WO2018099528A1

WO2018099528A1 - A container module, a method for manufacturing a container module and use of a container module

Info

Publication number: WO2018099528A1
Application number: PCT/DK2017/050384
Authority: WO
Inventors: Anders BACH-SØRENSEN; Henrik SØRENSEN
Original assignee: Worldflexhome Aps
Priority date: 2016-11-30
Filing date: 2017-11-20
Publication date: 2018-06-07
Also published as: EP3548236B1; DK179544B1; EP3548236A1; DK201670946A1

Abstract

Disclosed is a method for manufacturing a container module (1). The method comprises the steps of: forming at least four container panels (2) by means of the following steps: placing a casting frame (3) on or around an external plate (4) to form a casting mould (5), pouring concrete (6) into the casting mould (5), curing the concrete (6) and thereby forming a rigid connection between the external plate (4) and the concrete (6), assembling the at least four container panels (2) and optionally further panels to form the container module (1) as a rectangular parallelepiped, wherein the concrete (6) is facing inwards and the external plate (4) is facing outwards, and wherein a twist-lock element (7) is provided in each corner of the container module (1). A container module (1) comprising a number of container panels (2) together forming a rectangular parallelepiped is also disclosed along with use of a container module (1).

Description

A CONTAINER MODULE, A METHOD FOR MANUFACTURING A CONTAINER MODULE AND

USE OF A CONTAINER MODULE

Field of the invention

The invention relates to a method for manufacturing a container module. The invention further relates to a container module comprising a number of container panels together forming a rectangular parallelepiped, wherein each of the eight corners of the parallelepiped is provided with a twist-lock element. The invention also relates to use of a container module.

Background of the invention

Forming houses out of modules for temporary or permanent human habitation is known in the art e.g. at building sites and other. And to ensure that these modules can easily be transported it is known to form the modules so that they are suited for road, train and ship transport. However, these modules are often metal containers lined on the inside with plasterboards. But such modules are not particular safe in case of fire (the metal will easily weaken or even melt under high thermal stress) or seismic activity - especially if the modules are stacked - and such modules are not particularly soundproof.

Thus, from WO 2011/015836 Al it is therefore known to take a known new or used shipping container and then modify it by adding concrete onto both sides of the panels. However, this design requires a complex casting procedure and is still not particularly fireproof. And from US 2016/222649 Al it is known to form a fireproof concrete floor slab in a container, but this design is still not particularly fireproof.

An object of the invention is therefore to provide for an advantageous technique for forming a container module. The invention

The invention provides for a method for manufacturing a container module. The method is characterized in that the method comprises the steps of:

• forming at least four container panels by means of the following steps:

o placing a casting frame on or around an external plate to form a casting mould,

o pouring concrete into the casting mould,

o curing the concrete and thereby forming a rigid connection between the external plate and the concrete,

· assembling the at least four container panels and optionally further panels to form the container module as a rectangular parallelepiped, wherein the concrete is facing inwards and the external plate is facing outwards, and wherein a twist-lock element is provided in each corner of the container module.

Forming the modules as a rectangular parallelepiped is advantageous in that the many right angles makes them easier to manufacture and in that a rectangular parallelepiped is easy to stack and transport. Forming the container panel with an external plate is advantageous in that the external plate enables easy mounting of further external lining, further reinforcement and other - i.e. the external plate can provide qualities not provided by the concrete. Making the external plate form the larger area of the mould is advantageous in that the panel hereby is provided with an external plate in a simple and efficient manner. Furthermore, by forming the external plate as a part of the container panel, problems with getting the concrete part of the panel out of the mould is severely reduced.

Forming the container with concrete facing inwards is advantageous in relation to fire in that concrete can withstand very high temperatures (also in relation to e.g. metal) and in that the concrete will form a strong and durable container module. To ensure that the modules can be fixated during handling, transportation and subsequent use e.g. as modules in a block of flats, it is advantageous to provide each corner with a twist-lock element. Furthermore, given the existing amount of equipment suitable for handling ISO containers etc. provided with twist-lock elements, the twist-lock element will make handling of the modules less expensive.

