Logistics system for managing thermal conditioning of unit loads of PCM panels and method of use

• US 9,798,994 B2
• Filed: 02/24/2014
• Issued: 10/24/2017
• Est. Priority Date: 02/24/2014
• Status: Active Grant

• Current Assignee: Peli Biothermal Limited (Pelican Products Holdings, Inc.)
• Original Assignee: Pelican BioThermal LLC (Pelican Products Holdings, Inc.)
• Inventors: Mayer, William T.
• Primary Examiner(s): JULES, FRANTZ F
• Assistant Examiner(s): Tanenbaum, Steve
• Application Number:
  US14/188,395
• Publication Number:
  US 20150241120A1
• Time in Patent Office: 1,338 Days
• CPC Class Codes: F25D 3/06 Movable containers
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management

Abstract

A logistics system for monitoring and signaling the thermal condition of unit loads of PCM panels during a thermal conditioning cycle as between deep frozen, thermally dampened frozen, and thermally spent, and method of managing thermal conditioning of PCM panels utilizing such signals.

Claims

1. A thermal conditioning logistics system for use with a pallet supporting a unit load of PCM panels configured and arranged to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet, the system comprising:

(a) a temperature sensor operable for periodically measuring the temperature of an environmental microcosm formed by a unit load of PCM panels supported on a pallet, and electronically transmitting such measured temperature values,

(b) an electronic data capture component operable for receiving and recording the periodically measured temperature values transmitted by the temperature sensor, and

(c) an electronic data processing and display control unit configured, arranged and programmed to compare the measured temperature to a threshold temperature value representative of a temperature at which a given phase change material transitions from deep frozen phase change material to thermally-dampened phase change material, and generate (i) a human perceptible first signal when the measured temperature is indicative of a deep frozen unit load of PCM panels on the pallet, and (ii) a human perceptible second signal when the measured temperature is indicative of a thermally-dampened unit load of frozen PCM panels on the pallet.

2. The system of claim 1 wherein the data processing and display control unit is further configured, arranged and programmed to provide a human perceptible third signal when the measured temperature is indicative of a thermally spent unit load of PCM panels on the pallet.

3. The thermal conditioning logistics system of claim 2 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

4. The system of claim 1 wherein the data processing and display control unit further includes a system clock, and the data processing and display control unit is programmed to provide a human perceptible third signal when the measured temperature has been at a temperature indicative of a thermally-dampened unit load of frozen PCM panels for a time period longer than a threshold durational value.

5. The thermal conditioning logistics system of claim 4 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

6. The system of claim 1 wherein the system further includes a display controlled by the display control unit, the display configured and arranged for (i) physical attachment to a pallet whereby an attached display is default transportable with the pallet, and (ii) display of the human perceptible signals generated by the data processing and display control unit.

7. The system of claim 6 wherein the display is physically integrated with the pallet.

8. The system of claim 1 wherein the human perceptible signals are visual signals.

9. The system of claim 8 wherein the first human perceptible signal is blue and the second human perceptible signal is green.

10. The system of claim 1 wherein the system further includes a display physically separate and independent from the pallet.

11. The system of claim 10 wherein the display is releasably attachable to the pallet.

12. The system of claim 1 wherein the temperature sensor, data capture component, and data processing and display control unit are all physically integrated into a single unitary element.

13. The system of claim 1 wherein the temperature sensor is an RFID temperature sensor.

14. The thermal conditioning logistics system of claim 1 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

32. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 14,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto a pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels, and

(g) transporting the complete pallet from the refrigerator unit to an assembly area for utilization in a shipping container, after the thermal conditioning logistics system generates the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels.

33. The method of claim 32 wherein the threshold temperature is set to the melt temperature of the phase change material in the PCM panels stacked on the complete pallet.

34. The method of claim 32 wherein the refrigerator unit is set to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the complete pallet.

35. The method of claim 34 wherein the threshold temperature is set to the melt temperature of the phase change material in the PCM panels stacked on the complete pallet.

36. The method of claim 34 wherein the refrigerator unit is set to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the complete pallet.

38. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 3,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto a pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels,

(g) transporting the complete pallet from the refrigerator unit to one of;

(i) an assembly area for utilization in a shipping container provided the thermal conditioning logistics system has generated the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels, and has not generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels, and

(ii) the freezer unit when the thermal conditioning logistics system has generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels.

40. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 5,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto a pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels,

(g) transporting the complete pallet from the refrigerator unit to one of;

(i) an assembly area for utilization in a shipping container provided the thermal conditioning logistics system has generated the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels, and has not generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels, and

(ii) the freezer unit when the thermal conditioning logistics system has generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels.

