Note: Descriptions are shown in the official language in which they were submitted.
PASSIVE AND FORCED AIR COOLING FOR FRESII PRODUCE
BACKGROUND
The present invention relates to vented rigid plastic produce containers and
the
corresponding corrugated or plastic master shipping tray. More particularly,
the present
invention relates to a system or method of improved cooling of fresh produce
held within such
containers in both a passive stacked ventilation environment such as a field
or cooling dock and
in a horizontal forced air cooling system. hi addition, the present invention
also relates to the
creation of a new preferred case configuration with improved synchronized
venting structures,
unique air flow pathways, increased pallet cube, and superior cooling.
Horticultural crops are living organisms after harvest and must remain alive
and
healthy until they are processed or consumed. The energy needed to stay alive
comes from
food reserves in the produce through a process called respiration. Heat energy
is released
during respiration; however, the rate of release depends on the type of
produce, maturity,
injuries and internal temperature. Of these factors, produce temperature has
the most
influence on respiration. Rapid, uniform cooling immediately after harvest to
remove field
and product heat helps slow respiration and provide a longer shelf life. As a
rough guide, a
one-hour delay in cooling reduces a product's shelf life by one day. Although
this is not true
for all crops, it applies to very highly perishable crops during hot weather.
Lowering the
temperature also reduces the rate of ethylene production and moisture loss, as
well as the
spread of micro-organisms and deterioration from injuries to the fruit's
surface.
Berry crops, that grow in warm to hot weather, including strawberries,
raspberries,
blackberries, and blueberries are valuable and highly perishable commodities
with a high rate
of respiration. Of all these berry crops only blueberries are picked, sorted
by size, and pre-
cooled prior to packaging into vented rigid plastic containers of various
sizes and shapes for
sale. All other berry commodities are field packed directly from the plant or
bush into vented
rigid retail packaging that trap both field heat and product heat generated by
core fruit
temperature and respiration. These vented retail packages are often referred
to as
"clamshells" based on the nature of these containers being of a hinged middle
with both a
base and lid. These containers are the most widely used packaging products to
deliver berry
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crops and other produce commodities from the field to the consumer's
refrigerator; billions of
containers are packed each year worldwide.
Both the box/master case and the clamshells are vented to draw out the heat of
the
produce post-harvest to a "7/8" ratio as fast as possible in a process known
as forced air cooling
to control the rate of respiration and decay of the produce. There are three
main types of forced
air cooling (F.A.C.) with tunnel or straight horizontal airflow systems,
column vertical airflow
systems, and serpentine vertical/ horizontal airflow systems. Forced air
cooling with tunnel or
straight horizontal airflow systems are the most common with berry crops. In
this system, a
fan generates a vacuum either directly into a pallet or into a tunnel
separating a multi pallet
system. The top and the ends of the pallets are tarped to reduce short circuit
air flow during
the cooling process. This suction or vacuum is intended to draw out the hot or
warm air from
the produce and suck out all the trapped field heat, replacing it with cold
air from the cooler.
A "7/8" ratio is the industry standard when cooling berry crops, meaning the
time needed to
remove seven-eighths (87.5%) of the temperature difference between the initial
temperature
of produce and the temperature of the cooling medium (for forced air cooling
systems, the
cooling medium is refrigerated air ranging from 32-36 degrees).
The time is measured from the moment produce is first placed in the forced-air
cooler
to the moment it reaches the desired temperature. Achieving "7/8" cool time
ensures most of
the field heat and core product heat have been removed, the respiration rate
of the produce
has been lowered and the produce is very close to its optimum holding
temperature. In
theory, produce never reaches the cooling medium temperature. However, the
"7/8" cooling
process is intended to get produce as close as practical to the temperature of
the cooling
medium before release for sale.
Considering that most berry crop production is tied to warm or hot daily
temperatures
and long exposure to sunlight, the largest seasonal volumes will also coincide
with wannest
and longest days. Therefore, the greatest production of any berry crop will be
tied to the late
spring and early summer months of the year where production often exceeds
available
cooling capacity and thus increasing cooling times and respiration rates.
During the peak of
the season, picking and cooling times can often range from 1.5 to 4 hours per
pallet creating
poor conditions for fruit. Often pallets of fresh berries wait outside the
cooling facility on the
dock in shaded area for hours until a free spot opens up inside the cooler to
start the "7/8"
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cooling process. In such a delayed cooling environment, ripe fruit is often
left on the plant or
bush and never harvested due to the high perish rate and long cooling times.
The two main components that can reduce cooling times during these peaks are
the
produce box/master case/returnable plastic container and the rigid plastic
container.
However, produce boxes are manufactured by paper converters or injection
molded plastic
manufacturers while the plastic rigid containers are made by manufacturers
that convert rigid
plastic through a process known as thermoforming. These three businesses don't
work in
parallel to create the best uniform cooling process, but rather have separate
engineering and
development groups that work within their own processes to design, engineer,
and bring to
market the most cost effective product with little understanding of the
process as to how these
components can work together as one unit to cool fruit more efficiently.
Growers often purchase their rigid packaging needs and boxes based on price,
availability, and service, not based on any fundamental link between the box
ventilation of
one company and the clamshell design or ventilation of another company. This
link could
help save or capture millions of dollars each season based on improving
cooling times,
increased product availability, superior product quality, better shelf life,
and by lowering
costs.
Ventilation patterns of produce boxes/ master cases and rigid plastic
containers may
differ greatly across the industry, but all of the commodity boxes/containers
and commodity
clamshells have a uniform shape and size that is of a fixed length, width, and
height to
accommodate predetermined packaged units of saleable fruits or vegetables at
retail.
Moreover, the USDA has determined that all packaged produce must be priced
based on
weight or cubic volume with specific regulations that are controlled and
policed by a division
of the USDA called Weights and Measures. Underweight packages may result in
high fines,
penalties, and even the suspension or termination of the grower or shippers'
P.A.C.A. licenses.
Some basic weights of measure for the berry industry are the 6 oz., 12 oz.,
11b., 1 g oz., 21b., and
the 41b. club store packages. The USDA also states that the weight on the
package must "weigh
out" not only at the grower level but all the way through distribution, sale
at retail, and finally on
to the consumer's refrigerator.
The standardization of corrugated boxes/trays/returnable plastic containers
and the
internal packaging units therein (clamshells) relates to the standard produce
pallet being of
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48x40 inches with a specific number of boxes fitting on each layer or tie of
the pallet. There
are several main box configurations for the produce industry that have been
developed over
the last 3 decades to maximize cube, increase units per pallet spot, as well
as truckload
volume to reduce the impact of freight on the overall cost of produce to the
consumer. Within
the field packed berry category there are a number of box configurations that
have become
standard within the industry with the 5, 6, 8, and 12 down configurations
becoming the most
prevalent. The strawberry industry has a preferred 6 down corrugated box
footprint with 8 x 1
lb. strawberry "clamshells" within, with the average retail unit dimensions of
7.0" to 7.5" in
length, 4.7" to 5.0" in width, and 3.0" to 3.50" in height, with an average
corresponding box
configuration of 20 inches in length, 16 inches in width, and 3.5 to 3.75
inches in height. This
configuration is known as the 6-down box configuration with 8 x 1 lb.
strawberry "clamshells"
within or the "1 lb. 6 down" configuration. In addition to the configuration
of the pallet being
standardized, the arrangement of the internal packaging or "clamshells" within
are always
identical regardless of manufacturer, as each clamshell design and shape is
made for a specific
box size, a unit of product weight, and unit fit into the box by number of
rows and counts per
row within the box.
In addition to the preferred 6 down 1 lb. strawberry configuration being the
standard
pallet layout, it is also the standard case unit by which most retailers
purchase, set margins,
track spoilage rates, track profit, monitor case turns at store level,
estimate seasonal volumes,
and track and process many other important retail data. For example, a major
retail chain like
Walmart , with over 2,500 stores in the U.S. and Puerto, must have several
produce buying
groups working from one common ordering and buying platform in order to be
efficient and
track all relevant data with regards to perishable commodities. The inventory
management
and procurement platforms often notify the retail buyer daily or even hourly,
in some cases,
of how much product is available by case and price within their network of
growers and what
product is available to distribute out to stores from their regional produce
warehouses.
Managing this intricate system of supply and demand on perishable fresh
produce is a very
difficult process. In order to achieve the most fluid system of fresh produce
without gapping
or overloading the system with perishable product that can remain at store
level longer than
expected resulting in high shrink rates and spoiled product, retail buyers
rely heavily on the
standardization of their supply chain. Therefore, it is most advantageous for
growers to
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follow the industry standard when making packaging decisions for their crop.
Some
packaging companies design and develop new corrugated footprints, such as the
9 down
configuration, with new internal packaging counts of 6 or 12 instead of the
standard 8 retail
units, and tout various advancements in cooling, product density, and cube
efficiencies only
to be overlooked by the general marketplace, to a large degree, due to the
considerable
inertia and history with the standard 6 down configurations with 8 retail
units within berry
crops such as strawberries.
