phase change material in the associated phase change material tank 110 (e.g., 2° C or slightly more above the melt point temperature of the phase change material) and a temperature (T_Solid) indicative of frozen phase change material in the associated phase change material tank 110 (e.g., between 2° and 5° C below the freeze point temperature of the phase change material or alternatively at least 20° C below the freeze point temperature of the phase change material).

[0126] The holistic thermal integrity evaluation method comprising the steps set forth below wherein the numerical step designation does not indicate sequence of steps.

[0127] Step (1): Select a passive thermally controlled shipping container 10 of ID_n.

[0128] Step (2): Establishing thermal conditioning and threshold parameters for thermal conditioning of the selected passive thermal ly controlled shipping container 10 of ID_n including (A) examining and if necessary resetting the temperature T_Solid at which the phase change material in the passive thermally controlled shipping container 10 of ID_n is to be recogni zed as frozen, (B) examining and if necessary resetting the temperature T_Condition to which the chilling unit 500 is to chill the air to be emitted into and circulated around the thermally controlled chamber 19³, which temperature must be below T_Solid, (C) examining and if necessary resetting the lower threshold value of change in thermal conditioning time Δt_Low to be used in distinguishing between a thermally controlled shipping container 10 possessing satisfactory holistically thermal integrity and one possessing adequate but deteriorated holistically thermal integrity, (D) examining and if necessary resetting the higher threshold value of change in thermal conditi oning time Δt_High to be used in di stinguishing between a controlled shipping container 10 possessing adequate but deteriorated holistically thermal integrity and one possessing deficient holistic thermal integrity.

[0129] Step (3): Thermally conditioning the selected passive thermally controlled shipping container 10 of ID_n through a thermal conditioning cycle by (A) docking a forced- air chilling unit 500 to the passive thermally controlled shipping container 10 of ID_n with the phase change material in the onboard phase change material tanks 110 in a liquid phase at ambient temperature, (B) actuating the docked forced-air chilling unit 500 to cycle air into the thermal controlled chamber 19³ of the selected passi ve thermally controll ed shipping container 10 of ID_n to which the forced-air chilling unit 500 is docked at t_Condition at start time (to), (C) periodically sensing the temperature of the phase change material T_PCM in the passive thermally controlled shipping container 10 of ID_n to which the forced-air chilling unit 500 is docked and discontinuing actuation of the docked chilling unit 500 when T_PCM is equal to or less than T_Solid indicating fully frozen phase change material in the passive thermally controlled shipping container 10 of ID_n.

[0130] Step (4): Setting end time t_End of the thermal conditioning cycle. [0131] Step (5): Calculating the thermal conditioning time for the current thermal conditioning cycle t_Condition wherein t_Condition = t_End - t₀.

[0132] Step (6): Comparing t_Condition for the current thermal conditioning cycle witht_Condition for at least one previous, and preferably an average or median of three or more, thermal conditioning cycle for the same specific passive thermally controlled shipping container 10 of ID_n and preferably at the same or statistically comparable temperaturet_Condition to establish a Δt between these two values.

[0133] Step (7): Comparing Δt with Δt_Low and (i) when Δt is less than Δt_Low designating the passive thermally controlled shipping container 10 of ID_n to be a thermally controlled shipping container 10 possessing satisfactory holistically thermal integrity, continuing use of the thermally control led shipping container 10 of ID_n and discontinuing the evaluation, but (ii) when Δt is equal to or greater than Δt_Low designating the passive thermally controlled shipping container 10 of ID_n to be a thermally controlled shipping container 10 possessing adequate but deteriorated holistically thermal integrity and subjecting the passive thermally controlled shipping container 10 of ID_n to a further comparison of Δt with Δt_High. [0134] Step (8) After step (7), when Δt is equal to or more than Δt_Low comparing Δt with Δt_High and (i) when Δt is less than Δt_High designating the passive thermally controlled shipping container 10 of ID_n to be a thermally controlled shipping container 10 possessing adequate but deteriorated holistically thermal integrity, continuing use of the thermally controlled shipping container 10 of ID_n for the currently scheduled shipment, designating the passive thermally controlled shipping container 10 for refurbishment upon return from the currently scheduled shipment, and discontinuing the evaluation, but (ii) when Δt is equal to or greater than Δt_High designating the passive thermally controlled shipping container 10 of lD_n to be a thermally controlled shipping container 10 possessing deficient holistic thermal integrity, immediately pulling the thermally controlled shipping container 10 from any further use in shipping, designating the passive thermally controlled shipping container 10 for refurbishment, and discontinuing the evaluation.

