WO2008135773A1 - (shipping) containers - Google Patents

Abstract

A shipping container (10) is adapted for conformity with cell guide constraints in dedicated container shipping vessels and maximises internal capacity in relation to external footprint, using a (rear) end access opening (14) bounded by opposed corner end posts (16) of differential or asymmetric profile, to allow two standard 800mm by 1200mm palletised loads (20) to sit alongside across a transverse internal width of some 2438mm, with a penultimate load pallet being loaded dog-leg fashion (i.e. longitudinally then transversely) around and to sit behind one fatter corner post, leaving a final pallet to load longitudinally past a slender opposite corner end post.

Description

(Shipping) Containers

This invention relates to (shipping) containers, capacity and conformity to standards issues.

Internal Floor plan Capacity vs. External Footprint A general consideration of relative internal vs. external sizes arises.

The internal floor plan shape and size impacts upon load capacity not least for modular load elements of fixed standard format.

The external foot print impacts upon compatibility with handling facilities and stacking with other containers and in confined storage areas such as freight holds. A particular consideration is maximising accommodation of multiples of standard pallet formats juxtaposition for optimisation of internal container capacity.

Side wall thickness and profile along with end wall and access door mounting representing potential obstacles to snug fit. Otherwise, wasteful internal voids arise. No revenue benefit arises from moving space around which might otherwise have a productive load carriage role.

Some aspects are particularly, but not exclusively, concerned with shipping containers within freight holds and hold sub-division contrived to discipline and facilitate (un) loading and container passage within the hold.

In dedicated container ships a hold sub-division is commonly known as a cell, with cell boundaries defined by so-called 'cell guides'. Such guides represent a local external constraint within which containers must be adapted to fit.

Generally, cell guides are configured as 'vertical' or upright channels, ribs or runways in the below deck level cargo hold, spaced to accommodate an individual container external footprint to facilitate loading and vertical stacking. Viewed in plan a matrix or grid array of channels may be employed.

The guides also afford supplementary lateral restraint against below deck cargo shift in transit. A container must be freely movable within a guide and have an end profile of handling and stacking (corner) fittings in conformity with a standard to fit underlying and overlying containers. Cell Guide Intrusion

Bespoke vs. Standardised Components

Such cell guide 'intrusion' and their necessary intermediate spacing in themselves occupy space with a vessel cargo hold which might in principle otherwise be used for commercially productive payload. To compensate for this, specialist complementary inter-fitting corrugated container wall profiles have been devised, along with relatively thin, slim, slender or shallow depth walls such as the subject of various patents, including US 6109469. This approach provides a useful capacity benefit, but adoption of specialist parts and fabrication increases cost, so hitherto known bespoke cell containers have a cost penalty. The Applicant is concerned to configure a container with optimised load capacity, with minimal bespoke fabrication or rather one using many standardised component elements available cost-effectively.

Internal Capacity vs. External Dimensions

Gaining internal capacity without proportionate increase in external profile or footprint requires re-configuration of container wall construction. This challenge is addressed in the Applicant's previous patent position and is re-visited in the present case with raft of detail construction refinement which collectively has a cumulative benefit. Thus detailed improvements in side wall, end door and door corner post are envisaged, along with an asymmetric or differential end door and door support configuration for ease of final end access for tight-fitting loads. A (nominally rear) wall for load access poses special considerations and so differs from the wall at the opposite (front) end. Variant options are also envisaged in which only a selected few rather than all refinements are incorporated. In all cases without an uneconomic construction. Simplifications and homogenisation, such as more straightforward and effective door seal disposition, seal path and seal interaction are envisaged.

A bespoke, such as shallow, generously-spaced panel stiffener ribbed outer wall profile to an overall slim-depth wall affording marginally greater internal floor space especially width, preserves an option of inter-nest or inter-fit with a complementary profiled side wall of a corresponding juxtaposed adjacent container.

Container construction has become a commodity business so component commonality, consistency and conformity a desirable target to keep costs down. 'Specials' tend to militate against this ethos, so are resisted unless paramount operational factors justify their adoption. A balance must be struck.

Container internal capacity reflects internal footprint, itself a combination of longitudinal and transverse span. However, for structural integrity and robustness, a certain wall thickness is required. In conventional container construction this has restricted internal capacity and has impeded accommodation of metric loads, or rather multiples of certain metric loads, such as 1m standard pallets, within imperial outer standards. As a specific prime example, fitting two x1m or 1.2m square pallets side-by-side has been impossible in a conventional container span of nominally marginally just less than double that footprint. A so-called 'Sea Cell' (Trade Mark) or generic 'seacell' container resolves this conflict with a special container format.

