WO2021084318A1

WO2021084318A1 - System for handling container walls

Info

Publication number: WO2021084318A1
Application number: PCT/IB2020/000242
Authority: WO
Inventors: Uthai SRICHAI
Original assignee: Goodpack Ibc (Singapore) Pte. Ltd.
Priority date: 2019-11-01
Filing date: 2020-03-31
Publication date: 2021-05-06
Also published as: JP2023501935A; JP7430258B2; TW202132146A

Abstract

Described herein is a tool for reconfiguring collapsible containers for transportation of cargo, and methods of reconfiguring collapsible containers. In some embodiments, the tool includes a base frame having wheels connected thereto, and a forward support rail that extends away from the base at an oblique angle. The tool may further include a lift frame that is pivotably connected to an upper portion of the forward support rail. The lift frame may include an engagement protuberance that moves with the lift frame relative to the forward support rail. The tool may cooperate with a rack for temporary storage of container panels.

Description

SYSTEM FOR HANDLING CONTAINER WALLS TECHNICAL FIELD This application relates generally to containers, and more particularly to a system for handling and storing removable walls of a shipping container. BACKGROUND Reusable, stackable containers or cargo units can be useful for transporting various types of cargo, e.g., by rail, in overseas commerce, and in other contexts. Examples of containers are described in U.S. Patent No. 8,573,427, and U.S. Provisional App. No. 62/849,559, filed May 17, 2019, and entitled “Cargo Unit,” the disclosures of which are incorporated herein by reference. Some prior art containers have removable walls that are held in vertical positions on a horizontal container base by locking mechanisms while the containers are in transit. Some such container walls include a panel bordered by a frame that includes a horizontal structural member extending along the top of the wall, with the horizontal structural member having a generally horizontal underside near the top of the wall. When the containers arrive at a destination to be unloaded, the locking mechanisms are released, and the walls tilt outward, such that the underside of the structural member is no longer horizontal, but rather is inclined downward and away from the panel. The walls may then be manually removed, which may facilitate access to the contents of the containers, and also may enable the walls to be stacked horizontally on the base to reduce the volume occupied by the containers after the contents have been removed. In some prior art containers, removal of the walls involves application of upward and outward force, lifting the wall slightly and pulling the bottom of the wall outward to disengage the bottom of the wall from the base. In some cases, after the wall has been lifted slightly, the bottom of the wall remains engaged with the base, and a first side of the bottom of the wall may be pulled outward to disengage it from the base while the other side remains engaged, such that the wall is twisted slightly, with the first side of the bottom of the wall being disengaged before the second. In some cases, the wall is shifted sideways after one side has been pulled outward. As a specific example, in the prior art, removal of a wall may involve a worker facing the wall and grasping the wall with both hands, then lifting the wall slightly, then pulling the left side outward slightly, twisting the wall to release the bottom left side of the wall from engagement with the base, then shifting the wall to the left and pulling the right side outward to release the bottom right side of the wall. After removal, it may be desirable for one or more walls to be moved out of an area around the container to avoid interference with unloading of the container by forklift or by other means. Replacing a wall on the base may involve a reversal of the above-described process. In some instances, removable walls may be in excess of one meter in height and/or width, and may weigh 10-25 kilograms, or about 18 kg. In some instances, a user may find the walls to be unwieldy due to their size and weight, and due to the sequence of steps involved in removing or replacing them. SUMMARY Disclosed herein is a system for handling and storing removable walls. Some embodiments include a tool and related method for removal of walls tilted upward and outward from a container base at oblique angles, and for replacement of walls after removal. In some embodiments, the tool comprises a carriage, an abutment surface extending upward and rearward from the front of the carriage at an oblique angle, and a lifter mounted at or near an upper end of the abutment surface. In some embodiments, the lifter has a limited range of motion so as to be capable of engaging a container wall and slightly lifting the container wall with precision by a small predetermined distance, e.g., about 15 to 25 millimeters, to facilitate removal of the container wall from the container base. In some embodiments, the tool is capable of supporting the wall in stable equilibrium for transport, with both the lifter and the abutment surface engaging and supporting the wall at an oblique angle. In