GB2626127A - Thermally insulating transport container and panels therefor - Google Patents

Abstract

A thermally insulating panel 60 for use in the construction of at least one major external panel of a cold chain container, comprises first and second rectiplanar elements 61, 64 separated from each other by a distance of separation; insulation 67 is provided between respective inside faces of said first and second rectiplanar elements; an edge member associated with at least one of the first and second rectiplanar elements, the edge member providing rigidity and lateral closure to the panel, confirming the spacing between the first and second rectiplanar elements; each rectiplanar element is provided with substantially orthogonal edges which are fastened together to maintain a distance of separation between the rectiplanar elements and to provide a closed atmosphere within the panel; and one or more orthogonal members 62 are placed within the panel to support and maintain a distance of separation between the edges of the rectiplanar elements and between the insulation, to ensure a substantially constant thermal resistivity from a first side of the panel to the second side of the panel.

Description

THERMALLY INSULATING TRANSPORT CONTAINER AND PANELS

THE

Field of Invention

The present invention relates to a transport container which provides mechanical and thermal stability for a load and which container is fabricated as the container is loaded. In particular, the present invention relates to a container which can be readily transported on aircraft, such as an aircraft container.

Background to the Invention

In the field of logistics, that is the field of movement and supply of produce and materials, in particular in the transport of intermediate and finished products, containers have been developed which safely protect from physical damage a wide variety of product. Food and pharmaceutical products not only need protection from physical shock and pressures but also require temperature protection or stability during transportation; otherwise goods can be damaged and be unusable, whether such damage is apparent or not.

For example, in the pharmaceutical industry, product often needs to be maintained within a particular temperature range (sometimes referred to as a label-claim temperature range): product may be packed in relatively small containers, which containers are relatively fragile -accordingly insulation must provide both physical and thermal stability. Equally, in the food industry, fish suppliers will often have chilled fish boxes which are designed to accept, say 20Kg of product. The fish must be maintained at low temperatures, yet will be placed in containers which require a high degree of strength to prevent spillage.

As the standards of living increases, in developed markets, for example in Europe and North America, tropical foods -that is foods grown in far-away tropical places -are increasingly being stocked by supermarkets, delicatessens and the like. Short pick to distribution centre times in the producing country are matched by air carriers taking goods to the countries of consumption in similar lengths of time, whereby it is not uncommon for fruit to be on the plates of householders within two to three days of having been picked in a far-away country.

However, air transport poses a particular problem: Goods can be transported in tropical heat, packaged and placed upon pallets and the like containers and then transferred to aircraft style containers. Such goods may be left on runways at extreme temperatures (+40° C) and then placed within a hold where low pressures and low temperatures exist during flight. At a destination airport the temperatures may well be subzero. A corollary to this is the production of temperature sensitive pharmaceuticals in a "developed" country, which pharmaceuticals must be transported to another side of the world with similar temperature profiles, yet with sometimes even further reduced internal temperatures within the container.

These issues require contrary requirements: Strong yet light; Stable but highly insulating; Durable yet simple to fabricate. These issues place Cold Chain Distribution Managers in difficult positions. For air haulage, containers should weigh little and make use of non-rectangular hold spaces within aircraft; for the goods, they must be protected from shock, be maintained within a narrow temperature range, typically being equipped with temperature data loggers whereby a record of temperature within a container may determine whether or not a pharmaceutical is destroyed prior to use because of poor temperature handling. Refrigeration units may be provided with a container whereby temperatures maybe maintained, but then a source of electrical power or fuel for a powered generator is required.

To simplify transport with respect to airports, planes and handling equipment, there have been developed aircraft Unit Load Devices (ULDs) which comprise any type of pallet or container that can easily be loaded to the aircraft by a ground handler. Aircraft ULDs are units which interface directly with an aircraft loading and restraint systems, without the use of supplementary equipment. There are pre-defined ULDs, such as LD3, LD7, which correspond to standard configurations and can be utilised on certain types of aircraft. There are still further ULDs that are shaped such that they have a rectangular base yet are not generally cylindrical, that is to say they extend outwardly, beyond the sides of the base, as they extend upwardly from the base. There is also an increasing demand for many containers, especially aircraft ULDs that they are transported from a supplier in a flat-pack fashion and they are constructed prior to use. This enables warehousing requirements to be reduced by typically 66 -75%.

US4266670 provides a collapsible, reinforced, four sided container attached to a rigid base, of the type for transporting heavy products, such as iron. This design is collapsible whereby on a return journey it may be shipped in reduced size for reuse. This container is manufactured from reinforced corrugated cardboard. An example of this teaching is shown in Figure 1, which container 10 comprises a pallet base 40, upon which are placed side panels 10 -13. Each of the side panels have complementary edges having mortise and tenon elements, with an aperture running through, whereby stakes 107 -110 may be inserted to enable the sides to remain upright. The panels provide a limited amount of temperature insulation, especially taking into account the relatively large size of the cardboard panels, being approximately 15cm thick. One side may be easily opened for loading or unloading.