Therefore, it would be most advantageous to both the retailer and the berry
grower if
packaging companies focused their innovation efforts within the existing and
accepted industry
standard 6 down configuration framework or develop a new 6 down configuration
as depicted
within this invention that alters the dimensions and directional airflow of
the system but does not
change the layers on the pallet, or units within the case.
The Corrugated Box or Returnable Plastic Container (RPC)
The fundamental purpose of a corrugated box or plastic master carton is to
deliver fresh
fruits and or vegetables from the field to the market for purchase. There are
several key factors
that contribute to the overall success of its purpose:
1. The box/container provides a vehicle for stacking packages of product or
whole
produce from the field in an organized, stacked, and protected shipping
format.
2. The box/container provides the initial horizontal ventilation structure and
air flow
method for cooling the fruit or vegetables inside it. How these venting
structures are
cut and line up with the clamshell containers or whole produce inside is the
most
critical function of the box when attempting to cool the product in the most
efficient
and uniform method.
3. The box provides a transfer of air flow from the cooler into the rigid
plastic
containers within to cool the held fruit. It must also draw or transfer the
air flow to the
next box/container on the horizontal pallet to continue the process.
4. Air transfer within the box/container may include both vertical and
horizontal air flow
or transfer vents that could assist in an even and uniform cooling process. It
is critical
to review both directional air flows to maximize stacked ventilation and
create the
most effective method of cooling.
CA 2977887 2017-08-30
It is also critical to discuss the manufacturing and forming of the corrugated
master
tray or "produce box" when reviewing how the box will perform in conjunction
with the held
retail rigid plastic, "clamshell," units within. The manufacturing process
begins with varying
grades of container boards which are represented as "the medium" (the fluted
middle layer)
and "the linerboard" (the flat facings of the board). These two types of board
not only differ
in function and purpose but also are made from different types of trees as
well. After the
liner and the medium are combined by use of a cornstarch based adhesive to
form a single
faced web in a single facer machine, the web enters a double gluer machine and
double
backer machine that bonds the liner to the single web creating the completed
board. The
corrugate board is then slit and scored to the specifications required as well
as continues to
the cut off knife where it is cut to the specific dimensions of the requested
board. The sheets
are then stacked and prepared for shipment to the converting plants.
There are two main types of converting machines, the rotary die cutter and
flexo
folder gluer machine. Both play a role in adapting sheets of corrugate into
produce boxes
including printing designs and branding, cutting to proper dimensions, folding
and gluing
corners, and flaps and side walls. This last step has the greatest potential
for variance with
regards to the final formed tray. Unlike rigid plastic containers that are
thermoformed by a
single and exact mold and matching trim press, the corrugated box uses hot
melt glue in
between folded corners and flaps to hold its shape and dimensions. The
variance in internal
dimensions is critical as even a slight variance ranging from 1/8 to 1/64 of
an inch on each
corner of the tray may create a loose fitting internal packaging arrangement
of ''clamshells"
and thus create a failed air circuit in between clamshells within the case.
Failed air circuits
are the leading cause of air flow passing through the case without penetrating
the ventilation
structures of "clamshells" and thus increasing cooling times and decreasing
efficiencies.
After the sheet is converted into a box it is again stacked, palletized and
readied for
shipment to the grower, or a packaging company that will do the final assembly
for the grower. It
is here at final assembly where printed and branded corrugated boxes receive
the addition of
stacked sets of empty rigid plastic containers. After the corrugated boxes are
filled with the
predetermined size and number of "clamshells", the entire package is ready to
be shipped to the
field for packing.
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The Rigid Plastic Vented Produce Container or "Clamshell"
The fundamental purpose of a "clamshell" (or "punnet") is to deliver a
specific weight or
measure of fruits and or vegetables from the field to the market for sale.
There are several key
factors that contribute to the overall success of its purpose:
"Clamshells" provide a uniform packing unit with a weight specific size which
makes it
possible to pack, cool, ship, merchandise and sell at retail. Clamshells
provide an extra layer of
protection for fruit and or vegetables from the field to the market and are an
improvement over
pulp open trays or injection molded open top baskets.
Clamshells utilize clear plastic to help identify the product quality and
ripeness of
fruit to consumers. Most designs include: ribbing or smooth wall structures
that ensure the
package will stack at retail, a secure closure lock that holds the container
together both before
and after opening and reclosing multiple times, a ventilation pattern designed
to cool fruit
within, and a label platform for brand or grower identification. These are the
main
contributing factors that make it the method of choice for the produce
industry today.
The most overlooked attribute of the clamshell is its ability to cool the
fruit
effectively and uniformly to reduce produce respiration rates and increase the
product's shelf
life. With California being the largest berry growing state in the United
States, berries are
often picked, cooled, and then shipped all the way across the country for
sale. Therefore, the
greater the shelf life, the greater market opportunity for the grower.
All these attributes are critical to the functionality and performance of
these containers;
however, for over 25 years, the standard thermoformed clamshell design for all
fruit or vegetable
crops utilizes a tapered wall both on the lid and the base of the container
which has proven to
create a failed airflow circuit within the box/master case/RPC container. The
tapered nature of
the thermoformed clamshells can't be changed as the draft angle helps to form
the parts, stack the
parts together during transit, and enables the parts to be de-nested for
labeling application. All
these features and functions of the container makes it possible to manufacture
a light weight and
inexpensive package as not to burden the consumer with expensive packaging on
food items.
There is also a greater gap or "V channel" in-between the clamshells as the
draft angle
is increased, so the taller the clamshell the greater the failed circuit of
air becomes which
affects cooling times and increasing product respiration rates. The "V
channel" is the space in
between each row of clamshells and it is commonly referred to as a "V"
channel, though the
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true shape of the channel is an inverted V-shape. This inverted v-shaped
channel will be
referred to hereinafter as the "V" channel.
The greater the draft angle on the side walls the greater the gap in between
the
"clamshells." In addition, the longer the row of containers the larger the
failed air circuit.
The average clamshell has an overall base height of 2.75-3.00 inches with a
draft angle of 8-
degrees, creating a 35-50% failed circuit within the box. These failed
circuits occur when
cold air is pulled inside the box/container and bypasses the hot fruit or
vegetable inside the
"clamshell" by taking the path of least resistance through the "V channels"
and thus following
the vacuum or suction back out of the box/container. The "V channels' in-
between the
clamshells on both the top and the bottom of the clamshells will always be the
path of least
resistance regardless of the shape, location, and size of the two-dimensional
side vents within
the corrugated box or RPC. In addition to the "V" channels created on the
outside of the
packages, there also exists some "clamshell" designs with bottom pathways or
concaved air
flow channels. These pathways or concaved channels do offer some additional
ventilation into
the bottom of the package, however, they also provide a larger center failed
air circuit, or
open circuit within the case, as most of the airflow rushes past the 90-degree
ventilation
apertures without a significant pull or draw extending up and into the center
of the package.
An example of this can be seen in U.S. Patent No. 8,424,701. The ¶tunnel
vent" or bottom
"V" channel creates a larger than necessary bottom opening, or open circuit,
that greatly reduces
the efficiencies of a closed or non-connected bottom ventilation ramp or
bridge.
Combined System - Produce Box/RPC and Internal Rigid Parts
The corrugated box or RPC must work together with the internal packaging to
create
a total system of air flow, cooling, and respiration control. If one or more
of the properties
are not aligned together and thus not working as a complete system, the end
result will most
likely be a failure (a short circuit of air flow) which can lead to an
increase in cooling times
and poor quality of fresh produce. Considering that the draft angle of all
clamshells is a
fundamental design feature but also a fundamental design flaw when cooling
fruit or
vegetables inside a box with forced air cooling, the "V channels" must be
blocked or air must
be redirected away from them to close the failed circuit and direct air into
the clamshell's
vents to cool the fruit and vegetables inside.
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Assuming the "V channels" in-between the clamshells can be blocked either by
the
design of the corrugated paper or plastic master shipping case or by a
secondary component
added to the master case, a unique venting structure and pattern thereof must
still be designed
into the rigid plastic container to harness the newly directed airflow to
create the most
effective cooling method or process possible within the combined system. Most
of the current
ventilation patterns within rigid plastic containers on the market today use a
straight down
punch method that creates a punch, hole, or side wall vent at the base of a
tapered or
chamfered ribbed structure. By the nature of these ribbed structures and the
current punch and
die system used to create them, the ventilation patterns run along a
horizontal plane around
the perimeter of the container both on its base and lid; however, this pattern
or system of
ventilation creates no directional airflow or draw into the clamshell itself.