Mixed Internal vs. External Standards

Another issue of mixed container standards arises. Specifically, international imperial (i.e. feet and inch) standards apply to the external container handling and stacking inter-fit profile, but there is a need to fit European metric standard pallets spaced efficiently into the internal payload space. Absent that, uneconomic cargo space wastage or a jumbled load or load orientation mix must be countenanced.

Structural Integrity - Non-Standard Cost

Container structural integrity must be preserved upon wall thickness re-configuration and so special construction and fabrication techniques may be applied. These make the container non-standard compared with a regular container which has become virtually a commodity price point item. Container cost, and the tied-up capital, not least when multiplied over a large number of containers, is a disincentive to adoption. So the enhanced load capacity benefit must match, or outweigh, that disadvantage.

Prior Art The Applicant has previously devised a so-called 'Sea Cell' (TM) container format, the subject of US 6,108,469, which features inter alia: corrugated front; corrugated sides;

(unusual) slim (depth)end access doors - difficult to make; stacking reinforcement (with)in doors; 'special' seal lip under floor; door seal not in one plane - i.e. convoluted door seal path; generally, each 'special' (i.e. differentiated from conventional) feature adds to cost; low production runs and inherent complexity are a disincentive to adoption; so a multitude of such special features leads to a burdensome cost accumulation; thus even the front end wall was somewhat special + took up space; similarly, an element of speciality arose with the particular corrugated side walls; these might be retained in some variants of the Applicant's proposed future Sea Cell (SC) variant development (see SC2 described later), but substituted in others (see SC3 described later); complexities also arose with various other parts, including the doors; slim doors have a tendency to flex + are not easy to close; the complex door seals have proved susceptible to failure, but require special tools and skills to fabricate, repair or replace; commercial examples can be viewed at web site ... http://www.seacell.info/benefits.htm

Whilst representing an advance over conventional container limitations in 'liberating' internal load span, such a container construction requires many special parts, fabrication and assembly techniques and so does not lend itself to integrated production line build alongside standard containers. Rather, a premium must be sought for a bespoke build or reduced profit margins accepted.

Moreover, other disadvantages arising include .. a corrugated front wall takes up space; side wall corrugations require special build; a convoluted door seal profile - with risk of seal dislodgement, wear, fracture or failure, requiring special skills to maintain or repair;

Generally, whilst preserving pallet internal fit considerations, the Applicant now seeks to get away from 'specialism' of parts and construction, so the container can be processed in a conventional production line; specialism is imported from external production sources, as an option when needed.

Statement(s) of Invention

The content of the claims is imported by reference, along with a selection of the following features. A shipping container with differential or asymmetric cross-sectional profile corner end posts (16) to promote intervening load access aperture width or transverse span.

Such a container can be configured to fit between cell guides of a dedicated container ship cargo hold whilst accommodating a full twin rows of palletised load throughout the length, say of juxtaposed 800mm by 1200mm individual pallet sizes. Asymmetric corner end posts can be deployed to support respective hinged doors at a load access end, allowing a load entry between posts and load disposition around one (wider profile) post and against a side wall to admit a successive load past the parked load and the other (slimmer profile) post; the posts serving as end support and bracing frame members for an internal space frame upon which outer cladding panels are mounted.

One post could present a slim or slender transverse profile by being more orientated and or developed longitudinally, for minimal lateral intrusion into an adjoining end access aperture, relying upon compensating structure along the side wall from that corner without unduly increasing the overall side wall depth, so longitudinal span compensating for transverse depth.

A post on the opposite side can be somewhat bulkier or wider transversely, with correspondingly less longitudinal extent. A slim or shallow-depth wall panel construction is envisaged, with a plurality of discrete flat panels fastened, by say welding, in edge-to-edge abutment, with an applied surface dimpling as stress re-distribution or relief, the panel assembly being secured by welding to a support frame; allowing stresses attendant local welding heat to dissipate or re-distribute to inhibit local distortion upon panel unroll and separation from a roll or coil of wound strip material.

Internal capacity can be optimised in relation to external foot print, and configured to allow some two rows of 15 pallets or palletised load elements each of some 1200mm by 800m footprint, within an internal floor space footprint of some 12.097 or 12.1m length by 2.438m width and 2.694m height, all within a 1.2192m external length, 2.896m external height and 2.481m external width.

