Shipping System for Storing And/Or Transporting Temperature-Sensitive Materials

The present application is a continuation of U.S. patent application Ser. No. 17/366,944, inventors Ali Moghaddas et al., filed Jul. 2, 2021, which, in turn, claims the benefit under 35 U.S.C. 119 (c) of U.S. Provisional Patent Application No. 63/047,835, inventors Anthony Rizzo et al., filed Jul. 2, 2020, the disclosures of both of which are incorporated herein by reference in their entireties.

The present invention relates generally to shipping systems for storing and/or transporting temperature-sensitive materials and relates more particularly to a novel such shipping system.

It is often desirable to store and/or to transport temperature-sensitive materials, examples of such materials including, but not being limited to, pharmaceuticals, biological samples, foods, and beverages. As a result, various types of shipping systems for storing and/or transporting such materials have been devised, some of these shipping systems being parcel-sized shipping systems and some of these shipping systems being pallet-sized shipping systems. Typically, such parcel-sized shipping systems include an insulated container having a cavity for receiving a temperature-sensitive material. Often, the temperature-sensitive material is housed within a product or payload container, the product or payload container (with the temperature-sensitive material disposed therewithin) being placed in the cavity of the insulated container. Such shipping systems often also include a phase-change material disposed within the insulated container for maintaining the temperature-sensitive material within a desired temperature range. In many instances, such as when the desired temperature range for the temperature-sensitive material is below the ambient temperature outside the insulated container, the phase-change material is refrigerated or frozen prior to being placed in the insulated container so that the phase-change material can act as a coolant.

An example of a parcel-sized shipping system of the type described above is illustrated by U.S. Patent Application Publication No. US 2019/0210790 A1, inventors Rizzo et al., which was published Jul. 11, 2019, and which is incorporated herein by reference. According to this publication, 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.

Other documents of interest may include the following, all of which are incorporated herein by reference: U.S. Pat. No. 6,868,982, inventor Gordon, issued Mar. 22, 2005; U.S. Pat. No. 9,045,278, inventors Mustafa et al., issued Jun. 2, 2015; U.S. Pat. No. 5,897,017, inventor Lantz, issued Apr. 27, 1999; U.S. Pat. No. 6,257,764, inventor Lantz, issued Jul. 10, 2001; U.S. Pat. No. 5,924,302, inventor Derifield, issued Jul. 20, 1999; U.S. Pat. No. 6,044,650, inventors Cook et al., issued Apr. 4, 2000; U.S. Pat. No. 5,709,307, inventors Rosado et al., issued Jan. 20, 1998; U.S. Pat. No. 5,450,977, inventor Moe, issued Sep. 19, 1995; U.S. Pat. No. 5,501,338, inventor Preston, issued Mar. 26, 1996; U.S. Pat. No. 6,244,458, inventors Frysinger et al., issued Jun. 12, 2001; U.S. Pat. No. 6,192,703, inventors Salyer et al., issued Feb. 27, 2001; U.S. Pat. No. 7,950,246, inventors Mayer et al., issued May 31, 2011; U.S. Patent Application Publication No. US 2018/0328644 A1, inventors Rizzo et al., published Nov. 15, 2018; U.S. Patent Application Publication No. US 2005/0224501 A1, inventors Folkert et al., published Oct. 13, 2005; and U.S. Patent Application Publication No. US 2003/0102317 A1, inventor Gordon, published Jun. 5, 2003.

It is an object of the present invention to provide a novel shipping system for storing and/or transporting temperature-sensitive materials.

According to one aspect of the invention, there is provided a shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising (a) an outer box, the outer box comprising a cavity; (b) a product box, the product box disposed within the cavity of the outer box; and (c) a plurality of temperature-control members disposed within the cavity of the outer box, at least some of the temperature-control members comprising a container and a quantity of dry ice disposed within the container, at least some of the containers being self-contained closed structures that are separable from other containers.

