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 may include 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 includes 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.

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: Thermally insulated shipping system for use in transporting a pallet-sized payload. In one embodiment, the system includes a plurality of thermally insulating walls arranged to define an interior volume suitable for receiving a pallet-sized payload. The thermally insulating walls include a top wall, a bottom wall, a front wall, a rear wall, a left wall, and a right wall, of which all but the bottom wall include at least two slots facing towards the interior volume. One of the slots is an inner slot that is more proximal to the interior volume, and one of the slots is an outer slot that is more distal to the interior volume. The system also includes a plurality of inner cassettes disposed in at least some of the inner slots and a plurality of outer cassettes disposed in at least some of the outer slots. The inner and outer cassettes include phase-change materials.

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 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: Method and system for maintaining temperature-sensitive materials. According to one embodiment, the method involves positioning temperature-sensitive materials within a product box and positioning phase-change material around the product box. If the edges of the product box where adjoining sides meet are covered by phase-change material, then the product box and the phase-change materials are loaded into a frame-and-panel-type insulated container in which an insulating material having a higher R-value is located along the container edges and an insulating material having a lower R-value is spaced away from the container edges. By contrast, if the edges of the product box are not covered by phase-change material, then the product box and the phase-change materials are loaded into a frame-and-panel-type insulated container in which an insulating material having a lower R-value is located along the container edges and an insulating material having a higher R-value is spaced away from the container edges.

Abstract: A method and system for transporting and/or storing temperature-sensitive materials. In one embodiment, the system may be a hybrid system that includes an active temperature-control system and a passive temperature-control system. The active temperature-control system may be, for example, a portable refrigerator that includes an internal chamber for maintaining contents within a desired temperature range. The passive temperature-control system, which includes at least one phase-change material (PCM) member and space for receiving one or more temperature-sensitive materials, may be removably positioned entirely within the internal chamber of the active temperature-control system.

Abstract: Method and system for maintaining temperature-sensitive materials within a target temperature range for an extended time. In one embodiment, the system keeps materials within a temperature range of +2° C. to +8° C. and includes an insulated container, a product box, ice packs, and organic phase-change material (PCM) packs. The ice packs are preconditioned to a very low temperature, such as ?20° C. The organic PCM packs do not require preconditioning and may be kept at room temperature. In use, the frozen ice packs and the warm organic PCM packs may be loaded into the insulated container, together with a payload in the product box. Preferably, the frozen ice packs are sandwiched between a pair of organic PCM packs on each face of the product box. The masses of ice and organic PCM are selected so that, upon thermal equilibration, the ice and organic PCM are within the target temperature range.

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.