PALLETIZED LOAD REACTANT REGULATION HEATING

BACKGROUND

Many products are susceptible to damage due to extreme temperatures during shipping. Existing shipping methods are complex, time-consuming to implement and costly. Such existing shipping methods may not reliably protect the products during shipping in extreme temperatures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates an example thermal stabilization shipping system.

FIG. 2 is a flow diagram illustrating an example method for providing thermal stabilization during shipping.

FIG. 3 is a schematic illustration of an example heater of the thermal stabilization shipping system of FIG. 1.

FIG. 4 is a schematic illustration of another example heater of the thermal stabilization shipping system of FIG. 1.

FIG. 5 is a schematic illustration of another example heater of the thermal stabilization shipping system of FIG. 1.

FIG. 6 is a schematic illustration of another example heater of the thermal stabilization shipping system of FIG. 1.

FIG. 7 schematically illustrates another example thermal stabilization shipping system.

FIG. 8 is a sectional view of an example thermal stabilization unit of the thermal stabilization system of FIG. 7.

FIG. 9 is an exploded perspective view of an example implementation of the thermal stabilization unit of FIG. 8.

FIG. 10 is a partially exploded perspective view of the thermal stabilization unit of FIG. 9.

FIG. 11 is a schematic illustration of another example thermal stabilization shipping system.

FIG. 12 is an exploded perspective view of another example thermal stabilization shipping system with port is omitted for purposes of illustration.

FIG. 13 is a perspective view of the thermal stabilization shipping system of FIG. 12 be additionally provided with insulation and phase change material blankets.

FIG. 14 is a perspective view of the thermal stabilization shipping system of FIG. 13 with the installation phase change material blankets secured about a palletized load.

FIG. 15 is an enlarged perspective view illustrating a portion of the thermal stabilization shipping system of FIG. 14 illustrating one of the phase change material blankets of FIG. 14.

FIG. 16 is a perspective view of the thermal stabilization shipping system of FIG. 14 including additional insulation.

FIG. 17 is a perspective view of the thermal stabilization shipping system of FIG. 16 illustrate further securement of insulation about the palletized load.

FIG. 18 is a fragmentary sectional view of a portion of the thermal stabilization shipping system of FIG. 18.

FIG. 19 is a schematic illustration of the thermal stabilization shipping system of FIG. 12 omitting phase change material blankets and the insulation layers.

FIG. 20 is a top view of a palletized load of the thermal stabilization shipping system of FIG. 19.

FIG. 20 is a sectional view of the thermal stabilization shipping system of FIG. 19 taken along line 21-21.

FIG. 22 is a sectional view schematically illustrating an example thermal stabilization shipping unit prior to being implemented as part of the thermal stabilization shipping system of FIG. 19.

FIG. 23 is a sectional view schematically illustrating the thermal stabilization shipping unit of FIG. 22 after implemented as part of the thermal stabilization shipping system of FIG. 19.

FIG. 24 is a top view schematically illustrating an example implementation of the thermal stabilization shipping unit of FIG. 19.

FIG. 25 is a perspective view illustrating an example valve unit of the thermal stabilization shipping unit of FIG. 24.

FIG. 26 is a top view schematically illustrating another example implementation of the thermal stabilization shipping unit of FIG. 19.

FIG. 27 is a side view illustrating an example support of the thermal stabilization shipping unit of FIG. 26.

FIG. 28 is a top perspective view illustrating the support of FIG. 27.

FIG. 29 is an exploded perspective view of the support of FIG. 28.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIG. 1 schematically illustrates an example thermal stabilization shipping system 20. Thermal stabilization shipping system 20 protects palletized loads during shipping in extreme temperatures. As will be described hereafter, thermal stabilization shipping system 20 is relatively inexpensive and easily implemented.

Thermal stabilization shipping system 20 is for shipping a palletized load 22. Palletized load 22 comprises one or more articles that have been palletized, arranged to rest upon pallet 30 for shipment. In one implementation, palletized load 22 may comprise a three dimensional array of containers or boxes 23 containing the articles being shipped. Such articles being shipped may be susceptible to damage when experiencing extreme temperatures. For example, such articles may comprise electronic devices, such as laptop computers, tablet computers, personal data assistants and the like, which may have displays, such as liquid crystal displays, that may become damaged if exposed to prolonged temperatures below −30° C. During shipping, such as during shipping from China to Europe along the Trans-Siberian Railway, the palletized load 22 may encounter prolonged periods of cold temperatures that reach well below −30 degrees Celsius or even down to −40 degrees Celsius. Thermal stabilization shipping system 20 protects or reduces the likelihood or extent of damage to the articles of the palletized load 22 during shipping in such cold temperatures.

Thermal stabilization shipping system 20 comprises heater 34 which utilizes a supply of reactant 36. Heater 34 applies heat to palletized load 22 at selected times in response to one or more temperatures adjacent to, within or about palletized load 22. Heater 34 supplies additional heat to palletized load 22 at times when the temperature about or within palletized load 22 fall to a temperature at or below predefined threshold temperature which is based upon a minimum temperature specification of the articles forming palletized load 22. The minimum temperature specification of the articles is the minimum environmental temperature for the articles below which the articles may be susceptible to unacceptable levels of risk of damage. Heater 34 discontinues or reduces the rate at which heat is supplied to palletized load 22 at those times in which the temperature is at or above the predefined threshold temperature. As a result, heater 34 reduces the likelihood that palletized load will become damaged during shipping in extremely cold conditions. At the same time, heater 34 conserves heat producing resources at times when such additional heat may not be beneficial, prolonging the ability for heater 34 to protect palletized load 22 from damage due to cold conditions.

Heater 34 comprises exothermic composition 40 and regulator 42. Exothermic composition 40 comprises a composition that exothermically produces or releases heat to palletized load 22 when exposed to reactant (Rc) 36. In one implementation, exothermic composition 40 comprises a material or composition that generates heat upon being exposed to a gas. In one implementation, exothermic composition 40 comprise a material or composition that releases or produces heat upon being exposed to oxygen, such as oxygen in air. In one implementation, exothermic composition 40 comprises iron powder which oxidizes to produce heat when exposed to oxygen. For example, in one implementation, exothermic composition 40 comprises iron powder mixed with other ingredients such as water, activated carbon, vermiculite (one example of a porous material to facilitate air distribution), wood powder or sawdust (to preserve moisture) and salt. In one implementation, composition 40 comprises a commercially available composition such as those material sold under the mark UNIHEAT. In other implementations, other exothermic compositions may be employed for composition 40 in heater 34.

Regulator 42 controls or regulates the supply of reactant 36 to composition 40 to thereby control the timing and rate at which composition 40 reacts and is consumed to produce heat. In one implementation, regulator 42 regulates the supply of ambient air to composition 40. Such ambient air is obtained from the ambient environment surrounding palletized load 22 and within gaps or voids within and between boxes 23 of load 22. In other implementations, regulator 42 controls or regulates the supply of reactant 36 from a container, chamber or other enclosed volume. For example, in lieu of regulator 42 supplying air (oxygen) to composition 40 from the ambient air naturally surrounding load 22 or naturally occurring within voids within load 22, regulator 42 may supply air (or pure oxygen) from a container providing a contained volume of air (or pure oxygen). In some implementations, the air, oxygen or other gas within the container may be pressurized to store a greater amount of air or other gas (oxygen) within the container and to facilitate the flow of the air (or other gas) to composition 40.