In a more detailed feature of the invention, the product box may be rectangular and may comprise a top surface, a bottom surface, a front surface, a rear surface, a left side surface, and a right side surface, and the top surface, the bottom surface, the front surface, the rear surface, the left side surface, and the right side surface of the product box may be completely covered by the plurality of temperature-control members.

In a more detailed feature of the invention, the shipping system may further comprise insulation disposed within the cavity of the outer box, and the insulation may be exterior to the product box and the plurality of temperature-control members.

In a more detailed feature of the invention, the plurality of temperature-control members may comprise exactly six temperature-control members, and each of the six temperature-control members may contact and completely cover a different one of the top surface, the bottom surface, the front surface, the rear surface, the left side surface, and the right side surface of the product box.

In a more detailed feature of the invention, the shipping system may further comprise a liner assembly, the liner assembly may comprise a liner and a liner support, and the liner assembly may be removably mounted in the outer box.

In a more detailed feature of the invention, the liner may comprise a first liner piece and a second liner piece, the first liner piece may comprise a sheet reversibly transformable between a first planar structure and a first generally U-shaped structure, the second liner piece may comprise a sheet reversibly transformable between a second planar structure and a second generally U-shaped structure, and the first and second liner pieces may be arranged offset from one another by approximately 90 degrees.

In a more detailed feature of the invention, the liner support may be reversibly transformable between a third planar structure and a structure having a bottom, four sides, and an open top, and the first liner piece and the second liner piece may be arranged on the liner support.

In a more detailed feature of the invention, the plurality of temperature-control members may comprise an upper container holding a first quantity of dry ice, a lower container holding a second quantity of dry ice, and a scaffolding structure disposed between the upper container and the lower container for use in defining one or more compartments for holding additional dry ice.

In a more detailed feature of the invention, the scaffolding structure may be shaped to include a frame for receiving the product box and a plurality of baffles extending outwardly from the frame.

According to another aspect of the invention, there is provided a shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising (a) an outer box, the outer box comprising a cavity; (b) an insulation unit, the insulation unit disposed within the cavity of the outer box; (c) a liner assembly, the liner assembly removably mounted on or in the insulation unit, the liner assembly defining a receptacle having a cavity bounded by a bottom, four sides, and an open top, the liner assembly comprising (i) a first liner piece, wherein the first liner piece comprises a first planar sheet reversibly foldable into a first generally U-shaped structure; (ii) a second liner piece, wherein the second liner piece comprises a second planar sheet foldable into a second generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and (iii) a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; (d) a product box, the product box being removably disposed within the cavity of the liner assembly; and (c) at least one temperature-control member, the at least one temperature-control member being disposed within the cavity of the liner assembly.

In a more detailed feature of the invention, the shipping system may further comprise a riser, the riser may be removably disposed within the cavity of the liner assembly, and at least some of the at least one temperature-control member may be seated on the riser.

In a more detailed feature of the invention, the at least one temperature-control member may comprise dry ice.

In a more detailed feature of the invention, the at least one temperature-control member may comprise a flexible mat, the flexible mat may comprise exactly two pouches, each pouch may contain a quantity of phase-change material, and each pouch may substantially completely cover a surface of the product box.

According to yet another aspect of the invention, there is provided a kit for assembling a shipping system suitable for use in transporting and/or storing temperature-sensitive materials, the kit comprising (a) an insulation unit, the insulation unit shaped to include a cavity bounded by a bottom wall, four side walls, and an open top; (b) a liner assembly, the liner assembly being removably mounted on or in the insulation unit, the liner assembly being shaped to include a cavity, wherein the cavity of the liner assembly extends into the cavity of the insulation unit, wherein the liner assembly comprises (i) a first liner piece, wherein the first liner piece comprises a sheet foldable into a generally U-shaped structure; (ii) a second liner piece, wherein the second liner piece comprises a sheet foldable into a generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and (iii) a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; (c) a product box, the product box being removably disposed within the cavity of the liner assembly, the product box being designed to hold a payload; (d) an insulated lid, the insulated lid covering the cavity of the insulation unit; and (c) a plurality of alternative sets of temperature-control members, each alternative set of temperature-control members being removably disposed within the cavity of the liner assembly and being designed to maintain the payload within a different temperature range.

