GB2473812A - Flat pack ISO shipping container - Google Patents

Abstract

An intermodal freight shipping container comprises a plurality of parts that can be assembled and disassembled using a jig incorporating a lifting means. The container is designed to be transported erect and full in one direction and transported collapsed in the other direction. This is to reduce costs of returning containers when the transportation of goods is substantially one way. The jig that erects the container can be different to the jig that dismantles it.

Description

I

Shipping container This invention relates to shipping containers, otherwise known as intermodal freight shipping containers.

Such containers are adapted to be stacked one on top of the other (up to about five or six in a vertical stack), to be lifted by specially adapted cranes and heavy forklift trucks, and to carry a heavy load (having a maximum laden weight up to about 34 tonnes or so) by sea (stacked on the deck of a container ship) or land (resting singly on the flat bed of a lorry). They conventionally comprise welded steel boxes with corrugated sides, made for example from 2mm thick high tensile steel plate, and have standardised dimensions, usually either 6.lm or 12.2m in length, 2.4m wide and either 2.4m or 2.9m high with a pair of doors at one end only. Variant types exist. Usually the floor of the container is made from welded steel beams with a plywood or steel covering, and usually a heavy steel casting is arranged at each of the eight corners of the container, having holes in its three outward faces for receiving a locking element by which means the container may be secured to a crane, the flat bed of a lorry, or the like.

A problem with such containers is that freight is often unidirectional and the container occupies as much volume on the empty return journey as it does on the full, outward journey.

It is the object of the present invention to provide a shipping container that is more convenient in use.

According to a first aspect of the present invention there is provided an intermodal freight shipping container comprising a plurality of parts that can be assembled and disassembled.

According to a further aspect the invention provides a system comprising an intermodal freight shipping container and a jig, the container comprising a plurality of parts that can be assembled and disassembled using the jig, the jig being adapted to lift and move the parts between a stored position and an assembled position.

According to a still further aspect the invention provides a method of assembling and dismantling a shipping container, comprising providing a plurality of components, a first jig and a second jig, wherein each jig comprises lifting means for lifting and moving the components into an assembled position; assembling the components in the first jig to form the container; returning the container to one of the first and second jigs, dismantling the container and lifting the components into a storage position using the lifting means.

Further features and advantages will be evident from the illustrative embodiment that will now be described, purely by way of example and without limitation to the scope of the claims, and with reference to the accompanying drawings, in which: Fig. 1 shows a side panel of a first dismantiable shipping container; Fig. 2 shows a base panel, a corner post and a securing fastener of the first container; Fig. 3 is an enlarged view of the material of the panels of Figs. I and 2; and Fig. 4 shows a jig for assembling and dismantling the first container.

Referring to the figures, a first shipping container comprises a set of two side panels 10, one end panel (not shown) which is similar to the side panels 10 except for its relatively smaller length dimension, two doors (not shown), one base panel 30, one roof panel (not shown) which is similar to the base panel 30, and four corner posts 50. These eleven separate components (comprising two side panels, one end panel, one base panel, one roof panel, two doors, and four corner posts) may be assembled and disassembled using a jig 70.

The floor panel 30 comprises a flat sheet of a composite, laminar material 90, comprising two outer metal layers 91, e.g. steel or aluminium, bonded to an inner polymer layer 92, e.g. a polyurethane elastomer. A material of this type is available as SPS or Sandwich Plate System (TM) from Intelligent Engineering (UK) Limited of West Common, Buckinghamshire, United Kingdom. It may be for example around 25mm thick.

The present invention recognises that this material, as well as being strong and lightweight, may be capable of accepting relatively concentrated point loads, and hence it is particularly preferred, although in alternative embodiments a more conventional steel plate construction (comprising, e.g. a corrugated steel plate welded at its edges to a stiffening frame) may be adopted.

The side panel 10 comprises another flat sheet of the same material 90, with two flat flanges 11 extending for a short distance from its inner face 12. The ends 13 of each flange are mitred at 45 degrees to its long axis. Each flange has a series of holes 14 extending through it vertically in the use position as shown.

The base panel 30 has a corresponding linear series of pins 31 extending vertically upwardly adjacent each of its two long edges and one short edge, and a linear series of holes 32 arranged adjacent its other short edge. An aperture 33 is arranged near each of its four corners.

In use, the base panel 30 is arranged on the flat bed 71 of aug 70, which serves to raise the base panel from the ground so that its lower surface can be accessed, and also provides lifting means 72 (such as travelling beams 73, 73' with winches and hooks 74) by which means each component of the container can be lifted from a storage position into an assembled position.

Each corner post 50 comprises for example a round steel tube having reduced diameter threaded upper and lower ends 51 which meet the central portion of the tube to define flat collars 52. Using the lifting means 72, the corner posts 50 are arranged so that their threaded lower ends 51 pass through the apertures 33 in the base panel. Threaded fasteners 53 are then attached to the lower ends 51 from the underside of the base panel to secure the posts to the base panel 30. Of course, alternative fastening means might be used.