In one implementation, regulator 42 comprises a passive regulator constricting a rate at which the reactant is supplied to the composition 40 such that the rate at which composition 40 is consumed and the corresponding rate at which composition 40 produces heat is slowed to prolong a period of time during which composition 40 may release heat. For example, in one implementation in which composition 40 produces heat upon being exposed to a reactant in the form of air (oxygen), such as when composition 40 comprises iron powder, regulator 42 may comprise an airflow constriction that is sized such that the maximum rate at which air may flow to composition 40 is less than the rate at which reactant (oxygen) that may be consumed by composition 40. In one implementation, composition 40 may be arranged in a stacked or layered fashion such that the airflow constriction of regulator 42 results in the different layers or stacks of composition 40 being consumed and releasing heat in a staged or layer by layer fashion to prolong the duration during which heat is produced by composition 40. In some implementations, regulator 42 may comprise an airflow or reactant flow constriction that varies to control or regulate the rate or timing at which composition 40 is consumed.

In one implementation, regulator 42 comprises an active regulator, automatically regulating the supply of reactant 36 to composition 40 in response to temperature. In one implementation, regulator 42 comprises a valve mechanism that automatically regulates supply of reactant 36 to composition 40 in response to temperature. In one implementation, the valve mechanism of regulator 42 automatically actuates from a completely closed state to an open state in which the reactant 36 is supplied to composition 40. In one example, the valve mechanism of regulator 42 is configured to actuate from the closed state to the open state at an activation temperature having a value of less than or equal to −10° C.

In one implementation, regulator 42 is configured to automatically actuate between different reactant supply states based upon temperature in a singular uni-directional fashion. For example, regulator 42 may be configured to be in a closed state until a threshold temperature occurs. In response to the threshold temperature being attained, regulator 42 actuates from a closed state to an open state, allowing the supply of reactant to composition 40. Once in the open state, regulator 42 does not return to the previous closed state.

In another implementation, regulator 42 is configured automatically actuate between the different reactant supply states in a bi-directional fashion. For example, regulator 42 may be configured to be in a closed state until a threshold temperature occurs. In response to the threshold temperature being attained, regulator 42 actuates from the closed state to an open state, supplying reactant to composition 40. The supply of reactant to composition 40 is continued until the temperature rises above the threshold temperature, at which point, regulator 42 returns to the closed state. The actuation of regulator 42 between the open state and the closed state may repeatedly occur, accommodating multiple temperature fluctuations during shipment (such as daytime and nighttime temperature fluctuations).

In some implementations, regulator 42 automatically actuates to different degrees at which reactant 36 is supplied to composition 40 in response to temperature. For example, regulator 42 may supply reactant 36 to composition 40 at a first non-zero rate at a first temperature within or about palletized load 22 and may supply reactant 36 to composition 40 at a second greater rate at a second colder temperature within or about palletized load 22. Regulator 42 may have a valve that automatically and gradually actuates to more open states in response to colder temperatures. In some implementations, the valve of regulator 42 may conversely automatically and gradually actuate to more closed or smaller opening states as the temperature rises.

In one implementation, regulator 42 may comprise a manual actuator, such as a lever, slide bar, manual actuated vent or the like which facilitates manual movement or actuation of a valve mechanism to control or regulate supply of reactant 36 to composition 40. For example, in one implementation, the composition 40 and the vent mechanism of the regulator 42 may be located near a center of load 22, wherein a manually movable rod extends from the vent mechanism to an exterior of the load 22, allowing manual movement of the vent mechanism between open and closed states by a person to adjust the supply of reactant 36, the consumption of composition 40 and the production of heat based on temperature conditions.

FIG. 2 is a flow diagram illustrating an example method 100 for thermally stabilizing palletized load 22 using system 20. As indicated by step 102, exothermic composition 40 is provided to palletized load 22. As indicated by step 104, the supply of reactant 36 (either from ambient surroundings or voids or from a storage container) to composition 40 is regulated by regulator 42 as described above. By regulating the supply of reactant 36 to composition 40, additional heat is supplied to palletized load 22 at times when the temperature about or within palletized load 22 fall to a temperature at or below predefined threshold temperature which is based upon a minimum temperature specification of the articles forming palletized load 22. The supply of heat is discontinued or the rate at which heat is supplied to palletized load 22 is reduced or slowed at those times in which the temperature is at or above the predefined threshold temperature. As a result, the likelihood that palletized load will become damaged during shipping in extremely cold conditions is reduced. At the same time, the heat producing resources are preserved or conserved at times when such additional heat may not be beneficial, allowing palletized load to be protected from damage due to cold conditions for longer periods of time. In those implementations where the supply of reactant 36 is also limited, the supply of reactant 36 is also preserved.

FIG. 4 schematically illustrates heater 134, one example of a heater that may be used as heater 34 in system 20. Heater 134 is similar to heater 34 except that heater 134 specifically comprises regulator 142. Regulator 142 comprises a valve mechanism 150 and actuation material 152. Valve mechanism 150 comprises a valve situated between a supply of reactant 36 (the supply being the ambient surroundings or voids, or a container) and composition 40. Valve mechanism 150 actuates between a completely closed or occluded state in which the further supply of reactant 36 to composition 40 is terminated and an open state in which reactant 36 may flow to composition 40.

Actuation material 152 comprises a material operably coupled to valve mechanism 150 so as to move valve mechanism 150 between the closed state and the open state in response to temperature or changes in temperature. For purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. The term “operably coupled” shall mean that two members and/or materials are directly or indirectly joined such that motion may be transmitted from one member to the other member directly or via intermediate members. The term “fluidly coupled” shall mean that two are more fluid transmitting volumes are connected directly to one another or are connected to one another by intermediate volumes or spaces such that fluid may flow from one volume into the other volume.

In one implementation, actuation material 152 contracts in response to a temperature drop with respect to a predefined value, wherein such contraction causes valve mechanism 150 to move further towards a completely open state. Conversely, actuation material expands in response to a temperature rise with respect to a predefined value, wherein such expansion causes valve mechanism 150 to move further towards the completely closed state. In one implementation, actuation material 152 comprises a wax material which expands and contracts to move valve mechanism 150. In other implementations, actuation material 152 may comprise other substances or materials. In some implementations, actuation material 152 may alternatively expand in response to a temperature drop while contracting in response to a temperature rise to move valve 150. Because regulator 142 moves valve mechanism 150 using actuation material 152, regulator 142 may automatically actuate valve 150 while omitting motors, pressurized reactant, batteries or other mechanisms that would consume power and that might become depleted over time.

FIG. 5 schematically illustrates heater 234, another example of a heater that may be used as heater 34 in system 20. Heater 234 is similar to heater 34 except that heater 234 specifically comprises regulator 242. Regulator 242 comprises valve mechanism 250, battery 252, pump 254 and temperature controller 256. Valve mechanism 250 comprises a valve situated between a supply of reactant 36 (the supply being the ambient surroundings or voids, or a container) and composition 40. Valve mechanism 250 actuates between a completely closed or occluded state in which the further supply of reactant 36 to composition 40 is terminated and an open state in which reactant 36 may flow to composition 40. In the example illustrate, valve mechanism 250 comprises a check valve configured to move to the open state in response to a predetermined pressure threshold being exceeded and to automatically return to a default closed state and the predefined pressure threshold is no longer being satisfied.

Battery 252 comprises a source of power for pump 256 and temperature controller 252. In one implementation, battery 252 is rechargeable. In some implementations, the operation of battery 256 is discontinued when the temperature is above a predefined threshold, preserving power within battery 252.

