GB2281754A

GB2281754A - Porous constructions for storage,packaging,jacking,etc.

Info

Publication number: GB2281754A
Application number: GB9409192A
Authority: GB
Inventors: Joseph Patrick Dempsey; Brian Anthony Drewitt
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-05-06
Filing date: 1994-05-06
Publication date: 1995-03-15
Also published as: AU6683994A; GB9409192D0; GB9309380D0; WO1994026620A1

Description

2281754 - P56066 GB - Impermeably Covered Sponge-Like Constructions.

The present invention relates to impermeably covered sponge-like constructions which can be used in a wide variety of applications.

The impermeably covered sponge-like constructions of the present invention can be collapsed, e.g by application of a vacuum, pressurised or filled with fluids.

In particularly, though not exclusively the present invention relates to constructions which can contain fluids; constructions for the storage and transport of fluid, in particular, fluid in a liquid state; constructions for unloading material in powder or granular form from the enclosed space in which it is transported or stored; constructions to package items for transportion and storage; and constructions which can be used as buildings, building forms and other structures such as mattresses, furniture, boats, barges, drones, lifting jacks and insulatec containers.

In a first aspect of the present invention there is provided a container for fluids comprising a foam or sponge like cellular material contained within a closed housing or coated with an impermeable material and having means for charging and discharging fluid.

The container can be of any convenient shape and a rectangular, cylindrical or e.g. ellipsoidal section is likely to be preferred, but other polyhedronal structures may be applicable, such as a straight sided structure, hexagonal in section.

The cellular material is a compressible material, such as foam or synthetic sponge.

Suitable foam materials can be polyether or polyester foams. For example, foams known as KCME available from Kay-Metzeler Limited. Foam density and type are chosen according to the application. Such foams are flexible, collapsible, absorb shock, are fire retardant, and can be used repeatedly.

The closed housing can be formed from a plastics material such as a heavy gauge polythene sheet or a coating of polymer material. An impermeable polymer material is likely to be preferred.

For example, the polymer material can be polyester based such as DIPRANE available from Kemira Polyers, which produces a tough abrasion resistant polyurethane elastomer.

The means f or charging and discharging the container can comprise an inlet which can be connected to for example a pump enabling fluid to be pumped into the cellular material and for the fluid being transported to be extracted by means of a vacuum applied to the inlet. Alternatively, the container can be provided with separate inlets and outlets. The combined inlet/outlet, or separate inlets and outlets can be located at any suitable position, such as at the bottom of the container.

In a second aspect of the present invention there is provided a construction which can be shaped as a wedge and can be combined with a liner to the dimensions of a confined space or container such as a standard 20 foot ISO container and can be provided with means for pressurising the construction in order to tilt the floor of the liner within the confined space.

By this method material such as powder or granules can be discharged from the confined space without the need to incline the ISO container itself.

The wedge like shape can be formed as a single piece moulding from cellular material or it can be made from a number of sections of cellular material which when combined together def ine the shape of a ramp.

The wedge like shape can be provided with means for pressurising the volume eg. by pneumatic or hydraulic means.

4 As an alternative, the construction can be shaped to provide a "snow plough", and to provide a ram to drive the contents of the liner from the closed end of the confined space to the point of discharge at the open end.

As a further alternative there can be two constructions within the confined space of which one will inflate to provide an incline in one or more planes and the other to provide a ram.

In a third aspect the present invention provides a construction having a foam or sponge-like core which is coated with an impermeable material, the interior of the construction being pressurisable by a fluid medium which can be a liquid or a gas. The construction is provided with appropriate valves to enable the interior of the construction to be pressurised and for the pressure to be released, and for the constructions to be compressed. The constructions according to the present invention have a wide variety of applications in which the constructions will take a variety of shapes according to the application.

The constructions as set out above are particularly useful for the packaging for transportation and storage of large and possibly heavy items such as machine tools, electrical switchgear and aero engines, and also for items of artistic value, such as paintings and sculptures.

Such items usually require specially designed and constructed crates to be fabricated from wood. These crates are expensive to make and are usually only used once, after which they are destroyed or used for other purposes.

The present invention seeks to provide, amongst other things, a packaging construction which is relatively light, adaptable so that it can be used for the packaging for transportation and storage of a range of items, and which can be re-used.

The present invention specifically provides a packaging construction comprising a foam or sponge-like core coated with a polymer material, the core being pressurisable by a fluid.

The fluid can comprise a liquid or gas, e.g water or air.