Most of the airflow
surrounding the container simply bypasses the outer perimeter front facing
venting structures
by taking the least path of resistance and therefore creating a failed air
circuit which produces
little actual cooling of fresh produce inside the container. Containers that
don't rely on any
number of side wall ventilation apertures but rather on a system of linking
the box air flow
directly into the container through a large side air vent with a concaved base
channel, also
have challenges with failed air circuits present in the surrounding
"clamshells" due to case
dimensional variances during case erecting, as well as the failed air circuit
present within the
base concaved channel or pathway. Additionally, the loss of side ventilation
apertures in the
corners of the container can create hot spots and form condensation against
side walls, both
prior to and after the cooling process, and therefore subject produce to
increased respiration
rates over time.
As each produce box or returnable plastic container manufacturer touts their
own
unique ventilation pattern and the benefits or advantages therein so does each
rigid plastic
manufacturer. However, since the mid 1990's, both the University of California
Davis and the
University of Ontario Canada have concluded that the number of and size of
vents have little
overall effect on reducing both cooling times and respiration rates. An
increase in vent size
and number of vents on rigid containers simply don't equate into faster
cooling times and may
increase cooling times. Most manufacturers of rigid plastic containers, as
well as growers
alike, ignore these studies and follow the disproved theory that more vents
are better when
designing and developing air flow systems. The underlining problem that exists
with vacuum
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cooling is that air will take the path of least resistance when pulled through
the box or master
case so simply increasing the vent size and number of vents on rigid parts
does little to do
with increasing cooling times. If the air is not directed into the path of the
vent structures, or
if the vent structures themselves are two dimensional in nature causing air to
flow past along a
straight edge or line, the main underlining problem of the failed air circuit
remains. Moreover,
the current two-dimensional front facing venting structures are often blocked
by denser fruit
such as small strawberries, blackberries, raspberries, and most notably
blueberries, causing little
to no airflow being pulled from container to container. This problem causes
fruit within rigid
retail packages to be cooled from the outside in as the temperature of passing
air slowly cools air
and fruit within the container; therefore, a container that specifically
directs airflow to penetrate
the container at all layers of fruit and especially in between layers of fruit
is key to have
unobstructed airflow and cool fruit faster.
In greater detail, the overall misconception that more ventilation is better
is
compounded by the false perception that cooling from the outside of the
package inward, or
in some cases from the bottom of the clamshell upward, is the most effective
method of
cooling produce within. In most cases a dual method of cooling, from the
inside out, and
from the outside in, and at all layers of fruit would be the most efficient
method of rapidly
and evenly cooling produce within rigid plastic containers, however, there
isn't a rigid retail
unit, "clamshell" or punnet on the market today that has these features
incorporated into one
design in combination with the master shipper box or RPC.
The only two clamshell designs that do utilize an air tunnel, channel, or
pathway
system to allow air to reach the center or bottom of the container are the
system highlighted in
U.S. Patent No. 8,424,701 and the system highlighted in U.S. Patent No.
6,644,494. Both
systems use an air flow channel or channels by which to allow air to enter or
pull from the
bottom of the container. These tunnels or channels also have two-dimensional
venting
structures which are often located at the top or near top of tunnel structures
at 90-degree
angles from the air flow. It is very important to note that a 90-degree
ventilation aperture at
the top of a channel is very inefficient and a poor method of penetrating the
bottom of the
container, simple put there is no line of sight for air to penetrate the
container and instead
must draw from radical 90-degree vents to accomplish vertical cooling. In
addition, as air
CA 2977887 2017-08-30
travels at a high velocity, it fills all the available space within the tunnel
or channel and will
bypass the ventilation apertures located at the top 10% of the tunnel.
Moreover, the system venting structures and the relationships between the
interior and
exterior packaging (the "clamshells", and boxes or RPCs), must function in
both a passive
stacked ventilation environment and within a forced air cooling system.
Considering most
current box and "clamshell" packaging solutions take little to no account of
the two varying
stages of cooling, (1) field passive ventilation, and (2) forced air cooling,
it is advantageous to
develop a combined package that performs under all conditions, especially
considering that
the passive ventilation environment may persist for several hours until the
forced air process
can begin.
Passive Ventilation
Passive ventilation is the most overlooked of the two cooling stages. As the
pallet of
fruit or vegetables is being built at the field level, the Law of Convection
needs to be
considered to maximize the release of heat from the semi-closed pallet system.
By
understanding the Law of Convection, a system of interlocking both box and
"clamshell"
vents may be created to draw hot air up and out of the pallet and replace it
with cooler air
from the sides of the pallet.
Convection is the transfer of internal energy into or out of an object by the
physical
movement of a surrounding fluid that transfers the internal energy. Although
the heat is
initially transferred between the object and the fluid by conduction, the bulk
transfer of
energy comes from the motion of the fluid. Convection can arise spontaneously
(or naturally
or freely) through the creation of convection cells or can be forced by
propelling the fluid
across the object or by the object through the fluid. In our particular case
the "fluid" is
represented by air molecules surrounding the fruit or vegetable inside the
rigid plastic
container, "clamshell," as well as air molecules surrounding the internal
rigid packaging
within the box or RPC.
To create turbulence within the pallet and to a greater extent within the
vented rigid
container to generate movement of hot air upward, vertical pathways or funnels
must be created
as well as an overall strategy of how to capitalize on the creation of low
pressure within the
pallet when hot air rises to continually create upward and inward movement of
air. Stack
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ventilation uses temperature differences to move air without the presence of
wind. Hot air
rises because it expands and is less dense than air around it. Therefore, by
designing a
complete pallet system (box and clamshell) that takes into account stack
ventilation and by
understanding Bernoulli's Principle, a unique pallet structure can be built to
maximize
passive ventilation (the rising of hot air in a semi closed system). In
Bernoulli's Principle,
"cool air is sucked in through low inlet openings as hotter air escapes
through high outlet
openings. The ventilation rate is proportional to the area of the openings.
Placing openings at
the bottom and top of an open space will encourage natural ventilation through
the stacked
effect." Hot or warm air will exhaust through the top layer of the pallet,
resulting in cooler
air being pulled into the pallet from the outside through openings at the
bottom or sides.
Openings at the top, side, and bottom should be roughly the same size to
encourage even air
flow through the vertical space.
Forced Air Cooling
The process of Forced Air Cooling can range from 1 to 3 hours depending on the
power of the fan, fan size, number of pallets being cooled, initial
temperature of fruit, air flow
pathways within boxes and corresponding venting patterns within internal
packaging, density
of fruit, and the desired temperature at 7/8 ratio. When creating a strategy
for the most
efficient and uniform cooling process to use with Forced Air Cooling, the
number of internal
packages across the cooling web and the depth or number of clamshells within
each box layer
must be considered to ensure the least possible opportunities for a failed air
circuit to develop
within the pallet. For example, a box with an internal packaging lay out of 2
across and 4 deep
has a greater chance of creating a failed air circuit than a box that has a
clamshell layout 4
wide and only 2 deep across. In this particular example, the primary reason
why a shorter
width or depth box design is more efficient and less likely to cause a failed
air circuit is due to
reduced distance and reduced number of clamshells that air needs to travel
through horizontally
before getting repositioned into the next box, and so on.
Furthermore, the most efficient way to cool produce within internal rigid
packages,
"clamshells", would be to force the air to travel inside the containers and
not around it. In
order to accomplish this goal, each box vent must have a corresponding
internal packaging
vent with no gap existing between the two. Ideally each "clamshell" would have
an extended
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vent area that would be inserted directly into the box vent and force a
straight pass through
of air from one side of the box to the other passing though the internal
packaging and or
directed air flow.
Directed airflow is the key to unlocking faster cooling times, and by having
an
extended vent area that can split airflow within the corrugated walls of the
box into multiple
pathways is critical in dividing directable air flows into the container at
varying levels of
fruit height. For example, by splitting the airflow within the corrugated wall
of the box by
an 80/20 ratio in the master vent, air can be directed to the proportional
amount of fruit
weight by area ¨ 80% base and 20% lid. The ratio of split is directly related
to the size of the
container and its corresponding parts (base and lid). The larger the lid of
the container, the
greater the increased ratio of the lid airflow vent being split, this is due
to the fact that a
larger lid will also accommodate a larger percentage of fruit that lies above
the main basket
line, or gap vent in between the base and lid. Conversely a container with a
shallow or flat
lid will have a very minimal directional airflow split within the corrugated
walls as a larger
majority of fruit will be held within the base of the container.
Current clamshell packaging and box configurations do not split airflows
within the
corrugated walls of master cases but rather have a large opening vent that
distributes air
randomly between the lid and base and the air generally flows to the least
path of resistance
and not into the containers.
The present invention solves all of the above stated problems within the
preferred 6 down
configuration of the 8 - 1 lb. strawberry unit tray as well as identifies
unique embodiments and
features in both the produce tray and the clamshell in doing so.
DESCRIPTION OF RELATED ART
U.S. Patent Nos. 6,007,854, 6,644,494, 7,413,094, 8,083,085 and 8,424,701
disclose
various types of packaging and cooling systems designed to improve cooling of
fresh produce.