[0135] As an alternative, steps (7) and (8) can be combined with use of a single Δt_Threshold value instead of both Δt_Low and Δt_High values, for designating betw een a thermally controlled shipping container 10 possessing satisfactory holistically thermal integrity (i.e., Δt less than Δt_Threshold) and a thermally controlled shipping container 10 possessing unsatisfactory holistically thermal integrity (i.e., Δt equal to or greater than Δt_Threshold). [0136] Generally, a Δt_Threshold value of between about 5% and 10% detects the vast majority of shipping containers 10 having some type of thermal integrity challenge with minimal false positives. When low and high threshold values are used Δt_Low and Δt_High, a value of about 5% for Δt_Low and 10% for Δt_High is generally effective. Of course, other values can be used depending upon such factors as the value of the payload, the risk of the container 10 encountering extreme environmental ambient temperatures in transit, the risk of container 10 encountering delays in transit, etc.

Claims

We claim:

1. A passive thermally controlled shipping container, comprising:

(a) a pallet,

(b) an outer frame secured to and positioned atop the pallet,

(c) walls releasably secured to the outer frame and defining an enclosed chamber wherein at least one of the walls comprises an access door defining an access opening into the chamber,

(d) an inner frame secured to and positioned atop the pallet within the chamber,

(e) a core layer of thermal insulation releasably secured to a support structure selected from the inner frame and the outer frame and defining a thermally insulated chamber with an entry' opening aligned with the access opening,

(f) phase change material tanks secured to the inner frame and positioned within the thermally insulated chamber so as to define athermal controlled chamber.

2. The passive thermally controlled shipping container of claim 1 wherein the container is cuboidal, having a top wall, a bottom wall, a back wall, a pair of side walls and a front wall wherein the access door comprises the front wall.

3. The passive thermally controlled shipping container of claim 1 wherein the outer frame is cuboidal, and the walls include a top wall, a bottom wall, a back wall, a pair of side walls and a front wall wherein the access door comprises the front wall.

4. The passive thermally controlled shipping container of claim 1 wherein the thermal controlled chamber is cuboidal.

5. The passive thermally controlled shipping container of claim 4 wherein the thermal controlled chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

6. The passive thermally controlled shipping container of claim 1 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between an open position and a closed position.

7. The passive thermally controlled shipping container of claim 6 further comprising a pair of door holders, each operable for automatically releasably arresting pivoting of one of the access door halves when the door half is pivoted fully into the outward position.

8. The passive thermally controlled shipping container of claim 1 wherein the phase change material tanks are metal tanks filled with phase change material.

9. The passive thermally controlled shipping container of claim 2 wherein the phase change material tanks are secured at each end to the inner frame and line at least the top wall, back wall, and pair of side walls.

10. The passive thermally controlled shipping container of claim 9 wherein phase change material tanks lining each of the pair of side walls are horizontally elongated and vertically stacked.

11. The passive thermally controlled shipping container of claim 9 further comprising gaskets between adjacent phase change material tanks.

12. The passive thermally controlled shipping container of claim 1 wherein the core layer of thermal insulation is vacuum insulation panels.

13. The passive thermally controlled shipping container of claim 12 wherein (i) at least one wall has first and second layers of vacuum insulation panels with each layer comprising a plurality of insulation cartridges, (ii) each insulation cartridge includes a plurality of vacuum insulation panels secured together in-edge-to-edge arrangement, (iii) the insulation cartridges in each layer having seam s between the insulation cartridges, and (iv) at least some of th e seams in the first layer offset relative to the seams in the second layer.