some embodiments, the lifter is capable of applying a lifting force to the container wall in response to a manually applied force, wherein the magnitude of the lifting force is greater than the manually applied force. This may be achieved through the use of a mechanical device for providing a mechanical advantage such as a lever, a hydraulic system, or a cable or chain drive, or by use of one or more motors, electromagnetic devices, or other devices. In some embodiments, the method comprises placing a movable tool on a floor with only a lifter such as a lever in contact with the wall, lifting the wall by manually applying a downward force to a lever mounted at or near an upper end of the movable tool, with a forward end of the lever engaging the underside of a wall frame member, and moving the tool and wall laterally away from the shipping container to pull the wall away from the base, allowing the wall to swing from a first inclined position in which only the lever supports the wall to a second inclined position with both the lever and abutment surface supporting the weight of the wall. In some embodiments, moving the tool and wall laterally away from the base comprises first moving one side of the wall away from the base, e.g., a left or right side thereof, then moving the other side away from the base. The method may comprise allowing the wall to contact an abutment surface on the front of the tool before, during or after removal of the wall from the base, with the movable tool supporting some or all of the weight of the wall. In some embodiments, the abutment surface helps to maintain the wall in an inclined position on the tool, thereby helping to maintain engagement between the lifter and the underside of a wall frame member. In some embodiments, the lever includes a wall engagement end and a handle end, and lifting the wall comprises pivoting the lever about a fulcrum that is closer to the wall engagement end than the handle end. In some embodiments, the abutment surface comprises a front rail positioned below and in front of the lifter. In some embodiments, the upstanding frame has an oblique front surface that extends upward and rearward at an angle closer to vertical than the wall prior to engagement of the wall by the tool. In some embodiments, the lifter engages the wall by applying upward pressure to one or more surfaces of the wall. In some embodiments, the lifter may use one or more grippers, magnets, suction devices, and/or other means to engage the wall. In some embodiments, the tool includes a carriage or base frame supported on wheels, rollers or other means to facilitate movement, and a forward support frame that extends upward and rearward from the base at an oblique angle. In some embodiments, the tool further includes a lifter or lift frame that is pivotably connected to an upper portion of the forward support frame. The lift frame may include an engagement protuberance that moves with the lift frame relative to the forward support frame. In some embodiments, the method includes engaging the wall with a movable tool that includes a base, a forward support frame that extends from the base, and a lift frame that is pivotably connected to the forward support frame. The lift frame includes an engagement protuberance for engaging a groove of the wall. The method may further include pivoting the lift frame relative to the forward support frame to lift the wall away from the base. In some embodiments, the system includes a storage rack that has a bifurcated base defining a central space for receiving a cart, such that a cart may travel into the central space while supporting a portion of the wall, e.g., an upper central portion of the wall, then lower the wall so that it is supported by the bifurcated base, thereby unloading the cart. The wall may then be held for temporary storage on the rack, and the cart may be withdrawn and used to bring additional walls to the rack, such that the rack may be used for temporary storage of a plurality of walls. When it is desired to take a wall from the storage rack to a container base, a wall may be loaded onto the cart by positioning the cart in the central space and lifting the wall from the bifurcated base. The cart may then be withdrawn from the central space, and used to transport the wall to another location where it may be reunited with a container base. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a tool for moving removable walls of a shipping container. FIG.2 is a side view of the tool. FIG.3 is a front elevation view of the tool. FIG.4 is a top plan view of the tool. FIG. 5 is an enlarged view of a stop assembly of the tool with a lift frame in a resting position. FIG.6 is an enlarged view of the stop assembly of the tool with the lift frame in a raised position. FIG.7 is a perspective view of a shipping container having removable walls locked in vertical positions in an assembled configuration. FIG.8 shows the container of FIG.7 after release of locking mechanisms to permit the walls to tilt outward, and the tool of FIG.1 being pushed forward into contact with a wall. FIG.9 shows the tool engaging the removable wall prior to lifting it. FIG.10 shows