Pump 254 comprises a device to pump reactant 36 through valve mechanism 250 to composition 40. In one implementation, pump 254 pulses during pumping. In the example illustrated, pump 254 comprises a pneumatic pump to pump gas or oxygen to composition 40. Because regulator 242 utilizes pump 254 to assist in the flow of reactant 36 to composition 40, regulator 242 is active, not solely relying upon passive gas flow to composition 40. As a result, regulator 242 may provide composition 40 with reactant 36 at a higher rate such that heat is released from composition 40 at a higher rate so as to more quickly respond to drastic drops in temperature. As shown by FIG. 5, in one implementation, pump 254 is fluidly coupled or pneumatically coupled to and between valve mechanism 250 (on output side of valve mechanism 250) and composition 40, drawing reactant through valve mechanism 250. As indicated by broken lines, in another implementation, pump 254 may be fluidly coupled to and between valve mechanism 250 (the input side of valve mechanism 250) and the supply of reactant 36, pushing reactant through valve mechanism 250.

Temperature controller 256 comprises a temperature sensor to sense temperature and a processor or signal producing circuit that, in response to such sensed temperatures, transmit signals to pump 254 to selectively actuate pump 254. Temperature controller 256 transmits signals to pump 254 to increase the supply of reactant 36 to composition 40 in response to the sensed temperature falling about or within palletized load 22 falling to a temperature at or below predefined threshold temperature which is based upon a minimum temperature specification of the articles forming palletized load 22. Temperature controller 256 is further configured to transmit signals to pump 254 to slow or stop the supply reactant 36 to composition 40 at those times in which the temperature is at or above the predefined threshold temperature. As a result, the likelihood that palletized load will become damaged during shipping extremely cold conditions is reduced. At the same time, the heat producing resources are preserved or conserved at times when such additional heat may not be beneficial, allowing palletized load to be protected from damage due to cold conditions for longer periods of time.

In one implementation, temperature controller 256 actuates pump 254 between two states: an on state in which pump 254 pulses to periodically supply reactant 36 to composition 40 through valve 250 and an off state in which pump 254 does not operate, allowing valve 252 return to its default closed state discontinuing supply reactant 36 to composition 40. In another implementation, temperature controller 256 generates and transmits different control signals to pump 254 to actuate pump 254 to different pumping speeds or rates depending upon a temperature sensed by the temperature sensor of temperature controller 256. For example, in response to a temperature below a first predefined threshold, temperature controller 256 may transmit signals actuating pump 254 to a first pumping speed or rate. In response to a second temperature below a second colder predefined threshold, temperature controller 256 may transmit signals actuating pump 254 to a second greater pumping speed or rate. In response to a temperature below a third temperature colder than the second temperature, temperature controller 256 may transmit signals actuating pump 254 to yet a third pumping rate greater than the first and second pumping rates. As a result, regulator 242 may provide composition 40 with reactant 36 at a higher rate such that heat (H) is released from composition 40 at a higher rate in response to drastic drops in temperature. At the same time, regulator 242 does not supply composition 40 with reactant 36 at an excessive rate, beyond what the sensed temperature demands, to preserve power of battery 252, to preserve composition 40 and, in those implementations where the supply of reactant 36 is also limited, to preserve the supply of reactant 36.

FIG. 6 schematically illustrates heater 334, another example of a heater that may be used as heater 34 in system 20. Heater 334 is similar to heater 34 except that heater 334 specifically comprises regulator 342 and specifically utilizes reactant 36 compressed or pressurized within container 343. Regulator 142 comprises a valve mechanism 350, battery 252 and temperature controller 356. Valve mechanism 350 comprises a valve situated between container 343 containing pressurized reactant 36 and composition 40. Valve mechanism 350 actuates between a completely closed or occluded state in which the further supply of reactant 36 to composition 40 is terminated and an open state in which reactant 36 may flow to composition 40.

Temperature controller 356 is similar to temperature controller 256 except that temperature controller 356 utilizes the sensed temperature from its temperature sensing device to generate and transmit signals to valve mechanism 350 (rather than pump 254) to actuate valve 350 between one or more states. In such an implementation, valve 350 includes an actuator (electric solenoid, motor and cam arrangement or the like) which receives power from battery 252 and which moves valve 350 between the open and closed states in response to signals from temperature controller 356.

In one implementation, temperature controller 356 actuates valve mechanism 350 between two states: an open state in which valve mechanism 350 opens supply reactant 36 to composition 40 and a closed state in which valve mechanism 350 closes to discontinue supply of reactant 36 to composition 40. In another implementation, temperature controller 356 generates and transmits different control signals to valve mechanism 350 to valve mechanism 350 to different open states depending upon a temperature sensed by the temperature sensor of temperature controller 356. For example, in response to a temperature below a first predefined threshold, temperature controller 356 may transmit signals actuating valve 350 to a first open state in which reactant 36 flows at a first rate. In response to a second temperature below a second colder predefined threshold, temperature controller 356 may transmit signals actuating valve mechanism 350 to a second opening state providing a greater flow of reactant 36 to composition 40. In response to a temperature below a third temperature colder than the second temperature, temperature controller 356 may transmit signals actuating valve mechanism 350 to yet a third opening state facilitating the flow of reactant 36 to composition 40 at a greater rate. As a result, regulator 342 may provide composition 40 with reactant 36 at a higher rate such that heat (H) is released from composition 40 at a higher rate in response to drastic drops in temperature. At the same time, regulator 342 does not supply composition 40 with reactant 36 at an excessive rate, beyond what the sensed temperature demands, to preserve power of battery 252, to preserve composition 40 and to preserve the supply of reactant 36.

Because regulator 342 utilizes the pressure of reactant 36 within container 343 to move reactant 36 through valve 350 to composition 40, regulator 342 does not solely relying upon passive gas flow to composition 40. As a result, regulator 342 may provide composition 40 with reactant 36 at a higher rate (as compared ambient airflow) such that heat is released from composition 40 at a higher rate so as to more quickly respond to drastic drops in temperature. The same time, by utilizing the pressure within container 343 to drive reactant 36, pumps may be omitted.

As indicated by broken lines in FIG. 6, in some implementations, temperature controller 356 and battery 252 may be omitted in favor of actuation material 352. Actuation material 352 is identical to actuation material 152 (described above). In such an embodiment, regulator 342 is similar to regulator 142 except the regulator 342 utilizes pressurized reactant 36 within container 343 to assist in forcing reactant 36 to composition 40.

FIG. 7 schematically illustrates thermal stabilization system 420, an example implementation of thermal stabilization system 20. In the example implementation shown in FIG. 7, thermal stabilization system 420 comprises a heater box or thermal stabilization unit 423 comprising a carton, container or box 425 containing composition 40 and regulator 42 (and reactant 36 in some implementations) (schematically shown in FIG. 1). Unit 423 is centrally located between and amongst articles 23 of palletized load 22 upon pallet 30. For purposes of this disclosure, the phrase that a unit, box or container is centrally located within palletized load 22 means that the unit, box or container is spaced from opposite outer sides of the palletized load 22. In one implementation, the container or box 425 of unit 423 has dimensions that substantially match the dimensions of the containers or boxes containing articles 23. As result, unit 423 may be interchanged with such article containing boxes so as to not disrupt the stacking or packing pattern of load 22. Although FIG. 7 illustrates thermal stabilization system 420 as including a single thermal stabilization unit 423, in other implementations, system 420 may include multiple thermal stabilization units 423 dispersed throughout palletized load 22. In some implementations, thermal stabilization units 423 may be additional located along perimeters of load 22.