In practice, a modular construction can be adopted, using a mix of conventional and special or bespoke elements according to a target variant to be contrived. Thus a container can be considered as an elongate fabricated rectangular format tube with end closures. One (nominally, front) end is generally closed or blind, but features a base recess or cut-out for trailer chassis loading. The end wall is essentially a panel set upon an internal end frame. Another opposite (nominally, rear) end is open for load access and closed by opposed hinged end doors hung from inset corner end posts. Peripheral edge seals are operative between door edges or door frames, end frames and door support posts.

For ease and economy of mass market manufacture, the Applicant now seeks greater conformity with standardised container production techniques - for build without disruption on the same production line, but allowing selective introduction of 'special' sub-assemblies brought in from outside sources, in turn affording flexibility in bespoke build variation to customer requirements. Thus state of the art (say, motor industry style) selective option mix build parallels might be drawn.

In particular, the Applicant envisages two refinement versions preserving dual side-by side juxtaposed pallet load fit, designated for convenience SC2 and SC3, with features summarised as follows ... SC2 features ...

(a more conventional + so cheaper solution that SC3) the general ethos is 'as conventional as possible', consistent with role fulfilment + fit with other containers; customers may also prefer a container with a consistent overall visual appearance; i.e. radical different or 'stand-out' looks may be disconcerting; thus side panels may be as in the original SC1 model; particular features include ...

• conventional roof and top side rail;

< base visibly connected; > < side wall connection introduced; >

• flat (i.e. non-corrugated) front end wall (in-fill) panel;

... such a (relatively) flat end wall is less space-intrusive that a corrugated profile; this is important where space is at a premium or critical for dimensional fit with other elements such as cargo pallets; ... {an end frame sub-assembly can be fabricated off-site away from a production line; allowing customer tailored or bespoke end-frame and door in fill solutions;}

• dimpled (impressed /depression pattern) in fill panel in front wall; ... {generally, dimples tend to disguise blemishes such as operational knocks, dents and scuffs, such as lead to a deterioration in overall container appearance after a period of use; a simple flat panel face would be particularly susceptible to this; in practice the dimple profiles and pattern can be even, randomised or optimised;} • a rigid end frame to hold (in fill) panel;

... conformity with standard so-called 'goose-neck' mouth (base entry guidance recess or blind ended duct) configuration;

• 'standard' end (access) doors - but slightly slimmer (depth);

... strong / robust vertical (upright) door frames - but horizontal frame bars slimmer to fit in standard locking tubes;

• door end corner posts solid + longer; ... to be slim, yet strong against stacking;

• side panels as SC 1 ;

a flat wall construction is extended to side walls in SC3 variant described later;

• a conventional roof and top side rails can be retained; ... this has the advantage of standardisation and economy of manufacture; past problems with slim door flex, deformation or buckle - undermining secure closure and seal integrity - are resolved; this is an operational and performance advantage; an overall objective is a configuration adhering as far as possible to convention (i.e. reducing the 'specials' component count, yet providing the target internal pallet fit operational advantages); a front end wall sub-assembly can feature a peripheral or perimeter frame supporting an in-fill panel as a diaphragm - this to withstand end wall loading and resist buckling while accommodating a bottom edge cut-out of a goose neck base recess, by reliance upon flat upright corner posts

SC3 features ... rationale is a more 'special' construction, albeit at greater cost than SC2} • some commonality with SC2 construction;

• flat and/or dimpled (impressed multiple, repeat array or pattern) side wall panels;

... again, the dimple pattern form and disposition admits of considerable variation;

• asymmetrically located side posts; ... as with SC2, special consideration is given to corner end post configuration - that is cross-section, orientation and disposition; generally, taken in a plan view, a 'fat' left- hand (LH) and slim right-hand (RH) forms are adopted; this to allow straight-in pallet loading from the open access end on the RH alongside the RH corner end post, but with 'dog-leg' loading on the LH around and behind the corner post, to accommodate two metric format pallets side-by-side within a standard external footprint; whilst the door posts have different cross-sections for the dual pallet load fit considerations, they have much the same stiffness and contribute more or less equally to resisting stacking loads; door seals are typically carried with the doors themselves, so are cleared out of the way from load damage upon door opening for end access; seal interaction with the door support posts upon door closure is an important consideration;

• a simpler flatter or more co-planar door seal routing and disposition; • substitution of the foregoing dimpling and post asymmetry upon same end, door, base, roof structure of SC2 - at customer choice;

... such fiat end and/or side wall profiles represent a departure from corrugation, but with fabrication simplicity and panel seam (butt) joint weld and frame mounting local heat distortion resolved by dimpling (impression pattern) for stress relief or re- disposition;

The panels are joined at or adjacent bracing cross-members, such as struts or uprights, between rails. The disposition of such bracing on each side wall is asymmetric or mutually offset, for side-by-side complementary inter-nesting conformity with other corrugated containers, including for example those of the original SC1 design. The number of such struts is less than the number of corrugations by a 'form' factor, multiplier or sub-divisor, (say circa 3-5), with the effect that inter-nesting occurs less frequently than hitherto.