In a more detailed feature of the invention, the kit may further comprise a riser, and the riser may be removably disposed within the cavity of the liner assembly.

In a more detailed feature of the invention, the riser may comprise a rectangular frame having an opening, the opening may be dimensioned to receive the product box, and at least some of the temperature-control members may be positionable on the riser.

According to still another aspect of the invention, there is provided a kit for assembling at least one shipping system suitable for use in transporting and/or storing temperature-sensitive materials, the kit comprising (a) a first shipper, the first shipper comprising (i) a first insulation unit, the first insulation unit shaped to include a cavity bounded by a bottom wall, a plurality of side walls, and an open top, the plurality of side walls collectively defining a top edge, (ii) a first insulated lid, the first insulated lid removably mountable over the first insulation unit to close the cavity of the first insulation unit, (iii) a first liner assembly, the first liner assembly being removably mountable on or in the first insulation unit, the first liner assembly being shaped to include a cavity and a flange, wherein the cavity of the first liner assembly is dimensioned to extend into the cavity of the first insulation unit and wherein the flange of the first liner assembly is dimensioned to extend over the top edge of the first insulation unit, and (iv) a first product box, the first product box being removably positionable within the cavity of the first liner assembly, the first product box being designed to hold a payload; (b) a second shipper, the second shipper comprising (i) a second insulation unit, the second insulation unit shaped to include a cavity bounded by a bottom wall, a plurality of side walls, and an open top, the plurality of side walls collectively defining a top edge, (ii) a second insulated lid, the second insulated lid removably mountable over the second insulation unit to close the cavity of the second insulation unit, (iii) a second liner assembly, the second liner assembly being removably mountable on or in the second insulation unit, the second liner assembly being shaped to include a cavity and a flange, wherein the cavity of the second liner assembly is dimensioned to extend into the cavity of the second insulation unit and wherein the flange of the second liner assembly is dimensioned to extend over the top edge of the second insulation unit, and (iv) a second product box, the second product box being removably positionable within the cavity of the second liner assembly, the second product box being designed to hold a payload, wherein the second product box is dimensioned to hold a differently-sized payload than the first product box; (c) wherein each of the first and second liner assemblies comprises (i) a first liner piece, wherein the first liner piece comprises a sheet foldable into a generally U-shaped structure; (ii) a second liner piece, wherein the second liner piece comprises a sheet foldable into a generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and (iii) a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; and (d) a set of temperature-control members, the set of temperature-control members being dimensioned for alternative deployment in the cavity of the first liner assembly, snugly fitting around the first product box, or the cavity of the second liner assembly, snugly fitting around the second product box.

In a more detailed feature of the invention, at least some of the temperature-control members may comprise a container and a quantity of dry ice disposed within the container, and at least some of the containers may be self-contained closed structures that are separable from the other containers,

According to a further aspect of the invention, there is provided a method comprising (a) providing a shipping system of any of the types described above for use in transporting and/or storing temperature-sensitive materials; (b) using the shipping system to transport a first payload; (c) then, cleaning or replacing the liner assembly; and (d) then, using the shipping system to transport a second payload.

For purposes of the present specification and claims, various relational terms like “top,” “bottom,” “proximal,” “distal,” “upper,” “lower,” “front,” and “rear” may be used to describe the present invention when said invention is positioned in or viewed from a given orientation. It is to be understood that, by altering the orientation of the invention, certain relational terms may need to be adjusted accordingly.