The construction can be provided with an inlet for the pressurising medium together with an outlet for the pressuring medium and a pressure release valve.

The packaging formed from a construction according to the present invention can comprise two impermeably covered or coated foam cores which can be hingedly secured together, the co-operating surfaces of which are covered with an impermeable relatively resilient material whilst the remaining outer surfaces are coated with relatively stiff impermeable material.

The co-operating surfaces of the impermeably covered or coated foam cores can be formed with shaped depressions to correspond accurately or approximately to the shape of the object to be packaged for transporation and storage.

The two portions of the packaging can be provided with securing means to maintain the two portions in a closed position. The securing means can be in the form of straps, or zip fasteners.

Each of the two portions can be provided with means to allow the impermeably covered or coated foam cores to be pressurised by an appropriate pressurising medium such as water or air.

The inlets for the pressurising medium in each core can be provided with a non-return valve and the cores can be provided with pressure release valves.

The packaging can be provided with lifting means such as hooks or eyes and/or pockets for the forks of a fork lift truck.

Each or both can be provided with reinforcements in the form of plates or platforms formed from, for example, sheet steel or a fibre reinforced composite.

Each or both portions can be sub-divided into separately pressurisable volumes by means of non-porous dividers.

In a f ourth aspect the present invention provides a building structure including one or more beams comprising a foam or sponge-like core coated with an impermeable material in which the core is pressurised by a fluid medium.

In a fifth aspect of the present invention there is provided a building form, the building form defining an opening and the form comprising a foam or sponge-like core coated with an impermeable polymer material, the core being pressurised by a fluid.

The present invention will now be more particularly described with reference to the accompanying drawings in which:

Figure 1 shows a diagrammatic representation of one form of container according to the present invention; Figure 2 shows a detail of the container shown in figure 1; Figure 3 shows the application of a structure similar to the container shown in figures 1 and 2 to an ISO container; Figure 4 shows diagrammatically an inflatable wedge of a similar construction to the container shown in figure 1; Figure 5 shows an alternative form of the wedge to that shown in figure 4; Figure 6 shows a detail of the wedge shown in figure 5; Figure 7 shows a front elevation of one form of packaging construction according to the present invention; Figure 8 shows a side elevation of the packaging shown in Fig. 7; Figure 9 shows a plan view of the lower half of the packaging shown in Figures 7 and 8; Figures 10 and 11 show side and end elevations respectively of an alternative form of Packaging to that shown in Figures 7 to 9; and Figure 12 shows a part section of a portion of the packaging shown in Figures 7 to 11; Figure 13 shows a diagrammatic perspective view of one form of building according to the present invention; Figure 14 is a section on line A-A in figure 13; Figure 15 is a typical section of one of the beams of the building in figure 13; Figure 16 is a part sectional elevation of a column in a building; Figure 17 is a section on line B-B in figure 16; and Figure 18 is a part-section on line C-C in figure 17.

Referring to the drawings a container (10) particular for the transport of liquids is shown resting on a pallet (12). The container (10) is formed of a material (14) of a cellular structure contained within a housing (16).

The material (14) can be made from a compressible cellular material and the housing (16) can be formed from a plastics material such as a welded heavy gauge polythene or an impermeable coating, e.g a polymer. The housing (16) is provided with a charging and discharging tube (18) having a valve (20).

In order to charge the container (10) liquid from a bulk supply is pumped into the cellular material (14) through the pipe (18). It will be appreciated that because of the cellular structure of the foam material (14) the liquid will occupy all of the voids in the material. When the material (14) is completely f illed the delivery pump is stopped and the valve (20) closed.

In contrast to existing bulk liquid transporters it will be appreciated that the container (10) does not require internal baffles to prevent movement of the liquid within the container. Any movement of liquid within the cellular material (14) is naturally controlled by the structure of the material.

A container according to the present invention has further advantages: a) because it is flexible it is less liable to rupture in the event of impact.

b) because it can in itself be carried inside a confined space (such as an ISO container) it is further protected from shock.

c) whether wholly or partially filled, all air/gas/vapour can be extracted so as to prevent build up/carriage of explosive or noxious gas/vapour.

In order to unload material from the container (10) the valve (20) is opened and a vacuum is applied to the pipe (18) so that the liquid can be sucked from the material (14). Alternatively, the container can be provided with separate inlets and outlets.

The combined inlet and outlet (18) or the separate inlets and outlets can be located as shown in figure 1 or at the bottom of the container so the discharge will be gravity assisted, or at any other suitable position.