14. The passive thermally controlled shipping container of claim 13 further comprising a shell layer of vacuum insul ation panels secured to the outer frame, with (i) each of the core layer of vacuum insulation panels and the shell layer of vacuum insulation panels comprising a plurality of insulation cartridges, (ii) each insulation cartridge includes a plurality of vacuum insulation panels secured together in-edge-to-edge arrangement, (iii) the insulation cartridges in each layer having seams between the insulation cartridges, and (iv) at least some of the seams in the core layer offset relative to the seams in the shell layer.

15. The passive thermally controlled shipping container of claim 12 wherein (i) at least the top wall, back wall and pai r of side walls each have first and second l ayers of vacuum insulation panels with each layer comprising a pl urality of insulation cartridges, (ii) each insulation cartridge includes a plurality of vacuum insulation panels secured together in-edge- to-edge arrangement, (iii) the insulation cartridges in each layer having seams between the insulation cartridges, and (iv) at least some of the seams in the first layer offset relative to the seams in the second layer.

16. The passive thermally controlled shipping container of claim 15 wherein (i) each of the first layer insulation cartridges are mountable to and dismountable from the inner frame as a single integrated unit, and (ii) each of the second layer insulation cartridges are mountable to and dismountable from the outer frame as a single integrated unit.

17. The passive thermally controlled shipping container of claim 12 wherein the chamber lias corners and the lining of thermal insulation at one or more of the comers comprises vacuum insulation panels in beveled edge to beveled edge or edge-to-face abutting arrangement enclosed within a rigid L-shaped supporting sleeve.

18. The passive thermally controlled shipping container of claim 16 wherein the inner frame has comers and the thermal insulation releasably secured to the inner frame at one or more of the comers comprises vacuum insulation panels in beveled edge to beveled edge or edge-to-face abutting arrangement enclosed within a rigid L-shaped supporting sleeve.

19. The passive thermally controlled shipping container of claim 1 wherein select walls, thermal insulation and phase change material tanks are non-destructively accessible, removable and replaceable from exterior the thermal control chamber.

20. A passive thermally controlled shipping container, comprising:

(a) a base plate having thermally conductive structural elements,

(b) a receptacle having sidewalls and atop wall, the receptacle including thermally conductive components and thermally insulating components and defining a thermally insulated chamber, the receptacle secured atop the base plate at points of attachment, and

(c) a thermal isolating standoff positioned between the base plate and the recep tacl e at the points of attachment, thereby thermally isolating the thermally conductive components of the base plate from the thermally conductive components of the receptacle.

21. The passive thermally controlled shipping container of claim 20 wherein a thermally conductive metal frame on the base is secured to a thermally conductive metal frame on the receptacle at the points of attachment.

22. The passive thermally controlled shipping container of claim 20 wherein the base plate includes forklift accommodating openings for forklift transport of the container.

23. The passive thermally controlled shipping container of claim 20 wherein the thermal isolating standoff comprises a plurality of thermally isolating standoffs.

24. The passive thermally controlled shipping container of claim 20 wherein the thermally isolating standoffs are constructed from a material selected from natural wood, manufactured wood, wood composite, natural rubber, synthetic rubber, and plastic.

25. The passive thermally controlled shipping container of claim 20 wherein one of the sidewalls is an access door pivotable about a pivot axis for providing access to the thermally insulated chamber.

26. A passive thermally controlled shipping container, comprising:

(a) a container having walls defining an enclosed chamber wherein at least one of the walls comprises an access door having an interior surface and defining an access opening into the chamber,

(b) thermal insulation lining the chamber to define a thermally insulated chamber,

(c) at least one phase change material tank lining the thermally insulated chamber to define athermal controlled chamber,

(d) at least one quick detach phase change material door panel,

(e) a mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in athermal conditioning position inside the thermally controlled payload chamber with the access door open, and

(f) a mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in athermal attenuating positioning on the interior surface of the access door.

27. The passive thermally controlled shipping container of claim 26 wherein the at least one quick detach phase change material door panel has first and second major surfaces, and both major surfaces are spaced from the walls of the container when in the thermal conditioning position so as to provide an air flow gap between each major surface and the walls of the container.

