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

Abstract

Shipping system for storing and/or transporting temperature-sensitive materials. In one embodiment, the system includes an outer box having four side walls, bottom closure flaps, and top closure flaps. A vacuum insulated panel (VIP) is detachably coupled to one of the top closure flaps and is removably covered by a cover. An insulation unit is removably positioned within the outer box, the insulation unit including a plurality of VIPs arranged to define a cavity bounded by a bottom wall and four side walls. A disposable liner assembly is removably mounted on the insulation unit. The liner assembly includes a first liner piece, a second liner piece, and a liner support. A plurality of temperature-control members and a product box may be removably positioned in a cavity defined by the liner assembly. The temperature-control members snugly fit around all sides of the product box and each include a container containing dry ice.

What is claimed is: 
     
         1 . A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising:
 (a) an outer box, the outer box comprising a cavity;   (b) a product box, the product box disposed within the cavity of the outer box; and   (c) a plurality of temperature-control members disposed within the cavity of the outer box, at least some of the temperature-control members comprising a container and a quantity of dry ice disposed within the container, at least some of the containers being self-contained closed structures that are separable from other containers.   
     
     
         2 . The shipping system as claimed in  claim 1  wherein the product box is rectangular and comprises a top surface, a bottom surface, a front surface, a rear surface, a left side surface, and a right side surface and wherein the top surface, the bottom surface, the front surface, the rear surface, the left side surface, and the right side surface of the product box are completely covered by the plurality of temperature-control members. 
     
     
         3 . The shipping system as claimed in  claim 2  further comprising insulation disposed within the cavity of the outer box, the insulation being exterior to the product box and the plurality of temperature-control members. 
     
     
         4 . The shipping system as claimed in  claim 2  wherein the plurality of temperature-control members comprises exactly six temperature-control members and wherein each of the six temperature-control members contacts and completely covers a different one of the top surface, the bottom surface, the front surface, the rear surface, the left side surface, and the right side surface of the product box. 
     
     
         5 . The shipping system as claimed in  claim 1  further comprising a liner assembly, the liner assembly comprising a liner and a liner support, the liner assembly being removably mounted in the outer box. 
     
     
         6 . The shipping system as claimed in  claim 5  wherein the liner comprises a first liner piece and a second liner piece, wherein the first liner piece comprises a sheet reversibly transformable between a first planar structure and a first generally U-shaped structure, wherein the second liner piece comprises a sheet reversibly transformable between a second planar structure and a second generally U-shaped structure, and wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees. 
     
     
         7 . The shipping system as claimed in  claim 6  wherein the liner support is reversibly transformable between a third planar structure and a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on the liner support. 
     
     
         8 . The shipping system as claimed in  claim 1  wherein the plurality of temperature-control members comprises an upper container holding a first quantity of dry ice, a lower container holding a second quantity of dry ice, and a scaffolding structure disposed between the upper container and the lower container for use in defining one or more compartments for holding additional dry ice. 
     
     
         9 . The shipping system as claimed in  claim 8  wherein the scaffolding structure is shaped to include a frame for receiving the product box and a plurality of baffles extending outwardly from the frame. 
     
     
         10 . A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising:
 (a) an outer box, the outer box comprising a cavity;   (b) an insulation unit, the insulation unit disposed within the cavity of the outer box;   (c) a liner assembly, the liner assembly removably mounted on or in the insulation unit, the liner assembly defining a receptacle having a cavity bounded by a bottom, four sides, and an open top, the liner assembly comprising
 a first liner piece, wherein the first liner piece comprises a first planar sheet reversibly foldable into a first generally U-shaped structure; 
 a second liner piece, wherein the second liner piece comprises a second planar sheet foldable into a second generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and 
 a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; 
   (d) a product box, the product box being removably disposed within the cavity of the liner assembly; and   (e) at least one temperature-control member, the at least one temperature-control member being disposed within the cavity of the liner assembly.   
     
     
         11 . The shipping system as claimed in  claim 10  further comprising a riser, the riser being removably disposed within the cavity of the liner assembly, at least some of the at least one temperature-control member being seated on the riser. 
     
     
         12 . The shipping system as claimed in  claim 10  wherein the at least one temperature-control member comprises dry ice. 
     
     
         13 . The shipping system as claimed in  claim 10  wherein the at least one temperature-control member comprises a flexible mat and wherein the flexible mat comprises exactly two pouches, each pouch containing a quantity of phase-change material, each pouch substantially completely covering a surface of the product box. 
     