Containers of the type (10) can be used in multiples for example to fill a standard 20 foot or 40 foot ISO container and can be sized so that the containers (10) fill virtuaily the whole of the space within such ISO containers or other confined space.

The container can be of any convenient shape and a rectangular cylindrical or ellipsoidal section is likely to be preferred, but other polyhedronal structures may be applicable, such as a straight sided structure, hexagonal in section.

For example, the container can be sized so that when filled they can be packed into standard sized vehicle bodies without wasting space.

Also, a ship can be converted f rom a dry cargo vessel to a liquid/fluid carrier using containers according to the present invention. The loaded containers can occupy the dry cargo space and after delivery the containers can be collapsed and stored on deck. The vessel then reverts to use as a dry cargo vessel.

An important feature of the container (10) is that when it is empty it can be collapsed by the application of suction or other loads, eg external pressure so that the container will occupy f ar less volume then when loaded. It will be appreciated that this facility enables the container (10) to be returned or repositioned in for example an ISO container or other types of land, sea or air transport whilst occupying far less volume than when loaded if a return load. cannot be obtained. Also, this facility enables the container to be available for further use and to comply with existing and potential legal requirements for re-cycling, re-using or recovering packaging media.

The container (10) can be modified in shape so that it can be used in conjunction with a liner for a confined space such as an ISO container enabling the contents of the liner to be discharged without the necessity of physically inclining the confined space to discharge the whole of the contents carried in the liner of the ISO container.

Referring to figures 3 and 4 a wedge (22) (figure 4) is formed from the same or similar compressible cellular foam material (14) as shown in figure 2, and is contained within a housing formed from for example a heavy gauge polythene material (24) or an impermeable polymer material.

In figure 3 the wedge (22) is shown in a collapsed state on the floor of a confined space here a standard ISO container (26) in which is located a liner (28), the liner (28) containing a load (not shown) which compresses the wedge (22).

In order to discharge the load within the liner (28) the wedge (22) is pressurised by pneumatic or hydraulic means so that the floor of the liner (28) is inclined the load within the liner being discharged through an opening which is provided in the liner.

The wedge can be provided with any appropriate incline or inclines which is or are chosen depending upon the nature of the material being transported.

The wedge (22) is provided with a valve (not shown) or some similar form of connection enabling pressure to be applied either pneumatically or hydraulically to the wedge so that the voids in the material (14) are filled with for example either compressed air or hydraulic fluid.

In use, the wedge (22) is first placed on the floor of the confined space such as an ISO container under the lower surface of the liner (28). It may be necessary to collapse the wedge (22) before loading the liner (28) with the material to be transported and this can be achieved by applying suction to the wedge. However this may not be necessary since when the material to be transported is loaded into the liner (28) the - 14 weight of the material will naturally compress the wedge (22).

It will be appreciated that the provision of the wedge (22) enables the load to be discharged from the confined space such as the ISO container without the need which is at present required for the confined space to be physically inclined for example by cranes in order that the whole of the load can be discharged from the ISO container.

The wedge (22) can be formed as a single piece of cellular material though it can be formed from a number of pieces of shapes of cellular material as shown in figure 5 so that the final shape of the wedge can be built up from shapes with rectangular and triangular or other shaped sections of cellular material.

A form of the wedge can be used to assist in the discharge of cargo from a ship's hold. The wedge f or this purpose can be placed on the f loor of a hold. When discharging cargo, the wedge is pressurised causing the cargo eg grain, to flow to one end of the hold, enabling the cargo to be easily unloaded by suction.

For a ships hold a more complex structure than a simple wedge will be required, or more than one wedge.

For an ISO container, the ramp is unlikely to be a simple wedge, but will be shaped to channel or force the contents either to the centre or one corner of the ISO box.

It will be appreciated that the wedge described with reference to f igures 3 to 6 inclusive when compressed or depressurised occupies a very small volume within a confined space such as an ISO container and enables loads of a wide range of types to be readily discharged the only requirement being the need for a means of pressurising the wedges either pneumatically or hydraulically in order to obtain sufficient inclination of the floor of the liner in the confined space and compressing or depressurising the ramps after the contents of the liner have been discharged.

The wedges can be used repeatedly and the confined spaced can be provided with a fresh liner for each cargo to be transported, if required.