Applicants have developed various products with simple to erect structures, conveniently manufactured form foamed plastics, EPS, honeycomb cardboard and other known materials. Indeed, Applicants have a family of patents such as GB2459392 and G32470662 which teach, respectively of their SILVERPOD® range of pallet shippers and passive temperature control system therefor, as shown in Figure 2a.

Rebated edges of a first panel are resiliently accepted in a U-channel associated with a perpendicularly arranged mating panel, as shown in Figures 3a -3c, with a simple variant being shown in Figure 3d. Figures 4a and 4b show another pallet shipper which employs highly tensioned strap (>880Nm) to resiliently ensure that U-channels associated with a first panel are resiliently receive an edge member of a respective perpendicularly arranged mating panel.

US2556418 provides a thermally insulated container and pallet. Telescopic tubes are mounted upon each of the four corners of a pallet to provide an enclosure frame which is built up with canvas straps and subsequently insulated. Refrigerant gasses may be introduced into the enclosure once a canvas wrap is positioned around the container.

GB1382230 provides a heat-insulating protective cover for temperature-sensitive goods comprises a carrier frame adapted to be positioned over the top surface of the goods, which rest on a pallet, and provided with support legs for this purpose. Walls of flexible heat-insulating material extend around the carrier frame and can be lowered from a retracted position to a lowered position, the walls being connected at their upper edges to a layer of heat-insulating material.

U53955700 teaches of an aircraft container which has a moulded reinforced fibreglass enclosure, which has two removable panels on one side which provide access to the interior. Whilst this solution provides a strong and rigid -yet resilient -container, when empty the container takes as much space as when full, which is not acceptable for many supply industries. Furthermore, by providing an enclosure, limitations are placed with respect to the order of packing and the addition of goods to be despatched, which can provide complications and expense to any freight manager.

It is notable that the prior art designs suffer from not being readily recyclable products and in themselves are frequently of substantial weight; in present days, with fuel costs for all forms of transport increasing significantly, it is extremely beneficial in having a container that is not of substantial weight.

It is also notable that there are few thermally insulating cargo containers; either they are rigid yet not collapsible or are collapsible yet easily damaged when shifted by fork-lifts and other and/or are complex to assemble.

Object of the Invention The present invention seeks to provide a solution to the problems 30 addressed above. The present invention seeks to provide a component _part for a transport container which can be manufactured at low cost, from readily recyclable materials and can readily and easily be constructed. Additionally, the present invention seeks to provide a cold chain container that can be assembled from flat-pack components yet provide a rigid construction that can absorb rough handling that will inevitably arise in the use of a logistics container that is placed on forklifts, moved and stored in warehousing and distribution centres and placed in aircraft holds and upon lorries.

The present invention seeks to provide a transport container which can be erected at point of use. Furthermore, the present invention seeks to provide a container that when completed can maintain goods within a narrow temperature range. The present invention further seeks to provide a transport container which is compatible with standard Unit Load Device specifications. The present invention still further seeks to provide a panel structure for cold chain environment container which can be erected at point of use. Furthermore, the present invention seeks to provide a container fabricated form such panel structures that when assembled can maintain goods within a narrow temperature range.

Statement of Invention

In accordance with a general aspect of the invention, there is provided a thermally insulating panel for the fabrication of a thermally insulating collapsible transport container for use in the cold chain industry.

In accordance with a first specific aspect of the invention there is provided a thermally insulating panel for use in the construction of at least one major external panel of a cold chain container, wherein the panel comprises first and second rectiplanar elements separated from each other by a distance of separation; wherein insulation is provided between respective inside faces of said first and second rectiplanar elements; wherein an edge member associated with at least one of the first and second rectiplanar elements, the edge member providing rigidity and lateral closure to the panel, confirming the spacing between the first and second rectiplanar elements; wherein each rectiplanar element is provided with substantially orthogonal edges which are fastened together to maintain a distance of separation between the rectiplanar elements and to provide a closed atmosphere within the panel; and, wherein one or more orthogonal members are placed within the panel to support and maintain a distance of separation between the edges of the rectiplanar elements and between the insulation, to ensure a substantially constant thermal resistivity from a first side of the panel to the second side of the panel. Conveniently, the edge members are positioned by the use of one or more of the following: adhesive, adhesive tape, adhesive paper tape, adhesive film, mechanical interlocking and interference fit. By the use of such adhesive systems, manufacture can be readily automated. Conveniently, the dimensions of the panel are greater than 0.3m2 and the length -width aspect ratio is in the ratio of 1:1 -1:4, which dimensions generally correspond with pallet shippers and the like. Whilst the present invention has been initially developed with regards to pallet shippers, the specific benefits lend themselves to smaller cartons such as 48 litre cartons, but the specific benefits of providing strength in a panel centre are generally of use but with smaller cartons, the extra benefit becomes less significant, especially in further reduced volume containers.

