Composite container

Abstract

There is disclosed composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container. The thermally insulated inner container is configured to receive one or more phase change material (PCM) elements to define a payload enclosure. The one or more PCM elements are configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. The composite container can be used to ship temperature-sensitive payloads such as perishable goods (e.g., a COVID-19 vaccine such as the Moderna COVID-19 vaccine).

What is claimed is: 
     
         1 . A composite container comprising a thermally insulated inner container disposed within a thermally insulated outer container, the thermally insulated inner container configured to receive one or more phase change material (PCM) elements to define a payload enclosure, the one or more PCM elements configured to maintain a payload disposed in the payload enclosure initially at −20° C. between 8° C. and −25° C., such as between 2° C. and 8° C. or between −15° C. and −25° C., for a period of at least 48 hours in an ambient temperature of up to 35° C. when tested pursuant to ISTA 7D Test Procedure. 
     
     
         2 . The container of  claim 1 , wherein one or both of the thermally insulated inner container and the thermally insulated outer container are made from a foam material. 
     
     
         3 . The container of  claim 2 , wherein the foam material is selected from the group consisting of expanded polypropylene (EPP), expanded polystyrene (EPS), expanded polyethylene (EPE), porous EPP and expanded PS/PE. 
     
     
         4 . The container of  claim 2 , wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from a different foam. 
     
     
         5 . The container of  claim 2 , wherein the thermally insulated inner container is made from EPS and the thermally insulated outer container is made from EPP. 
     
     
         6 . The container of  claim 2 , wherein the foam material has a density of at least about 1.5 pcf. 
     
     
         7 . The container of  claim 1 , wherein the inner container is separable from the outer container. 
     
     
         8 . The container of  claim 1 , wherein at least one of the inner container and the outer container is integral. 
     
     
         9 . The container of  claim 1 , wherein the inner container comprises an inner container lid element removably coupled to an inner container receptacle element. 
     
     
         10 . The container of  claim 1 , wherein the inner container is shaped as a cube or rectangular cuboid. 
     
     
         11 . The container of  claim 1 , wherein the outer container comprises a an outer container lid element removably coupled to an container receptacle element 
     
     
         12 . The container of  claim 1 , wherein the outer container is shaped as a cube or rectangular cuboid. 
     
     
         13 . The container of  claim 1 , wherein the one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −25° C. 
     
     
         14 . The container of  claim 1 , wherein one or more phase change material (PCM) elements are configured to be pre-conditioned to a temperature of at least about −30° C. 
     
     
         15 . The container of  claim 1 , comprising a plurality of phase change material (PCM) elements combining to define the payload enclosure. 
     
     
         16 . The container of  claim 15 , wherein a first phase change material (PCM) element is configured to be in abutting relationship with a second phase change material (PCM). 
     
     
         17 . The container of  claim 15 , wherein a first phase change material (PCM) element is configured to be in a detachably coupled relationship with a second phase change material (PCM). 
     
     
         18 . The container of  claim 1 , wherein the phase change material (PCM) element comprises a rigid container have disposed therein a gel material. 
     
     
         19 . The container of  claim 1 , wherein the container is configured to comply with ISTA 3A Test Procedure. 
     
     
         20 . The container of  claim 1  wherein the container is used to transport payload disposed in the payload enclosure from a shipping location to a destination location.