A somewhat wasted, canted or tapered edge wall contour may be created by securing panels to a profiled former. Conventional Container Comparison

In order to emphasise the compatibility of the proposed SC 2 and SC3 construction with a standard 'conventional' container format, a retrospective comparison with conventional containers reveals certain differences, thus:

• base as SC 1 , 2 and 3; • roof as SC 2 and 3; doors as SC 2 and 3; front end different; rear frame different; sides different; Summarising key product features ...

• sides flexible, but strong; can support ISO side loads, but are more flexible; so leans on adjacent containers, so intervening gap is now smaller; typical gap for standard container is 25mm, but with SC2 and SC3 gaps is reduce to circa 6mm. • internal length is 12100mm with conventional style of construction for base, roof, end frame; side assembly methods used on conventional production lines, thus productivity and cost benefits;

• marketing benefit;

• doors now close together upon conventional seal which helps spares and repair; • stacking strength achieved, without need of door reinforcement;

• dimpled panel suppresses weld distortion; wear and tear not visible

External stiffener ribs or formers may be applied to an otherwise flat panel construction, say at or adjacent the abutting or marginally overlaid) edge joints between successive panels. Such ribs may be spaced longitudinally to inter-fit with corrugations (if any) on other juxtaposed containers. A tapered, waisted or so-called 'birds beak' section may be used.

Whilst not identical, given the access doors at one (rear) end, some commonality in end frame construction might be adopted. Similarly, as between SC2 and SC3 variants, some commonality in construction may be adopted.

If load depths to not occupy the entire container internal depth, given a head space between end frames, the depth of a corrugated roof construction does not intrude upon the side-by-side fit constraints which impact upon the side wall construction.

In a particular construction, a plurality of generally flat panels (such as might be severed from an unwound continuous rolled sheet) is juxtaposed in edge-to-edge abutment and edge seam welded in a continuous wall; the assembly then being secured by welding to a frame assembly of longitudinal elements and cross struts

Generally, the invention provides a container in which internal capacity is increased, if not maximised, without (dis)proportionate change in external profile, so as to remain in conformity with general international stacking and handling standards, the depth of the container side and/or end walls or doors being reduced, in turn to reduce the differential in external vs. interna! dimensions - but without compromising structural integrity.

One consequence might be that the 'median' wall plane is displaced somewhat outward. Another might be that corner support post intrusion in between corners is reduced to improve load access. This might be achieved with a novel corner post cross-section, outer profile and disposition in relation to the walls.

Asymmetric Side Wall Corrugation

An (asymmetric) container wall configuration of relatively widely-spaced stiffener ribs or 'strakes', fitted to an array of panels secured to a common perimeter frame, and located at multiples of the corrugation spacing of conventional corrugated wall containers adapted for optimised inter-nesting in container ship cell guide usage, to allow mutual compatibility in inter-nested stacking and packing.

Wall Panel Fitment to Frame Wall panels may be edge-butted or marginally overlapped. Intervening panel sealing may be applied. Ribs run 'vertically' or upright between top and bottom rails of a container frame and are applied after panel fitment. Such stiffener ribs can be riveted, and optionally bonded or sealed, to the overall panel assembly.

Periodic Corrugation Inter fit Overall, the wider-spaced, less numerous ribs of the present invention interact periodically with corrugations of conventional sea cell container wall profiles - say a relative interval or ratio of one in three or so to one in five or so.

Panel Pre-stress Relief / Redistribution

Deliberate controlled mechanical disturbance, such as a multiple array of local pressed dimples, may be applied to re-distribute internal stresses arising in fabrication and assembly from the application of local joint or seam welding heat. Shallow End Wall

A shallow depth end wall at one end and special access door mounting upon asymmetric opposed corner end posts at the other end can be used with such a side wall, along with a conventional floor and/or roof.

Door (End Corner) Support Posts

Bespoke door support post profiles must be sufficiently rigid to serve as corner end posts to a container frame and withstand container stacking loads, as well as integrating with the container frame to preserve a rectangular profile and inhibit profile distortion such as bulging or 'lozenging', particularly with end doors open.