Additional objects, as well as aspects, features and advantages, of the present invention will be set forth in part in the description which follows, and in part will be obvious from the description or may be learned by practice of the invention. In the description, reference is made to the accompanying drawings which form a part thereof and in which is shown by way of illustration various embodiments for practicing the invention. The embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense.

Referring now to, there are shown various views of a first embodiment of a shipping system suitable for use in storing and/or transporting temperature-sensitive materials, the shipping system being constructed according to the present invention and being represented generally by reference numeral. For clarity and/or case of illustration, certain details of shipping systemthat are discussed elsewhere in this application or that are not critical to an understanding of the invention may be omitted from one or both ofand/or may be shown in one or both ofin a simplified manner.

Systemmay be used to maintain a payload within a desired temperature range for an extended period of time. Solely for illustrative purposes and not to be limited thereto, systemmay be configured to maintain a parcel-sized payload within a temperature range of +2° C. to +8° C. for a period of up to 96 hours or longer or, alternatively, may be configured to maintain a parcel-sized payload within a temperature range of +15° C. to +25° C. for a period of up to 96 hours or longer or, alternatively, may be configured to maintain a parcel-sized payload within a temperature range of −15° C. to −25° C. for a period of up to 96 hours or longer. Systemmay comprise an outer box. Outer box, which may be, for example, a conventional corrugated cardboard box or carton, may comprise a rectangular prismatic cavitybounded by a plurality of rectangular side walls-through-, a plurality of bottom closure flaps (not shown), and a plurality of top closure flaps-through-. Adhesive strips of tape or other closure means (not shown) may be used to retain, in a closed condition, the bottom closure flaps and/or the top closure flaps-through-. A labelmay be adhered to or otherwise affixed to outer box.

Systemmay further comprise an insulation unit(seen best in). Insulation unitmay comprise a plurality of vacuum insulated panels-through-, which may be conventional and may be similar or identical to one another in size, shape and/or composition. Vacuum insulated panels-through-may be arranged with vacuum insulated panels-through-positioned perpendicularly relative to and sitting directly on top of vacuum insulated panel-so as to define a generally prismatic cavity bounded by a bottom wall and four side walls. The four side walls may be positioned relative to one another in a “pinwheel”-type arrangement, wherein one end of each vacuum insulated panel abuts the inside major surface of its adjacent vacuum insulated panel. Alternatively, the four side walls may be positioned relative to one another so that one end of each of two parallel vacuum insulated panels abuts the inside major surface of each of the two remaining parallel vacuum insulated panels.

Insulation unitmay additionally comprise a support. Support, which may be made of corrugated cardboard or the like, may be a blank adapted to be folded into a unitary box-like structure configured to include a central portionand four side portions-through-. (When folded, the adjacent edges of side portions-through-may be spaced apart by a small distance.) Central portionmay be rectangular, and each of four side portions-through-may extend upwardly from a different one of the four sides of the central portion. Supportmay be appropriately dimensioned so that the central portionof supportmay be positioned under vacuum insulated panel-and so that side portions-through-of supportmay be positioned along the outside faces of vacuum insulated panels-through-, as well as along the peripheral edges of vacuum insulated panel-. As will be discussed further below, supportmay be used, in conjunction with other structural members, to help keep vacuum insulation panels-through-assembled together. In addition, supportmay also provide some additional thermal insulation to insulation unit. A labelmay be affixed to support.

Insulation unitmay further comprise a plurality of plastic binding straps-through-. Straps-through-, which may be conventional binding straps, may be wrapped around the four sides of supportand may be used to help retain vacuum insulated panels-through-in an assembled state and to keep supportin a folded state. It is to be understood that, although three straps-through-are shown in the present embodiment, there could be as few as one strap or as many as four or more straps.

