Abstract: Product box for use in a shipping system for temperature-sensitive materials and shipping system including the product box. In one embodiment, the product box includes a front, a rear, a left side, and a right side. The upper edges of the front and the rear are higher than the upper edges of the left side and the right side. The box also includes upper flaps hingedly connected to the upper edges of each of the front, the rear, the left side, and the right side and further includes lower flaps hingedly connected to the lower edges of each of the front and the rear. When folded, the upper flaps of the front and the rear are spaced above the upper flaps of the left side and the right side, thereby forming an air gap. Wings at the upper edges of the four sides center the product box within a container.

Abstract: System suitable for storing and/or transporting temperature-sensitive materials. In a preferred embodiment, the system may include a cooler made of expanded polystyrene foam. The cooler may include a base and a lid. The base may be a unitary structure that includes a cavity bounded by a bottom wall and four side walls. The base also may include an integral support that may include a platform elevated from the bottom wall, as well as a stanchion extending upwardly from the bottom wall along each of the side walls. The support may be constructed to removably receive a product box in the cavity and to orient the product box at an angle offset from the cavity. Dry ice pellets may be positioned around and under the product box, and additional dry ice pellets may be positioned in a tray mounted on the stanchions over the product box.

Abstract: Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls, bottom closure flaps, and top closure flaps. A vacuum insulated panel (VIP) is detachably coupled to one of the top closure flaps and is removably covered by a cover. An insulation unit is removably positioned within the outer box, the insulation unit including a plurality of VIPs arranged to define a cavity bounded by a bottom wall and four side walls. A disposable liner is removably mounted on the insulation unit. The liner may be a thermoformed sheet and may cover the interior and top surfaces of the insulation unit. A plurality of temperature-control members and a product box may be removably positioned in the liner. Preferably, the liner is shaped so that the temperature-control members snugly fit around all sides of the product box.

Abstract: Shipping system for temperature-sensitive materials. In one embodiment, the shipping system includes a frame defining an enclosure. The frame includes a bottom, a top, a front, a rear, a left side, a right side, a left corner gusset, and a right corner gusset. The front serves as a door. Thermal breaks are provided in one or more of the bottom, the front, the left corner gusset, and the right corner gusset. Vacuum insulated panels are positioned along all sides of the frame. Many of the vacuum insulated panels are encapsulated between the frame and an outer shell. A plurality of phase-change material assemblies are positioned within the frame along all sides. Heat-spreaders are positioned interior to the phase-change material assemblies. The shipping system are dimensioned so that four such shipping systems are seated on a prorate manual cargo sheet.

Abstract: Method and system for maintaining temperature-sensitive materials within a desired temperature range for an extended time. In one embodiment, the system includes an outer box having a rectangular cavity. An insulation unit is snugly but removably positioned in the rectangular cavity. The insulation unit includes a support and a thermal insulation member. The support may be a generally rectangular sleeve with four sides, an open bottom and an open top. The thermal insulation may be a bilayer material wrapped around the four sides of the support to form a spiral structure. The bilayer material may include a first sheet of an expanded slit-sheet packaging material and a second sheet of tissue paper. The system may additionally include a bottom insulation member at the bottom of the support, a top insulation member at the top of the support, and a payload and temperature-control members between the top and bottom insulation member.

Abstract: Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls, bottom closure flaps, and top closure flaps. A vacuum insulated panel (VIP) is detachably coupled to one of the top closure flaps and is removably covered by a cover. An insulation unit is removably positioned within the outer box, the insulation unit including a plurality of VIPs arranged to define a cavity bounded by a bottom wall and four side walls. A disposable liner assembly is removably mounted on the insulation unit. The liner assembly includes a first liner piece, a second liner piece, and a liner support. A plurality of temperature-control members and a product box may be removably positioned in a cavity defined by the liner assembly. The temperature-control members snugly fit around all sides of the product box and each include a container containing dry ice.

Abstract: Shipping systems for temperature-sensitive materials and methods of making and using same. In one embodiment, the shipping system includes a cooler base and a lid. The base includes an inner portion and an outer portion. The inner portion includes a thermal insulation unit including a bottom wall and four side walls. A thermally-conductive member is positioned on the bottom wall. A polymeric bag encapsulates the thermally-conductive member and some of the thermal insulation unit. The outer portion includes thermally-insulating material and defines an opening. The inner portion is permanently bonded to the outer portion, with cavities defined therebetween. A product box is placed in the inner portion directly over the polymeric bag and the underlying thermally-conductive member. First temperature-control members are disposed within the inner portion, with at least one temperature-control member directly over the polymeric bag and the underlying thermally-conductive member.