Preservation of the open end profile helps ensure ease of door opening and closing along with unimpeded load access to the full container depth.

Asymmetric Door Post Profile

In one particular asymmetric door post configuration one post presents a slim or slender profile to the corresponding end face representing minimal intrusion into an adjoining end access aperture, but compensating structure along the side wall from that corner but without unduly increasing the overall side wall depth, so longitudinal span compensating for transverse depth.

The other corner end post at the opposite side of the end access opening features a portion intruding more into the end face to bolster frame torsional stiffness at that end and thus contribute to overall rigidity against lozenge deformation.

Stacking Load Support by Stouter Corner End Post

Given that containers can be a snug mutually conformal or complementary inter- nesting fit with conformal walls when disposed alongside one another within respective cell guides a slender side wall thickness allows a marginally greater side wall span and thus internal capacity span than would otherwise be achievable. This whilst remaining within overall cell guide constraints. That is somewhat more efficient use is made of the cell guide capacity by allowing more load intrusion or utilisation into available space than hitherto achievable, without change in cell guide disposition. Of an asymmetric corner end post pair on opposite container sides, a more robust corner post for door support is itself able to withstand stacking loads, without need for or reliance upon a more robust and thus intrusive heavy and cumbersome door to support as with hitherto used arrangements. This compensates for the more slender corner post for door support at the opposite side, where overall end access internal width or span between corner end posts is a priority consideration. The side wall structure on that side, with a greater longitudinal post intrusion aligned with the wall serves to help support and stiffen the slender post - or rather the wall and post elements are mutually supportive.

Door Sealing Door sealing and door seal path between door, support posts and container frame must be preserved. A simpler seal routing or pathway is preferred for ease of fitment, installation and preserving seal location, compression action upon door closure and physical contact efficacy at opposed seal edge margins.

A seal routing such as formerly employed with awkward twists and turns risks seal distortion in seeking compliance between seal and pathway upon seal fitment and seal departure, displacement or deformity in operation, upon repeated door opening and closing cycles of seal crushing and relaxation, so undermining seal contact. A simpler, straighter or less convoluted seal pathway or run thus both helps seal efficacy and is easier to install and maintain without specialist labour.

Smooth Internal Wall Face

A fiat, smooth-sided and continuous internal wall or wall face, as opposed to one periodically interrupted by profile excursions or discontinuities such as corrugations is an advantage for load access, capacity and transfer or throughput - i.e. shifting a load (portion) along a floor within container confines.

External Wall Stiffener Ribs

External ribs contribute wall stiffness, but do not intrude internally. Moreover, in themselves they represent a modest protuberance, so do not increase the external profile unduly. Nor do they add unduly to passive mass and weight.

Internal Capacity

Internal 'capacity' at any point and cumulatively or collectively is a function of internal platform footprint or plan form - which in turn reflects transverse and longitudinal spans) - and depth or height. Even nominally minor local interruptions, discontinuities, 'intrusions' or reductions can materially impede load access and reduce overall capacity. An 'ideal' would be a consistent uniform dimension throughout the container. Variations or departures from one end to another cause not only local difficulties, but spill-over into overall usability. Generally, in striving for extra internal capacity within a container structure which meets external imperial standard constraints, in particular the crucial (sometimes small but significant) extra margin(s) needed for accommodating whole (whether odd or even) multiples of metric loads within an imperial structure, 'every inch (or indeed contributory fraction of an inch) counts'. Incremental contributions by individual structural refinements can cumulatively mean the difference between matching or falling short of a target dimension.

Metric vs. Imperial Multiples

Thus, say, to accommodate two x1 metre (Euro) standard footprint square pallets, along with a manufacturing error tolerance and a manoeuvring clearance, a total internal transverse span of some 2.4+ metres plus is required. This is nominally greater than that available in a standard container built to imperial external standards, with a maximum nominally 7 foot 7 inches or 2.33 metres width internally. A 20 foot externally container would have a nominal internal length of some 5.87 metres and a 40 foot container, some 12.0 metres. Door apertures of some 2.8 metres width are typical.

Overall wall depth along with frame structure and end access opening can all contribute to internal capacity and access (for a full metric load or multiple load unit width) considerations. A thin wall structure throughout must not be weaker than a standard container or any more liable to twist, buckle or distort under load or in handling.