By the term "twist-lock element" is to be understood a corner casting fitted at each corner of the module. The twist-lock element typically has an approximate size of 7x7x4.5 inches (180x 180x 1 10 mm) and is provided with slits (which are roughly 4.1 inches (104.1 mm) long and 2.2 inches (55.9 mm) wide) so that it can act as the female part of a twistlock connector where the male component is the twistlock itself, which is fitted to e.g. a crane or transport bases. The twistlock can be inserted through the slits in the twist-lock element, whereafter the top portion of the twistlock (normally pointed to make insertion easier) is rotated 90° so that it cannot be withdrawn. The mechanism is the same as that of a Kensington lock, but on a much larger scale. The twistlock is also known as a Tantlinger lock.

In an aspect of the invention, the twist-lock elements are provided in each corner of the container module by rigidly connecting one or more of the twist-lock elements to the container panels before forming the rectangular parallelepiped.

Forming the twist-lock elements as parts of the container panels is advantageous in that this ensures that stress is better distributed when e.g. lifting the module and in that it simplifies assembly of the module.

In an aspect of the invention, the twist-lock elements are rigidly connecting to the container panels by welding the twist-lock elements to the external plate. Connecting the twist-lock elements by welding them to the external plate is advantageous in that it ensures a strong hold and a quick and simple mounting.

In an aspect of the invention, the casting frame is removed before forming the rectangular parallelepiped.

Removing the casting frame before assembly is advantageous in that the panels hereby is formed with concrete edges on the inside, which ensures that the entire inside surface of the assembled module is formed by concrete.

In an aspect of the invention, the least four container panels are assembled to form the rectangular parallelepiped by means of welding.

Welding is a simple, fast and strong assembly process and it is therefore advantageous to assemble the container module by welding the external plates together - plastic welding, metal welding or other. Furthermore, the welding will seal the joints and thereby protect against moisture or other entering the inside of the module. In an aspect of the invention, the rigid connection between the external plate and the concrete is enhanced by providing the external plate with one or more anchoring devices protruding into the concrete.

When the concrete is curing while resting directly against the external plate, a strong bond will be formed between the two. But thermal expansion, impacts, moisture or other could over time damage this bond and it is therefore advantageous that this bond is supplemented by anchoring devices protruding into the concrete from the external plate. In an aspect of the invention, the one or more anchoring devices comprises concrete reinforcement placed in the casting mould before pouring concrete into the casting mould and wherein the concrete reinforcement is connected to the external plate. Reinforced concrete is much stronger that un-reinforced concrete. And by connecting the concrete reinforcement to the external plate an enhanced bond between the concrete and the external plate is formed.

In an aspect of the invention, the container panels comprise at least four side panels, at least one roof panel and at least one floor panel which is advantageous in that by use of four side panels, a roof panel and a floor panel it is possible to form a fully enclosed container module.

In an aspect of the invention, the container panels are formed so that the outer contour of the container module is substantially formed as a forty foot ISO container having an external length of approximately 12.2 meters, width of approximately 2.4 meters and height of approximately 2.6 or 2.9 meters or as a twenty foot ISO container having an external length of approximately 6.1 meters, width of approximately 2.4 meters and height of approximately 2.6 or 2.9 meters.

Forming the module as a standardized forty or twenty foot container is advantageous in that the module then can be transported efficiently and inexpensively within the global containerized intermodal freight transport system. An ISO container - also e.g. known as freight container, intermodal container, shipping container, hi-cube container, box, conex box and sea can - is a standardized reusable box used for the safe, efficient and secure storage and movement of materials and products within the global containerized intermodal freight transport system. In an aspect of the invention, the four container panels are selected from a group consisting of at least four side panels, at least one roof panel and at least one floor panel. Hereby is achieved an advantageous embodiment of the invention.

In an aspect, the method further comprises the step of welding one or more reinforcement profiles to at least a part of the external plate between a roof panel and a floor panel of the container module.

Especially when using the modules to form blocks of flats it is advantageous to provide the modules with extra reinforcements to be able to handle the vertical load.

In an aspect, the external plate and the twist-lock elements are made from metal, such as steel.

Forming the external plate and the twist-lock elements from metal is advantageous in that this enables interconnection by means of welding, and in that metal is less brittle than concrete and therefore advantageous as a protective outer shell to the concrete.

In an aspect, the method further comprises casting concrete in the outer corner between adjacent container panels after the rectangular parallelepiped has been formed. Connecting the external plate to the concrete through the curing process of the concrete is a simple and inexpensive way of forming a strong connection between the two.

Forming a shed, a storage or temporary accommodation from one or more containers might be acceptable and appealing for a short period of time but if a container module has to function as permanent human habitation, aspects such as durability, fire safety, soundproofing and other becomes highly important, hereby making a container module according the present invention particularly suited for permanent human habitation.