Insulation unitmay further comprise a plurality of corner boards-through-. Corner boards-through-may be identical to one another. Corner boards-through-may be made of Kraft paper and may have a thickness, for example, of 0.06 to 0.08 inch. Corner boards-through-may be positioned vertically at the four exterior corners defined by supportand may help to increase the thermal life of insulation unitby keeping panels-through-together and tighter for a longer period of time and by protecting supportand panels-through-from physical damage that may be caused by straps-through-, particularly at the four corners of insulation unit. Corner boards-through-also may help to increase the length of time that straps-through-are able to hold a minimal required tension in a reuse application.

Insulation unitmay be assembled as follows: First, supportmay be folded and then placed in a fixture (not shown), whereby side portions-through-may be maintained in a generally perpendicular orientation relative to central portion. Next, panel-may be positioned with its bottom major surface flush on top of central portion. Next, panels-through-may be positioned on top of panel-in a “pinwheel” arrangement. (Preferably, the seams of panels-through-face outwardly towards support.) Next, corner boards-through-may be placed around the exterior four corners defined by the support.

Next, straps-through-may be wrapped around supportand corner boards-through-. (Preferably, each of straps-through-provides a tension of at least 10 psi.) The resulting structure is a five-sided unit defining a cavity bounded by a bottom and four sides and having an open top. As can be appreciated, in the absence of the combination of support, straps-through-, and corner boards-through-, there is nothing keeping panels-through-in an assembled state.

Systemmay further comprise a liner assembly(seen best in). Liner assembly, which may be removably mounted on insulation unit, may comprise a two-piece liner, namely, a first liner pieceand a second liner piece, and may further comprise a liner support.

First liner piecemay comprise a sheet of material foldable into a generally U-shaped structure. More specifically, when folded, first liner piecemay include a bottom wallextending generally horizontally, a left inner wallextending generally perpendicularly upwardly relative to bottom wall, and a right inner wallextending generally perpendicularly upwardly relative to bottom wall, with left inner walland right inner wallextending from opposite ends of bottom wall. In addition, first liner piecemay further include a left top wallextending generally perpendicularly outwardly from the top of left inner walland a left outer wallextending generally perpendicularly downwardly for a short distance from the outer edge of left top wall. Moreover, first liner piecemay further include a right top wallextending generally perpendicularly outwardly from the top of right inner walland a right outer wall (not shown) extending generally perpendicularly downwardly a short distance from the outer edge of right top wallanalogously to left outer wall.

Second liner piecemay comprise a sheet of material foldable into a generally U-shaped structure. More specifically, when folded, second liner piecemay include a bottom wallextending generally horizontally, a front inner wallextending generally perpendicularly upwardly relative to bottom wall, and a rear inner wallextending generally perpendicularly upwardly relative to bottom wall, with front inner walland rear inner wallextending from opposite ends of bottom wall. In addition, second liner piecemay further include a front top wallextending generally perpendicularly outwardly from the top of front inner walland a front outer wallextending generally perpendicularly downwardly a short distance from the outer edge of front top wall. Moreover, second liner piecemay further include a rear top wallextending generally perpendicularly outwardly from the top of rear inner walland a rear outer wall (not shown) extending generally perpendicularly downwardly a short distance from the outer edge of rear top wallanalogously to front outer wall.

Each of first liner pieceand second liner piecemay be made of a material that is substantially liquid-impermeable and that may easily be cleaned if soiled, and first liner pieceand second liner piecemay be made of the same type of such a material. For example, first liner pieceand second liner piecemay be made of a molded polymer (such as a polyethylene terephthalate) or a similarly suitable material.