Embodiments

There now follows a description of some particular embodiments of the invention, by way of example only, with reference to the accompanying diagrammatic and schematic drawings, in which: A combination of scanned more detailed CAD drawings and simplified illustrations are presented in turn, with some intentional overlap, redundancy or duplication in some areas in the interests of clarity and completeness. This given the need to adjust the drawing scale on occasion to fit page constraints,with attendant compaction of detail.

Drawing Sheets

A total of some 22 sequentially numbered sheets of drawings are included, with the individual sheet content summarised as follows:

CAD Sequence of Sheets 1 through 11 :

Sheet 1 shows exterior elevations and side wall longitudinal section;

Sheet 2 shows load access end wall and end door closures with sectional detail;

Sheet 3 shows supplementary end door and sectional detail to Sheet 2; Sheet 4 shows sectional views of end door construction and co-operative interaction for end access closure along with differential or asymmetric respective corner end post door hinged mounting support;

Sheet 5 shows local detail of door construction;

Sheet 6 shows side wall format and relative corner end post disposition; Sheet 7 shows longitudinal side sectional and plan views with side wall stiffener rib disposition and relative offset;

Sheet 8 develops side-wall profile detail along with end wall pivot hinge detail;

Sheet 9 reflects panel profile and surface treatment options;

Sheet 10 shows side wall internal frame and external panel co-operative construction; Sheet 11 shows opposite end in-fill panel detail compared to the access door end of Sheet 3;

Illustrative Sequence of Sheets 12 through 22:

Sheet 12 shows differential corner end post sections and end access door (270 deg) opening fold back and closure inter-fit; Sheet 13 shows concluding stages of an end access loading sequence, with dog-leg offset of a penultimate (palletised) load around a larger section corner post section, to allow straight-in loading of a final (pallet) load alongside a relatively slender corner end post on the opposite side;

Sheet 14 shows (as a re-draw) end wall in-fill detail comparable to that of Sheet 11 ; Sheet 15 shows sectional detail of a robust or stouter profile (i.e. more intrusive into the end access opening) corner end post and door hinge mounting detail on one side along with peripheral door seal interposition between door edge and end frame;

Sheet 16 shows an external fragmentary over-view with local panel surface (dimpled - for stress relief purposes) treatment detail for an end wall, along with a corrugated profile side wall;

Sheet 17 shows both dimpled end and side wall treatments; a element of mix and match options is thus available according to circumstances and anticipated operational demands;

Sheet 18 shows diagrammatically transverse sections and internal capacities between and around differential or asymmetric corner end posts for end access door hinged mounting; it will be noted that corner top and bottom handling fittings lie outside the embrace of the internal constraints;

Sheet 19 shows diagrammatically end door construction and locking bolt disposition; Sheet 20 shows panel separation from a rolled strip and corrugation and surface (say dimpled) treatment options;

Sheet 21 shows end door hinge mounting and attendant respective corner end post profile detail; and

Sheet 22 shows diagrammatically final stages of modular (say palletised) loading through the access end between and around asymmetric corner end posts, with end doors folded back open.

Duplication

Some duplication arises between the CAD and illustrative drawings; this is tolerated to avoid loss of detail within the CAD versions and for ease of discussion of features. Figure Numbers and Component References.

As to the content of the foregoing sheets, a designated Figure sequence is generally as follows, with Figure numbering dictated by sheet numbering.

In those Figures certain components are selected for individual component reference, but this is not necessarily to undermine the relative importance or contribution to the whole construction of components not so referenced.

Figures 1 A through 1 D on sheet 1 show variously clad space or lattice frame construction; thus:

Figure 1 A shows a side frame assembly, with optional fork lift truck tine pockets in a base side rail of a base frame; Figure 1 B shows a (rear) load access door end assembly;

Figure 1C shows a (front) end panel wall in-fill;

Figure 1 D shows a roof assembly;

Figure 2 group shows a (front ) end panel construction;

Figures 3A through 3E shows (rear) door construction; thus: Figure 3A shows an end elevation with doors closed together;

Figure 3B shows a side elevation of door edge with corner post and top and bottom capture and handling fittings;

Figure 3C shows a section along the line A-A' in Figure 3A, with rear top header beam and lower sill framing the access aperture, itself bound by a marginal inset 'C'-section resilient peripheral seal;

Figure 3D shows door hinge bracket detail;

Figure 3E shows a section along line C-C in Figure 3A;

Figures 4A through 4E shows a transverse section of the door, door corner mounting posts and associated rear end frame construction of Figure 3; thus: Figure 4A shows end access aperture plugged by combined end door width with intervening seal;