Abstract: Method and system are designed for storing and/or transporting temperature-sensitive materials. The system is designed to keep a payload within a desired temperature range of +2° C. to +8° C. for an extended time in a warm ambient environment. The system includes a thermally insulated container and first and second phase-change materials, each of the phase-change materials having a different solid/liquid phase-change temperature. Both phase-change materials are preconditioned to a solid state for pack-out. The first phase-change material has a solid/liquid phase-change temperature that is within the desired temperature range and that is at or below a hibernation temperature of about +5° C. to +6° C. The second phase-change material has a solid/liquid phase-change temperature that is above the hibernation temperature.

Abstract: Product box for use in a shipping system for temperature-sensitive materials and shipping system including the product box. In one embodiment, the product box includes a front, a rear, a left side, and a right side. The upper edges of the front and the rear are higher than the upper edges of the left side and the right side. The box also includes upper flaps hingedly connected to the upper edges of each of the front, the rear, the left side, and the right side and further includes lower flaps hingedly connected to the lower edges of each of the front and the rear. When folded, the upper flaps of the front and the rear are spaced above the upper flaps of the left side and the right side, thereby forming an air gap. Wings at the upper edges of the four sides center the product box within a container.

Abstract: Method and system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system is designed for use as a dry ice shipper and includes an outer box, a vacuum insulated panel (VIP) base assembly, a VIP lid assembly, and a gas flow director. The VIP base assembly is positioned within the outer box and includes five VIPs arranged to form a container having a bottom, four sides, and an open top. The VIP lid assembly, which may be coupled to a top closure flap of the outer box, includes a VIP dimensioned to close the open top of the VIP base assembly. The gas flow director, which may comprise a bag having an opening at its top end, may be positioned within the outer box and may be used to receive the VIP base assembly. The gas flow director inhibits convective gas flow that promotes excessive dry ice sublimation.

Abstract: Method and system for customized configuration of a shipper for transporting temperature-sensitive materials. In one embodiment, a webpage application is used to allow a user to input certain information. Such information may include the shipping origin zip code, the shipping destination zip code, an indication of the courier used to transport the shipper, an indication of the desired temperature range at which the materials are to be maintained by the shipper, and an indication of the maximum payload size desired. Based on the inputted information and a selection methodology that determines the average ambient temperature to which the shipper will likely be exposed, a shipper is then selected from among a pre-selected collection of possible shipper configurations. Such a collection may include, for example, configurations designed to protect against hot ambient temperatures, cold ambient temperatures and intermediate ambient temperatures.

Abstract: Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls, bottom closure flaps, and top closure flaps. A vacuum insulated panel (VIP) is detachably coupled to one of the top closure flaps and is removably covered by a cover. An insulation unit is removably positioned within the outer box, the insulation unit including a plurality of VIPs arranged to define a cavity bounded by a bottom wall and four side walls. A disposable liner is removably mounted on the insulation unit. The liner may be a thermoformed sheet and may cover the interior and top surfaces of the insulation unit. A plurality of temperature-control members and a product box may be removably positioned in the liner. Preferably, the liner is shaped so that the temperature-control members snugly fit around all sides of the product box.

Abstract: A system for protecting temperature sensitive products. The system comprises a cover that fits over a product. The cover has a first component, a second component, and a closure system. The first component covers the top of the product and at least a portion of a first side of the product, and the second component covers at least a portion of the other sides of the product. The closure system closes openings between the first component and the second component and tightens the cover around the product. The cover is removable from the product by releasing the closure system and pulling the second component of the cover in a horizontal or downward direction away from the first side of the product.

Abstract: A pallet cover suitable for use in covering at least a portion of a payload on a pallet and a kit for use in making the pallet cover. In one embodiment, the pallet cover includes a top wall, a front wall, a rear wall, a left side wall, and a right side wall, wherein the walls are detachably joined to one another. Each of the top wall, the front wall, the rear wall, the left side wall, and the right side wall includes a first fabric sheet and a second fabric sheet, the first and second fabric sheets being joined together to form a plurality of pockets. Each pocket may removably receive a temperature-control member containing a phase-change material. At least one of the top wall, the front wall, the rear wall, the left side wall and the right side wall may include a plurality of detachably joined portions.