28. The passive thermally controlled shipping container of claim 26 wherein the enclosed chamber has a vertical height, a lateral width and a longitudinal depth, and the mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in a thermal conditioning position inside the thermally controlled payload chamber comprises (i) a pair of vertically aligned longitudinally extending support channels in the container, and (ii) a pair of footings on the at least one quick detach phase change material door panel, each configured and arranged for supportive engagement within a corresponding channel.

29. The passive thermally controlled shipping container of claim 28 wherein the channels and footings are configured and arranged for longitudinal slidable insertion and removal of the footings into and out from the channels from the access opening when the access door is open.

30. The passive thermally controlled shipping container of claim 26 wherein the enclosed chamber has a vertical height, a lateral width and a longitudinal depth, and the mechanism for releasably and stably supporting the at least one quick detach phase change material door panel in a thermal attenuating positioning on the interior surface of the access door comprises

(i) a pair of vertically aligned support brackets on the interior surface of the access door, and

(ii) a pair of receivers on the at least one quick detach phase change material door panel, each receiver configured and arranged for engaging with a corresponding support bracket so as to secure the at least one quick detach phase change material door panel to the bracket.

31. The passive thermally controlled shipping container of claim 30 further comprising a locking mechanism for (i) selective reception and release of a bracket by a corresponding receiver for mounting and dismounting of the at least one quick de tach phase change material door panel in a thermal attenuating positioning on the interior surface of the access door when in an unlocked state, and (ii) securing the bracket to the corresponding receiver to stably fasten the at least one quick detach phase change material door panel in a thermal attenuating positioning on the interior surface of the access door when in a locked state.

32. A passive thermally controlled shipping container chill-in-place system, comprising:

(a) a passive thermally controlled shipping container in accordance with any of claims 1 through 31 wherein (i) the access door is pivotable about a vertical axis as between an open position and a closed position, and (ii) the phase change material tanks contain a phase change material having a phase change temperature, and

(b) a powered forced-air chilling unit configured and arranged to sealingly dock with the passive thermally controlled shipping container over the access opening when the access door is pivoted into the open position and the swing gate is pivoted into the conditioning position, the chilling unit operable for cycling air from within the thermal controlled chamber through the chilling unit to cool the air to a temperature at or below the phase change temperature of the phase change material and then back into the thermal controlled chamber.

33. The passive thermally controlled shipping container chill-in-place system of claim 32 wherein the chilling unit is baffled to direct the flow of cooled air exiting the chilling unit along the periphery of the thermal controlled chamber and pull return air back into the chilling unit from a central area of the access opening.

34. The passive thermally controlled shipping container chill-in-place system of claim 32 wherein the chilling unit is mounted on wheels.

35. The passive thermally controlled shipping container chill -in-place sys tem of claim 34 wherein the wheels are casters.

36. A method of thermally conditioning phase change material tanks in-place within a passive thermally controlled shipping container, comprising:

(a) obtaining a passive thermally controlled shipping container chill-in-place system in accordance with claim 32,

(b) docking the forced-air chilling unit to the passive thermally controlled shipping container with the access doors in the open position,

(c) actuating the forced-air chilling unit to (i) cycle air from within the thermal controlled chamber of the passive thermally control led shipping container through the chilling unit and back into the thermal controlled chamber, and (ii) cool the air cycled through the chilling unit, and

(d) continui ng actuation of the docked chi lling unit until the phase change material in the phase change material tanks freezes.

37. A method of loading a passive thermally controlled shipping container in accordance with any of claims 26-31 after the at least one phase change material tank in the passive thermally controlled shipping container has been thermally conditioned in-place and the at least one quick detach phase change material door panel has been thermally conditioned while in the thermal conditioning position within the passive thermally controlled shipping container, comprising the steps of:

(a) with the access door in the open position, repositioning the thermally conditioned at least one quick detach phase change material door panel from the thermal conditioning position inside the thermally controlled payload chamber to the secured thermal attenuating position on the interior surface of the access door,

(b) pivoting the access door from the open position to the closed position and securing the access door in the closed position to form a portable thermally conditioned unladen shipping con tainer,

(c) transporting the portable thermally conditioned unladen shipping container to a loading site,

(d) pivoting the access door from the closed position to the open position at the loading site,

(e) loading a payload into the passive thermally controlled chamber through the access opening in the thermally conditioned unladen shipping container, and (f) pivoting the access door from the open position back into the closed position and securing the access door in the closed position to form a transportable thermally conditioned loaded shipping container.