The orthogonal members can be made or defined in a number of a ways, as will be apparent to one skilled. For example, they can comprise an edge board member -which are widely available and known in the packaging industry and typically comprise an extrusion having a general "L" profile of section. They are readily available formed as an medium density fibreboards (MDF) or as a plastics extrusion, but are not limited to such and are available in a number of sizes and strengths. Conveniently, to which is attached to an inside face of a first rectiplanar element and extends toward an inside face of a second rectiplanar member.

Applicants have also found that the orthogonal member can comprise a die-cut section of a first rectiplanar element that is subsequently folded such that, upon placement, an extending edge abuts an opposite inside face of the other rectiplanar element, whereby to maintain the distance of separation between the rectiplanar elements, a distance from the edges.

The orthogonally extending member from the first rectiplanar element can be provided with a tongue section extending from a shoulder portion of the orthogonal element such that the tongue can be inserted within one of a slit or a depression associated a second rectiplanar element, with the shoulder portion abutting a separate section of the second rectiplanar element. A further variation can be realized by having a die-cut section longer that the spacing require; the die-cut section is folded a second time such that it is parallel with the first rectiplanar member and presents a planar surface to an inside face of the second rectiplanar member, whereby adhesive can be applied during manufacture to assist in the making of a rigid insulating panel. In the limit, a number of orthogonal members of reduced length in the form of an array of several point specific orthogonal members can be provided.

During assembly of a panel in accordance with the invention, the orthogonally extending member of a first rectiplanar element can be secured to a second rectiplanar element by way of adhesive tape, liquid or gel. The insulation materials employed can be of many types, for example, but not limited to such: cushion paper of two or more layers, so-called "air-laid" tissue, embossed and fluted papers, recycled cotton and loose cellulose, including wood pulps.

The substantially planar members of the panel can be fabricated from readily available materials such as card, polypropylene sheet, corrugated card, corrugated sheet and moulded plastics. To reduce thermal transmission rates, the use of metallic sheeting as such is not preferred, although mirror finishes as provided by spray coating, vacuum evaporation of aluminium or sputter coating of aluminium, the application of metallic foils may be helpful, especially where use of a container is likely to be employed outside, especially in sunny climates.

It has been found that by associating a thermally insulating panel with a similarly manufactured panel comprising further insulation or a temperature control element carrying body, then the two members can be adhesively attached to present a panel with greater strength. The secondary panel can be of reduced rectilinear dimensions, which can assist in placement when being assembled, by providing a readily distinguishable orientation. Moreover by having the thermal control elements within, the panels can be pre-conditioned in a cool room prior to use to assist in assembly of a container. The thermal control elements can comprise high heat capacity materials or phase change materials as are widely used on the cold chain industry. It will also be appreciated, when a single sheet is folded over, with overlapping flaps, then the appearance of a resultant panel can be improved having the two panels abutting each other by such folded-over portions, conveniently with a sealant edging/filling adhesive about the join, to prevent a passage of debris etc. in any gap between the two panels, although tape may similarly be employed, for example.

In accordance with a further aspect of the invention, there is provided a thermally insulating collapsible transport container that has been fabricated from such panels. In particular, a container can be formed from at least one set of co-operating first and second panels arranged substantially at right angles to one another, the first and second panels having first and second major surfaces and a circumferential edge portion, wherein a first panel defines a rebated channel on an inside face of the panel wherein a first panel defines a rebated channel on an inside face of the panel, the channel being adjacent to at least one edge, the rebate being defined in cross-section by an edge face of the panel and a general [-section member, a first arm of the [-section member defining, in use, part of the outside wall of the first member the second arm of the [section member having an inside face opposing said edge face of the panel whereby, to define a rebate into which an edge portion of the second panel can be resiliently received and retained therein. By having separate panels resiliently retained, air passage between an inside and an outside of a container is prevented.

Conveniently, the container comprises at least a base and upstanding wall panels, wherein the base panel corresponds to the first panel type and the wall panels correspond to the second panel type. Conveniently, the panels are of rectangular shape in plan view. The container can have a variety of forms, but a rectangular box would be the most frequently employed, even though it would be possible to have square section or cylindrical section boxes; indeed, the walls could be non-vertical, at least in part. The separate [-shape members can conveniently be made from one of wood pulp, polypropylene, aluminium, glass fibre, resin, carbon fibre. The edge portion of the first panel can be stepped, wherein, in use, the edge portion of the second panel abuts against a portion of the step.