Figure 4B shows opposite corner end post detail of Figure 4A; Figure 4C group shows hinge bracket detail for each side; Figure 4D group shows hinge pin assembly detail for each side;

Figure 4E shows local enlargement detail of circled area D in Figure 4A; Figures 5A through 5D shows door, hinge and post detail; thus: Figure 5A shows end door closure and associated end post disposition; Figure 5B group shows opposite side post assembly and wall panel detail; Figure 5C group shows hinge pin and bracket assemblies on each side; Figure 5D shows a hinge jig fixture block for hinge mounting alignment; Figures 6A and 6b show shows a corrugated roof assembly; thus:

Figure 6A shows multiple (some eleven) roof panels in abutment, along with corner protection plates around capture and handling fittings upon corner posts; Figure 6B shows a section through Figure 6A with bowed edge profile and panel to frame seal;

Figures 7A through 7C show opposite side wall assemblies and offset relative disposition of respective panel stiffener ribs; thus:

Figure 7A shows relative offset between opposite side panel corrugation; with an in-fill panel at one (front) end and door closure of an access opening at the opposite (rear) end;

Figure 7B shows a right hand side view along arrow B in Figure 7A;

Figure 7C shows a left hand side view along arrow A in Figure 7A;

Figures 8A through shows side wall panel assemblies and section details; thus: Figure 8B shows a sectional foot print of corner detail at opposite ends and sides along with asymmetric door post profile and respective hinge mounting detail;

Figure 8A shows juxtaposed side panel (upright) edge-to-edge abutment and but weld fixture;

Figure 8C group shows in-fill end panel and roof edge cant towards an internal frame junction;

Figure 8D shows bottom side rail sectional detail; Figure 8E shows corrugated panel section detail;

Figures 9A through 9D show various alternative panel dimpling treatments or effects, along the ribbed superimposition upon otherwise flat sheet panel format; Figures 1OA through 1OC show side wall frame assembly reinforcement detail; thus: Figure 10A shows opposite (left and right hand) side panel frames;

Figure 1OB shows hook and plate component detail for mounting a side reinforcement assembly;

Figure 1OC shows sectional detail of horizontal reinforcement tie rails in Figures 1OA using the mounting detail of Figure 1OB;

Figures 11A through 11 D on sheet 11 show front end wall construction; thus: Figure HAshows (front) end in-fill panel construction from but welded ribbed panels; Figure 11 B shows a section along line C-C in Figure 11 A; Figure 11 C shows a section along line B-B¹ in Figure 1A of corner detail; Figure 11 D shows a section along line A-A¹ in Figure 11 A of end detail, with timber floor panel or planking in-fill;

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Figures 12A through 12C show (rear) end door hinge mounting, opening range and closure seal detail; Figures 13A through 13D show (rear) end (pallet) loading stages initially with doors open back against respective side walls and finally with doors closed behind a tightly packed load, with the final juxtaposed pallet pair a snug fit within container confines;

Figures 14A through 14D show (front) end in-fill panel assembly, along with top header (with lashing point), bottom sill and inset floor disposition bounding the end access opening; with Figure 14B being a section taken along line A-A' in Figure 14A; Figure 14C being a section taken along the line C-C in Figure 14; and Figure 14D being a section taken along the line B-B' in Figure 14A;

Figures 15A and 15B show end closure in-fill and local door hinge mounting enlargement detail; Figure 16 shows with local enlargement detail end panel in-fill surface treatment;

Figure 17 shows with local enlargement detail both end and side panel in-fill surface treatment;

Figures 18A and 18B show transverse sectional views of container internal width capacities between differential or asymmetric corner end posts for door mounting; with a double opposed door in Figure 18A and a single side-mounted door option in Figure 18B;

Figures 19A through 19C show (rear) end access opening, local door construction detail with upright bolt disposition and local sectional detail for one post of relatively slender profile extended into the respective side wall in comparison with a conventional post section;

Figures 2OA and 2OB show cladding panel separation and deployment along with corrugated profile and local surface treatment detail;

Figures 21 A through 21 C show (rear) end access opening detail between asymmetric corner posts and different door configuration on each side; Figures 22A through 22D show (rear) end (palletised) load insertion through the access opening of Figures 21 A through 21 C; Referring to the drawings ...

Both in terms of inherent performance and refinement of the Applicant's previous sea cell container formats, the minutiae of constructional detail and capacity dimensions are critical to contriving modest, but crucial, extra capacity from an overall container format constrained by established standardisation.