     
         14 . A kit for assembling a shipping system suitable for use in transporting and/or storing temperature-sensitive materials, the kit comprising:
 (a) an insulation unit, the insulation unit shaped to include a cavity bounded by a bottom wall, four side walls, and an open top;   (b) a liner assembly, the liner assembly being removably mounted on or in the insulation unit, the liner assembly being shaped to include a cavity, wherein the cavity of the liner assembly extends into the cavity of the insulation unit, wherein the liner assembly comprises
 (i) a first liner piece, wherein the first liner piece comprises a sheet foldable into a generally U-shaped structure; 
 (ii) a second liner piece, wherein the second liner piece comprises a sheet foldable into a generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and 
 (iii) a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; 
   (c) a product box, the product box being removably disposed within the cavity of the liner assembly, the product box being designed to hold a payload;   (d) an insulated lid, the insulated lid covering the cavity of the insulation unit; and   (e) a plurality of alternative sets of temperature-control members, each alternative set of temperature-control members being removably disposed within the cavity of the liner assembly and being designed to maintain the payload within a different temperature range.   
     
     
         15 . The kit as claimed in  claim 14  further comprising a riser, the riser being removably disposed within the cavity of the liner assembly. 
     
     
         16 . The kit as claimed in claimed in  claim 15  wherein the riser comprises a rectangular frame having an opening, wherein the opening is dimensioned to receive the product box, and wherein at least some of the temperature-control members are positionable on the riser. 
     
     
         17 . A kit for assembling at least one shipping system suitable for use in transporting and/or storing temperature-sensitive materials, the kit comprising:
 a first shipper, the first shipper comprising
 a first insulation unit, the first insulation unit shaped to include a cavity bounded by a bottom wall, a plurality of side walls, and an open top, the plurality of side walls collectively defining a top edge, 
 a first insulated lid, the first insulated lid removably mountable over the first insulation unit to close the cavity of the first insulation unit, 
 a first liner assembly, the first liner assembly being removably mountable on or in the first insulation unit, the first liner assembly being shaped to include a cavity and a flange, 
   wherein the cavity of the first liner assembly is dimensioned to extend into the cavity of the first insulation unit and wherein the flange of the first liner assembly is dimensioned to extend over the top edge of the first insulation unit,
 a first product box, the first product box being removably positionable within the cavity of the first liner assembly, the first product box being designed to hold a payload; 
   a second shipper, the second shipper comprising
 a second insulation unit, the second insulation unit shaped to include a cavity bounded by a bottom wall, a plurality of side walls, and an open top, the plurality of side walls collectively defining a top edge, 
 a second insulated lid, the second insulated lid removably mountable over the second insulation unit to close the cavity of the second insulation unit, 
 a second liner assembly, the second liner assembly being removably mountable on or in the second insulation unit, the second liner assembly being shaped to include a cavity and a flange, wherein the cavity of the second liner assembly is dimensioned to extend into the cavity of the second insulation unit and wherein the flange of the second liner assembly is dimensioned to extend over the top edge of the second insulation unit, 
 a second product box, the second product box being removably positionable within the cavity of the second liner assembly, the second product box being designed to hold a payload, wherein the second product box is dimensioned to hold a differently-sized payload than the first product box; 
   wherein each of the first and second liner assemblies comprises (i) a first liner piece, wherein the first liner piece comprises a sheet foldable into a generally U-shaped structure; (ii) a second liner piece, wherein the second liner piece comprises a sheet foldable into a generally U-shaped structure, wherein the first and second liner pieces are arranged offset from one another by approximately 90 degrees; and (iii) a liner support, wherein the liner support is foldable into a structure having a bottom, four sides, and an open top, and wherein the first liner piece and the second liner piece are arranged on or in the liner support; and   a set of temperature-control members, the set of temperature-control members being dimensioned for alternative deployment in the cavity of the first liner assembly, snugly fitting around the first product box, or the cavity of the second liner assembly, snugly fitting around the second product box.   
     
     
         18 . The kit as claimed in  claim 17  wherein at least some of the temperature-control members comprises a container and a quantity of dry ice disposed within the container, at least some of the containers being self-contained closed structures that are separable from the other containers. 
     
     
         19 . A method comprising:
 providing the shipping system of  claim 1 ;   using the shipping system to transport a first payload;   then, cleaning or replacing the liner assembly; and   then, using the shipping system to transport a second payload.   
     
     
         20 . A method comprising:
 providing the shipping system of  claim 10 ;   using the shipping system to transport a first payload;   then, cleaning or replacing the liner assembly; and   then, using the shipping system to transport a second payload.