In use, the base member may be positioned upon a pallet and subsequently placed upon an aircraft container base or similar. Additionally or alternatively, the base member may be supported upon a tray or tray-like member before being placed upon a pallet, conveniently with the addition of a weatherproof sheet to prevent ingress of water, where a container is subject to outside use in wet climates. Conveniently, the weatherproof sheet provides a thermal barrier. Conveniently the weatherproof sheet can be retained by a cargo net, which attaches within a recess of a pallet base to provide an integrated weatherproof container system. Conveniently, the cargo net comprises any one or more of webbing or elasticated cords.

In accordance with another aspect of the invention, there is provided a method of fabricating a transport container, wherein the container comprises at least one set of co-operating first and second panels arranged substantially at right angles to one another, the first and second panels having first outside and second inside major surfaces and a circumferential edge portion, wherein a first panel having a general [shape cross-section element defines a rebate along an edge portion and is operable to accept an edge portion of the second panel, a first arm of the L-shape section comprising part of the outside wall of the first member, the second arm of the [-shape section opposing an edge face of the first pane, wherein the method includes the step of introducing an edge portion of a second panel into the rebate, urging an outer face of the second panel against an inside face of the upstanding arm of the [-shape member, until the edge of the second panel abuts an inside rebate surface, whereby first and second panels can be resiliently retained, one with respect to another. By repeating the steps with respect to associated adjacent edges, a container can be simply formed. Conveniently a base is provided upon which the panels can be placed, which base preferably provides a degree of protection when placed wet surfaces.

Brief Description of the Figures

For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein:-Figure 1 illustrates a prior-art transport container; Figure 2a illustrate a known flat-pack container in assembled perspective view; Figure 3a -3d detail how edge members of the container per Figures 2a & 2b can be associated upon construction; Figure 4a & 4b illustrate another pallet shipper; Figure 5 show a flat-pack container fabricated using panels in accordance with the invention in perspective exploded view; Figures 6, 6a & 6b show aspects of a panel in accordance with the present invention; Figures 7a -7d show variations in providing low thermal conductivity strengthening members of a first form in accordance with the invention; Figures 8a -8d show variations in providing low thermal conductivity strengthening members of second and third forms in accordance with the invention; Figures 9 & 9a show views of a thermal conditioning panel in accordance with the present invention; and, Figure 10 shows a combined thermally insulating and thermally conditioning panel in accordance with the invention; Figure 11 a -lie show further views relating to the thermally insulating panel and corresponding insulation material inserts; Figures 12a -12f relate to further embodiments and features associated therewith; Figures 13a -13f show various forms of insulating material that can be employed in the present invention; Figure 14 shows a completed panel formed from a metallicized outer layer; Figures 15a and 15b show temperature profiling within an LD7 QTR package under simulated summer and winter external temperature profiles over a 120 hour (five day period); and Figures 16a and 16b show how a load can be transported in a container made using panels in accordance with the present invention.

Detailed description of the Preferred Embodiments

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

Figure 5 shows a first configuration of a pallet shipper 50 with panels made in accordance with the present invention. A base pallet element 51 supports a base panel 52, with front and rear panels 53 upstanding at opposite ends, linked by a pair of side panels 54. A top panel 55 is operably secured to the top edges of the four upstanding wall elements 53, 54. The panels enclose a temperature sensitive load 56 upon a pallet 57. On the inside walls of the upstanding wall panel are provided temperature control assemblies, which are foldable for flat packing yet retain phase change packets to maintain a stable temperature within the pallet shipper, as is known from GB2459392B in the name of present Applicants.

Figure 6 shows a first panel 60 in accordance with the present invention in spaced apart diagrammatic form, 60, which comprises a base element 61 formed from a sheet material, such as a cardboard sheet material such as a C-flute cardboard sheet, noting that alternative cardboard products such a twin-flute (tri-wall) or tri-flute (four wall) cardboard can provide a greater degree of rigidity that may be required for an element that needs to support a greater load. The base sheet panel has up-turned edges 63. In this spaced-apart diagram, the mid-section indicates the bracing and insulation members: Conveniently, the bracing comprises support elements 62 commonly referred to as an edge board member -being an elongate member having an "L" or "V" profile with a right-angle internal angle -formed from wood fibre commonly referred to as MDF and is produced in extruded section. Similar members can be formed form plastics, cardboard and other materials, as is known. The edge board member is stiff and of typical approximate dimension of 1.5 cm depending form the apex, with a thickness of 1.5 mm and is retained in place using either an interference fit or an adhesive, conveniently, a PVA glue, which adhesives are well known and readily available -albeit there are many other alternative adhesives that could be employed. Hot melt adhesives can also be used, some of which have a reduced thermal rate transmission compared to cardboard. A lid element 64, having a top surface 65 with depending edges 66 is provided, which when brought together with the base element 61 -after insulation material 67 (indicated within the confines of the edge board frame by dashed lines) has been inserted in the compartments 68a, 68b. Figure 6a shows a perspective view of a base and a lid component of a panel from an underside perspective view; Figure 6b show a perspective view of an inside perspective view of a lid and a base.