the tool and wall after lifting. FIG.11 shows the tool and wall after removal of the wall. FIG.12 is a front side perspective view of another tool for moving removable walls of a shipping container. FIG.13 is a rear side perspective view of the tool of FIG.12. FIG.14 is a front upper perspective view of the tool. FIG.15 is a rear upper perspective view of the tool. FIG.16 is an enlarged view of a stop assembly of the tool with a lift frame in a resting position. FIG. 17 shows the tool and a removable wall after removing the wall from a shipping container. FIG.18 is a side perspective view of a rack for storing removable walls. FIG.19 is a front perspective view of the rack. FIG.20 is a side elevation view of the rack. FIG.21 shows the tool depositing removable walls on the rack. FIG.22 shows the removable walls being moved from the rack to a shipping container for transporting of the removable walls. DETAILED DESCRIPTION Embodiments of the invention are described herein for purposes of example. Other embodiments may take different forms. The figures are not necessarily to scale. Any of the various features illustrated and/or described may be combined with any other such features. Referring to FIGS. 1-4, a cart or mobile tool 10 for handling walls of a shipping container is shown. The tool 10 includes one or more frames, including a carriage or base frame 12, a support frame 14 that extends upwardly from the base frame 12, and a lifter or lift frame 16 that is pivotably connected to the support frame 14. The base frame 12 may include a forward rail 20, a rear rail 22, and side rails 24 that connect to the forward rail 20 and the rear rail 22. The side rails 24 may extend forwardly beyond the forward rail 20. The side rails 24 may also or instead extend rearwardly beyond the rear rail 22. Casters 30 are secured at or near each of the four corners of the base frame 12 to facilitate movement of the tool 10 along a floor surface. A forward caster 30 may be secured (e.g., welded or mechanically fastened) to the forward rail 20, to a side rail 24, or to both the forward rail 20 and a side rail 24. Similarly, a rearward caster 30 may be secured to the rear rail 22, to a side rail 24, or to both the rear rail 22 and a side rail 24. Each caster 30 may include one or more wheels or rollers such that the tool 10 may be a rollable tool 10. One or more of the casters 30 may include a brake or locking mechanism (not shown) for providing resistance to rotation, or for locking the wheel(s) of the caster 30, to thereby slow, impede or inhibit movement of the tool 10. In the illustrated embodiment, the tool 10 is configured to facilitate manual operation, with a worker pushing and pulling the tool as necessary to move, position and stop the tool during operation. In some embodiments, one or more drive mechanisms may be provided to reduce or eliminate the need for manual forces to be applied. In some embodiments, a drive mechanism(s) may be controlled by a manually operated or autonomous electronic controller on the tool, or by a remote control hard-wired or wirelessly connected to the tool, or by other means. In some embodiments, the tool may operate as a robotic unit. The illustrated tool 10 includes a lower support lip 40 that extends from the base frame 12. The lower support lip 40 may include a cross bar 42 and inclined surfaces or ramped supports 44 at opposing ends of he of the cross bar 42. Opposing end portions of the cross bar 42 may be secured (e.g., welded or mechanically fastened) to end faces of the side rails 24. As shown in FIG.2, the cross bar 42 may extend below (e.g., in the Z direction) at least a portion of the side rails 24. In this way, upper regions of the end portions of the cross bar 42 may be welded to lower regions of the end faces of the side rails 24. A ramped support 44 may have a lower end that is welded to the cross bar 42 and an upper end that is welded to an end face of a side rail 24. The support frame 14 extends generally upwardly (e.g., in the Z direction) from the base frame 12. More particularly, the support frame 14 may include opposing side frames 50, with each side frame 50 extending generally upwardly from a respective side rail 24. In the approach shown, a side frame 50 includes a forward support rail 52 that extends generally upwardly from a forward portion of a side rail 24, and a rear support rail 54 that extends generally upwardly from a rear portion of a side rail 24. The rear support rails 54 may cooperate to form a rear support frame 54^ (also referred to herein as a rear support). Lower ends of the forward support rails 52 and the rear support rails 54 may be secured (e.g., welded or mechanically fastened) to the side rails 24. In one approach, the upper end of a forward support rail 52 is secured to the upper end of a rear support rail 54. In another approach, a side frame 50 includes integrally-formed forward and rear support rail portions. In either approach, a side frame 50 may generally define an A-frame structure. Other shapes, which may include intermediary rails, connectors, etc., are also contemplated. As shown in FIG. 2, a forward support rail 52 may extend generally upwardly and