Figures

The invention will be described in the following with reference to the figures in which fig. 1. illustrates a cross section through a casting mould, as seen from the side, fig. 2 illustrates a cross section through a casting mould with reinforcement arranged on the external plate, as seen from the side, fig. 3 illustrates a cross section through a casting mould after concrete have been poured in, as seen from the side, fig. 4 illustrates a cross section through a container panel, as seen from the side, fig. 5. illustrates a cross section through a casting mould for a floor panel, as seen from the side, fig. 6 illustrates a cross section through a casting mould for a floor panel with reinforcement arranged on the external plate, as seen from the side, illustrates a cross section through a casting mould for a floor panel after concrete have been poured in, as seen from the side, illustrates a cross section through a floor panel, as seen from the side, fig. 9 illustrates a section cut-out of a floor panel, as seen in perspective, fig. 10 illustrates a floor panel and four side panels, as seen in perspective, fig. 11 illustrates an assembly process of a container module, as seen in perspective, fig. 12 illustrates a container module, as seen in perspective, and fig. 13 illustrates a twist-lock element, as seen in perspective.

Detailed description

Fig. 1 illustrates a cross section through a casting mould 5, fig. 2 illustrates a cross section through the casting mould 5 with reinforcement 9 arranged on the external plate 4, fig. 3 illustrates a cross section through the casting mould 5 after concrete 6 have been poured in and fig. 4 illustrates a cross section through a container panel 2, all as seen from the side.

In this embodiment the container panel 2 to be casted is an entire side panel 10 but in another embodiment the container panel 2 could be a roof panel 11 or a floor panel 12 or parts of these panels. In this embodiment an external plate 4 is first arranged with the outside face facing downwards. Thereafter is a casting frame 3 placed on the external plate 4 so that the casting frame 3 forms an eternal barrier of the casting mould 5. In another embodiment the casting frame 3 could have a different shape - such as rectangular, polygonal, hollow pipe or other - and it could be placed differently on the external plate 4 or it could be arranged around the plate 4.

In this embodiment the casting frame 3 is not connected to the external plate 4 in that it is only held into place by means of gravity. However, in another embodiment the casting frame 3 could be connected to the external plate 4 by means of spot welding, screws, clamps or other.

Either before or after the casting frame 3 is placed on the external plate 4 the external plate 4 is in this embodiment provided with anchoring device arranged to ensure a strong bond between the concrete and the external plate 4. In this embodiment the anchoring devices 8 are metal hooks welded to the external plate 4, but in another embodiment the anchoring devices 8 could be formed as plates, pins, tubes or other and/or the anchoring devices 8 could be connected to the external plate 4 in a different way - such as by screws, bolts, soldering, adhesives or other - and/or the anchoring devices 8 could be formed in another material such as plastic, Kevlar, a composite material or other.

In this embodiment concrete reinforcement 9 is subsequently connected to the anchoring devices 8. In this embodiment the concrete reinforcement 9 is a large metal mesh but in another embodiment the concrete reinforcement 9 could be in the form of wires, rebars, plates or other. In this embodiment the concrete reinforcement 9 is connected to the anchoring devices 8 through the hook design of the anchoring devices 8 but in another embodiment the concrete reinforcement 9 could be connected to the anchoring devices 8 by means of string, wire, welding, screws or other or the concrete reinforcement 9 could be connected directly to the external plate 4 - i.e. panels 2 would not comprise the anchoring devices 8 - or the concrete reinforcement 9 would not be connected to the external plate 4 nor the anchoring devices 8.

In another embodiment further piping, wiring, fittings, mounts or other could be arranged in the casting mould 5 to enable or simplify subsequent installation of electricity, water, heating, telecommunications, sewer, drain or other. Next step in the panel manufacturing method is to pour liquid or at least semi-liquid concrete 6 into the casting mould 5 and ensure that the concrete reaches all corners of the mould 5. Thereafter the concrete 6 is left to cure and in this process a strong bond is formed between the inside surface of the external plate 4 - i.e. the side of the external plate 4 facing upwards on figs. 1-4.

Once the concrete 6 has cured sufficiently the casting frame 3 is removed.