The two side panels 10 (of which only one is shown) and the end panel (not shown) are then lifted and lowered onto the base panel so that the lower flange 11 on each side panel 10 extends adjacent the long edge 34, 35 of the base panel, with the corresponding flange of the end panel (not shown) extending along the short edge 36, and the pins 31 enter into the holes 14 in each respective flange.

The pins 31 may be secured to the flanges 11 using conventional threaded nuts or the like, or any other convenient fastening means (not shown). The two side and one end panel meet at their respective mitred ends to defme the vertical corners of the assembled container. In a development, the ends of the panels may abut each other squarely, or alternatively may comprise fastening means whereby they are fastened together. For example, the adjoining ends of the panels may be provided with flanges similar to the flanges 11, whereby the panels may be secured to one another.

A pair of doors (not shown) are then lowered into position adjacent the short edge 37 of the base panel. The doors may be pivotably mounted in an integral frame, or may be separately pivotably attached to the base, roof and/or side panels. Once in position, a set of fastening pins 100 maybe inserted upwardly through the holes 32 to secure the doors and/or their integral frame in position.

The roof panel (not shown) is then lowered into position so that the upper threaded ends 51 of the corner posts extend through holes similar to the holes 33 in the base panel, and pins similar to pins 31 extend downwardly from the roof panel through the holes 14 in the upper flanges 11 of the side and end panels. The corner posts are secured to the roof panel with fasteners 53 which engage against the upper (outer) surface of the roof panel, and the pins may be secured in similar fashion to those of the floor panel. Once assembled, the container has dimensions and load bearing capacity similar to those of a conventional shipping container (being for example either 6. im or 12.2m in length, 2.4m wide and either 2.4m or 2.9m high), and is capable of being stacked fully laden up to about 5 or 6 high with the corner posts transferring the compressive load from the containers above to those below. Advantageously, the material 90 transfers the point load from the pins, flanges and fasteners to the adjacent panels. in a development, the polymer 92 may be locally replaced, e.g. with metal, so as to locally strengthen the panel, e.g. adjacent the flanges.

Corner castings similar to those used on a conventional container may be attached, e.g. to the upper and lower ends of the corner posts. The corner castings may incorporate the fasteners 53. Alternatively, corner castings may be separately attached to the side, end, floor and roof panels.

Once assembled, the container may be loaded, lifted and transported in the same way as a conventional container. After it is unloaded, it can be dismantled by depositing it in a similar jig 70 and disconnecting its eleven principal components, of which the panels can then be stacked vertically in a stored position (conveniently resting against the vertical pillars of the jig) using the lifting means of the jig. In this way, the component flat panels of several containers may be stored in the volume occupied by a single assembled container, so that the cost of the return journey is reduced. Preferably, the components of one container are interchangeable with those of other containers, so that like components may be grouped and transported in the most convenient way.

The component panels and doors of the dismantled container may also be assembled together to form other structures, such as dwellings, bridges, storerooms, and the like. Advantageously, the material 90 may confer blast resistance to such structures, making them suitable for use in military environments.

The means of attachment (flanges, pins and so forth) of the component, generally flat panels are adapted according to the material from which the panels are made, which is preferably light, strong and of relatively small thickness.

Desirably, a sealant is applied to the mating surfaces of the panels and flanges prior to assembly. This may be for example a silicon mastic, or a non-setting mastic. Alternatively, elastomeric seals may be captured in each joint.

Each flange may include a ridge 15 and recess 16 which engage respectively with a corresponding recess 40 and ridge 41 on the mating surface of the respective panel to form a watertight seal.

In an alternative embodiment, rather than employing pins that engage through perforated flanges as shown, each panel may comprise a plurality of spaced apart lugs along each of its edges, which cooperate in the assembled position to define a plurality of fixing holes spaced apart along each corner of the assembled container. A removable pin may then be inserted into each fixing hole defmed by two cooperating lugs (one on each panel) to join the two panels together.

In a development, the base panel may comprise a stiffening structure similar to that of a conventional container.

Further adaptations will be evident to those skilled in the art on perusing the foregoing description, and it is to be understood that the scope of the invention is limited only by the claims.

Claims (4)

1. Claims 1. An intermodal freight shipping container comprising a plurality of parts that can be assembled and disassembled.
2. 2. A system comprising an intermodal freight shipping container and a jig, the container comprising a plurality of parts that can be assembled and disassembled using the jig, the jig being adapted to lift and move the parts between a stored position and an assembled position.
3. 3. A method of assembling and dismantling a shipping container, comprising providing a plurality of components, a first jig and a second jig, wherein each jig comprises lifting means for lifting and moving the components into an assembled position; assembling the components in the first jig to form the container; returning the container to one of the first and second jigs, dismantling the container and lifting the components into a storage position using the lifting means.
4. 4. An intermodal freight shipping container substantially as described with reference to the accompanying drawings.