FIG. 8 schematically illustrates thermal stabilization unit 523, an example implementation of thermal stabilization unit 423. Thermal stabilization unit 523 comprises box 525, insulation 527, sealing enclosure 529, composition packages 531, flow gallery 533 and regulator 42. Box 525 surrounds and encloses the remaining components of unit 523. In some implementations, box 525 may have outer dimensions corresponding to the dimensions of the boxes of palletized load 22 containing articles 23. In some implementations, box 525 may include perforations to facilitate reactant supply from the surrounding area.

Insulation 527 comprises one or more layers of insulation surrounding sealed enclosure 529 and composition packages 531. In some implementations, insulation 527 may be omitted, such as where the trigger point for releasing heat by unit 523 is based upon the insulative properties of both containers containing articles 23.

Sealed enclosure 529 surrounds composition packages 531 to inhibit the flow of reactant 36 (oxygen or air in the example illustrated) to composition 40 (schematically shown). In one implementation, sealed enclosure 529 comprises a polymeric bag enclosing and sealed about composition packages 531. In other implementations, sealing enclosure 529 may have other configurations.

Composition packages 531 comprise packages or containers containing composition 40 (described above). Composition packages 531 include one or more openings through which reactant, such as air or oxygen, may pass into contact with composition 40. In the example illustrated, each of packages 531 includes one or more perforations or slits 535 through which the reactant may flow into contact with composition 40.

Flow gallery 533 comprises one or more structures forming a manifold, plenum or other flow passage through which reactant 36 may flow from regulator 42 to each of composition packages 531 and further through such composition packages 531 to composition 40. In one implementation, flow gallery 533 comprises a pair of perforated spacers spacing packages 531 opposite to regulator 42.

Regulator 42 is described above with respect to system 20. In operation, in response to temperature, regulator 42 selectively supplies reactant 36 (oxygen or air in one implementation) into sealed enclosure 529. In particular, regulator 42 supplies reactant 36 into flow gallery 533, wherein reactant 36 is allowed to pass to locations adjacent to composition packages 531 and further through perforations 535 so as to expose composition 40 to reactant 36. Upon being exposed to reactant 36, composition 40 exothermically produces or releases heat which is transmitted to palletized load 22 to protect articles 23 from thermal damage.

FIGS. 9 and 10 illustrate thermal stabilization unit 623, a particular implementation of thermal stabilization unit 523. Thermal stabilization unit 623 is configured to be deployed at a central location or at perimeter locations as part of a palletized load 22. Thermal stabilization unit 623 comprises box 625, insulation 627, sealing enclosure 629, composition packages 631, flow gallery 633 and regulator 642. Box 625 surrounds and encloses the remaining components of unit 523. In some implementations, box 625 may have outer dimensions corresponding to the dimensions of the boxes of palletized load 22 containing articles 23. In some implementations, box 625 may include perforations to facilitate reactant supply.

Insulation 627 comprises one or more layers of insulation surrounding sealed enclosure 629 and composition packages 631. Sealed enclosure 629 surrounds composition packages 631 to inhibit the flow of reactant 36 (oxygen or air in the example illustrated) to composition 40 (shown in FIG. 8). In one implementation, sealed enclosure 629 comprises a polymeric bag enclosing and sealed about composition packages 631. In other implementations, sealing enclosure 629 may have other configurations.

Composition packages 631 comprise packages or containers containing composition 40 (described above). Composition packages 631 include one or more openings through which reactant, such as air or oxygen, may pass into contact with composition 40. In the example illustrated, each of packages 631 includes one or more perforations or slits 635 through which the reactant may flow into contact with composition 40.

Flow gallery 633 comprises one or more structures forming a manifold, plenum or other flow passage through which reactant 36 may flow from regulator 642 to each of composition packages 631 and further through such composition packages 631 to composition 40. In one implementation, flow gallery 633 comprises a pair of perforated plates 634 separated by spacers spacing plates 634 to form a flow passage adjacent to and along packages 631 opposite to regulator 642.

Regulator 642 regulates supply of oxygen or air (the reactant in the example) into sealed enclosure 629 for exposing composition 40 such that composition 40 reacts and emits heat. Regulator 642 comprises base 644, valve mechanism 650 and actuator 651. Base 644 comprise a structure supporting valve mechanism 650 and actuator 651. Base 644 is sealed to sealed enclosure 629 between an interior and an exterior of sealed enclosure 629.

Valve mechanism 650 comprises a valve formed by openings 654 and grill 656. Openings 654 extend through base 644 between grill 656 and the interior of sealed enclosure 629. In the example illustrated, openings 654 extend opposite to the flow passage between plates 634 of gallery 633. Grill 656 comprises a plate having alternating grill panels 658 and grill openings 660. Grill 656 is movably supported and guided by base 644 for sliding linear movement between a closed position and an open position. In the closed position, grill panels 658 overlap openings 654 to inhibit flow through openings 654 and through valve mechanism 650. In the open position, grill openings 660 at least partially overlap openings 654 to permit flow-through openings 654 and through valve mechanism 650. In other implementations, valve 650 may have other configurations. For example, in other implementations, grill 656 may alternatively comprise a disk having grill panels 658 and grill openings 660, wherein grill 656 is configured to rotate between a closed position closing openings 654 and an open position opening openings 654 and valve 650.

Actuator 651 comprises a mechanism to move grill 650 between the closed position and the open position. In the example illustrated, actuator 651 contains actuation material 152 (described above), a material operably coupled to valve mechanism 150 so as to move valve mechanism 650 between the closed state and the open state in response to temperature or changes in temperature.

In one implementation, actuation material 652 contracts in response to a temperature drop with respect to a predefined value, wherein such contraction causes valve mechanism 650 to move further towards a completely open state. Conversely, actuation material expands in response to a temperature rise with respect to a predefined value, wherein such expansion causes valve mechanism 650 to move further towards the completely closed state. In one implementation, actuation material 652 comprises a wax material which expands and contracts to move valve mechanism 650. In other implementations, actuation material 652 may comprise other substances or materials. In some implementations, actuation material 652 may alternatively expand in response to a temperature drop while contracting in response to a temperature rise to move valve 650. Because regulator 642 moves valve mechanism 650 using actuation material 652, regulator 642 may automatically actuate valve 650 while omitting motors, pressurized reactant, batteries or other mechanisms that would consume power and that might become depleted over time.

In operation, in response to temperature, regulator 642 selectively permits reactant 36 (oxygen or air in one implementation) to flow into sealing enclosure 629. In particular, regulator 642 allows reactant 36 to flow into flow gallery 633, wherein reactant 36 is allowed to pass to locations adjacent to composition packages 631 and further through perforations 635 so as to expose composition 40 to reactant 36. Upon being exposed to reactant 36, composition 40 exothermically produces or releases heat which is transmitted to palletized load 22 to protect articles 23 from thermal damage.

FIG. 11 schematically illustrates thermal stabilization system 720, another example implementation of thermal stabilization system 20 shown in FIG. 1. Thermal stabilization system 720 is similar to thermal stabilization system 420 except that thermal stabilization system 720 comprises thermal stabilization units 723 and 724. Thermal stabilization units 723 are similar to thermal stabilization unit 523 except that thermal stabilization units 723 are configured to horizontally extend across a plurality of articles 523 and their containers. In the example illustrated, each unit 723 extends completely across palletized load 22, forming a layer of palletized load 22. Each unit 723 comprises a support structure 725, composition 40, regulator 42 and flow passage 727.

Support structure 725 comprises a structure configured to extend horizontally between multiple articles 23 so as to form a layer of palletized load 22 while supporting those articles above the layer. Support structure 725 contains composition 40, regulator 42 and flow passage 727. In one implementation, support structure 725 comprises a substantially horizontal box. In one implementation, support structure 725 may additionally include posts or a grid of supporting walls.