None of these references disclose a passive air flow system linking box
funnels with gaps
within internal rigid packaging, a central box vent corresponding to split
airflows within the
corrugated case wall directing air to a main vent and a lid vent area, and
lastly none offer a
five-tiered venting system (1, bottom ramp vent, 2. bottom side wall vent, 3.
mid-range vent, 4.
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main gap vent, and 5. side wall lid vent) within the rigid packaging to
maximize both passive
ventilation and forced air cooling.
SUMMARY OF INVENTION
This section provides a general summary of the disclosure and one or more of
its
advantages and is not a comprehensive disclosure of the full scope of all the
features, of all
the alternatives or embodiments or of all the advantages. Additionally,
specific featured
embodiments are not limited to examples given below and may be transferred to
new
packaging shapes, sizes, and weight designations depending on the intended or
required
solution.
The Corrugated f3ox/RPC
To better understand the disclosed invention and how the new corrugated
configuration influences cooling efficiencies, it is best to outline and
compare the differences
between the old style and the new configuration. The old style 6 down
configuration utilizes
a rough box dimension of 20 inches in length, 16 inches in width and 3.5
inches in height
with 2 rows of 4 deep clamshells within, and a 3 by 2 (6 total) box tie on a
pallet in the
cooling direction of 48 inches on the pallet. This configuration allows for an
initial cooling
exposure of 2 clamshells per box, 3 boxes wide, or 6 clamshells in total
across the cooling
web. The new corrugated configuration utilizes a rough box dimension of 24
inches in
length, 13.3 inches in width, and 3.50 inches in height with 4 rows of 2 deep
clamshells
within, and a 2 by 3 (6 total) box tie on the pallet in the cooling direction
of 48 inches on the
pallet. This configuration allows for an
initial cooling exposure of 4 clamshells per box, 2 boxes wide, or 8
clamshells in total across the
cooling web. Thus increasing the cooling web by 25% which greatly effects the
number of
containers immediately exposed to the coldest air during the forced air
process (from 6 to 8).
Newton's Law of Cooling states that the rate of temperature of a body is
proportional
to the difference between the temperature of the body and that of the
surrounding medium, as
well as, the cooling of an object results from energy flow from the body to
its surroundings.
It is also relevant to understand how there exists an exponential decline of
the cooling
temperature of the surrounding medium as it is pulled through the box and
exposed to the
energy flow from various new bodies (hot fruit). Therefore, it is
exponentially more efficient
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to cool 8 units at 6 deep across a cooling web than 6 units at 8 deep. The
farther the frigid
air travels across hot fruit the lesser its effect of cooling are, as its own
temperature rises due
to the transfer of energy and heat.
To understand this more completely, the following example is given. As the
cooling
medium, air, travels over the body (hot produce held within a "clamshell"), it
will inevitably
decline in cooling effectiveness as its own temperature is increased as the
body (hot produce)
transfers its energy (heat) to the surrounding medium (air) making it less
effective over each
"clamshell" unit across the depth direction of the web. Therefore, it is most
advantageous to
pull the cooling medium (air) across the greatest number of initial units in a
row with the least
number of subsequent units behind it. A further detailed analysis shows that
this new
configuration pulls air across 8 pounds of initial hot produce with only 6
pounds of
subsequent depth across the cooling web at a relevant starting temperature
ranging between
32-36 degrees in the forced air cooling environment versus the old
configuration which pulls
air across only 6 pounds of initial hot produce with a larger subsequent 8
pounds remaining
across the web. As previously noted, this new box configuration increases the
number of
"clamshell" units being cooled across the web from 6 to 8, or an increase of
25% with the
added benefit of a reduction in the exponential decline of the cooling medium.
Moreover, this
new configuration with its new internal dimensions are also relevant to the
development of
alternative "clamshell" shapes and sizes that can be beneficial within a
stacked ventilation
cooling environment. The new shapes and sizes may also be specifically
designed to limit cube
within the container to help reduce over packing of' weight units. Current
clamshell designs
range from 10-30% of overpacked fruit within each container which also
increases the cooling
times as overpacking fruit means more fruit weight to cool that the grower is
not being
compensated for by consumers.
Internal Rigid Packaging "Clamshell"
The new configuration allows many new "clamshell" shapes and sizes across many
produce commodities, but for the purpose of this explanation and comparison
the one-pound
standard strawberry "clamshell" will be further explained. Within the new box
configuration,
the standard one pound rectangular "clamshell" is altered to almost a square
design of
roughly 6.13" in length, 5.63" in width and 3.25-3.50" in height with rounded
corners. The
rounded corners on each clamshell come together when placed into the box to
form a
CA 2977887 2017-08-30
rounded semi 4-pointed star shape located 3 across the center of the length
direction of the
box or RPC. When these rounded semi-star shaped openings are linked to a hole
or cut out in
the box or RPC directly beneath it there exists 3 center air funnels that
extend unobstructed
from the base of the pallet to the top within each case or box layer. These
funnels are
extremely advantageous in a passive stacked ventilation environment as the
rising less dense
hot air has a direct path up and out of the pallet. Each box will have 3
unobstructed stacked
funnels linked together with a total of 18 funnels per pallet layer creating
the largest
opportunity for hot air to rise within the pallet without degrading the
construction and
functionality of the pallet. Additional funnel vents may be added to the box
on each corner
and each half semi-round pointed star at the edges of each clamshell if
desired.
In addition to the unobstructed funnel vents that line the bottom of the case,
there are 16
minor vent funnels in each box (2 per "clamshell" space) that are directly
linked to ventilation
holes in the base of the "clamshell.'' These vent funnels may be attached to
special ramps within
the clamshell with vent apertures or similar vent apertures may be recessed
into the box to help
hot air escape up and out of the pallet through the various funnels.
In this one-pound standard strawberry case and "clamshell" example, there are
a total
of 19 funnel vents (3 large unobstructed center case vents and 16 minor vents)
specifically
designed to encourage natural passive ventilation through the stacked effect.
Hot or wainn air
will exhaust up through the funnel vents and out through the top layer of the
pallet, resulting
in cooler air being pulled into the pallet from the outside through the
openings at the bottom
or sides of the pallet. Considering cool air will be entering the pallet from
the sides, it is
critical that the "clamshell" is directly linked into the side of the box to
enhance the natural
cooling effect of stacked ventilation. This link between the box and clamshell
is
accomplished by means of an extended vent area on the clamshell that inserts
into a larger
area of the box thus linking the two directly as one complete vent.
To summarize all the disclosed embodiments or features, herein is a rigid
plastic
container (clamshell, tub, or punett with lid) and a master case which may
include any
combination of the below disclosed features resulting in improved airflow
within the
combined set, with particular significance pertaining to the removal of hot
field air or product
heat within, during both passive ventilation and forced air cooling processes:
BOX or
MASTER CASE (a) any number, shape, location, or size of unobstructed vertical
funnel vents
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to create a natural convection effect within the pallet, (b) any number,
shape, location or size
of a main horizontal air flow transfer vent with interlocking rigid plastic
container features
designed to link the box directly to the container within to reduce failed air
circuits and split
airflows within the corrugated walls and within the combined set, (c) any
number, shape,
location, or size of minor vertical funnel vents located beneath rigid plastic
containers to
create a natural convection effect within the pallet; RIGID PLASTIC CONTAINER
(a) any
number, shape, location, or size of a three dimensional front or side facing
venting structure
on the outer wall of the base of the container that is open on one or more
sides, (b) any
number, shape, location, or size of a two or three dimensional front or side
facing venting
structure on the inner walls of a tunnel, channel, or pathway arrangement
running through the
bottom or base of the rigid part in whole or in part, (c) any number, shape,
location, or size of
a three dimensional front or side facing venting structure on the outer wall
of the lid portion
of the container that is open on one or more sides walls, (d) any shape, wave,
curve, or
internal ribbed feature present inside the three dimensional venting structure
that directs air
flow within the rigid part, (e) any special shape or form present within the
three dimensional
venting structure located on the non-vented portion of the walled structure
that aids in
directing air flow in and out of the container, (f) any special shape or form
present within the
three dimensional venting structure located on the non-vented portion of the
walled structure
that aids in the creation of air turbulence within the rigid part, (g) any
number of tunnels,
channels, ridges, or pathways and corresponding vented apertures in the base
of the container
that allows the vacuum cooling process to reach the front, center, and back
portions of the
container, (h) any number, shape, location, or size of a singular or multiple
opening or cut
within the tunnel, channel, ridge or pathway that pulls air from the container
during the
cooling process utilizing a ramp style method of pulling air from the
container and reducing
the angle from which air travels in and out of the container, (i) any three
dimensional vented
structure, or cut on an angle which faces the desired direction of the vacuum
to pull air from
within the container reducing the potential of a failed circuit within the
combined set, (j) any
space, shape, cone, circle, ring, ramp, or tunnel like structure in the base
of the container
designed to circulate or transfer cold air into the base of the container, (k)
any style, shape,
size, or location of a series of vents within the tunnel, channel, ridge, or
pathway structure
that forces air up and into the container, (1) any style, shape, size, or
location of a series of
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mid-range venting structures located within the rigid side walls to create
open pathways of air
transfer in between layers of fruit, (m) any style, shape, size, or location
of a main air transfer
vent with interlocking case features to create a direct pathway from outside
the case to inside
the rigid container reducing the possibility of a failed air circuit, (n) any
style, shape, size, or
location of a series of venting structures located within the lid of the
container that correspond
to the minor funnel vents located within the master shipping case to create
pathways for air to
exhaust up and out of the container's lid, (o) any style, shape, size, or
location of a lid bridge
with vent apertures designed to both strengthen the lid structure and provide
ventilation or air
transfer in the lid that link to minor air funnels located either directly
above or adjacent to the
bridge structure on the base of the master shipping case, (p) any style,
shape, size or location
of indented pathways or channels with venting apertures within the base of the
rigid plastic
container that are flush with a raised lid bridge with venting apertures on
the lid while
identical containers are stacked at retail, and (q) and style, shape, size, or
location of an
extended vent that separates the airflow with the corrugated wall of the
master box by
percentage of air needed to cool fruit by weight location within the base and
lid of the
container.