38. A method of replacing at least one phase change material tank on a passive thermally controlled shipping container in accordance with any of claims 13 and 15-19, comprising the steps of:

(a) nondestructively detaching a wall and associated thermal insulation from the container from external the container to expose the at least one phase change material tank thereunder,

(b) nondestructively detaching the exposed at least one phase change material tank from external the container to create an empty space,

(c) attaching a replacement phase change material tank to the container in the empty space from external the container, and

(d) reattaching the wall and associated thermal insulation to the container from external the container.

39. A method of replacing at least one phase change material tank on a passive thermally controlled shipping container in accordance with claim 14, comprising the steps of:

(a) nondestructively detaching a wall from the outer frame from external the container to expose the core layer of thermal insul ation thereunder,

(b) nondestructively detaching the exposed core layer of thermal insulation from the inner frame from external the container to expose the at least one phase change material tank thereunder,

(c) nondestructively detaching the exposed at least one phase change material tank from the inner frame from external the container to create an empty space,

(d) attaching a replacement phase change material tank to the inner frame in the empty space from external the container,

(e) reattaching the core layer of thermal insulation to the inner frame from external the container, and

(f) reattaching the wall to the outer frame from external the container.

40. A method of holistically evaluating the thermal integrity of a passive thermally controlled shipping container in accordance with any of claims 1 through 31 equipped with a plurality of temperature sensors, each operable, configured and arranged in association with a phase change material tank onboard the passive thermally controlled shipping container for sensing the temperature of the phase change material in the associated phase change material tank as between a temperature (T_Liquid) indicative of liquid phase change material in the associated phase change material tank and a temperature (T_Solid) indicative of frozen phase change material in the associated phase change material tank, the method comprising the steps of:

(a) thermally conditioning the passive thermally controlled shipping container through athermal conditioning cycle by:

(1) docking a forced-air chilling unit to the passive thermally controlled shipping container with the phase change material in the onboard phase change material tanks in liquid phase at ambient temperature and access doors in the open position,

(2) actuating the docked forced-air chilling unit to cycle air into the thermal controlled chamber having a temperature (T_Condition) below T_Solid at start time (to), and

(3) continuing actuation of the docked chill ing unit for a time period (t_Condition) measured from to until each of the plurality of temperature sensors senses a temperature change ΔT of the phase change material from T_Liquid to T_Solid,

(b) recording the value of t_Condition,

(c) comparing tcondition for a current thermal conditioning cycle with tcondition for at least one previous thermal conditioning cycle for the same specific passive thermally controlled shipping container to establish a Δt between these two values,

(d) pulling the specific passive thermally controlled shipping container from service when Δt exceeds a threshold value indicative of a thermal integrity breach in the specific passive thermally controlled shipping container.

41. The method of claim 40 wherein the passive thermally controlled shipping container is in accordance with claim 9 and at least one of the temperature sensors is operable, configured and arranged in association with a phase change material tank lining each of the top, back and side walls.

42. The method of claim 40 wherein T_Liquid is at least 2° C above the melt point temperature of the phase change material.

43. The method of claim 40 wherein T_Solid is between 2° and 5° C below the freeze point temperature of the phase change material.

44. The method of claim 40 wherein T_Solid is at least 20° C below the freeze point temperature of the phase change material.

45. The method of claim 40 wherein ambient temperature is between 15° and 30° C.

46. The method of claim 40 wherein:

(a) the temperature of the phase change material in the onboard phase change material tanks at to is measured and associated with each current and previous t_Condition, and

(b) t_Condition for a current thermal conditioning cycle is compared only to a previous t_Condition for the same specific passive thermally controlled shipping container when the associated temperature of the phase change material in the onboard phase change material tanks at to are within 10 °C.

