Thermally controlled packaging device and method of making

Abstract

A phase change device for controlling temperature within a confined environment, comprising a foam material, a phase change material, the phase change material being absorbed into the foam, and a protective covering encasing the foam material/phase change material. A method for making a phase change device for controlling temperature within a confined environment, comprising providing a phase change material, providing a foam material, absorbing the phase change material into the foam material, and sealing the foam material/phase change material within a protective covering.

1 . A phase change device for controlling temperature within an environment, comprising:
 a foam material with both macropores and micropores connected to macropores, wherein the foam material is characterized as having macropores of a diameter between about 100 to 400 microns, and micropores of a diameter between about 0.5 to 100 microns;   a phase change material, the phase change material being absorbed into the foam material; and   a protective covering encasing the foam material and phase change material.   
     
     
         2 . The device of  claim 1 , wherein the foam material is selected from the group consisting of phenolic foam, phenol-aldehyde resol resin, phenol derivatives, polyurethanes, polystyrenes, and mixtures and combinations thereof. 
     
     
         3 . The device of  claim 1 , wherein at least a portion of the micropores are in a lattice within a macropore. 
     
     
         4 . The device of  claim 2 , wherein the foam material is characterized as having a density between about 0.00069 to 0.00084 pounds per cubic inch. 
     
     
         5 . The device of  claim 1 , wherein the phase change material is selected from the group consisting of salts, hydrated salts, fatty acids, paraffins, and solutions and mixtures thereof. 
     
     
         6 . The device of  claim 5 , wherein the phase change material is a salt solution comprising sodium chloride, the salt composition being between about 20 to 23 weight percent of the solution. 
     
     
         7 . The device of  claim 1 , wherein the phase change material is absorbed into the foam material at greater than about 91 percent by volume, and greater than about 98 percent by weight. 
     
     
         8 . The device of  claim 1 , wherein temperature is controlled between about −19 to −21 degrees Celsius. 
     
     
         9 . The device of  claim 1 , wherein the protective covering comprises a Nylon layer, an adhesive layer, a white polyethylene layer, and an LLDPE sealant layer. 
     
     
         10 . The device of  claim 1 , wherein the protective covering comprises a 60 g Biax Nylon layer, an ink layer having a thickness of about 0.03 mils, an adhesive layer having a thickness of about 0.07 mils, and a white LLDPE layer having a thickness of about 2.5 mils. 
     
     
         11 . A method for making a phase change device for controlling temperature within a environment, comprising:
 providing a phase change material;   providing a foam material having both macropores and micropores connected to macropores, wherein the foam material is characterized as having macropores of a diameter between about 100 to 400 microns, and micropores of a diameter between about 0.5 to 100 microns;   a step for absorbing the phase change material into the foam material; and   a step for sealing the foam material/phase change material within a protective covering.   
     
     
         12 . The method of  claim 1 , wherein the foam material is selected from the group consisting of phenolic foam, phenol-aldehyde resol resin, phenol derivatives, polyurethanes, polystyrenes, and mixtures and combinations thereof. 
     
     
         13 . The method of  claim 12 , wherein at least a portion of the micropores are in a lattice within a macropore. 
     
     
         14 . The method of  claim 12 , wherein the foam material is characterized as having a density between about 0.00069 to 0.00084 pounds per cubic inch. 
     
     
         15 . The method of  claim 11 , wherein the phase change material is selected from the group consisting of salts, hydrated salts, fatty acids, paraffins, and solutions and mixtures thereof. 
     
     
         16 . The method of  claim 15 , wherein the phase change material is a salt solution comprising sodium chloride, the salt composition being between about 20 to 23 weight percent of the solution. 
     
     
         17 . The method of  claim 11 , wherein the phase change material is absorbed into the foam material at greater than about 91 percent by volume. 
     
     
         18 . The method of  claim 11 , wherein temperature is controlled between about −19 to −21 degrees Celsius. 
     
     
         19 . The method of  claim 11 , wherein the protective covering comprises a Nylon layer, an adhesive layer, a white polyethylene layer, and an LLDPE sealant layer. 
     
     
         20 . The method of  claim 11 , wherein step of absorbing the phase change material into the foam material is accomplished in between about 15 to 45 seconds. 
     
     
         21 . The method of  claim 11 , wherein the step of providing a foam material comprises providing a foam material workpiece wherein the average thickness to surface area ratio ranges from about 1% to about 8%. 
     
     
         22 . The method of  claim 11 , wherein the phase change material is absorbed into the foam material at greater than about 98 percent by weight. 
     
     
         23 . The method of  claim 11 , further comprising forming with a portion of the protective covering a pocket to receive the foam material and to hold the phase change material during absorption of the phase change material into the foam material. 
     
     
         24 . The method of  claim 23 , wherein the step of forming the pocket comprises forming a pocket with a depth greater than the thickness of the foam material received in the pocket. 
     
     
         25 . A device produced by the method of  claim 11 . 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . (canceled)