The present disclosure relates generally to air freight shipping containers and, more particularly, to a passive temperature controlled packaging system meeting specifications for a unit load device (ULD).
A unit load device (ULD) is a pallet or container used to load luggage, freight, mail or other types of cargo into wide-body aircraft and into certain narrow-body aircraft. ULDs come in standard sizes that may be compatible with the specific aircraft in which they are loaded, and allow large quantities of cargo to be bundled into a single unit. Consolidation of the cargo into the ULDs leads to fewer individual units to load into the cargo area, thereby saving ground crews time and effort, and helping to keep flights on schedule. Typically, each ULD will have an accompanying packing list or manifest that allows the contents of the ULD to be tracked.
ULDs typically come in two forms: pallets and containers. ULD pallets are rugged sheets of aluminum with rims designed to lock onto cargo net lugs. The ULD pallets have fork openings for receiving forks of forklifts or other cargo handling equipment to move the ULDs onto and off of the aircraft. ULD containers, which may be referred to as cans and pods, are closed containers typically made of aluminum or a combination of a frame fabricated from aluminum and walls fabricated from Lexan or other appropriate polycarbonate material. Depending on the nature of the goods to be transported, a ULD container may have a built-in refrigeration unit for maintaining a specified temperature within the ULD container.
The refrigeration units in presently known ULD containers are active temperature control devices that operate to adjust the temperature inside the ULD container to keep the internal temperature within a specified temperature range. The active temperature control devices are electrical cooling and heating systems that operate in response to internal temperature sensors to regulate the internal temperature. Such active temperature control devices in ULD containers may be expensive and require routine maintenance to manage the mechanical components. Failure of the mechanical components can cause nearly immediate temperature excursions and spoilage of the temperature-reliant cargo stored therein, which can be particularly problematic for life saving pharmaceutical products.
Passive temperature control solutions, on the other hand, are insulated boxes or containers without any active temperature control. Consequently, passive temperature control packaging does not have systems to make temperature adjustments in response to changes in the internal temperature of the container. Existing passive temperature-controlled packaging solutions are not ULD containers, and typically do not conform to the standard sizes designated for ULD containers. The non-ULD containers are typically loaded onto ULD pallets for consolidation with other packages. Labor is required for the secondary step of positioning the passive temperature-controlled non-ULD containers on the ULD pallets and covering the non-ULD containers with cargo nets. This often leaves open space that is not consumed by cargo but still incurs cargo fees. The nonconformity of the passive temperature-controlled packaging may require additional labor and handling for loading the cargo onto aircraft, which can reduce aircraft loading efficiencies and result in departure delays. Moreover, the non-uniform containers may not have the same tracking capability and customs clearances as the ULD containers, which can further increase processing times through the air freight supply chain.
In one aspect of the present disclosure, a container suitable for use in a shipment of a cargo by air is disclosed. The container may include a container body having a top wall, a bottom wall, a front wall, a rear wall and oppositely disposed side walls, wherein the container body defines a cargo space within the container, and a passive temperature control system located within the cargo space. The passive temperature control system may include a plurality of insulation panels, wherein each of the plurality of insulation panels is connected to an inner surface of a corresponding wall of the container body, a rack proximate one of the top wall and one of the oppositely disposed side walls, the rack defining a slot, and a plurality of refrigerant bottles filled with a thermal medium. The plurality of refrigerant bottles and the thermal medium may be one of cooled and heated to a predetermined temperature for the cargo being shipped in the container and inserted into the slot of the rack to passively maintain a cargo space temperature in the cargo space during the shipment of the cargo.
In another aspect of the present disclosure, a container suitable for use in a shipment of a cargo by air is disclosed. The container may include a container body and a passive temperature control system. The container body may have a top wall, a bottom wall, a front wall, a rear wall and oppositely disposed side walls, wherein the container body defines a cargo space within the container, and wherein the container body may be fabricated as a structure that is a compliant unit load device (ULD) container meeting specified aviation authority structural requirements. The passive temperature control system is located within the cargo space and may have a plurality of insulation panels each connected to an inner surface of a corresponding wall of the container body, at least one rack proximate a corresponding one of the top wall and the oppositely disposed side walls of the container body, and a plurality of refrigerant bottles filled with a thermal medium and received by the at least one rack to passively maintain a cargo space temperature in the cargo space during the shipment of the cargo.