Composition 40 and regulator 42 are described above with respect to system 20. In the example illustrated, composition 40 is located in a central location of load 22 and in a central location with respect to the layer formed by support structure 725. As a result, heat generated by composition 40, upon being exposed to reactant 36, may emanate from a central or middle portion of load 22. In other implementations, composition 40 may alternatively be located at perimeter locations in the layer formed by support structure 725 to supply heat to the portions of load 22 where such portions of load 22 are more exposed to cold temperatures.

Flow passage 727 comprises a passage extending from an exterior of load 22 to composition 40. Flow path 727 extends between spaced apart consecutive and opposite surfaces 729 within palletized load 22. Flow path 727 may be formed by spacings or voids form between containers of articles 23 or may be formed by a structure such as a tube, pipe, hose, groove or channel. Flow passage 727 helps to ensure that reactant 36 (the oxygen in the air) may be adequately supplied at an adequate rate to composition 40. In the example illustrated, flow path 727 pneumatically connects the exterior air surrounding palletized load 22 to regulator 42 which is in turn fluidly coupled to composition 40. In other implementations, regulator 42 may alternatively be located at a perimeter of palletized load 22, wherein flow path 727 pneumatically connects regulator 42 to composition 40.

Thermal stabilization unit 724 is formed within pallet 30. As shown by FIG. 11, unit 724 comprises one or more chambers or cavities 730 containing composition 40 (schematically shown). In one implementation, composition 40 is sealed within each of chambers 40 but for being selectively connected to outside air by flow passage 734. Thermal stabilization unit 724 further comprises regulator 42 (described above) and flow passage 734. Flow passage 734 comprises a passage extending from regulator 42 to composition 40 contained in each of cavities 730. Based upon temperature, regulator 42 supplies reactant 36 (oxygen or air in the example) through flow passage 734 to compositions 40, whereby upon being exposed to reactant 36, compositions 40 react with the reactant to generate heat. Although unit 724 is illustrated as including a single flow path 734 and a single regulator 42 for servicing compositions 40 contained in each of chambers 730, in other implementations, unit 724 may include dedicated regulators 42 and dedicated flow passages 734 for the compositions 40 in the different chambers 730. In those implementations that contain dedicated flow passages 734 and dedicated regulators 42 for each of chambers 730 or for individual subsets of chambers 730, composition 40 within the different chambers 730 may be supplied with reactant at different times or at different rates to accommodate different temperatures that may be experienced at different horizontal locations of load 22.

FIG. 12 is an exploded perspective view illustrating thermal stabilization shipping system 820, an example implementation of thermal stabilization shipping system 20. Thermal stabilization shipping system 820 comprises pallet 830, bottom sheet 838, bottom tray 840, palletized load 922 (one article 23 of which is shown in FIG. 12), corner or edge protectors 843, insulation 848 (shown in FIG. 13), blankets 850A, 850B (shown FIG. 13), insulation 852 (shown in FIG. 16), top panel 854, insulation 856 (shown in FIGS. 17 and 18) and thermal stabilization unit 923.

Pallet 830 is similar to pallet 30. Pallet 830 underlies the palletized load 922 that serves as a platform for moving the palletized load 922. Pallet 830 comprises body 832 and phase change material 834. Body 832 is formed from foam, such as expanded polystyrene (EPS) so as to serve as a layer of insulation for the bottom of the cargo or palletized load 922. In the example illustrated, body 832 comprises a bottom surface having a two-dimensional array or grid of nine blocks 835 to facilitate material handling with forklifts and pallet jacks from all four sides. At the same time, the top side of body 832 facilitates stacking of containers or boxes to form palletized load 922.

Body 832 includes cavities 836. Cavities 836 comprise depressions formed into body 832 below the upper surface of body 832 with support palletized load 922. Cavities 836 each contain phase change material 834. In the example illustrated, cavities 836 contain cartridges, liquid bottles, liquid bags or other liquid containers 337 that contain phase change material 834. In one implementation, the containers 337 containing the phase change material 834 may comprise cut or separated portions or segments of blankets 850. In other implementations, cavities 836 may themselves comprise enclosed compartments that are fillable with phase change material 834 through fill passages integrated into body 832. Although body 832 is illustrated as including six symmetrically located in spaced cavities 836, in other implementations, body 832 may include a greater or fewer of such cavities 836.

Phase change material 834 has a composition such that it releases heat upon reductions in external air temperature. In particular, phase change material 834 undergoes a phase change from a liquid to a solid when the phase change material is exposed to a temperature at the phase change temperature of the phase change material 834. While undergoing the phase change, material 834 releases stored heat. In one implementation, the composition of phase change material 834 is adjusted or modified so as to specifically tune the phase change temperature of material 834 (the trigger point at which the greatest amount of heat is released) based upon a minimum temperature specification of the articles forming palletized load 922. By tuning the composition of the phase change material 834 based upon the minimum temperature specification of the articles, the stored heat within the phase change material is preserved until the release of such heat is most beneficial. In one implementation, the phase change material 834 has a phase change temperature based on a minimum temperature specification of the palletized load, wherein the phase change temperature is at least the minimum temperature specification and less than 5 degrees above the minimum temperature specification. In one implementation, phase change material 834 comprises a brine having a phase change temperature of −17° C. In other implementations, phase change material 834 may be provided with other phase change temperatures. In other implementations, phase change material 834 may be utilized in combination with other heat emitting materials or mechanisms carried within body 832. Although pallet 830 is described as being used with blankets 850, in other implementations, pallet 830 may be utilized independent of such blankets.

Bottom sheet 838 comprises a sheet of liquid impermeable material extending between a top of pallet 830 and palletized load 922. Bottom sheet 838 provides a liquid barrier to prevent palletized load 922 from experiencing condensation resulting from rising water vapor. Bottom sheet 838 extends across an entire upper surface of pallet 830 and drapes down alongside of pallet 830. As will be described hereafter with respect to FIGS. 17 and 18, during assembly of system 820, those downward extending portions of sheet 838 are subsequently secured in an upwardly extending position to wrap about a lower portion of palletized load 922. As a result, bottom sheet 838 provides a convection barrier, inhibiting cold air coming from below and in between different layers of insulation and blankets 850 along a perimeter of the palletized load. In one implementation, bottom sheet 838 comprises a sheet of polyethylene having dimensions of 1800×1600 mm, wherein pallet 830 has dimensions of 1200×1000 mm. In other implementations, bottom sheet 838 may be formed from other liquid impermeable materials and may have other dimensions.

Bottom tray 840 comprises a tray facing upwardly and located above sheet 838 and below palletized load 922. Bottom tray 840 cooperates with top tray 344 to facilitate and retain boxes or containers in a stacked arrangement. In some implementations, bottom tray 840 may be omitted.

Corner or edge protectors 843 extend along the corners of the rectangular stack of containers forming palletized load 22 to protect such corners from impact and provide alignment.

Although not shown, in some implementations, stretch wrap film may be applied about and along sides of pallet 830 and palletized load 22. Stretch wrap film 346 provides a water impermeable barrier between palletized load 22 and blankets 850. As a result, upon accidental puncturing of blankets 850, such liquids may not infiltrate palletized load 22 where such liquid may damage the products or articles being shipped. Such a stretch wrap film further stabilizes the palletized load or cargo. Insulation 848 comprises one or more layers of thermally insulative sheets or materials wrapped and secured about palletized load 922 between blankets 850 and palletized load 922.