All of these features or embodiments will differ from container configuration,
size and
shape of container, layers of fruit intended within each container, weight
distribution of fruit
between the base and lid, and commodity intended for each container, but all
will be similar
in nature to the above embodiments described in the MASTER CASE (a-c) and the
RIGID
PLASTIC CONTAINER (a-q) listed above. In addition, the features and
embodiments may
also differ in size, shape, number, length and width, three-dimensional shape,
angle or cut of
vents to match the directional air flow intended within the box.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims which particularly point out and
distinctly claim the invention, it is believed the present invention will be
better understood
from the following description of certain examples taken in conjunction with
the
accompanying drawings, in which like reference numerals identify the same
elements and in
which:
FIG. 1 is an isometric of the invention depicting both hot and cold air flow.
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FIG. 2 is an isometric view perspective view of the present invention
depicting the
base only with particular attention to the channel/pathway and venting
structure within.
FIG. 3 is an isometric view of a three-dimensional air vent depicting open
vents on 2
sides of the ribbed structure and a directional air feature on the non-vented
or non-cut wall.
FIG. 4 is an isometric view of a combination air channel/pathway combined with
a three-
dimensional air vent at both the front and back of the pathway and two ramp
style channel vents.
FIG. 5 is an isometric view of a channel or pathway with 8 ramp style vents
along the
base, as well as, a close up view of the ramp style vent.
FIG. 6 is an isometric view of a dual ramp style pathway vent.
FIG. 7 is an isometric view of several preferred embodiments depicted within a
rigid
retail container.
FIG. 8 is an alternative isometric view of several preferred embodiments
within a rigid
retail container.
FIG. 9 is of 2 top down views of rigid retail containers with differing bottom
preferred
embodiments.
FIG. 10 is a similar view of a rigid retail container in fig. 9 with a
different preferred
embodiment on the lid structure.
FIG. 11 is a diagram depicting how the rigid retail units may be stacked both
within the
master case and on the retail shelf.
FIG. 12 is an isometric view of a master shipping case with its corresponding
rigid retail
unit configuration.
FIG. 13 is of two differing isometric views of the same master shipping
container and its
corresponding retail found in fig. 12.
FIG. 14 is a top down view of a pallet in the preferred embodiment
configuration.
FIG. 15 is an isometric view of the pallet configuration in fig. 12.
FIG. 16 is an isometric view of a corrugated vent pattern and "clamshell" vent
structures within.
FIG. 17 is a similar isometric view of Fla 16 with an alternative corrugated
vent
pattern that is specific to the internal packaging vents.
FIG. 18 is an identical isometric view of FIG. 16 with the percentage vent
split
between the lid vents and the main vents identified for reference.
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FIG. 19 is an isometric view of a cross section where the rigid plastic
container
extends into the corrugated wall and divides the airflow into separate
pathways (main vent
80% and lid vent 20%).
FIG. 20 is an isometric view of a cross section depicting the lower corrugated
vent and
the aligning rigid plastic vents including the mid-range vent, bottom side
vent, and the bottom
ramp vent.
FIG. 21 is an isometric view of a cross section of the case depicting how 2
rigid
containers interlock and the airflow pathways on the lower level of the
container.
FIG. 22 is an isometric view similar to FIG. 21 depicting the lowest airflow
pathway
and the flow through the case vent into the case beneath to complete the
circuit.
FIG. 23 is an isometric view of the front panel of the rigid container and a
close up of
the ramp vent depicting the two angled side vents at 30 degrees.
FIG. 24 is an isometric view of the new preferred six down case with
clamshells
depicting the funnel vent pathway and hot air escaping the case during a
passive stacked
environment.
The drawings are not intended to be limiting in any way, and it is
contemplated that
various embodiments of the invention may be carried out in a variety of other
ways,
including those not necessarily depicted in the drawings. The accompanying
drawings
incorporated in and forming a part of the specification illustrate several
aspects of the present
invention, and together with the description serve to explain the principles
of the invention; it
being understood, however, that this invention is not limited to the precise
arrangements
shown.
DETAILED DESCRIPTION
The following description of certain examples of the invention should not be
used to limit
the scope of the present invention. Other examples, features, aspects,
embodiments, and
advantages of the invention will become apparent to those skilled in the art
from the following
description, which is by way of illustration, one of the best modes
contemplated for carrying out
the invention. As will be realized, the invention is capable of other
different and obvious
aspects, all without departing from the invention. Accordingly, the drawings
and descriptions
should be regarded as illustrative in nature and not restrictive.
CA 2977887 2017-08-30
It will be appreciated that any one or more of the teachings, expressions,
versions, examples,
etc. described herein may be combined with any one or more of the other
teachings, expressions,
versions, examples, etc. that are described herein. The following-described
teachings, expressions,
versions, examples, etc. should therefore not be viewed in isolation relative
to each other. Various
suitable ways in which the teachings herein may be combined will be readily
apparent to those of
ordinary skill in the art in view of the teachings herein. Such modifications
and variations are
intended to be included within the scope of the claims.
FIG. 1 shows the front and side view of a rigid retail unit and use of three-
dimensional side
vents (10) with two open side vents directed into the path of the vacuum. Dark
arrows, indicated by
the hot air flow (20) being pulled from the rigid container via the three-
dimensional side vent
structure (10) and cold air flow (30) entering the container from alternative
suction points along the
width direction of the container.
FIG. 2 shows how the pathway or channel at base of clamshell (40) running
along the base of
the container can be formed by raising the base of the container off the box
floor with a series of
corner blocks or feet at base of clamshell (50). The drawing also shows how
two oblong vent
structures at front of ramp vents (70) at either end of the channel can be cut
into the side wall of the
container thus creating a pathway to reach the channel or pathway within. In
addition, this drawing
shows the use of two alternating ramp style vents (70) adjacent to the center
pathway to pull air at
alternating points within the container and therefore causing turbulence from
within the container.
FIG. 3 shows a detailed view of two three-dimensional side vent structures
(10) side by side,
with two open side wall cuts on adjacent side walls (100) of a ribbed feature
(110) and a third
smooth indented wall feature (120) on the non-vented structure to push or
guide airflow into the
container as the forces of the vacuum draw directly into the vent. A ribbed
indented wall feature (90)
is provided as illustrated.
FIG. 4 shows a detailed side view of a center pathway or channel at base of
clamshell (40)
combined with two large three dimensional side vents (10) located at the
beginning and ending of
the pathway or channel at base of clamshell (40). The pathway or channel at
base of clamshell (40)
draws air from the center of the container by use of two center ramp style
vents (70) while the two
large three dimensional side vents (10) pull air from the outside of the
container. This combined
effect creates a two directional flow air, both outside in and
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18390408v2
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inside out at the same time, causing turbulence inside the container rarely
reached by
conventional venting of one method or another. Additionally, smooth side walls
(100) as well
as the use of ribbed features (110) create the three-dimensional side venting
structures (10).
Two directional ramp style vents (70) are used in the center of pathway or
channel at base of
clamshell (40) to create the most effective penetration of the air into the
container as the air
follows up the ramp of the first style vent (70) penetrating the container and
then exists down
the second ramp style vent (70) on the backside.
FIG. 5 depicts the base of a rigid retail package with 8 ramp style vents (70)
running in a
two by four parallel down the center of the pathway or channel at base of
clamshell (40) with
curved walls, creating a smooth transition on base of container (180) into the
pathway or channel
at base of clamshell (40) to protect soft fruit from rough edges or hard
transitions. This system of
using directional ramp style vents (70) inside of a pathway or channel at base
of clamshell
(40) may be utilized if the directional air flow of the vacuum can be
predictable and reliable.