Liner supportmay be similar in structure to supportbut may be smaller in size so that liner supportmay be removably inserted into the cavity defined by vacuum insulated panels-through-of insulation unit. Liner supportmay comprise a single sheet of corrugated cardboard or similar material and may be folded to define a bottom, a front, a rear, a left side, and a right side. Liner supportmay be dimensioned so that, when liner supportis inserted into insulation unit, bottommay be seated on vacuum insulated panel-(or may be closely spaced therefrom), and one or more of left side, rear, right side, and frontmay be abutting vacuum insulated panels-through-, respectively (or may be closely spaced therefrom). Liner supportmay be incapable of maintaining a folded state on its own and may be maintained in a folded state by virtue of being snugly received within the cavity of insulation unit; alternatively, liner supportmay be maintained in a folded state on its own or may be maintained in a folded state by adhesive tape or other suitable means.

First liner piecemay be removably inserted into liner supportand, by virtue of being inserted into liner support, may be transformed from a generally planar state to the above-described folded state. (First liner piecemay be incapable of maintaining a folded state on its own.) When inserted into liner support, bottom wallof first liner piecemay be seated directly on top of bottomof liner support, left inner wallof first liner piecemay be positioned against or proximate to left sideof liner support, left top wallof first liner piecemay be positioned directly over or proximate to the top of left sideof liner support, and left outer wallof first liner piecemay be positioned parallel to and spaced a short distance away from left sideof liner support. In addition, right inner wallof first liner piecemay be positioned against or proximate to right sideof liner support, right top wallof first liner piecemay be positioned directly over or proximate to the top of right sideof liner support, and the right outer wall connected to right top wallmay be positioned parallel to and spaced a short distance away from right sideof liner support.

Second liner piecemay also be removably inserted into liner supportand, by virtue of being inserted into liner support, may be transformed from a generally planar state to the above-described folded state. (Second liner piecemay be incapable of maintaining a folded state on its own.) More specifically, bottom wallof second liner piecemay be seated directly on top of bottom wallof first liner piece, front inner wallof second liner piecemay be positioned against or proximate to frontof liner support, front top wallof second liner piecemay be positioned directly over or proximate to the top of frontof liner support, and front outer wallof second liner piecemay be positioned parallel to and spaced a short distance away from frontof liner support. In addition, rear inner wallof second liner piecemay be positioned against or proximate to rearof liner support, rear top wallof second liner piecemay be positioned directly over or proximate to the top of rearof liner support, and the rear outer wall connected to top wallmay be positioned parallel to and spaced a short distance away from rearof liner support.

First liner pieceand second liner piecemay be appropriately dimensioned so that, when insulation unitand liner assemblyare brought together, the top portions of liner support, vacuum insulated panels-through-, and supportmay be covered by the combination of first liner pieceand second liner piece. For example, the top portions of left sideof liner support, vacuum insulated panel-, and side-of supportmay be positioned between left inner walland left outer wallof first liner piece. In this manner, first liner pieceand second liner piecemay provide some protection to the top portions of vacuum insulated panels-through-. In addition, the inner-facing exposed surfaces of vacuum insulated panels-through-may be covered by (and, thus, protected by) bottom, left side, rear, right side, and front, respectively, of liner support. The protection to the inner-facing exposed surfaces of vacuum insulated panels-through-that is afforded by liner supportmay be particularly advantageous since first liner pieceand second linermay have exposed edges that otherwise could cause damage to vacuum insulated panels-through-. First liner pieceand second liner piecemay additionally provide some protection to the top, outer surfaces of vacuum insulated panels-through-.

Systemmay further comprise a riser(seen best in). Risermay be a unitary structure shaped to define a rectangular frame having a front-, a rear-, a left side-, a right side-, and a central opening. Riser, which may be made of a dimensionally stable foam or similarly suitable material, may be dimensioned to be removably received within the cavity jointly defined by first liner pieceand second liner piece. As will be discussed further below, risermay be used to position one or more temperature-control members relative to a product box also positioned in the cavity jointly defined by first liner pieceand second liner piece.

Referring now to, there is shown the assembled combination of insulation unitand liner assembly.