Blankets 850 form an arrangement of blankets that overlap one another to extend along all four sides of palletized load 922. Blanket 850A underlies blanket 850B, extending more closely to palletized load 922 along a top of palletized load 922. In the example illustrated, side portions of blanket 850A include compartments 854 containing phase change material 834 while having a top portion that omits compartments. In other implementations, the top portion may alternatively include compartments 854, wherein such compartments 854 contain a lesser amount of phase change material 834 or wherein such compartments 854 are empty and substantially flat. As a result, the compartments and phase change material of blanket 850B that overlies the top portion of blanket 850A remain closer to palletized load 922, wherein the top portion of blanket 850B protects blanket 850A from being punctured along its top side. In addition, phase change material 834 more uniformly extends about the top and sides of palletized load 922.

Blankets 850A and 850B comprise compartments 854. FIG. 15 illustrates compartments 854 in detail. FIG. 15 further illustrates fill passages 856, fill valves 858 and Seals 860. As shown by FIG. 15, compartments 854 each comprise an elongate tubular chamber having a major dimension that extends along a vertical axis. In the example illustrated, compartments 854 form a row of vertically extending compartments. Because compartments 854 extend in a vertical direction (as compared to the horizontal direction of compartments 854, if a compartment 854 is punctured, only liquid above the puncture leaks. For example, if a puncture forms such as puncture 865, only phase change material 834 above the puncture hole (above line 866) will leak.

As shown by FIG. 14, in the example illustrated, each compartment 854 has a vertical height less than a height of an individual container or box of the stack of boxes that form palletized load 922. Each of the compartments 854 are further arranged in an aligned row also having a height less than the height of an individual container or box of the stack of boxes that form palletized load 922. Adjacent rows of compartments 854 are vertically separated from one another by a horizontally extending portion 870 that omits or does not contain a compartment. As a result, each of blankets 850 comprises multiple horizontally extending, vertically spaced rows of compartments 854, allowing blankets 850 to be segmented into a plurality of segments without the edges of such segments extending through the interior of a compartment 854. Thus, the vertical length or height of blankets 850 along a side of the palletized load may be easily trimmed or cropped based upon the number of boxes stacked to form palletized load 922. Alternatively, the compartments 854 of particular segments may be left empty.

In the example illustrated in FIG. 14, the palletized load 922 has a height formed from six stacked containers or boxes (shown in FIG. 19). Likewise, blankets 850 each have a height form from six segments or six horizontally extending rows of compartments 854. To accommodate an alternative palletized load having a height of only four stacked containers or boxes, each of blankets 850 may be modified by easily removing the lowermost two segments or rows of horizontally extending compartments 854. In other implementations, compartments 854 may be provided with a vertical height such that a plurality of consecutive vertical compartments 854, collectively, have a height that is slightly less than the height of an individual container or box forming the stack of palletized load 22. In such an implementation, the horizontal portions 870, extending between the vertically extending compartments 854 and omitting such compartments 854, will still align with the horizontal edges of the individual boxes forming the stack of palletized load 922. In other words, portions 870 align with the horizontal boundaries between adjacent containers or boxes. Consequently, blankets 850 may be easily trimmed to accommodate and substantially match different numbers of boxes or containers stacked upon one another to form palletized load 922. Alternatively, those compartments 854 which do not extend adjacent to a box containing articles being shipped may be left unfilled with phase change material 834 and may be simply folded and taped or otherwise secured over adjacent compartments 854 that are filled with phase change material 834. In other implementations, compartments 854 may have other heights such that compartments 854 overlapping the boundaries between adjacent containers or boxes of the stack of palletized load 22.

As further shown by FIG. 15, fill passages 856 comprise passages within, through or along blankets 850 by which phase change material 834 may be supplied to compartments 854. In the example illustrated, fill passages 856 extend along an upper end of each row of compartments 854 to service all of the compartments 854 of the row. In one implementation, fill passages 856 are formed by the lamination of the sheets forming blanket 350. In other implementations, separate tubular members may be inserted, attached are molded into blankets 850.

Valves 858 are located at a top of each of compartments 854 between the passage 856 and compartment 854. In the example illustrated, valves 858 comprise one-way valves which open to allow phase change material 60 to flow into compartments 854 from fill passages 856 but closed to inhibit reverse flow of phase change material 60 out of compartments 854 back into fill passage 456. Because valves 858 are located at the top of each compartment 854, the leaking of phase change material 834 back into fill passage 856 is reduced even upon failure of valves 858. In other implementations, other forms of valves may be employed. In still other implementations, valves 858 may be omitted, such as where inlet openings of compartments 854 are closed, such as through heat sealing, after being sufficiently filled with phase change material 834. In still other implementations, valves and fill passages may be omitted where the phase change material (such as a liquid brine) is deposited or is used to fill compartments 854 at the formation of blanket 850 such as when the compartments 854 (formed as bubbles) are being formed and sealed.

In example illustrated, once each compartment 854 has been filled with phase change material 834, seals 860 are further formed. Seals 860 seal off or close the ends of fill passages 856. As a result, leakage of liquid remaining in fill passage 856 is further inhibited. In one implementation, Seals 860 comprise a thermal heat seal, such as a heat seal formed with the heat seal clamping fixture. In other implementations, Seals 860 may be omitted.

As further shown by FIG. 15, in one implementation, each of blankets 850 further comprises a fabric or woven layer 874 on a face of each of blankets 850 that is to face palletized load 922. Layer 874 may be wrapped, bonded, welded, fastened or laminated to the polymeric sheets forming the rest of blankets 850. Layer 874 protects blankets 850 from abrasion, damage and puncturing when placed against palletized load 922. In other implementations, layer 874 may be applied to both sides or may be omitted.

Insulation 852 (shown in FIG. 16) comprises one or more layers of insulation formed about blankets 850. In the example illustrated, insulation 852 comprises two layers of roll stock insulation wrapped about blankets 850. Insulation 852 assists in retaining heat about palletized load 22.

Top panel 853 (shown the FIG. 7) comprises a panel of thermally insulative material. Panel 853 is placed over blankets 850. In one implementation panel 853 comprises expanded polyethylene (EPE). In other implementations, top panel 853 may comprise other thermally insulation materials or may be omitted.

Insulation 856 (shown in FIGS. 17 and 18) comprises one or more layers of insulation material formed about insulation 852 and further formed over top panel 853. In the example illustrated, insulation 856 comprises two layers of roll stock insulation. In the example illustrated, insulation 856 comprises the same thermally insulating material as insulation 848 and 852. Insulation 856 assists in retaining heat about palletized load 22. In one implementation, insulation 852 and 856 comprise closed cell polyethylene foam and provide a total insulation thickness of approximately 15 mm. Insulation 852 and insulation 856 retard heat transfer between the phase change material 834 and the outside environment. In one implementation, a stretch wrap film extends about insulation 856 to form a final cargo stabilizing water impermeable barrier about palletized load 922.

As shown by FIG. 17, insulation 856 is formed about insulation 852 and over panel 853. Insulation 856 is also secured by taping. As shown by FIG. 18, each of insulation 848, blankets 850, insulation 852 and insulation 856 extend along outer sides of palletized load 22 across a junction of palletized load 22 and pallet 830, and along sides of pallet 830. The ends of insulation 848, blankets 850, and insulation 856 terminate above the bottom 382 of the top deck of pallet 830. In the example illustrated, such ends terminate a minimum distance D of, for example, at least 10 mm above bottom 382 and, for example, no greater than 100 mm above bottom 382. As a result, reliable thermal seals formed at the junction of palletized load 22 and pallet 830. At the same time, the insulation and blankets along the sides of pallet 830 do not interfere with the use of material handling equipment such as forklifts and pallet jacks. As further shown by FIG. 17, sheet 838 is wrapped up across the lower ends of insulation 848, blankets 850, insulation 852 and insulation 856, and up alongside of insulation 856 where it is secured by taping 886. As a result, sheet 838 further protects the ends of the insulation layers and blankets 850 from fraying, abrasion and damage.

