Method and system for storing and/or transporting temperature-sensitive materials

Abstract

Method and system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system is designed for use as a dry ice shipper and includes an outer box, a vacuum insulated panel (VIP) base assembly, a VIP lid assembly, and a gas flow director. The VIP base assembly is positioned within the outer box and includes VIPs arranged to form a 5-sided container with an open top. The VIP lid assembly, which may be coupled to a top closure flap of the outer box, includes a VIP dimensioned to close the open top of the VIP base assembly. The gas flow director, which may comprise a bag having an open top end folded over upon itself so as to be closed, but not sealed shut, may be positioned within the VIP base assembly, under the VIP lid assembly, to inhibit convective gas flow that promotes excessive dry ice sublimation.

What is claimed is: 
     
         1 . A system for storing and/or transporting a payload of temperature-sensitive materials, the system comprising:
 (a) an insulation base, the insulation base comprising a plurality of vacuum insulated panels joined together at one or more interfaces to define a cavity, the insulation base having an open top; and   (b) a gas flow director, the gas flow director comprising a receptacle having a top end, the top end comprising an opening, the receptable being adapted to receive a payload and a quantity of dry ice, the gas flow director being disposed within the cavity of the insulation base so as to reduce the egress of carbon dioxide gas from the cavity of the insulation base through the one or more interfaces.   
     
     
         2 . The system as claimed in  claim 1  wherein the insulation base is 5-sided and comprises a bottom vacuum insulated panel and four side vacuum insulated panels, the four side vacuum insulated panels joined to the bottom vacuum insulated panel. 
     
     
         3 . The system as claimed in  claim 1  further comprising an insulation lid, the insulation lid being removably positionable over the open top of the insulation base. 
     
     
         4 . The system as claimed in  claim 1  wherein the opening at the top end of the gas flow director is closed but not sealed airtight. 
     
     
         5 . The system as claimed in  claim 4  wherein the closed opening at the top end of the gas flow director is closed by folding the gas flow director over upon itself. 
     
     
         6 . The system as claimed in  claim 4  further comprising an insulation lid, the insulation lid being removably positionable over the open top of the insulation base, the closed opening at the top end of the gas flow director being positioned below the insulation lid when the insulation lid is positioned over the insulation base. 
     
     
         7 . The system as claimed in  claim 6  further comprising a payload box, the payload box being adapted to hold the temperature-sensitive materials and being removably received within the gas flow director. 
     
     
         8 . The system as claimed in  claim 7  further comprising a first refrigerant cassette, the first refrigerant cassette being adapted to hold a first quantity of dry ice and being removably received within the gas flow director. 
     
     
         9 . The system as claimed in  claim 8  wherein the first refrigerant cassette is positioned below the payload box. 
     
     
         10 . The system as claimed in  claim 9  further comprising a second refrigerant cassette, the second refrigerant cassette being adapted to hold a second quantity of dry ice and being removably received within the gas flow director above the payload box. 
     
     
         11 . The system as claimed in  claim 10  further comprising a scaffolding, the scaffolding being removably received within the gas flow director around the payload box to define a plurality of vertical cavities adapted to receive dry ice. 
     
     
         12 . The system as claimed in  claim 11  wherein the first refrigerant cassette further comprises dry ice, wherein the second refrigerant cassette further comprises dry ice, and further comprising dry ice in at least some of the plurality of vertical cavities. 
     
     
         13 . The system as claimed in  claim 1  wherein the opening at the top end of the receptacle is closable and sealable airtight and wherein the gas flow director further comprises a one-way valve mounted in the receptacle to permit gas to escape from the receptacle while preventing outside gas from entering the receptacle. 
     
     
         14 . A system for storing and/or transporting a payload of temperature-sensitive materials, the system comprising:
 (a) an insulation base, the insulation base comprising a plurality of vacuum insulated panels joined together at one or more interfaces to define a cavity for receiving the payload of temperature-sensitive materials, the insulation base having an open top;   (b) an outer box, the insulation base being disposed within the outer box; and   (c) a gas flow director, the gas flow director comprising a receptacle having an opening at a top end thereof, the gas flow director being disposed within the outer box so as to reduce the egress of gas from the cavity of the insulation base through the one or more interfaces.   
     
     
         15 . The system as claimed in  claim 14  wherein the gas flow director is disposed within the insulation base. 
     
     
         16 . The system as claimed in  claim 14  wherein the insulation base is disposed within the gas flow director. 
     
     
         17 . The system as claimed in  claim 14  further comprising an insulation lid, the insulation lid being removably positionable over the open top of the insulation base. 
     
     
         18 . The system as claimed in  claim 14  wherein the opening at the top end of the gas flow director is closed but not sealed airtight. 
     
     
         19 . The system as claimed in  claim 18  wherein the closed opening at the top end of the gas flow director is closed by folding the gas flow director over upon itself. 
     
     
         20 . The system as claimed in  claim 19  further comprising an insulation lid, the insulation lid being removably positionable over the open top of the insulation base, the closed opening at the top end of the gas flow director being positioned below the insulation lid when the insulation lid is positioned over the insulation base. 
     
     
         21 . A system for storing and/or transporting a payload of temperature-sensitive materials, the system comprising:
 (a) an insulation base, the insulation base comprising a plurality of pieces joined together at one or more interfaces to define a cavity for receiving the payload of temperature-sensitive materials, the insulation base having an open top;   (b) an outer box, the insulation base being disposed within the outer box; and   (c) a gas flow director, the gas flow director reducing the egress of gas from the cavity of the insulation base through the one or more interfaces, the gas flow director comprising a receptacle having a first opening, the first opening being located at a top end of the receptacle, the gas flow director being disposed within the outer box, with the first opening having at least some patency.   
     
     
         22 . The system as claimed in  claim 21  wherein the insulation base is disposed within the gas flow director. 
     
     
         23 . The system as claimed in  claim 21  wherein the gas flow director is disposed within the insulation base. 
     
     
         24 . The system as claimed in  claim 21  further comprising a quantity of dry ice positioned within the cavity of the insulation base. 
     
     
         25 . The system as claimed in  claim 21  further comprising a product box for receiving the payload of temperature-sensitive materials, the product box disposed within the cavity of the insulation base. 
     
     
         26 . The system as claimed in  claim 21  wherein the insulation base comprises a bottom and a plurality of sides and wherein the gas flow director covers substantially all of the bottom and the plurality of sides of the insulation base. 
     
     
         27 . The system as claimed in  claim 26  wherein the insulation base is 5-sided and comprises a bottom vacuum insulated panel and four side vacuum insulated panels, the four side vacuum insulated panels positioned on top of the bottom vacuum insulated panel. 
     
     
         28 . The system as claimed in  claim 26  wherein the gas flow director does not cover any of the open top of the insulation base. 
     
     
         29 . The system as claimed in  claim 26  wherein the gas flow director covers a portion, but not an entirety, of the open top of the insulation base. 
     
     
         30 . The system as claimed in  claim 21  wherein the receptacle comprises a flexible bag and wherein the flexible bag comprises a minimally breathable polymer film or sheet. 
     
     
         31 . The system as claimed in  claim 21  wherein the patency of the first opening is adjustable in size. 
     
     
         32 . The system as claimed in  claim 21  further comprising an insulation lid, the insulation lid being removably positionable over the open top of the insulation base. 
     
     
         33 . The system as claimed in  claim 32  wherein the first opening of the gas flow director is positioned below the insulation lid when the insulation lid is positioned over the insulation base.