Referring back now to, systemmay further comprise a product box. Product boxmay be used to removably receive temperature-sensitive materials (not shown). Product box, which may be a conventional corrugated cardboard box, may be appropriately dimensioned to be removably received within the cavity collectively defined by first liner pieceand second liner piece. In the present embodiment, product boxmay be dimensioned to hold a payload volume of approximately 6L; however, it is to be understood that product boxmay be altered to accommodate a lesser or greater volume and/or may have a different shape than that shown.

Systemmay further comprise a plurality of temperature-control members-through-. Temperature-control members-through-, which may be identical to one another, may be appropriately dimensioned to be received, along with product box, within the cavity collectively defined by first liner pieceand second liner piece. Materials suitable for use as temperature-control members-through-are exemplified by, but are not limited to, conventional ice packs, conventional gel packs, or refrigerant packs of the type disclosed in U.S. Pat. No. 9,598,622 B2, inventors Formato et al., issued Mar. 21, 2017, and U.S. Patent Application Publication No. US 2018/0093816 A1, inventors Longley et al., published Apr. 5, 2018, both of which are incorporated herein by reference. A labelmay be affixed to each of temperature-control members-through-.

According to one embodiment, temperature-control members-through-may be in the form of flexible mats having a plurality of discrete sealed pouches, each pouchcontaining a quantity of a phase-change material (PCM). The phase-change material may be any phase-change material including any water-based or organic phase-change material. For example, if the phase-change material is water-based, the phase-change material may be water, a mixture of water and a thickener (e.g., a polysaccharide thickener) to produce a gelled water mixture, or a water/salt solution with an optional thickener.

Alternatively, if the phase-change material is an organic phase-change material, the phase-change material may be a gelled organic phase-change material, such as is disclosed in U.S. Pat. No. 9,598,622 B2 and U.S. Patent Application Publication No. US 2018/0093816 A1. More specifically, a suitable gelled organic phase-change material may comprise one or more n-alkanes, such as n-tetradecane (C14), n-pentadecane (C15), n-hexadecane (C16), n-heptadecane (C17), n-octadecane (C18), or combinations thereof, together with a gelling agent in the form of a styrene-ethylene-butylene-styrene triblock copolymer and/or a styrene-ethylene-propylene-styrene triblock copolymer. Solely for purposes of illustration, where, for example, systemis designed to keep a payload within a temperature range of +2° C. to +8° C., the gelled phase-change material may comprise a mixture of n-tetradecane (C14) and KRATON™ G1654 styrene-ethylene-butylene-styrene (SEBS) tri-block copolymer. Alternatively, where, for example, systemis designed to keep a payload within a temperature range of +15° C. to +25° C., the gelled phase-change material may comprise a mixture of n-hexadecane (C16) and KRATON™ G1654 styrene-ethylene-butylene-styrene (SEBS) tri-block copolymer. Each pouch of temperature-control members-through-may contain suitable masses of the phase-change material and the gelling agent for the particular application to which systemis put. For example, for the particular applications described above, each pouch may contain approximately 150-200 g of the n-alkane(s) and approximately 12-18 g of the gelling agent.

In the present embodiment, there are three temperature-control members-through-, and each of temperature-control members-through-has two generally rectangular pouches, each pouchbeing adapted to substantially cover the entirety of a different face of product box; however, it is to be understood that the number of temperature-control members-through-and the number and shape of pouchesin temperature-control members-through-are merely illustrative. Consequently, the number of temperature-control members, as well as the number and shape of pouchestherein, may be varied while still coming within the scope of the present invention. Moreover, while, in the present embodiment, each pouchof temperature-control members-through-contains the same quantity and type of phase-change material, this need not be so as some of temperature-control members-through-may contain different phase-change materials than others of temperature-control members-through-and/or different pouches of the same temperature-control member may contain different types of phase-change materials. Furthermore, although not shown in the present embodiment, systemmay include multiple layers of temperature-control members, such as an inner layer of temperature-control members and an outer layer of temperature-control members, which layers may contain the same or different phase-change materials.