In the manufacture of the panels, once the insulation material has been placed between one or more edge board dividers, the first and second panel blanks are folded so that their respective edges upstand relative to the main faces of the panel and provide edges with a sufficient depth to provide a sufficient thickness of insulation material, typically in the range of 25 mm -100 mm (1" -4"), preferably, 25 mm -75 mm (1" -3"), and, more commonly, 25 mm -50 mm (1" -2"). Conveniently a jig can be employed in the manufacture of panels, with a pre-cut and pre-scored cardboard panel initially placed within a jig, with a first corner of a panel formed with two adjacent sides having their edges folded up whereby to accurately place the panel within a fixed corner of the jig. This step is followed by the placement and attachment by either an interference fit or adhesive of edge board lengths to the panel, with third and fourth sides being folded upwardly and placement of further edge boards and placement of insulation material between the edge boards. Adhesive can then be applied to the top surface of the insulation material followed by the folding of first and second opposite sides to complete the enclosure, with further adhesive being applied to make the panel secure. Whilst the present invention can be employed in a number of types of container, when used with the pallet shipper or similar in accordance with the teaching of GB2459392B, then further edge board rebate alignment pieces are then folded over sitting on top of the panel, with the panels remaining within a jig until the adhesive has set. It will be appreciated that hot melt glues can provide a reduced period before a jig can be employed for a further panel, but the skilled man will be knowledgeable of other operating procedures to provide a faster methods of fabrication.

Figures 7a -7d show a few possible variations in the manner of use of one or more edge boards 62, 62' to maintain a separation distance 71 between first and second main sheet elements 61, 64 defining an insulation panel. Figure 7a shows a first arrangement in section, similar to the situation discussed in relation to Figure 6; the outside surface 72 of one orthogonal arm of the edge board is attached to an inside surface 61 of a first panel and a distal edge 73 of the edge board 62 abutting against an inside face 64 of a second panel. Insulation between the two panels is not shown, for clarity. Figure 7b shows a configuration where two edge boards are employed, with the distal edges 73 of the respective edge board arms extending from the plane of the panel to which they are attached abutting on an inside face 74 of the orthogonal arm of the respective opposing edge board 62, 62' that is attached to its respective inside face of the panel, 61, 64, with the inside faces 75 of the extending arms of the two edge boards abutting each other. By having the distal edge 73 of one edge board 62 abutting an inside surface 74 of an opposing edge board 62', a more durable and resilient arrangement is provided, with a reduced likelihood of the distal edge penetrating or otherwise damaging a surface of the opposing panel 61, 64. Figure 7c shows a similar arrangement to the arrangement of Figure 7a, save for the fact that instead of there being a single edge board 62, there are two edge board, arranged such that their distal edges are parallel. Figure 7d shows a still further simpler variation, wherein there are edge board elements 62, 62' associated with respect to panels 61, 64, with the outside faces 76 of the extending arms of the two edge boards abutting each other.

Figure 8a shows a first variation form the edge board construction, wherein an "I" section extrusion is employed; whilst this form of reinforcement is of benefit when used for a base panel in a shipping container, since the weight can be spread over a greater area of cardboard base, the carboard base panel is less likely to become damaged. Nonetheless, the thermal path has a reduced resistance and it may be necessary to have a greater thickness to provide greater thermal resistance. It would also be worthwhile in having apertures in the "I" section channels in a shipping container to reduce the effective conductivity of such "I" support members.

Figures 8b and 8c employ the use, respectively, of one and two "C" section members 85, wherein their parallel-spaced apart arms (in cross-section) provide areas 86 and 87 on upper and lower arms respectively to provide support and maintain a distance between the lower and upper panel walls 61 & 64, respectively. In Figure 8c, the mid-section of the two "C" section members are placed in an abutting relationship; insulation material can be introduced within the internal gap of the "C" section. In contrast and with reference to Figure 8d, the distal portions of the two extending arms of the "C" section abut the lower panel 61 whilst the central section abuts the upper panel 64. This suffers from having a closed space -which could be filled with an insulator material, but it would be less easy to fabricate / be more liable to failure. It is also to be noted, in common with the normal edge board, the sections could also be apertured to reduce thermal transmission, without sacrificing overall strength.

In the cold chain industry, especially with flat-pack panels for containers, it has been found to be convenient to have the means for maintaining a temperature associate with the walls. Specifically, the walls are provided with phase change materials retained in protective sleeves. The phase change materials are conditioned in a freezer or other suitable continuous temperature room in order to ensure that an internal volume defined aby a container once assembled is kept within a design temperature -which can vary dependent upon a load and the anticipated variations in climate the a container will encounter during a cold chain transport event. Whilst the phase change materials could be placed in a cavity once they have been conditioned, it has been found convenient to have the phase change materials retained with a wall panel of a container -as much for convenience, since a wall panel will be conditioned as a whole, together with the phase change materials. Accordingly, with reference to Figure 9, there is shown a cardboard enclosure 90 which is shown as a general diamond shape to provide a greater overall strength as shall be made clear below. Generally diamond-shaped board 90 defines a generally rectangular central area, defined in part by a number of edge board elements 93 placed thereon, which define a perimeter and four channels -two narrow outer channels 94 for the placement of insulation and two central channels 95 for the placement of phase change materials -or other thermally moderating bodies in general. The skilled man will be aware that only one channel may be filled with a phase change material or indeed, that all channels should be filled with such phase change materials, dependent upon a particular load, with a selected temperature range and duration of anticipated travel, as would be known.

