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

A shipper for use in a shipping system for transporting and/or storing temperature-sensitive materials, the shipper comprising:

• (a) a cooler base, the cooler base comprising
• (i) an inner portion, the inner portion comprising a thermal insulation unit, the thermal insulation unit comprising a bottom wall and four side walls, the bottom wall and the four side walls collectively defining a chamber,
• (ii) an outer portion, the outer portion comprising thermally-insulating material shaped to include a bottom wall, four side walls, and an opening, wherein the inner portion is disposed within the opening of the outer portion, wherein the bottom wall of the inner portion is permanently bonded to the bottom wall of the outer portion, and wherein the inner portion and the outer portion collectively define a plurality of cavities therebetween adapted to receive coolant;
• (b) a product box, the product box disposed within the inner portion of the cooler base and seated on the bottom wall of the inner portion, the product box having a plurality of faces;
• and
• (c) a cooler lid, the cooler lid being mounted on the cooler base to selectively permit access to contents of the cooler base.

A method of making a shipper for use in transporting and/or storing temperature-sensitive materials, the method comprising the steps of:

• (a) fabricating an inner portion of a cooler base, the inner portion comprising a thermal insulation unit, the thermal insulation unit comprising a bottom wall and four side walls, the bottom wall and the four side walls collectively defining a chamber,
• (b) fabricating an outer portion of the cooler base, the outer portion comprising thermally-insulating material and defining an opening, wherein the outer portion of the cooler base comprises a bottom wall;
• (c) positioning the inner portion of the cooler base within the opening of the outer portion of the cooler base and permanently bonding the inner portion of the cooler base to the outer portion of the cooler base by positioning an adhesive between the exterior of the bottom wall of the inner portion of the cooler base and the interior of the bottom wall of the cooler base and applying pressure to effect a permanent joining, whereby the cooler base is formed in which the inner portion and the outer portion collectively define a plurality of cavities therebetween adapted to receive coolant;
• (d) positioning a cooler lid on the cooler base to selectively permit access to contents of the cooler base.

A shipping system for use in transporting and/or storing temperature-sensitive materials, the shipping system comprising:

• (a) a cooler base, the cooler base comprising
• (i) an inner portion, the inner portion comprising a thermal insulation unit, the thermal insulation unit comprising a bottom wall and four side walls, the bottom wall and the four side walls collectively defining a chamber, and
• (ii) an outer portion, the outer portion comprising thermally-insulating material and defining an opening, wherein the inner portion is disposed within the opening of the outer portion and is permanently bonded to the outer portion, and wherein the inner portion and the outer portion collectively define a plurality of cavities therebetween,
• (iii) wherein the inner portion of the cooler base is permanently bonded to the outer portion of the cooler base with an adhesive, wherein the outer portion of the cooler base comprises a bottom wall and four side walls, wherein the bottom wall of the outer portion of the cooler base comprises a recessed area, and wherein the recessed area is dimensioned to matingly receive the inner portion of the cooler base;
• (b) a product box, the product box disposed within the inner portion of the cooler base and seated on the bottom wall of the inner portion, the product box having a plurality of faces;
• (c) a first plurality of temperature-control members, the first plurality of temperature-control members being disposed within the inner portion of the cooler base on one or more faces of the product box, wherein no temperature-control members are positioned under the product box;
• (d) a second plurality of temperature-control members, wherein at least some of the second plurality of temperature-control members are disposed within the cavities;
• and
• (e) a cooler lid, the cooler lid being mounted on the cooler base to selectively permit access to contents of the cooler base.