If the directional air flow changes from one direction to the other depending
on which way
the box is positioned on the pallet layer, then a dual sided ramp vent, not
pictured, must be
used as not to block the path of the incoming vacuum along the base of the
pathway or
channel at base of clamshell (40).
FIG. 6 is of a close-up of a dual directional ramp style three-dimensional
vent
structure, (200). These dual directional ramp vent structures (200) may be
placed anywhere
on the base of the container where air is directed to draw air from or into
the container. The
dual sloping ramp vent base feature (160) is far superior to that of a simple
round or circular
vent positioned at the top of a channel or pathway because the angle is not as
steep and
creates a smooth transitional draw of air into the container. Air flows into
the container
through the ramp vent aperture (140) transitions up into the container and
then back out
down the dual directional ramp vent (200). This feature is especially
advantageous while air
is traveling at a high rate of speed.
FIG. 7 is an isometric view of a rigid plastic retail unit, "clamshell," with
preferred
embodiments which are advantageous to the increased cooling of fresh produce
within. These
preferred embodiments are part of a five-tiered system of ventilation, (Top
Vent, Master Side
Vent, Mid-Range Vent, Bottom Side Vent, and Base Vent/Ramp Vent) that provide
cooling
effects in both a passive stacked ventilation environment and in a forced air
cooling system.
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The container (80) has both top external lid vents (230) as well as internal
lid vents (240) on
the label and stacking platform. These top side vents are particularly
advantageous to cool
fruit in a vertical stacked system as well as reduce the amount of
condensation present on the
lid. The main clamshell vent (210) with its extended main vent lip (220) locks
into the master
case to provide both a source of cooler airflow within a stacked ventilation
system, as well
as, a forced air cooling source linked directly from outside of the pallet
into each clamshell
within the cooling web. The mid-range vent (250) allows for air circulation in
between layers
of packed fruit. This unique mid-range vent breaks up the side walls (100) or
the ribbed
feature (110) allowing for both the vertical air flow in a passive stacked
ventilation system,
as well as, the horizontal air flow in a forced air cooling environment. It is
critical to have
both directional airflows at this key range of product heat to best ventilate
each stacked layer
of fruit along the walls of the container. The bottom side vents (260) are
positioned at the
base of the container to allow for both vertical and horizontal airflow. The
pathway or
channel at base of clamshell (40) creates space for the base or bottom tier of
vents, not
pictured. This bottom tiered vent system links to the minor funnel vents
located within the
master shipping case to maximize the rise of hot air up the pallet in-between
the pallet layers.
FIG. 8 shows an alternative isometric view found in FIG.7 the bottom side
view.
Positioned within the pathway or channel at base of clamshell (40) is the
preferred
embodiment bottom ramp vent two-dimensional (270). The ramp or tunnel and
corresponding bottom vent allows for a near center ventilation of the base
layer of fruit
without creating a failed air circuit within the shipping case, as previously
noted with a
continuous tunnel or pathway. Airflow is pulled from the bottom layer of fruit
by the forced
air cooling environment with 100% of the air drawing up from the closed tunnel
or ramp vent
system. Any combination, number, or shape of bottom ramp vent two-dimensional
(270) in
combination with the minor funnel vents within the master case, may be created
to maximize
the airflow from the bottom of the container and within the case.
FIG. 9 is a top down view of the preferred embodiments found in FIG 7, and
FIG. 8 with
an alternative indented vent aperture (280). The indented vent aperture (280)
differs from the
tunnel or ramp vent system in that the vent aperture extends into cut outs
within the master
case while the ramp vent aperture (140) is raised off the master case floor.
The indented
aperture rests just above the lid area of the lower clamshell in the stacked
pallet layer, this
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CA 2977887 2017-08-30
creates a unique pulling of air in-between pallet layers creating a larger
passive stacked effect
of air rising throughout the system. Air will rise or be pulled from the
surrounding side vent,
mid-range vent, and master vent along the cooling web to both draw hot air up
and out of the
pallet. Additionally, the indented vent aperture (280) may be more
advantageous with soft fruit
as the indented aperture is not raised and does not come in contact with fruit
but yet provides
adequate lower ventilation.
FIG. 10 is of both a top down view and an isometric view of the preferred
embodiments found in FIG. 7, and FIG. 8 with the addition of a lid bridge vent
(290). The
center bridge vent or possible multiple bridge vents across a lid platform,
not pictured, are
advantageous when combined with the bottom indented vent aperture (280)
especially on
larger pack sizes such as a 21b, 31b, and 41b container. Traditionally these
larger containers
have large label platforms with little to no ventilation causing condensation
and trapping of
hot air within the stacked ventilation environment. The lid bridge vent (290)
corresponds in
height to the depth of the indented vent aperture (280) allowing for the even
stacking or
layering of clamshells at retail with the combined continued ventilation of
both systems. The
combination of the raised bridge vent and the inverted base vent also provide
a greater
rigidity to the light weight rigid container allowing for greater number of
stacked containers
without risk of lid failure or collapse that may result in the toppling of the
container stack on
retail shelves, especially with heavier containers. Furthermore, the raised
bridge vent may
also be combined with a raised bridge or tunnel on the base separating the
container into
compartments. The raised vented compartments walls may
also have side vents that correspond in size and number to that on the raised
bridge to increase
airflow within the separate compartments. Non-uniform venting patterns and
structures within
both the raised compartment bridge or tunnel and the raised lid bridge may
also be
advantageous depending on the commodity of fresh produce and the size and
shape of each
compartment, not pictured.
FIG. 11 is an example of how the raised lid bridge vent (290) and the lower
indented
vent aperture (280) might be positioned both within the stacked at case (310)
with the
corrugated tray layer in between (300) and the stacked at retail shelf (320)
once removed from
a master shipper case.
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FIG. 12 is an isometric view of the preferred master shipping case (330) and
the
preferred clamshell arrangement or rigid retail unit configuration (350) as
well as, the
primary vertical master vent slots location (340). In this particular example,
the preferred
new master case configuration is a two by three layer across the cooling web
of 48" long by
40" deep. The preferred internal clamshell arrangement (350) is four
containers long and two
containers deep within each case. The vertical master vent slots (340) are
present on both
sides of the case creating a straight airflow system that exists within the
clamshell. Air flow
is repositioned every two units as it passes through three trays during the
forced air cooling
process.
FIG. 13 is of both an isometric view and a top down view of the master
shipping case
(330) highlighting both the master funnel vents (360) and vertical minor
funnel vents (370).
In this example of the preferred master shipping ease (330) there arc three
master funnel
vents (360) and sixteen minor funnel vents (370). The master funnel vents
(360) are aligned
to gaps in-between the clamshell arrangement. This is best depicted in the top
down
perspective in which the major funnel vents can be seen through the rounded
corners in-
between the clamshell arrangement. Both the master funnel vents (360) and
minor funnel vents
(370) are designed to maximize the amount of hot air escaping out the top of
the pallet while
cooler air is drawn into the pallets through the master vent slots (340)
during the passive stacked
ventilation cooling process.
FIG. 14 is a top view of a master pallet configuration (380) with 18 master
funnel
vents (360) present within the pallet layer. A typical pallet layer
configuration with a box
height of 3.50 inches, would consist of twenty to twenty-two cases high or 360
to 396 master
funnel vents within the total pallet configuration. This massive increase in
air flow during the
passive stacked cooling environment greatly improves air flow within the
system both while
the pallet is being built in the field and while it waits on a cooling dock.
FIG. 15 is an isometric view of a pallet configuration of the preferred
embodiment
pallet configuration (390) with an internal clamshell arrangement (350) four
long and two
deep within each case across the cooling web. This figure best shows how cold
air will travel
across the cooling web through the master vent slots (340) on the master
shipping case (330)
during the forced air cooling process. It also is particularly visible that
the air will be
repositioned every two units in width as the cold air is pulled by a vacuum
from one side of
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the pallet to the other through three master shipping cases. This diagram also
depicts how
eight units might be cooled at one time across the cooling web versus the
current 11b.
strawberry unit of six units, not pictured. Cooling a larger number of units
across the web, as
well as, repositioning airflow over a shorter number of units within each case
is the most
efficient use of cold air while cooling fresh produce in a horizontal forced
air cooling
environment.
FIG. 16 is an isometric view of the side panel of the master corrugated box
(300) and
retail container unit, "clamshell" (80) held within. In the main vent view the
drawing clearly
shows the main vent (210) the extended lip (220) that locks the retail unit
(80) into the box
(300) and splits the air flow pathways. This unique interlocking feature
serves a dual
purpose in securing the container to the box to limit failed air circuits but
also slits the air
flow pathway into the main vent and the lid vent located directly above (230).