Thermal stabilization unit 923 (shown in FIGS. 12 and 19) cooperates with blankets 850 to protect palletized load 922 from thermal damage. Thermal stabilization unit 923 is similar to thermal stabilization unit 723 discussed above in that thermal stabilization forms a complete layer horizontally across the articles forming palletized load 922. As shown by FIG. 20, the articles 23 forming palletized load 922 are arranged in a “pinwheel” arrangement which results in a vertical vent or passage 927. Passage 927 provides a source of reactant air for thermal stabilization unit 923 and further serves as a passage for transferring heat produced by thermal stabilization unit 923. In other implementations, the articles of load 922 may be stacked or arranged in other fashions, eliminating passage 927.

FIGS. 19 and 21 illustrate thermal stabilization unit 923 in more detail. FIG. 19 illustrates thermal stabilization system 820 assembled, but omitting sheet 838, tray 840, corner protectors 843, panel 853 and the surrounding blankets 850, insulation layers and layers of stretch wrap or stretch film. As shown by FIG. 19, thermal stabilization unit 923 extends between the topmost articles of load 922 and panel 853. Because thermal stabilization unit 923 extends on a top of or proximate to a top of palletized load 922, thermal stabilization unit 923 is more responsive to outside environmental temperature drops, being less insulated from articles of palletized load 922. Because thermal stabilization unit 923 extends on a top of or proximate to a top of palletized load 922, the heat produced by thermal stabilization unit 923 is thermally conducted by phase change material 834 of blankets 850 along a top and along a sides of palletized load 923. Moreover, in the example illustrated in which thermal stabilization unit 923 is triggered to release heat at temperature higher than the temperature at which the change phase change material 834 of blankets 850 begins to release heat, the useful heat emitting life for blankets 850 is prolonged. In one implementation, thermal stabilization unit 923 has a heat emitting life and is configured to begin releasing heat at a temperature such that the heat emitting time periods of unit 923 and blankets 850 do not substantially overlap. In one implementation, phase change material 834 begins releasing heat at −20° C. while thermal stabilization unit 923 begins releasing heat at −10° C. In other implementations, other trigger points may be utilized.

In one implementation, pallet 830 further comprises thermal stabilization unit 724 as described above with respect to FIG. 11. As a result, palletized load 922 receives heat from thermal stabilization unit 923 located at a top of palletized load 922 and further receives heat from thermal stabilization unit 724 (shown in FIG. 11) located within pallet 830. Each layer of articles 922 is spaced from either unit 923 or unit 724 by a distance commensurate with provision of even heating to the articles 23 forming load 922 (the distance that heat is conducted through palletized load 922 from an individual thermal stabilization unit). In other implementations, pallet 830 may omit thermal stabilization unit 724, wherein one or more additional thermal stabilization units 923 may be provided between the top and bottom of palletized load 922 such that each layer of articles 922 is spaced from either a thermal stabilization unit 923 by distance commensurate with provision of even heating to the articles forming load 922.

As schematically shown by FIGS. 21 and 23, thermal stabilization unit 923 comprises container 930, exothermic composition 40 (described above), and regulator 942. Container 930 encloses and supports composition 40 and regulator 942. Container 930 supports structures that may overlie container 930 such as when thermal stabilization unit 923 is stacked below other articles 23 of palletized load 922. Container 930 further seals about composition 40, inhibiting exposure of composition 40 to reactant air, but for when such reactant air is supplied through and by regulator 942. Regulator 942 regulates the supply of reactant air to composition 40. In the example illustrated, regulator 942 is similar to regulator 142 (described above). Regulator 942 comprises valve mechanism 950 and actuation material 952. Valve mechanism 950 comprises an openable and closable vent or grill (similar to the grill of valve mechanism 650 described above with respect to FIG. 9) situated between a supply of reactant air and composition 40. In the example illustrated, air is supplied to valve mechanism 950 through (a) a hose, tube or pipe 953 (shown in FIGS. 14, 15 and 18) extending from a corner of the palletized load 922 and receiving air at the corner between the juncture of blankets 850 and (b) from an air portal 955 (shown in FIGS. 14, 21 and 23) extending from exterior perimeter of container 930 to valve mechanism 950. Valve mechanism 950 actuates between a completely closed or occluded state in which the further supply of reactant air to composition 40 is terminated and an open state in which reactant air may flow to composition 40. In one implementation, reactant air may be further supplied from passage 927 through an opening 959 within container 930.

In the example illustrated, valve mechanism 950 is supported so as to extend diagonally (oblique with respect to the floor and ceiling of container 930) from a top to bottom of container 930. As a result, the surface area of valve mechanism 950 and the size of the openings of valve mechanism 950 through which reactant air may flow when mechanism 950 is opened may be larger without substantially increasing the collective height of container 930 and palletized load 922. In other implementations, valve mechanism 950 may be provided at other orientations.

Actuation material 952 comprises a material operably coupled to valve mechanism 950 so as to move valve mechanism 950 between the closed state and the open state in response to temperature or changes in temperature. In the example illustrated, actuation material 955 is operably coupled to valve mechanism 950 by a rod 957, wherein actuation material 952 a located proximate to a perimeter of palletized load 922 while valve mechanism 950 is located proximate a center or midpoint of palletized load 922. Because actuation material 952 is located proximate to an exterior outer perimeter of palletized load 922, actuation material 952 is less insulated and may more quickly respond to external environmental temperature drops that may first affect the less insulated and less thermally protected outermost articles 23 of palletized load 922. In other implementations, actuation material 952 may be located in close proximity with valve mechanism 950 near a horizontal center point of palletized load 922. In yet other implementations, both valve mechanism 950 and actuation material 952 may be located proximate to a horizontal exterior of palletized load 922, proximate a side of palletized load 922.

As with actuation material 152, actuation material 952 contracts in response to a temperature drop with respect to a predefined value, wherein such contraction causes valve mechanism 950 to move further towards a completely open state. Conversely, actuation material expands in response to a temperature rise with respect to a predefined value, wherein such expansion causes valve mechanism 950 to move further towards the completely closed state. In one implementation, actuation material 952 comprises a wax material which expands and contracts to move valve mechanism 950. In other implementations, actuation material 952 may comprise other substances or materials. In some implementations, actuation material 952 may alternatively expand in response to a temperature drop while contracting in response to a temperature rise to move valve mechanism 950. Because regulator 942 moves valve mechanism 950 using actuation material 952, regulator 942 may automatically actuate valve 950 while omitting motors, pressurized reactant, batteries or other mechanisms that would consume power and that might become depleted over time.

FIGS. 22 and 23 schematically illustrate thermal stabilization unit 1023, an example implementation of thermal stabilization unit 923. FIG. 22 schematically illustrates thermal stabilization unit 1023 prior to being implemented as part of thermal stabilization system 820. As shown by FIG. 22, prior to being implemented, thermal stabilization unit 1023 comprises container 1030 and multiple spaced containers or packets 1039 of composition 40. Container 1030 seals about packets 1039 of material 40 and forms portal 1055 (shown in FIG. 23) between packets 1039. Portal 1055 comprises a volume or space between packets 1039 that is sized to receive valve mechanism 950. In the example illustrated, container 1030 comprises an internal carton or container 1060 providing structural support for container 1030 and a sealing layer 1062 comprising a bag, layer, film or coating that seals the interior of container 1060 from outside reactant air. Although illustrated as extending about an exterior of container 1060, sealing layer 1062 may alternatively be located along an interior of container 1060 or may be provided as part of container 1060. For example, in one implementation, container 1060 may comprise a cellulose or cardboard material enclosing or received by a bag serving as sealing layer 1062. In another implementation, container 1060 may itself be air impermeable, such as when container 1060 is formed from an air impermeable material (such as an imperforate polymer) or includes an air impermeable film, coating or other air impermeable layer.