As the casting mould 5 in this embodiment is placed on the external plate 4 the concrete part 5 will in this embodiment be smaller than the external plater 4. Thus, when the sides are assembled - as will be described in details in the following - with joins between the abutting external plates 4, the remaining hole in the corners will in some embodiments subsequently have to be filled with liquid concrete if a complete encapsulation of concrete is desired. Fig. 5 illustrates a cross section through a casting mould 5 for a floor panel 12, fig. 6 illustrates a cross section through a casting mould 5 for a floor panel 12 with reinforcement 9 arranged on the external plate 4, fig. 7 illustrates a cross section through a casting mould 4 for a floor panel 12 after concrete 6 have been poured in and fig. 8 illustrates a cross section through a floor panel 12, all as seen from the side. In this embodiment the floor panel 12 comprises peripheral profiles 16 connected along the edges of the external plates 4 by means of welding. In this embodiment the external plates 4 abuts a twist-lock element 7 in each corner - as can be seen in fig. 9. Thus, in this embodiment the twist-lock elements 7 are connected to the external plate 4 before the concrete 6 is added. In another embodiment the twist-lock elements 7 could also or instead be connected to the roof panel 11, the side panels 10 or at least some of the twist-lock elements 7 could be connected to the container module 1 after curing of the concrete 6, during the assembly of the container module 1 or other. Also, in another embodiment the peripheral profiles 16 would not be present or they could be formed differently.

In principle the concrete 6 could be casted inside the peripheral profiles 16 but since a thicker layer of concrete 6 is desired in this embodiment, a casting frame 3 is in this embodiment placed on the peripheral profile 16 as described above. And from here the manufacturing process resembles the process described in relation with figs. 1-4.

Fig. 9 illustrates a section cut-out of a floor panel 12, as seen in perspective. Once the concrete is cured and the casting frame 3 is removed the corner of the floor panel 12 could look as this.

Fig. 10 illustrates a floor panel 12 and four side panels 10, as seen in perspective. In this embodiment the panels 10, 11, 12 are produced in close proximity of each other to simplify the subsequent assembly process. However, in another embodiment the panels 10, 11, 12 could be produced at separate locations.

In this embodiment one of the side panels 10 is provided with a window opening 15 but in another embodiment more window opening 15 or other openings - such as door opening, ventilation openings, supply openings or other - could be formed in this or other panels 10, 1 1, 12.

Fig. 11 illustrates an assembly process of a container module 1, as seen in perspective.

In this embodiment the container module 1 is formed by four side panels 10, a roof panel 11 and a floor panel 12 forming a substantially complete rectangular parallelepiped. However, in another embodiment the container module 1 could e.g. be formed with only four panels 10, 11, 12 such as without the side panels 10 at the ends of the module 1 or it could be formed with only five panels 10, 11, 12 such as without a roof panel 11 or other.

In this embodiment the panels 10, 11, 12 are connected to each other by welding the external plates 4 together. However, in another embodiment the panels 10, 11, 12 could also or instead be connected by means of adhesive, screws, bolts, rivets, fittings or other or any combination thereof.

Fig. 12 illustrates a container module 1, as seen in perspective. In this embodiment the module 1 is formed as a rectangular parallelepiped in that the module 1 has the outer contour of a twenty foot ISO high-cube container having an external length EL, width EW and height EH of approximately 6.1, 2.4 and 2.9 meters. However, in another embodiment of the invention the module 1 could be formed differently - such as ten foot, forty foot, forty-five foot, forty-eight foot, fifty-five foot or other long, standard height or high-cube, a deviating width or even with outer measurements which do not comply with the ISO standard for shipping containers. Each corner of the module 1 is in this embodiment provided with a twist-lock element 7. The openings 17 in the twist-lock element 7 enables access for the male part of a twistlock fixation device, lifting device or other. The module 1 is illustrated without windows or doors but in a preferred embodiment the module 1 comprises at least one door to allow access to the inside of the module 1 and most likely the module 1 would be provided with one or more windows 15.

In a preferred embodiment the doors and the windows are mounted in the module 1 at the module manufacturing plant. In fact, in a preferred embodiment most of the interior of the modules 1 are pre-fitted at the module manufacturing plant. I.e. one module 1 could be pre-fitted with a complete kitchen including kitchen cupboard, domestic appliances, electrical installations, pluming and so on - and possible a more suitable inner wall covering and flooring in case the raw concrete face is not appropriate. The module 1 could also be pre-fitted with a bathroom and/or toilet, it could be arranged as a living room, a dining room, a bedroom, an office or other.