Referring to the drawings Fig. 7 shows packaging container 110 formed in two parts 112 and 114 which are secured together by means of a hinge 116. The two portions 112 and 114 are clamped together by means of straps 118 and 120. Each of the portions 112 and 114 are formed from a core of foam material 122 (Fig. 12) which is covered with a coating of an impermeable polymer material 124 by spraying or other means.

16 - For example the foam core can be a polyether foam known as E20 or E49 available from the Kay-Metzler division of British Vita PLC. The polymer impermeable coating can be a coating known as Hyperlast available from Kemira Coatings Ltd.

The foam material is fluid permeable enabling the core to be filled with either a liquid or a gaseous material.

The co-operating surfaces 112A and 114A of the portions 112 and 114 are shaped either closely following or roughly identical with the shape of the item to be transported in the container 110. The surfaces 112A and 114A can be coated with an impermeable polymer material which is more elastic than the outer coating 124.

Each of the portions 112 and 114 has an inlet 126 and 128 to enable a pressurising medium to be forced into the foam core of each portion. The inlets 126 and 128 can each be provided with non-return valves (not shown) and the portions 112 and 114 can be provided with pressure relief valves (not shown) to ensure that the pressure within the portions 112 and 114 does not exceed a pre-determined value.

The portions 112 and 114 are also provided with outlets (not shown) to enable the pressurising medium within the portions to be released.

Referring to Fig. 9 which shows a plan view of the lower portion 112, the foam core of the lower portion is shaped to receive in this example a large diameter drive shaft, say for a marine propeller. 0 The corresponding surface 114A of the portion 114 is also shaped in a similar fashion and as has been mentioned the surfaces 112A and 14A are coated with a relatively elastic impermeable polymer material.

The shaft to be transported in the packaging container 110 is placed within the recess provided in the lower portion 112A and the upper portion 14 is closed over the shaft, the two portions are clamped together by the straps 118 and 120.

Both portions 112 and 114 are pressurised through the inlets 126 and 128 with an appropriate pressurising medium which can be, for example, water or air, until the required internal pressure within the foam cores is reached.

As shown in Fig. 7 the packaging container 110 is provided with lifting eyes 130 enabling the packaging container 110 to be hoisted into position.

It will be appreciated that due to the construction of the packaging container and the pressurising of the foam cores the item being transported is protected from shock which may arise at any time during loading and unloading, and transportation.

The packaging container can be made to a standard size so that a number of packaging containers 110, each perhaps carrying a different item, can be easily loaded within either a standard ISO container or in a ships hold or on a road vehicle with the minimum wastage of space.

Also the packaging container 11o can be re-used for the transportation of a wide range of items, particularly if the cores of the portions 112 and 114 are only roughly shaped or perhaps not even shaped at all providing that the impermeable polymer coating and the foam material is relatively elastic so that the coating and the core can adapt to the shape of a wide range of items which are to be transported.

When the packaging container is unloaded at its destination the pressure within the cores is released by operating the outlets allowing either the air to be released or the water to be drained from the cores. The straps 118 and 120 can then be released and the two portions 112 and 114 can be opened and the item being transported can be removed from the packaging container.

The packaging container can then be re-used to transport another item to a further destination. Alternatively the packaging container 110 can be returned to its despatch location in a compressed state by applying a partial vacuum to the cores which will cause the two portions of the packaging container to - 19 partially collapse. It will be appreciated that the packaging container 110 will then occupy far less volume for its return to the point of despatch.

Instead of the straps 118, 120, zip fasteners can be used.

Preferably the zip fasteners are waterproof. Suitable zip fasteners are those known as BDM zippers available from New Zipper Co. Ltd.

Packaging containers according to the present invention provide a considerable number of benefits. They are lightweight and reusable. There is a volume reduction for return of the containers. They are stackable and easily made at a relatively low cost.

Referring to figures 10 and 11 there is shown a packaging container comprising two parts (112) and (114), which are similar in construction and operation to the corresponding portions described with reference to figures 7, 8 an 9. In the present case the portion (114) is provided with a recess (126) to allow access for the forks of a fork lift truck.

Referring to figures 13, 14 and 15 a building frame comprises a number of vertical columns (128) and horizontal beams (130) mounted on an inflatable floor (134) beneath which is a layer (132) of non-inflatable material which is sponge-like or flexible - 20 in nature and designed to take up minor undulations in the surface on which the construction rests and to provide protection for the floor.