Abstract: A gel composition possessing good cohesive properties. In one embodiment, the gel composition includes a phase-change material. The phase-change material is preferably an aqueous salt solution. The gel composition also includes a cross-linkable thickener. The cross-linkable thickener preferably is compatible with an aqueous salt solution and preferably includes one or more cross-linkable hydroxyl groups. The gel composition additionally includes a boron-containing cross-linker that is present in an amount that is sufficient to gel the formulation. The weight ratio in the gel composition of boron to thickener is preferably in the range of about 1:250 to 1:50. When packaged in a container, the gel composition resists flowing when the container is torn or punctured. The present invention is also directed at a method of preparing the gel composition, at a thermal exchange implement including the gel composition, and at methods of preparing and using the thermal exchange implement.

Abstract: Gel including a phase-change material and a gelling agent. In one embodiment, the phase-change material may be n-tetradecane, n-hexadecane or mixtures thereof. The gelling agent may be a high molecular weight styrene-ethylene-butylene-styrene (SEBS) triblock copolymer with a styrene:rubber ratio of about 30:70 to 33:67% by weight. To form the gel, the phase-change material and the gelling agent may be mixed at an elevated temperature relative to room temperature to partially, but not completely, dissolve the gelling agent. The mixture may then be cooled to room temperature. Alternatively, the phase-change material and the gelling agent may be mixed at room temperature, and the mixture may then be heated to form a viscoelastic liquid, which is then cooled to room temperature. The invention is also directed at a method of preparing the gel, a thermal exchange implement including the gel, and a method of preparing the thermal exchange implement.

Abstract: A pallet cover suitable for use in covering at least a portion of a payload on a pallet and a kit for use in making the pallet cover. In one embodiment, the pallet cover includes a top wall, a front wall, a rear wall, a left side wall, and a right side wall, wherein the walls are detachably joined to one another. Each of the top wall, the front wall, the rear wall, the left side wall, and the right side wall includes a first fabric sheet and a second fabric sheet, the first and second fabric sheets being joined together to form a plurality of pockets. Each pocket may removably receive a temperature-control member containing a phase-change material. At least one of the top wall, the front wall, the rear wall, the left side wall and the right side wall includes a plurality of detachably joined portions.

Abstract: A pallet cover suitable for use in covering at least a portion of a payload on a pallet and a kit for use in making the pallet cover. In one embodiment, the pallet cover includes a top wall, a front wall, a rear wall, a left side wall, and a right side wall, wherein the walls are detachably joined to one another. Each of the top wall, the front wall, the rear wall, the left side wall, and the right side wall includes a first fabric sheet and a second fabric sheet, the first and second fabric sheets being joined together to form a plurality of pockets. Each pocket may removably receive a temperature-control member containing a phase-change material. At least one of the top wall, the front wall, the rear wall, the left side wall and the right side wall may include a plurality of detachably joined portions.

Abstract: Shipping container for a temperature-sensitive payload. In one embodiment, the shipping container includes an insulated base having a bottom wall and four side walls. A first thermally conductive member is positioned on the bottom wall. A payload box is centered on top of the first thermally conductive member, and four frozen packs, each having a thickness matching the height of the payload box, are positioned along the four sides of the payload box. An insulating frame may be placed around the payload box to keep the frozen packs from directly contacting the payload box. A second thermally conductive member is positioned on top of the payload box and the four frozen packs, and an insulated lid is positioned on top of the second thermally conductive member and the four side walls of the base. One, both or neither of the thermally conductive members may be removed to optimize seasonal suitability.

Abstract: Shipping systems for temperature-sensitive materials and methods of making and using same. In one embodiment, the shipping system includes a cooler base and a lid. The base includes an inner portion and an outer portion. The inner portion includes a thermal insulation unit including a bottom wall and four side walls. A thermally-conductive member is positioned on the bottom wall. A polymeric bag encapsulates the thermally-conductive member and some of the thermal insulation unit. The outer portion includes thermally-insulating material and defines an opening. The inner portion is permanently bonded to the outer portion, with cavities defined therebetween. A product box is placed in the inner portion directly over the polymeric bag and the underlying thermally-conductive member. First temperature-control members are disposed within the inner portion, with at least one temperature-control member directly over the polymeric bag and the underlying thermally-conductive member.