47. The method of claim 40 wherein the threshold value for Δt is at least 5%.

48. The method of claim 40 wherein the threshold value for Δt is at least 10%.

49. The method of claim 40 wherein tcondition for a current thermal conditioning cycle is compared to an average t_Condition for at least three previous thermal conditioning cycles.

50. The method of claim 40 wherein tcondition for a current thermal conditioning cycle is compared to a median tcondition for at least three previous thermal conditioning cycles.

51. The m ethod of claim 40 wherein the specific passive thermally controlled shipping container is immediately pulled from service prior to any further use in shipping a thermally sensitive payload when Δt is at or above a higher value indicative of a container vulnerable to loss of thermal control of a payload enroute, and pulled from service after a currently scheduled shipment of a thermally sensitive payload when Δt is at or above a lower value but below tiie higher value indicative of a container capable of maintaining thermal control during the currently scheduled shipment.

52. A method of thermally conditioning phase change material tanks in-place within a passive thermally controlled shipping container, comprising:

(a) obtaining a passive thermally controlled shipping container chill-in-place system, comprising:

(1) a shipping container, including:

(A) walls defining an enclosed chamber wherein at least one of the walls comprises an access door defining an access opening into the chamber,

(B) a layer of thermal insulation lining the walls to form an insulated chamber. (C) at least one phase change material tank containing a phase change material having a freeze point temperature of T_Freeze within the insulated chamber to form a passive thermal controlled chamber, and

(D) at least one temperature sensor for sensing the temperature of the phase change material within tlie at least one phase change material tank,

(2) a forced-air chilling unit operable for generating a flow of chilled air at a temperature (T_Condition) below T_Freeze when actuated, and

(3) a control unit in communication with (i) the at least one temperature sensor for periodically receiving temperatures sensed by the temperature sensor indicative of the temperature of the phase change material within the at least one phase change material tank, and (ii) tlie forced-air chilling unit for controll ing actuati on of th e forced-air chilling unit,

(b) docking the forced-air chilling unit to the passive thermally controlled shipping container,

(c) actuating the docked forced-air chilling unit to (i) cycle air from within the thermal controlled chamber of the passive thermally controll ed shipping container through tlie chilling unit and back into the thermal controlled chamber, and (ii) cool the air cycled through the chilling unit to T_Condition,

(d) periodically communicating the temperature sensed by the at least one temperature sensor to the control unit while the forced-air chilling unit is actuated, and

(e) automatically deactivating the chilling unit when a received temperature is at or below a previously determined threshold temperature (T_Threshold) that is between T_Condition and T_Freeze.

53. The method of claim 52 wherein the shipping container is cuboidal, having a top wall, a bottom wall, a back wall, a pair of side walls and a front wall wherein the access door comprises the front wall.

54. The method of claim 52 wherein the thermal controlled chamber is cuboidal.

55. The method of claim 52 wherein the thermal controlled chamber has a floor dimensioned to alternatively retain four 1016x1219 mm ISO pallets or five 800x1200 mm Euro pallets without reconfiguration of the shipping container.

56. The method of claim 52 wherein the access door is a vertically split door with each half pivotable approximately 270° about a respective vertical axis between an open position and a closed position.

57. The m ethod of claim 53 wherein the at least one phase change material tank is secured at each end to the shipping container and lines at least one of the top wall, back wall, and pair of side walls.

58. The method of claim 53 wherein the shipping container includes a plurality of phase change material tanks each containing a phase change material having a freeze point temperature of T_Freeze lining at least the top wall, back wall, and pair of side walls.

59. The method of claim 58 wherein the shipping container further comprises gaskets between adjacent phase change material tanks.

60. The method of claim 52 wherein the layer of thermal insulation is a layer of vacuum insulation panels.

61. The method of claim 52 w'herein the shipping container includes a plurality of temperature sensors with at least one of th e plurali ty of temperature sensors operabl e, configured and arranged in association with a phase change material tank lining each of the top, back and side walls.

62. The m ethod of claim 61 wherein the control unit is operable for automatically deactivating the chilling unit when a received temperature for each and every of the plurality of temperature sensors is at or below T_Threshold .