In the example illustrated, sealing layer 1062 comprises a bottom opening 1064, removable cover 1066, top opening 1068, removable cover 1070 and perimeter cover portion 1072. Bottom opening 1064 comprises an opening extending through at least sealing layer 1062 and located so as to extend over passage 927 (shown in FIG. 19) when container 1030 is positioned as part of palletized load 922. Removable cover 1066 comprises a panel, sheet, door or the like covering a sealing off opening 1064. In one implementation, cover 1066 comprises a tear away panel or sheet adhesively secured to see layer 1062 across opening 1064 for being peeled away from opening 1064. In another implementation, cover 1066 may be integrally formed as a single unitary body with sealing layer 1062, wherein scores, partial perforations or the like facilitate separation of cover 1066 to open opening 1064.

Similar to bottom opening 1064, top opening 1068 comprises an opening extending through at least sealing layer 1062 and located so as to extend below passage 927 (shown in FIG. 19) when container 1030 is positioned as part of palletized load 922. Removable cover 1070 comprises a panel, sheet, door or the like covering and sealing off opening 1068. In one implementation, cover 1070 comprises a tear away panel or sheet adhesively secured to see layer 1062 across opening 1068 for being peeled away from opening 1068. In another implementation, cover 1070 may be integrally formed as a single unitary body with sealing layer 1062, wherein scores, partial perforations or the like facilitate separation of cover 1070 to open opening 1068. Openings 1064 and 1068 and their corresponding covers 1066, 1070 enable the interior of container 1030 to be pneumatically connected to passage 927 which serves as a source of reactant air in the center of palletized load 922 and would serve as a passage for vertically distributing heat within palletized load 922. In some implementations, passage 927 may facilitate the flow of reactant air to others thermal stabilization units 923, wherein such others thermal stabilization units 923 may not be pneumatically connected to the exterior palletized load 922 for reactant air. As a result, a majority of reactant air for multiple thermal stabilization unit 923 for palletized load 922 may be supplied through a single side opening or port and a single tube 953, reducing the extent to which the thermal barrier of the blankets 850 and outer insulation layers are compromised for the purpose of supplying reactant air. In some implementations, one or both of openings 1064, 1068 and covers 1066, 1070 may be omitted.

Perimeter cover portion 1072 comprises a portion of sealing layer 1062 along an outer perimeter edge of container so as to outwardly face away from palletized load 922. Perimeter cover portion 1072 is configured to be torn away, punctured or broken, opening the interior of sealing layer 1062 along an edge of container 1030. Perimeter cover portion 1072 is sized to facilitate insertion of valve mechanism 950 (shown FIG. 23) and actuation mechanism 952 (shown in FIG. 23) into portal 1055 of container 1030 from the outside. In one implementation, perimeter cover portion 1072 is weakened along its outer edges to facilitate puncturing or tearing. In another implementation, perimeter cover portion 1072 is adhesively secured to a remainder of sealing layer 1062 to facilitate peeling away of or separation of cover portion 1072.

Packets 1039 comprise perforate packages or containers of exothermic composition 40. In the example illustrated, packets 1039 are secured in place to container 1060 at spaced locations by either an adhesive 1075, such as spray glue, or two-sided tape 1077. Because packets 1039 are secured in place, packets 1039 may be retained at spacings to facilitate the flow of reactant air between and over such packets 1039 during generation of heat by composition 40. In the illustrated, container 1060 has a vertical height greater than the vertical height of packets 1039 to further facilitate the flow of reactant air within container 1060 when they subsequently inserted valve mechanism 950 is opened to supply reactant air. In one implementation, a clearance of at least 0.25 inches and nominally at least 0.5 inches between a top of packets 1039 and a sealing of container 1060 is provided.

FIG. 23 illustrates implementation of thermal stabilization unit 1023 as part of palletized load 922. FIG. 23 illustrates an example implementation wherein thermal stabilization unit 1023 is to be positioned on top of palletized load 922 as shown in FIG. 19. As a result, cover 1066 is removed while cover 1070 is left intact. In the example illustrated in FIG. 23, valve mechanism 1150 is provided at the end of an elongate, air impermeable tube 1153. When inserted into container 1030 through the punctured or torn away cover portion 1072 (shown in FIG. 22), the outer sides of tube 1153 sufficiently abut against or seal against sealing layer 1062 to inhibit the flow of reactant air between tube 1153 and sealing layer 1062 past valve mechanism 1150.

As discussed above with respect to thermal stabilization unit 923, actuation material 952 is operably coupled to valve mechanism 950 by rod 957. Actuation material 952 serves to selectively open and close valve mechanism 950 in response to changes in temperature proximate to the perimeter of container 1030.

FIG. 24 illustrates thermal stabilization unit 1023 in more detail. As shown by FIG. 24, container 1060 additionally comprises support posts 1180 extending between the floor and ceiling of container 1060. Support posts 1080 assist in supporting any overlying load placed on top of container 1030 and assist in maintaining airflow clearance above packets 1039.

FIG. 25 illustrates an example valve unit 1151 comprising a tube 1153 supporting valve mechanism 950 and containing actuation material 952 and rod 957. As shown by FIG. 25, tube 1153 includes bottom and top openings 1182, 1184 which are configured to be aligned with openings 1064 and 1068, respectively. Openings 1182 in 1184 facilitate airflow from passage 927 into the input side of valve mechanism 950.

FIG. 26 is a top view schematically illustrating thermal stabilization unit 1223, another implementation of thermal stabilization unit 1023. Thermal stabilization unit 1223 is identical to thermal stabilization unit 1023 except that thermal stabilization unit 1223 comprises support 1288. Those remaining components of thermal stabilization unit 1223 which correspond to components of thermal stabilization unit 1023 are numbered similarly. Support 1288 comprises a grid-like support structure extending from the floor of container 1030 to the ceiling of container 1030 to support any overlying load placed upon container 1030. Support 1288 further partitions and separate packets 1039 of exothermic composition 40.

FIG. 27 is a side view of a portion of support 1288. As shown by FIG. 27, support 1288 comprises walls 1290 (one of which is shown) having a series of channels 1292 formed therein. Channels 1292 facilitate the flow of reactant air throughout the interior of container 1060 from the discharge side 1293 of valve mechanism 950.

FIGS. 30 and 31 illustrate one example of support 1288. As shown by FIG. 29, the walls 1290 include corresponding upper and lower notches 1294, 1296, respectively, facilitating interlocking of walls 1292 forming a crisscross support structure as shown in FIG. 28. As a result, walls 1290 may be assembled or disassembled to modify the size or area of the grid provided by support 1288 to accommodate palletized loads having different lengths and widths. In other implementations, the grid of support 1288 may alternatively be formed by walls 1290 releasably or permanently joined to one another in other fashions or integrally formed as a single unitary body.

Although the present disclosure has been described with reference to example embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the claimed subject matter. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example embodiments and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements.

PALLETIZED LOAD REACTANT REGULATION HEATING

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