Phase change material insulation for containers

Abstract

Phase change materials (PCM) such as a liquid salt hydrate may be stored in capsules of various sizes and applied to fabrics and fibers to fabricate PCM features that provide passive temperature control for shipping containers and goods. In one implementation, PCM fabric covers may be placed over palletized cargo and over individual goods. Modular fabric pieces may be combined and interconnected to cover goods. Fabric covers may emphasize thermal performance over comfort or aesthetics when selecting microcapsule size and coating materials. In another implementation, PCM capsules may be combined with fiber filler, shaped as desired, and sealed within an exterior skin to produce rigid PCM panels having various shapes. Panels may be used to line interiors or exteriors of shipping containers or goods. Panels may be shaped to include contours that fit snugly against a desired surface, or to include interior portions in which goods can be fit into.

What is claimed is: 
     
         1 . A passive temperature control device for one or more goods during shipment, the passive temperature control device comprising:
 at least one outer layer;   at least one inner layer; and   at least one core positioned between the at least one outer layer and the at least one inner layer, wherein the at least one core comprises a phase change material including a plurality of polymer microcapsules containing a liquid salt hydrate;   wherein the passive temperature control device is configured to be conditioned in a cool environment to cool the phase change material to a desired temperature;   wherein the passive temperature control device is configured to provide passive temperature control for the one or more goods during shipment.   
     
     
         2 . The passive temperature control device of  claim 1 , wherein the passive temperature control device comprises a cover configured to be positioned about at least a portion of the one or more goods. 
     
     
         3 . The passive temperature control device of  claim 2 , wherein the at least one outer layer and the at least one inner layer each include a flexible thermal foil that is configured to reflect radiant heat. 
     
     
         4 . The passive temperature control device of  claim 2 , wherein the at least one core includes a flexible cloth having a coating comprising a plurality of the polymer microcapsules containing the liquid salt hydrate. 
     
     
         5 . The passive temperature control device of  claim 4 , wherein the coating is configured to cure as a semi-flexible rubberized coating. 
     
     
         6 . The passive temperature control device of  claim 2 , wherein the cover includes a first flexible portion and a second flexible portion, wherein the first flexible portion is more flexible relative to the second flexible portion. 
     
     
         7 . The passive temperature control device of  claim 2 , wherein the cover includes a first edge and a second edge, wherein the first and second edges overlap. 
     
     
         8 . The passive temperature control device of  claim 7 , wherein the first and second edges are coupled with each other. 
     
     
         9 . The passive temperature control device of  claim 1 , further comprising a conditioning indicator coupled with the passive temperature control device, wherein the conditioning indicator is configured to indicate a temperature of the at least one core. 
     
     
         10 . The passive temperature control device of  claim 1 , wherein the passive temperature control device is formed as an envelope having a body and an openable flap that define an interior envelope section for receiving the one or more goods therein. 
     
     
         11 . The passive temperature control device of  claim 1 , wherein the passive temperature control device comprises a panel that is sufficiently rigid to provide physical protection to the one or more goods. 
     
     
         12 . The passive temperature control device of  claim 11 , wherein the passive temperature control device is enclosed in a continuous exterior skin. 
     
     
         13 . The passive temperature control device of  claim 11 , wherein the at least one core comprises a composite including the plurality of polymer microcapsules, a plurality of structural fibers, and a binding material. 
     
     
         14 . The passive temperature control device of  claim 11 , wherein the panel is insertable within a shipping container configured to receive the one or more goods therein. 
     
     
         15 . The passive temperature control device of  claim 11 , wherein the panel is molded to receive the one or more goods within the panel. 
     
     
         16 . A container for shipping one or more goods, wherein the container comprises:
 a structure defining an interior for storing one or more goods within the interior; and   a passive temperature control device comprising:
 at least one outer layer; 
 at least one inner layer; and 
 at least one core positioned between the at least one outer layer and the at least one inner layer, wherein the at least one core comprises a phase change material including a plurality of polymer microcapsules containing a liquid salt hydrate, wherein the passive temperature control device is configured to be conditioned in a cool environment cool the phase change material to a desired temperature; 
   wherein the passive temperature control device is configured to provide passive temperature control for the one or more goods stored within the container.   
     
     
         17 . The container of  claim 16 , wherein the passive temperature control device comprises a cover configured to be positioned about at least a portion of the one or more goods. 
     
     
         18 . The container of  claim 16 , wherein the passive temperature control device comprises a panel positioned within the interior of the container. 
     
     
         19 . A method of manufacturing a passive temperature control device for one or more goods during shipment comprising the steps of:
 fabricating a core comprising a phase change material including a plurality of polymer microcapsules containing a liquid salt hydrate; and   applying additional layers to the core by sealing the core within an outer layer to produce a panel.   
     
     
         20 . The method of  claim 19 , further comprising:
 conditioning the panel by cooling the panel to a desired temperature; and   installing the panel about the one or more goods to provide passive temperature control to the one or more goods.