Referring to figure 15 in particular a vertical column (128) comprises a foam or sponge-like interior (134) having an impermeable polymer coating (136), the interior of the beam being pressurised by a fluid medium.' The horizontal beams (130) are constructed in a similar manner, and it will be appreciated that the pressuring medium provides the necessary strength to the beams and columns. The beams and columns can be secured together by any suitable means. The building frame can be covered with any suitable material to provide a roof and walls.

Referring to figures 16, 17 and 18 there is shown a concrete floor or deck (138) of a building together with a reinforced concrete pillar (140) which includes reinforcing bars (142) extending through the floor or deck of the building.

In order to extend the pillar through the floor a building form (144) is provided around the reinforcing bars enabling concrete to be poured within the interior of the building form.

The building form comprises a foam or sponge-like core (146) which is covered on all surfaces with an impermeable polymer material (148), the form being provided with an inlet enabling the interior of the form to be pressurised with a suitable fluid, and an outlet enabling the pressuring medium to be released. It will be appreciated that a building form of this construction will be re-usable and relatively light to manoeuvre.

The various constructions described can be manufactured by spraying the impermeable polymer coating material onto the foam core as has been mentioned., Alternatively, the coating can be sprayed onto a mould, and the void charged with f oam f orming materials so that the foam can be made in the coating and fills the space defined by the coating material.

Constructions according to the present invention can be used in a number of ways. They can be used to create building structures and forms for use in the construction of buildings as described, mattresses and furniture where a degree of resilience is required, and in the construction of boats, barges and drones.

Instead of being pressurised with water or air constructions according to the present invention can be filled with petroleum products, for example on oil tankers, so as to provide safe transportation of such hazardous materials, or for the safe storage of such hazardous materials, or as fuel tanks, either static or incorporated with land, sea and air vehicles of any description.

Constructions according to the present invention can also be used for lifting and raising objects, e.g aircraft and vehicles. A deflated construction or constructions can be located beneath the object and air or liquid pumped in so as to pressurise the construction thereby lifting the object. A vehicle which has been turned over can be righted in this manner. Also an aircraft can be lifted and transported if the construction or constructions are positioned on a trailer.

Further, constructions according to the present invention can be used as insulators. A collapsed construction is laid out in a vehicle or confined space and is inflated using gases or liquids. The inflated construction is used to line the walls of the vehicle body or confined space and protect the cargo against temperature loss or gain.

Claims

1. An impermeably covered sponge-like construction as a container for fluids comprising a foam or sponge-like cellular material contained within a closed housing or coated with an impermeable material and having means for charging and discharging fluid.

2. A construction as claimed in claim 1 in which the cellular material is compressible such as a foam or synthetic sponge.

3. A construction as claimed in claim 2 in which the cellular material can be a polyether or polyester foam.

4. A construction as claimed in claim 1 in which the closed housing can be formed from a plastics material such as heavy polythene sheet or a coating of impermeable polymer material.

5. A construction as claimed in claim 4 in which the impermeable polymer material can be polyester based such as the DIPRANE polymer system.

6. A construction as claimed in any one of the preceding claims in which the means for charging and discharging the container comprises inlets and outlets which are connectable to a pumping device enabling fluid to be pumped into the cellular material and for fluid to be extracted by means of a vacuum.

7. A construction as claimed in any one of the preceding claims in which the construction is shaped in a wedge like form and can be combined with a liner used for transportation of materials, the construction being pressurisable in order to tilt the floor of the liner which may be contained within the confined space e.g an ISO container.

8. A construction as claimed. in any one of the preceding claims in which the container is pressurisable by a fluid medium which can be either a liquid or gas, the container or a number of similar containers being usable as packaging for transportation and storage of objects.

9. A construction as claimed in claim 8 comprising a packaging container including at least two pressurisable -constructions each of which comprise foam cores covered with an impermeable material, the foam cores hingedly secured together, the co-operating surf aces of the foam cores formed with shaped depressions to correspond accurately or approximately to the shape of the object to be packaged for transporation and storage.

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10. A construction as claimed in claim 1 in the f orm of a building structure including one or more beams comprising a foam or sponge-like core coated with an impermeable material in which the core is pressurised by fluid medium.

11. A construction as claimed in claim 1 in the shape of a building form, the building form defining an opening and the form comprising a foam or sponge-like core coated with an impermeable material, the core being pressurised by f luid.

12. A construction as claimed in claim 1 for use as a jack in which the construction is collapsed, placed under or adjacent an object to be lifted and moved, the construction being pressurised thereby lifting and moving the object.

13. Containers and constructions, constructed and arranged for use and operation substantially as herein described, and with reference to the accompanying drawings.