The temperature controlling element, after placement of the required insulation material and phase change material, is then closed, conveniently using adhesive; opposite edges 97' and 97" are brought towards each other, folded about the edge board and then opposite edges 96' and 96" are brought towards each other, folded about the other orthogonally arranged edge board edges, to provide a three-dimensional panel as shown in Figure 9a. As mentioned earlier, the diamond configuration provides additional strength when the board is made of in a corrugated fashion; by having the corrugations arranged diagonally with respect to the central rectangular regions upon folding it will be appreciate that the corrugations of the respective first and second panels are orthogonally with respect to each other, whereby providing additional rigidity. It will be appreciated, nonetheless, that it is not mandatory to use corrugated board -whether of plastics, carboard or other materials.

With reference to Figure 10, it can be seen that a wall or top panel for a container can then be simply fabricated by, for example, gluing the temperature control panel of Figure 10 to the wall panel as shown in Figure 6.

It will be appreciated that a tremendous number of variations are possible in the design. With reference to Figures ha -lie, there is shown five panel and edge board combinations with pre-cut insulation to be placed in the spaces defined by the edge boards. It will be appreciated that there are a great number of insulation materials and combination of materials that can provide excellent thermal insulation. Nonetheless, initial trials have been performed with a product commonly referred to a "cushion paper", available from Huhtamaki amongst other suppliers, with one type having specific attributes per table 1.

In contrast to the panels show in Figures 11a -11e, given that the card employed can be selected from a number of types of card such as c-flute corrugated board. As is known, c-flute corrugated board -which has the outer layers of 0.25mm in thickness, being separated by corrugations being having a peak-to-peak distance of 7.4mm and a total thickness of 3mm, noting that it can be manufactured as a plastics extrusion, or more commonly as a cellulose fibre board, albeit from various strength and water-resistant ratings. Using such board, it has been found that it is possible to create a cut-out in one side to provide, once formed using folding techniques, to provide a rigid support in a central position -about the respective inside faces of the panels, per Figures 12a and 12b -or alternatively, in number of positions. In particular, with reference to Figure 12a, there is show a pressed element 120 which comprises, once folded as an integral "L"-cross-section member, presenting a footing surface 122 which can be adhesively attached to an inside surface of an opposing panel (not shown) to which it is to be attached. Figure 12b presents a simple rectangular upstanding element 123 with a reduced width leading section 125 -which can be referred to as a tongue section, the length of the leading section corresponding to the depth of the opposing panel (not shown), which is also provided with a slit in correspondence therewith, whereby upon application of adhesive and insertion into such slit, an extremely secure location and spacing member can be provided. Either side of the tongue section 125, there are provided shoulders 127 which can abut against the recti-planar panel. It will be appreciated that one or more such spacing members can be provided; it will be seen that the axes of folding of the card, is shown as being perpendicular to any fluting direction 124.

Figures 12c -12f relate to a further embodiment, wherein the orthogonal member 127 comprises a generally candlestick like element, having a base 127b and upper support 127s, providing diametrically opposite support surfaces in general correspondence, to provide a support area in contact with an inside face of each opposing panel. The distance between the base and the upper support corresponding with the required distance across the panel, to provide a uniform R value across the panel, whilst providing sufficient support, the orthogonal member conveniently being of a two-part construction. In this case, a resilient head member of component 128 is resiliently received in an aperture 129a of component 129. The components 128, 129 can conveniently be made from a plastics such as Acrylonitrile Butadiene Styrene (ABS) plastics, which has a low R value, is thermally stable, tough, durable product and readily available. By having separable individual elements, one part can be glued, or otherwise fastened, the insulation sheet placed around, with the columnar part of the candlestick form extending through a small aperture in the insulation, thereby maximizing use of insulation sheet, with the corresponding other member being attached to the other panel. In the alternative, the other member is attached and the upper surface is associated with an inside face of the other panel, whereby to provide a simple yet effective thermally insulating panel.