The lid vent
(230) pictured here is a slot or side wall vent punch on the lid, but it may
also be advantages
for future designs to have a horizontal vent located directly above the
extended lip and on the
wall of the lid, not pictured. The lower case vent (400) clearly exposes both
mid-range vents
(250) and the lower ramp vent apertures (270). The lower-case vent (400)
provides a direct
line of sight of the bottom air flow pathways into the retail container,
"clamshell", and thus
limit the percentage of failed circuit airflow on the lower portion of the
container. In
addition, these multiple ventilation pathways allow cool air to penetrate the
fruit within the
container at varying depths and layers of fruit. This system provides the most
allowable air
flow pathways into the container and fruit within, while limited the potential
failed circuit
pathways. Considering that hot air will rise and transfer heat from lower
levels to top layers
of fruit it is critical to remove heat from container/fruit at varying layers
to decrease heat or
energy transfer.
FIG. 17 is an isometric view similar to FIG. 16 with an alternative bottom
corrugated
vent shape (410). The alternative corrugated vent is to show how the size and
shape of the
vent may be altered to increase access to the various retail container unit
ventilation while
limiting failed air circuits. The shape and size of the vent may be contoured
to match any
number of vents along the side wall of the container including but not limited
to the mid-
range vents (250) the side wall bottom vent (not pictured), or the ramp vent
(270).
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FIG. 18 is the identical isometric view of FIG. 16 with the percentage of
internal
corrugated wall air flow pathway division explained by percentages depicted by
an air flow
area (420) and an air flow area (430). The ability to lock the retail
container unit within the
corrugated wall and split the airflow ratio within its structure is unique in
the field and
represents an enormous leap in the cooling process. Considering that fruit
within the retail
container unit is held within both the lid and the base of the container and
that fruit may
block some of the main vent due to fruit size, shape or position within the
container it is most
advantageous to split the airflow pathway in relation to the percentage of
fruit that may be
positioned above the base basket line and held in the lid. In this illustrated
example of the
present invention, the retail container unit has a height of 3.25 inches with
a split between the
base and the lid structure of roughly 80/20. Therefore, by splitting the
airflow within the
corrugated wall at the same ratio it is certain that the proportional amount
of airflow will be
distributed within the clamshell. As illustrated in FIG. 18, the air flow is
split into two
portions, with the first portion being 80% of the incoming air, depicted as
air flow area (420)
and with the second portion being 20% of the incoming air, depicted as air
flow area (430).
This system of airflow diversification also helps to ensure that there are no
hot spots in the
comers of the containers or areas for condensation to build. It is important
to be able to
adjust the percentages of the air flow pathway split to match the amount of
fruit that may be
held or not held within the lid portion of the container. If by design the
container has a taller
lid to encompass more fruit capacity while the base remains the same then the
ratio must be
altered to reflect the amount of fruit expected to be held within the lid
area. For example, if
a similar container needed an expanded lid to hold larger fruit sizes and the
ratio of base to
lid is altered to 70/30 two things would be required (1) a taller box would be
needed to hold
the larger container, and (2) a larger main side wall vent to match the new
larger dimensions
and the new ratio of base to lid. Conversely is the lid is reduced to hold a
lesser amount of
fruit capacity than the opposite adjustments would be required (1) a smaller
box to hold the
decreased container size, and (2) a reduced main side wall vent to match the
smaller
dimensions and the new ratio of base to lid.
FIG. 19 is a cross section of the master box and the retail container unit at
the
intersection of the air flow pathways in the corrugated wall and the air flow
pathways
directional flow into the retail container unit. The cross section of the
master case wall (440)
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provides a clear visual of the extended main vent lip (220) that not only
locks the retail unit
into the master corrugated box but also splits the airflow pathway in the
desired percentage
based on the container base and lid dimensions and the expected fruit held
within. Extended
main vent lip (220) is comprised of an upper lip (221) primarily responsible
for dividing the
air flowing into container (80) and lower lip (222) primarily responsible for
locking
container (80) with master shipping case (330).
In the present example, the main air flow pathway (450) flows directly into
the
container at 80% of the corrugated opening, while the lid air flow pathway
(460) flows
towards the lid vent apertures (230) at 20% of the corrugated opening. This
ratio is
determined by the placement of upper lip (221) relative to the size of main
clamshell vent
(210) and the size of container (80) and may be adjusted along with other
features of
container (80) to reach the desired ratio of air flowing into the lid and base
of container (80).
As cooling fluid is forced into master vent slot (340) of master shipping case
(330), a
first potion of the fluid is directed toward along lid vent airflow path (450)
and into lid vent
apertures (230). Similarly, as fluid is forced into master vent slot (340), a
second portion of
the fluid is directed along main vent air flow pathway (450) and into main
clamshell vent
(210). In some versions of the present container (80), the structural
component responsible
for dividing the forced fluid is upper lip (221) of extended main vent lip
(220). As shown in
FIG. 19, upper lip (221) may be angled to ramp or "cam" the inflowing fluid
upwardly
toward external lid vents (230) and ultimately into the lid portion of
container (80).
Inasmuch as the inflowing cooling fluid is divided into two portions, fluid,
also flows below
upper lip (221) and into main clamshell vent (210) to cool the base portion of
container (80).
FIG. 20 is the exact isometric view of FIG 19 with illustrations identifying
the lower
ventilation air flow pathways. The three lower air flow pathways are
identified as: the mid-
range air flow pathway (470) the bottom side wall airflow pathway (480) and
the ramp vent air
flow pathway (490) each air flow pathway travels into the retail container
unit through the
corresponding vent opening, mid-range aperture (250), side wall vent aperture
(260), and the
bottom ramp aperture (140). It is critical to not only have a multiple of
bottom airflow pathways
as differing locations and sizes during the forced air cooling process to
quickly expel heat from
the container as fast as possible but also during the passive stacked air
cooling process. As hot
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air is expelled up an out of the pallet through the master funnel vents cooler
air will flow into
from the sides through the identified lower aperture vents outlined above.
FIG. 21 is an isometric view of a cross section of the width direction of the
master case
encompassing two interlocked retail container units. The units are locked into
one another and
locked into the corrugated case walls. The illustration is depicting the
airflow pathways of the
mid-range (470) and the ramp aperture (490). The multilayered air flow
pathways are depicted
how they would travel through the interlocking retail container units within
the case. It is critical
not only to lock the containers to the corrugated box but also interlock them
together to create
the best possible air flow transfer during the forced air cooling process.
FIG. 22 is an identical isometric view of FIG. 21 but highlights the lowest
air flow
pathway in the case (500). The bottom-most pathway doesn't penetrate the
retail container unit
but rather travels through the ramp vent and down into the case beneath it
through a minor funnel
vent opening, and into the lid of the retail container unit beneath. It is
critical to allow some air
flow to he unrestricted in order to keep the air flow moving throughout the
system. Directing an
air flow pathway into the center portion of the lid of the case beneath is
also a great way to create
elevate trapped heat in the center of the lid area. The jump of air is minor
to the overall airflow
pathway and is intentionally limited as to not create a large center failed
air circuit like in the
previously stated examples of tunnels that are present at the bottom of
container and found in
U.S. Patent Nos. 6,644,494 and 8,424,701.
FIG. 23 is of an isometric view of the ramp vent (70) and aperture (140) plus
a close-up
view of the same. Unlike any other current tunnel vent listed in prior art
these aperture vents arc
not straight down punches but are at a 30-degree angle, and therefore
providing a clear line of
sight from the vent location to the air flow pathway. This is particularly
advantageous as the
ramp (70) is lowered at a lesser degree to the bottom of the corrugated case
and thus forces most
of the airflow pathway to pull up and into the retail container unit through
the ramp aperture
(140) as the ramp narrows. These two bottom apertures (140) are critical to
providing an air
flow pathway to the center part of the retail unit without creating a large
failed air circuit. An
enlarged view of ramp aperture (140) is depicted as element (510).
FIG. 24 is an isometric view of the new preferred six down case (300) with 8
retail
container units (80), round funnel vents in the case (360), star shaped funnel
vents (530), in
between the intersecting retail container units (80), and the corresponding
and hot air escaping
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the case (520) during a passive stacked environment. Considering during the
peak of the
season it may takes hours before a pallet of fresh fruit can reach the forced
air coolers, it is
most advantageous to have a pallet system that allows hot air to continually
escape the pallet
and thus reducing the core temperature of the pallet prior to forced air
cooling. The specific
rounded corners of the retail container unit (80) allow for the creating of
the star shaped
funnel vent (530) when grouped together within the case. It is not
advantageous enough to
have vents on the bottom of the case at random. Each corrugated bottom vent
(360) must
correspond with a matching container funnel vent (530) to create an
unobstructed pathway up
and out of the pallet. Unobstructed hot air rises faster and creates a larger
energy force
leading to the evacuation of center pallet core heat with the addition of
cooler air being pulled
in from the sides of the pallet causing a natural convection effect to cool
the pallet before the
forced air cooling process.