A loading floor footprint capacity of some 15 palletised loads of 0.8m longitudinally orientated depth (by 1.2m transverse orientated width) is achievable in two corresponding longitudinal rows to within circa 12.1m length.

An allowance for some sixteen nominal 6mm intervening gaps gives a total requirement of 12096mm, within an external 12192 outer shell, leaves a 96mm difference with a nominal 13mm end wall depth leaves an 83mm shortfall which doubles up to 165mm requirement.

An end door access aperture or opening width of some 2.359m is just too narrow to accommodate two nominal (0.8 by) 1.2m wide palletised loads side by side. In order to overcome this constraint, the present invention uses differential corner end post profiles for door mounting. This to enable a penultimate loading stage of 'dog-leg' longitudinal insertion and lateral or transverse displacement 'shuffling' around one larger (or wider transverse) profile corner end post is adopted. A usable internal width of some 2.438m is achieved within an overall outer width of some 2.481 mm. A cubic capacity of some 79cu m or 2790 cu feet is attained with an internal height of some2.894m and length of some 12.097m, say12.1m.

That post allows room closely behind as the side wall junction is slender, whereas at the opposite side post, an narrower transverse span is compensated for by a somewhat fatter side wall transition. The overall post sectional size and thus local stiffness contribution is thus achieved somewhat differently between corner end posts, with profile being paramount for load insertion access and compact internal packing.

Combined post strength is sufficient to withstand anticipated suspension handling and stacking loads with different post sections or profiles. The special construction is economically achievable for cell guide conformity and yet is not overly bespoke but rather has wider applicability for load capacity optimisation. Thus there is a considerable underlying commonality with the Applicant's generic clad frame construction and sub-assembly fabrication.

Transition and integration between corner post and associated side wall is more carefully contrived, with slender width post intrusion into the side wall more extensive than for the fatter post.

A peripheral door sealing gasket lies or is contained in a single common plane on each outer side of the door pair and between door inner edges on one door with an abutment ledge on the other door. A non-intrusive door closure bolt configuration allows a shallow overall door depth helping promote internal length capacity in relation to external span.

Hinge arms and pivot disposition are also consistent with a constrained outer profile and are generally inset as depicted in, say, Figures 12B and 12C.

A stepped upper header roof panel transition allows full internal depth to be available. Component List

10 container

11 side panels

12 roof panels

13 end panels

14 hinged door

15 hinge

16 corner post

17 seal

18 top header

19 bottom sill

20 pallet

30 corrugations

31 stiffener ribs

32 surface dimples

33 inset door bolts

34 end wall in-fill

35 door frames

36 reinforcement plates

37 step transition

38 side rails

Claims

Claims

1.

A shipping container with differential or asymmetric cross-sectional profile corner end posts (16) disposed at opposite sides at one (say, rear) load access end to supplement intervening load access aperture width or transverse span.

2.

A container of Claim 1 , configured to fit between cell guides of a dedicated container ship cargo hold whilst accommodating a full twin rows of palletised load throughout the length, say of juxtaposed 800mm by 1200mm individual pallet sizes.

3.

A container of either preceding claim with asymmetric corner end posts disposed to support respective hinged doors at a load access end, allowing a penultimate load entry between posts and load disposition around and inboard of one (wider profile) post and against a side wall to admit a following final load past the parked load and the other (slimmer profile) post; the posts serving as end support and bracing frame members for an internal space frame, upon which outer cladding panels are mounted.

4.

A container of any preceding claim wherein one post presents a slim or slender profile to the corresponding end face for minimal intrusion into an adjoining end access aperture, and compensating structure along the side wall from that corner without unduly increasing the overall side wall depth, so longitudinal span compensating for transverse depth.

5.

A container of any preceding claim, using a slim or shallow-depth wall panel construction with a plurality of discrete flat panels fastened, by say welding, in edge- to-edge abutment, with an applied surface dimpling as stress re-distribution or relief, the panel assembly being secured by welding to a support frame; allowing stresses attendant local welding heat to dissipate or re-distribute to inhibit local distortion upon panel unroll and separation from a roll or coil of wound strip material.

6.

A container of any preceding claim with internal capacity optimised in relation to external foot print, and configured to allow some two rows of 15 pallets or palletised load elements each of some 1200mm by 800m footprint, within an internal floor space footprint of some 12.097 or 12.1m length by 2.438m width and 2.694m height, all within a 1.2192m external length, 2.896m external height and 2.481m external width.

7.

A container substantially as hereinbefore described with reference to and as shown in the accompanying drawings.