Figures 13a -through to 13f, show various forms of insulation which have been found to be suitable, including, for example, but not limited to such: cushion paper of two or more layers, so-called "air-laid" tissue, embossed and fluted papers, recycled cotton and loose cellulose, including wood pulps. Vacuum insulation panels as are known could also be employed, with the edge board imparting a greater degree of resilience against compression; the VIP panels have an interior existing in a vacuum; the cover sheet to such panes can thus be easily damaged and become significantly less beneficial in cold chain. Accordingly, of present in enclosures which maintain a spacing, then their benefits can reliably be depended upon. Figure 14 provides another form of panel 141 that has been additionally wrapped in a metallic foil to assist in a reduction of transfer of heat by thermal radiation. The adhesive tape employed can also be provided as a form of metallic tape.

Initial trials have been performed with a quarter PMC system which has been developed for a Load Device 7 (LD7 QTR) having a base foot print of 62.5" x 44" . In tests, the LD7 QTR was provided with a half-payload of pharmaceutical placebo product and the standard pack out used in the equivalent Technical Insulation Foam (TIE) systems. With reference to the simulated summer and winter temperature profiles as indicated, respectively in Figures 15a and 15b, the temperatures remained within the range of between 2°C and 8°C for 120 hours / five days. Figures 16a and 16b show how panels in accordance with the invention can be grouped together to provide typical sizes of unit load dimensioned containers for cold chain transport.

As discussed above, the insulation panels have been designed to be used as structural and insulation With reference to the edge board or "L" member in accordance with the invention, the member is of a rigid construction and can be fabricated from a number of possible materials, such as wood-pulp, steel, polypropylene, glass fibre, carbon fibre, for example; whilst aluminium could be used, the R-value would be compromised since it is ideally of as low a thermal conductivity as possible. . In the context of the thermal packaging industry, the R-value is a measure of how well a two-dimensional barrier, such as a layer of insulation, an external container wall or internal separation wall, resists the conductive flow of heat. R-value is the temperature difference per unit of heat flux needed to sustain one unit of heat flux between a warmer surface and a relatively colder surface of a barrier under steady-state conditions. The R-value is therefore the standard reference for thermal resistance "per unit area" -the SI unit is K.m2 / W and can be employed with reference to a given material (e.g. for polyethylene foam), or for an assembly of materials (e.g. a wall with a composite constructions. In the case of materials, it is often expressed in terms of R-value per metre. R-values are additive for layers of materials, and the higher the R-value the better the performance. As will be appreciated, the R-value is the inverse of the overall heat transfer coefficient and the R-Value can also be determined -with the use an appropriate tables -as e/A, where e corresponds to a thickness (m) of the material under consideration and A corresponds to a thermal conductivity of the material of the material under consideration in W/m.K. The lambda value is also referred to as the thermal k value) It should be noted that a change to the material thickness, i.e. through compression, will impact the R-Value. Table 2 indicates the change in observed lambda value for the same specimen sample material (Cushion paper sandwiched between corrugated cardboard) at full thickness and then compressed by 2mm each test. The lambda value fluctuates as the density changes; however, the R-values follows a linear pattern with the increase or decrease in thickness. Without the lambda fluctuations, a 50% decrease in thickness would translate to a 50% decrease in R-value and therefore thermal performance.

The thickness of the L-member is dependent upon the material from which it is manufactured, but for wood-pulp, a thickness of 4 -6 mm is typical. Importantly, this will not have any appreciable affect upon the manner of the base sitting upon a pallet etc., for example. The exact dimension of the [-member will vary upon application, but for the present application, the horizontal and vertical arms can conveniently be 37.5mm (1.5"). In contrast to industry assumptions, the placement of the edge boards within highly insulative container panels has not reduced the efficiency to any great extent, with the edge boards reducing the efficiency by 1.5 -0.50/0, with improvements increasing in further development. Certainly the benefit have proven to be counterintuitive.

The invention provides simple to fabricate panels for a container and a container made from such panels that can exceed present requirements using easy to source and easily recyclable components which can retain goods reliably at a specified temperature due to the use of appropriate cold chain thermal stability agents such as phase change materials and the like. A container in accordance with the present invention may be assembled in a rapid and expeditious manner. The parts making up our box may be stacked for storage in a relatively small space. A distinct benefit of the present invention is that the construction permits different sized boxes to have common parts to provide more cost-effective construction and/or different functionality.

Claims (24)