Exemplary Combinations
The following examples relate to various non-exhaustive ways in which the
teachings
herein may be combined or applied. It should be understood that the following
examples are
not intended to restrict the coverage of any claims that may be presented at
any time in this
application or in subsequent filings of this application. No disclaimer is
intended. The
following examples are being provided for nothing more than merely
illustrative purposes. It
is contemplated that the various teachings herein may be arranged and applied
in numerous
other ways. It is also contemplated that some variations may omit certain
features referred to
in the below examples. Therefore, none of the aspects or features referred to
below should be
deemed critical unless otherwise explicitly indicated as such at a later date
by the inventors or
by a successor in interest to the inventors. If any claims are presented in
this application or in
subsequent filings related to this application that include additional
features beyond those
referred to below, those additional features shall not be presumed to have
been added for any
reason relating to patentability.
Example 1
A cooling system for produce comprising: a case comprising a wall, a master
vent slot
defined by the wall and configured to pass a fluid therethrough; and a
container configured to be
received in the case in a cooling position and configured receive the fluid
passed through the
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master vent slot, the container comprising a base, a lid, wherein the lid
includes a lip, a main
clamshell vent defined between the lid and the base and configured to fluidly
communicate with
the master vent slot when the container is disposed in the base in the cooling
position, wherein
the lip is positioned to direct a portion of the fluid passing through the
master vent slot away
from the main clamshell vent when the container is disposed in the base in the
cooling position.
Example 2
The cooling systems or methods of Example 1 or any of the subsequent Examples,
wherein the master vent slot includes a master vent slot size, wherein the lip
is positioned based
at least in part on the master vent slot size.
Example 3
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the main clamshell vent includes a main clamshell vent size, wherein the lip
is positioned based
at least in part on the main clamshell vent size.
Example 4
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the lid includes a lid height, wherein the base includes a base height,
wherein the lip is positioned
based at least in part on the lid height and the base height.
Example 5
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the lid includes a side wall and a lid vent defined in the sidewall, wherein
the lip is positioned to
direct the portion toward the lid vent.
Example 6
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the lip extends into the master vent slot when the container is disposed in
the base in the cooling
position.
Example 7
A cooling system for produce comprising: a set of containers, each container
comprising:
a base, wherein the base includes two opposed sidewalls, two opposed end
walls, and a bottom
wall; a lid, wherein the lid includes two opposed sidewalls, two opposed end
walls, and a top
wall; an end recess, wherein the end recess includes an end portion recessed
into one of the end
walls of the base and a bottom portion recessed into the bottom wall of the
base; a side recess,
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wherein the side recess is recessed into one of the side walls of the base; a
first mid-range vent
defined by one of the end walls of the base and disposed in the end portion of
the end recess; a
second mid-range vent defined by one of the sidewalls of the base and disposed
in the side
recess; a bottom ramp vent defined by the bottom wall of the base and disposed
in the bottom
portion of the end recess; and a case, wherein the case includes two opposed
sidewalls, two
opposed end walls, and a bottom wall, wherein the case is configured to
receive the set of
containers therein, the case comprising: a plurality of master vent slots
defined by each end wall
of the case; and a plurality of funnel vents defined by the bottom wall of the
case.
Example 8
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the case further comprises an imaginary longitudinal center line extending
along the center of the
bottom wall of the case from one end wall to the other end wall, wherein the
plurality of funnel
vents includes a set of master funnel vents disposed along the imaginary
longitudinal center line.
Example 9
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the plurality of funnel vents includes a set of minor funnel vents disposed on
both sides of the
imaginary longitudinal center line.
Example 10
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
a group of four containers in the set of containers define an opening
therebetween, wherein the
opening is in fluid communication with at least one of the master funnel vents
when the group of
four containers is disposed in the case.
Example 11
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the set of containers is a set of eight containers, wherein the case is sized
to receive the eight
containers in two rows and four columns therein with three openings defined
therebetween,
wherein the set of master funnel vents comprises three master funnel vents
disposed whereby
each funnel vent is in fluid communication with an opposing one of the three
openings.
Example 12
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The cooling systems or methods of any of the previous or subsequent Examples,
wherein
each container is a clamshell container, each container further comprising a
hinge, wherein the
lid is connected to the base via the hinge.
Example 13
A method comprising: disposing a first container, a second container, a third
container,
and a fourth container in a case, wherein the first container, the second
container, the third
container, and the fourth container define an opening therebetween; aligning a
master funnel vent
defined by a bottom wall of the case with the opening, wherein the master
funnel vent and the
opening are in fluid communication; defining a pair of first main clamshell
vents between a lid of
the first container and a base of the first container; defining a pair of
second main clamshell
vents between a lid of the second container and a base of the second
container; and aligning a
pair of master vent slots defined by a pair of sidewalls of the case with the
pair of first main
clamshell vents and the pair of second main clam shell vents, wherein the pair
of master vent
slots, the pair of first main clamshell vents, and the pair of second main
clamshell vents are in
fluid communication.
Example 14
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising forcing fluid into one of the pair of master vent slots, through
the pair of first main
clamshell vents, through the pair of second main clamshell vents, and out the
other one of the
pair of master vent slots.
Example 15
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising forming a bottom ramp vent in a bottom wall of the base of the
first container.
Example 16
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising aligning a minor vent slot defined by a bottom wall of the case
with the bottom ramp
vent, wherein the minor vent slot and bottom ramp vent are in fluid
communication.
Example 17
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising forming a mid-range vent in an end wall of the base of the first
container.
Example 18
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The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the bottom ramp vent is disposed in a recessed portion of the bottom wall of
the base of the first
container.
Example 19
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the mid-range vent is disposed in a recessed portion of the end wall of the
base of the first
container.
Example 20
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the recessed portion of the bottom wall and the recessed portion of the end
wall are contiguous.
Example 21
A method of cooling produce, the method comprising: filling a set of four
containers with
produce; disposing the set of four containers in a case, wherein the set of
four containers are
disposed in the same general plane in a two by two configuration; allowing
fluid to passively rise
via convection from below the case to above the case through a master funnel
vent defined by a
bottom wall of the case and an opening defined between the set of four
containers; and in
response to the fluid passively rising through the master funnel vent, drawing
heat out of the set
of four containers through a plurality of vents defined therein to entrain the
heat in the passively
rising fluid.
Example 22
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising: defining a first master slot in a first sidewall of the case,
wherein the first sidewall
extends from the bottom wall; defining a second master slot in a second
sidewall of the case,
wherein the second sidewall extends from the bottom wall, wherein the first
sidewall and the
second sidewall are parallel; and forcing fluid into the first master slot,
wherein the fluid forced
into the first master slot passes through a first container in the set of four
containers and a second
container in the set of four containers and out the second master slot.
Example 23
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising orienting the first container and the second container within the
case to dispose a first
main clamshell vent of the first container proximate the first master slot, a
second main clamshell
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vent of the first container proximate a first main clamshell vent of the
second container, and a
second main clamshell vent of the second container proximate the second master
slot.
Example 24
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising: forming a bottom recessed portion in a bottom wall of a base of
the first container,
wherein the bottom recessed portion is recessed inwardly toward an interior of
the first container;
and venting the interior of the first container through a bottom ramp vent
defined by the bottom
wall of the base and within the bottom recessed portion.
Example 25
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising: forming an end recessed portion in a side wall of the base of the
first container,
wherein the end recessed portion is recessed inwardly toward the interior of
the first container;
and venting the interior of the first container through a mid-range vent
defined by the end wall of
the base and within the end recessed portion, wherein the bottom recessed
portion and the end
recessed portion are contiguous.
Example 26
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising: inserting a portion of a first container in the set of four
containers into a master vent
slot defined by a sidewall of the case, wherein the sidewall extends from the
bottom wall; forcing
fluid into the master vent slot toward the first container; dividing the
forced fluid into a first
portion and a second portion; receiving the first portion of the forced fluid
in a lid vent defined
by a lid of the first container; and receiving the second portion of the
forced fluid in a main
clamshell vent defined by the lid and a base of the first container.
Example 27
The cooling systems or methods of any of the previous or subsequent Examples,
wherein
the first portion and the second portion are based on a size of the master
vent slot and a size of
main clamshell vent.
Example 28
A method of cooling produce, the method comprising: forcing a fluid through a
case
toward a container disposed within the case; and directing a first portion of
the fluid through a lid
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of the container; and directing a second portion of the fluid into a main
clamshell vent defined
between the lid and a base of the container.
Example 29
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising directing the first portion through the lid of the container via an
element of the
container.
Example 30
The cooling systems or methods of any of the previous or subsequent Examples,
further
comprising directing the second portion through the main clamshell vent via
the element.
Example 31
The cooling systems or methods of any of the previous Examples, wherein the
element is
an angled lip.
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