In this embodiment the reinforcement profiles 13 are added to the vertical corners of the module 1 after assembly of the panels 10, 11, 12. In this embodiment the reinforcement profiles are metal profiles welded to the external plates 4 of the panels 10, 11, 12 to make the modules 1 stronger against vertical loads, but in another embodiment the reinforcement profiles could be formed or placed differently or the container module 1 would not comprise reinforcement profiles 13. In another embodiment the container module 1 would further comprising external cladding, lining, external panels or other either for esthetic reasons, to form a climate shield or other.

Fig. 13 illustrates a twist-lock element 7, as seen in perspective The twist-lock element 7 is typically made of steel and is welded to the module 2 metal structure - i.e. external plates 4, reinforcement profile 13, peripheral profiles 16 and/or other - but it could also be made in a different material and connected by means of screws, bolts, rivets or similar or it could be connected to the panels 2 in the casting process e.g. by providing the twist-lock element 7 with some sort of anchoring device arranged to protrude into the concrete. Each twist-lock element 7 is in this embodiment provided with an opening 17 on each of the three sides while the three remaining sides are solid to prevent concrete from entering the twist-lock element 7 during the casting process.

The invention has been exemplified above with reference to specific examples of container modules 1, container panels 2, casting moulds 5 and other. However, it should be understood that the invention is not limited to the particular examples described above but may be designed and altered in a multitude of varieties within the scope of the invention as specified in the claims.

List

1. Container module

2. Container panel

_^ j . Casting frame

4. External plate

5. Casting mould

6. Concrete

7. Twist-lock element

8. Anchoring device

9. Concrete reinforcement

10. Side panel

1 1. Roof panel

12. Floor panel

13. Reinforcement profile

14. Internal concrete element

15. Window

16. Peripheral profile

17. Opening in twist-lock

EL. External length of ISO container

EW. External width of ISO container

EH. External height of ISO container

Claims

1. A method for manufacturing a container module (1), characterized in that said method comprising the steps of:

• forming at least four container panels (2) by means of the following steps:

o placing a casting frame (3) on or around an external plate (4) to form a casting mould (5),

o pouring concrete (6) into said casting mould (5),

o curing said concrete (6) and thereby forming a rigid connection between said external plate (4) and said concrete (6),

• assembling said at least four container panels (2) and optionally further panels to form said container module (1) as a rectangular parallelepiped, wherein said concrete (6) is facing inwards and said external plate (4) is facing outwards, and wherein a twist-lock element (7) is provided in each corner of said container module (1).

2. A method according to claim 1, wherein said twist-lock elements (7) are provided in each corner of said container module (1) by rigidly connecting one or more of said twist-lock elements (7) to said container panels (2) before forming said rectangular parallelepiped.

3. A method according to claim 2, wherein said twist-lock elements (7) are rigidly connecting to said container panels (2) by welding said twist-lock elements (7) to said external plate (4).

4. A method according to any of the preceding claims, wherein said casting frame (3) is removed before forming said rectangular parallelepiped.

5. A method according to any of the preceding claims, wherein said least four container panels (2) are assembled to form said rectangular parallelepiped by means of welding.

6. A method according to any of the preceding claims, wherein said rigid connection between said external plate (4) and said concrete (6) is enhanced by providing said external plate (4) with one or more anchoring devices (8) protruding into said concrete (6).

7. A method according to claim 6, wherein said one or more anchoring devices (8) comprises concrete reinforcement (9) placed in said casting mould (5) before pouring concrete (6) into said casting mould (5) and wherein said concrete reinforcement (9) is connected to said external plate (4).

8. A method according to any of the preceding claims, wherein said container panels (2) comprises at least four side panels (10), at least one roof panel (11) and at least one floor panel (12). 9. A method according to any of the preceding claims, wherein said container panels (2) are formed so that the outer contour of said container module (1) is substantially formed as a forty foot ISO container having an external length (EL) of approximately 12.2 meters, width (EW) of approximately 2.4 meters and height (EH) of approximately 2.6 or 2.9 meters or as a twenty foot ISO container (10) having an external length (EL) of approximately 6.1 meters, width (EW) of approximately 2.4 meters and height (EH) of approximately 2.6 or 2.

9 meters.

10. A method according to any of the preceding claims, wherein said four container panels (2) are selected from a group consisting of at least four side panels (10), at least one roof panel (11) and at least one floor panel (12).