1. CLAIMS: 1. A thermally insulating panel for use in the construction of at least one major external panel of a cold chain container, wherein the panel comprises first and second rectiplanar elements separated from each other by a distance of separation; wherein insulation is provided between respective inside faces of said first and second rectiplanar elements; wherein an edge member associated with at least one of the first and second rectiplanar elements, the edge member providing rigidity and lateral closure to the panel, confirming the spacing between the first and second rectiplanar elements; wherein each rectiplanar element is provided with substantially orthogonal edges which are fastened together to maintain a distance of separation between the rectiplanar elements and to provide a closed atmosphere within the panel; and, wherein one or more orthogonal members are placed within the panel to support and maintain a distance of separation between the edges of the rectiplanar elements and between the insulation, to ensure a substantially constant thermal resistivity from a first side of the panel to the second side of the panel.
2. 2. A thermally insulating panel according to claim 1, wherein the edge members are sealed by the use of one or more of the following: adhesive, adhesive tape, adhesive paper tape; adhesive film.
3. 3. A thermally insulating panel according to claim 1 or 2, wherein the orthogonal members comprise an edge board member, which is positioned with respect to an inside face of a first rectiplanar element and extends toward an inside face of a second rectiplanar member.
4. 4. A thermally insulating panel according to any one of claims 1 -3, wherein an orthogonal member comprises a die-cut section of a first 30 rectiplanar element that is subsequently folded such that, upon placement, an extending edge abuts an opposite inside face of the other rectiplanar element, whereby to maintain the distance of separation between the rectiplanar elements, a distance from the edges.
5. 5. A thermally insulating panel according to any one of claims 1 -3, wherein an orthogonal member comprises a die-cut section within a section of a panel face that is subsequently folded along an edge section along two fold lines such that, upon placement, subsequent to folding, a planar section abuts an opposite inside face of the other rectiplanar element, whereby to maintain the distance of separation between the rectiplanar elements, a distance from the edges.
6. 6. A thermally insulating panel according to claims 5, wherein the orthogonally extending member from a first rectiplanar element is provided with a tongue that can be inserted within one of a slit or a depression associated a second rectiplanar element.
7. 7. A thermally insulating panel according to any one of claims 3 -6, wherein the orthogonally extending member of a first rectiplanar element is secured to a second rectiplanar element by way of adhesive tape, liquid or gel.
8. 8. A thermally insulating panel according to any one of claims 1 -7, wherein the orthogonally extending members comprise one of cellulose card, polypropylene sheet, corrugated card, corrugated plastics or plastics moulding.
9. 9. A thermally insulating panel according to any one of claims 1 -8, further comprising a secondary panel that is secured to an outside face of said thermally insulating panel.
10. 10. A thermally insulating panel according to claim 9, wherein the secondary panel retains one or more thermal control elements, such as phase change materials, to provide an integrated insulation and thermal control panel.
11. 11. A thermally insulating panel according to claim 9, wherein the secondary panel is provided with insulation material.
12. 12. A thermally insulating panel according to claim 1, wherein the orthogonal member comprises a number of individual supports providing an "I" section form of support.
13. 13. A thermally insulating panel according to claim 14, wherein the "I" section orthogonal member comprises a two-part element.
14. 14. A thermally insulating panel according to claim 1, wherein the dimensions of the panel are greater than 0.3m2 and the length -width aspect ratio is in the ratio of 1:1 -1:4.
15. 15. A thermally insulating panel according to any one of claims 9 -11, wherein the secondary panel is of reduced rectilinear dimensions.
16. 16. A thermally insulating collapsible transport container fabricated from at least one panel as claimed in any one or more of claims 1 -15.
17. 17. A thermally insulating collapsible transport container according to claim 16 wherein fabricated from at least one set of co-operating first and second panels arranged substantially at right angles to one another, the first and second panels having first and second major surfaces and a circumferential edge portion, wherein a first panel defines a rebated channel on an inside face of the panel wherein a first panel defines a rebated channel on an inside face of the panel, the channel being adjacent to at least one edge, the rebate being defined in cross-section by an edge face of the panel and a general L-section member, a first arm of the L-section member defining, in use, part of the outside wall of the first member the second arm of the [-section member having an inside face opposing said edge face of the panel whereby, to define a rebate into which an edge portion of the second panel can be resiliently received and retained therein.
18. 18 A thermally insulating transport container according to claim 17 wherein the container comprises at least a base and upstanding wall panels, wherein the base panel correspond to the first panel type and the wall panels correspond to the second panel type.
19. 19. A thermally insulating transport container according to claim 18, wherein the container further comprises one or more insulating cover panels, wherein the or a number of insulating cover panels correspond in type with either the first or second panel type, whereby the cover panel can be resiliently retained with respect to an upstanding wall panel.
20. A thermally insulating transport container according to any one of claims 17 -19, wherein the base member comprises a unitary moulded 5 member, with the rebate and [-section member being defined from a single plastics moulding.
21. 21. A thermally insulating transport container according to any one or more of claims 17 -20, wherein the [-section member is made from a material selected from the group comprising: wood pulp, polypropylene, aluminium, glass fibre, resin and carbon fibre.
22. 22. A thermally insulating transport container according to claim 21, wherein the [-shape member is attached by adhesive to the first panel.
23. 23. A thermally insulating transport container according to any one of claims 17 -22, wherein the base member, having an upper load bearing surface and an underside, is provided with channels within the underside.
24. 24. A thermally insulating transport container according to any one or more of claims 17 -23, wherein the edge portion of the first panel is stepped, wherein the edge portion of the second panel abuts against a portion of the step.