15. A thermal conditioning logistics system for PCM panels, comprising:

(a) a pallet operable for supporting a unit load of PCM panels configured and arranged to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(b) a temperature sensor operable for periodically measuring the temperature of an environmental microcosm in thermal communication with the sensor and electronically transmitting such measured temperature values, the sensor configured and arranged for integration into a unit load of PCM panels on the pallet whereby the temperature of the environmental microcosm in thermal communication with an integrated temperature sensor is governed by the temperature of the unit load of PCM panels,

(c) an electronic data capture component operable for receiving and recording the periodically measured temperature values transmitted by the temperature sensor, and

(d) an electronic data processing and display control unit configured, arranged and programmed to compare the measured temperature to a threshold temperature value representative of a temperature at which a given phase change material transitions from deep frozen phase change material to thermally-dampened phase change material, and generate (i) a human perceptible first signal when the measured temperature is indicative of a deep frozen unit load of PCM panels on the pallet, and (ii) a human perceptible second signal when the measured temperature is indicative of a thermally-dampened unit load of frozen PCM panels on the pallet.

16. The system of claim 15 wherein the data processing and display control unit is further configured, arranged and programmed to provide a human perceptible third signal when the measured temperature is indicative of a thermally spent unit load of PCM panels on the pallet.

17. The system of claim 16 wherein the system further includes a display controlled by the display control unit, the display configured and arranged for (i) display of the human perceptible signals generated by the data processing and display control unit in physical proximity to the pallet, and (ii) default transportation with the pallet.

18. The system of claim 16 wherein the human perceptible signals are color coded visual signals.

19. The system of claim 18 wherein the first human perceptible signal is blue, the second human perceptible signal is green and the third human perceptible signal is a color selected from white, red and orange.

20. The thermal conditioning logistics system of claim 16 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

21. The system of claim 15 wherein the data processing and display control unit further includes a system clock, and the data processing and display control unit is programmed to provide a human perceptible third signal when the measured temperature has been at a temperature indicative of a thermally-dampened unit load of frozen PCM panels for a time period longer than a threshold durational value.

22. The thermal conditioning logistics system of claim 21 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

23. The system of claim 15 wherein the pallet has load registration elements configured and arranged to encourage formation of a unit load having a predefined stacked arrangement of PCM panels on the pallet.

24. The system of claim 15 wherein at least one of the human perceptible signals is a flashing visual signal and at least one other of the human perceptible signals is a constant visual signal.

25. The system of claim 15 wherein the system further includes a remotely located display controlled by the display control unit for displaying the human perceptible signals generated by the data processing and display control unit correlated to a unique identifier for the pallet associated with the displayed human perceptible signals.

26. The system of claim 15 wherein the temperature sensor is physically integrated with the pallet.

27. The system of claim 15 wherein the temperature sensor is physically separate and independent from the pallet.

28. The system of claim 27 wherein the temperature sensor is releasably attachable to the pallet.

29. The system of claim 15 wherein the pallet, temperature sensor, data capture component, and data processing and display control unit are all physically integrated into a single unitary element.

30. The system of claim 15 wherein the temperature sensor is an RFID temperature sensor.

31. The thermal conditioning logistics system of claim 15 wherein the electronic data processing and display control unit (i) stores the threshold temperature value, (ii) generates the first human perceptible signal when the measured temperature is several degrees below the threshold temperature value, and (iii) generates the second human perceptible signal when the measured temperature is proximate the threshold temperature.

37. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 31,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto the pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels, and

(g) transporting the complete pallet from the refrigerator unit to an assembly area for utilization in a shipping container, after the thermal conditioning logistics system generates the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels.

39. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 20,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto the pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels,

(g) transporting the complete pallet from the refrigerator unit to one of;

(i) an assembly area for utilization in a shipping container provided the thermal conditioning logistics system has generated the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels, and has not generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels, and

(ii) the freezer unit when the thermal conditioning logistics system has generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels.

41. A method for thermal management of PCM panels, comprising the steps of:

(a) obtaining a thermal conditioning logistics system according to claim 22,

(b) stacking a unit load of PCM panels containing a phase change material having a known melt temperature onto the pallet so as to form an environmental microcosm whose temperature is governed by the temperature of the unit load of PCM panels on the pallet,

(c) placing the temperature sensor into thermal communication with the environmental microcosm to form a complete pallet,

(d) setting the threshold temperature to a temperature proximate the melt temperature of the phase change material in the PCM panels stacked on the pallet,

(e) placing the complete pallet in a freezer unit set to a temperature several degrees below the threshold temperature for purposes of forming a deep frozen unit load of PCM panels on the complete pallet,

(f) transporting the complete pallet from the freezer unit to a refrigerator unit set to a temperature capable of thermally-dampening deep frozen PCM panels, after the thermal conditioning logistics system generates the human perceptible first signal indicating that the unit load of PCM panels on the complete pallet is a deep frozen unit load of PCM panels,

(g) transporting the complete pallet from the refrigerator unit to one of;

(i) an assembly area for utilization in a shipping container provided the thermal conditioning logistics system has generated the human perceptible second signal indicating that the unit load of PCM panels on the complete pallet is a thermally-dampened unit load of frozen PCM panels, and has not generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels, and

(ii) the freezer unit when the thermal conditioning logistics system has generated the human perceptible third signal indicating that the unit load of PCM panels on the complete pallet is a thermally spent unit load of PCM panels.