In a further aspect of the present disclosure, a refrigerant bottle for a container suitable for use in a shipment of a cargo by air is disclosed. The container may have an inner insulation layer and a rack proximate an insulation panel of the inner insulation layer and defining at least one slot. The refrigerant bottle may include a reservoir body that is sized to be inserted into the at least one slot of the rack, and a connection mechanism defined in the reservoir body and configured to connect a plurality of refrigerant bottles in series for insertion and removal of multiple refrigerant bottles into and out of the at least on slot together. The refrigerant bottle may be one of cooled and heated to a predetermined temperature for the cargo being shipped in the container and inserted into the slot of the rack to passively maintain a cargo space temperature in a cargo space of the container during the shipment of the cargo.
Additional aspects are defined by the claims of this patent.
As shown in
In the illustrated embodiment, the pallet 12, the outer enclosure 14 and a door 20 (i.e., container body) of the container 10 may be cubic and have dimensions that are compliant with particular ULD container specifications. In this embodiment, the container body designed and tested in accordance with specified requirements of the Federal Aviation Administration (FAA) or other appropriate national aviation authority to obtain certification for safe transport of cargo. For example, the container body may be designed and tested by a facility licensed with the aviation authority to meet the requirements of an applicable technical standards order (TSO), such as FAA TSO C90 for cargo pallets, nets and containers which is incorporated by reference herein, and with the test results scrutinized and accepted by the FAA or other aviation authority for issuance of certification indicating that the container body is a compliant ULD container.
In alternative embodiments, compliant and non-compliant ULD containers in accordance with the present disclosure may have an overall width that is larger than a base width depending on the particular ULD container specifications to which the ULD container is being constructed. The outer enclosure 14 as illustrated includes a top wall, a rear wall and oppositely disposed side walls that may be fabricated by thermoforming a plastic sheet using thermoforming techniques known in the art to form the top, rear and side walls as a single unitary component. The outer enclosure 14 may be thermoformed to add stiffness to the edges where the walls intersect so that additional reinforcing framework may be unnecessary. The outer enclosure 14 may be mounted to the pallet 12 and secured by appropriate attachment mechanisms (not show), such as rivets, nuts and bolts, screws and anchors, and the like. The door 20 may constitute a front wall of the outer enclosure 14 and container body, and may be connected to a front edge of one of the side walls by a hinge 22 to rotate between a closed position (
Referring to
To provide structural stability and stiffness to the internal structure of the cargo space 26, the container 10 and the passive temperature control system 16 may include a baseplate 30 that will rest on top of a bottom insulation panel 32 as shown in
Within the passive temperature control system 16 is a rack system (
The refrigerant bottles 40 are illustrated in greater detail in
The refrigerant bottles 40 may further include features to facilitate loading and unloading multiple bottles 40 in each slot. In the illustrated embodiment, a connection mechanism for adjacent refrigerant bottles 40 is formed by one or more bottle tabs 60 may extend outward at one end of the reservoir body 52, and a corresponding number of bottle sockets 62 may be defined in the opposite end of the reservoir body 52. The bottle tabs 60 and the bottle sockets 62 are configured to interlock as shown in
Returning to
The bottom insulation panel 32 may include corresponding break holes 88 (
While temperature control within the container 10 is a passive system, the container 10 may still include active elements for monitoring and tracking of the container 10. Consequently, the container 10 may include an onboard telemetry device (not shown) that provides worldwide communication for location tracking and condition monitoring. Temperature, along with the humidity, pressure, light, shock, tilt, door position, latch status and other parameters may be monitored via appropriate sensors. The information from the telemetry system may provide visibility allowing customers to drive risk out of transport of temperature dependent cargo through the air freight supply chain.
The containers 10 in accordance with the present disclosure may be effective to reliably transport temperature sensitive cargo. At the time of packing, the refrigerant bottles 40 and the thermal medium therein may be cooled or warmed to a desired temperature. The bottle tabs 60 and the bottle sockets 62 of adjacent bottles 40 may be interlocked so that multiple bottles 40 can be inserted into the slots in the racks 42, 44. After the cargo is loaded, the door 20 may be closed to passively yet reliably maintain a necessary temperature within the cargo space 26 during transit. After arrival and unloading of the cargo from the container 10, the front bottles 40 may be grasped by the handles 64 to pull the connected bottles 40 from the slots so they can be heated or cooled to the appropriate temperature for a subsequent shipment.
The passive temperature-controlled container 10 in the form of a ULD container, in contrast to previously known non-ULD passive temperature-controlled containers, more easily moves through the air freight supply chain, thereby reducing labor and handling requirements, reducing deliver time and flight delays, and increasing aircraft yield. Additionally, the passive temperature-controlled container 10 has many fewer failure paths that can cause changes in temperature within the container 10 that can cause spoilage of temperature-sensitive cargo being transported therein.
While the preceding text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of protection is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.
It should also be understood that, unless a term was expressly defined herein, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to herein in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term be limited, by implication or otherwise, to that single meaning.