rearwardly (e.g., toward a rear support rail 54) from a side rail 24 such that a forward support rail 52 forms an angle 60 with the side rail 24. In one approach, the angle is an oblique angle, such as an acute angle within the range of approximately 70 degrees to approximately 89 degrees, and more particularly, in the range of approximately 75 degrees to approximately 85 degrees, and even more particularly, approximately 77 degrees or approximately 83 degrees. The forward support rails 52 may cooperate to form a forward support frame 52^ (also referred to herein as a front support). In a similar manner, a rear support rail 54 may extend generally upwardly and forwardly (e.g., toward a forward support rail 52) from a side rail 24 such that a rear support rail 54 forms an angle 62 with the side rail 24. In one approach, the angle is an oblique angle, such as an acute angle within the range of approximately 70 degrees to approximately 89 degrees, and more particularly, in the range of approximately 75 degrees to approximately 85 degrees, and even more particularly, approximately 77 degrees or approximately 83 degrees. As shown in FIG. 1, the support frame 14 may include a forward support rod 70 that extends between opposing forward support rails 52. The support frame 14 may also, or may instead, include a rear support rod 72 that extends between opposing rear support rails 54. The forward support rod 70 and rear support rod 72 may be secured (e.g., welded or mechanically fastened) at opposing ends to forward support rails 52 and rear support rails 54, respectively. The lift frame 16 includes a pivot bar 80 and opposing lift rails 82 that extend from the pivot bar 80. One or more mechanical fasteners 96 may be provided to pivotably connect the lift frame 16 to the support frame 14. For example, screws or bolts may pivotably connect forward ends of the lift rails 82 (or both the lift rails 82 and the pivot bar 80) to upper ends of respective forward support rails 52. In this way, the mechanical fasteners 96 may function as a fulcrum about which the lift rails 82 (or both the lift rails 82 and the pivot bar 80) may pivot. Use of mechanical fasteners here and elsewhere may also provide an advantage with respect to enabling tool components to be transported prior to assembly in a compact arrangement, e.g., as a kit, to a warehouse or other location where the tool is to be used, then assembled at the warehouse or other location. The lift frame 16 further includes a handlebar 84 that extends between the lift rails 82. The handlebar 84 extends along a direction parallel to a pivot axis 98 of the lift frame 16. An upper support rod 86 also extends between the lift rails 82 and is disposed between the pivot bar 80 and the handlebar 84. In use, an operator may pivot the lift frame 16 relative to the support frame 14 and base frame 12 by lifting and lowering the handlebar 84 to pivot the lift rails 82 about the pivot axis 98. The lift frame 16 further includes at least one, and preferably two, engagement protuberances 90. The engagement protuberances 90 are disposed at or near a forwardmost end of the lift frame 16 proximate the forward support rails 52. First and second engagement protuberances 90 may be aligned along an axis parallel to the pivot axis 98 of the lift frame. With respect to FIGS.2 and 5-7, an engagement protuberance 90 may comprise a piece of angle iron having a length or horizontal dimension of 1 to 3 in. that includes a protuberance base 92 that is secured (e.g., welded) to a forward end of a lift rail 82. The protuberance base 92 may have a surface that is parallel with an upper surface of the lift rail 82. An engagement protuberance 90 may further includes a protuberance extension or flange 94 that extends upward and forward from the protuberance base 92. In the approach shown, the protuberance extension 94 extends orthogonally from protuberance base 92, and as such, extends orthogonally from the lift frame 16. In some embodiments, the flange 94 has a length or horizontal dimension of about 1.5 in. and extends between 0.125 in. and 1.5 in., or about 0.75 in., from the base. In other embodiments, the flange may have other dimensions. Other protuberance extension shapes are also contemplated. Referring to FIGS. 5 and 6, the tool 10 may include means to cushion certain impact loads or the like that may be transmitted to and/or from the lifter, comprising a stop assembly 100. As the lifter is actuated to lift a wall, as the lifter approaches the end of its lifting motion, the stop assembly may act to slow the lifting motion and bring the lifter to a gradual stop. Also, the stop may help to dissipate loads experienced by the tool during transportation of a wall on the tool, e.g., loads associated with movement of the lifter and/or irregularities in a floor surface over which the tool is rolling, so that such loads are not fully transmitted to the wall. The stop assembly may thus reduce the likelihood of the wall being inadvertently dislodged from the tool. The stop assembly 100 may include a base flange 102 that extends from a rear support rail 54. The base flange 102 includes a through-hole (not visible) for receiving a fastener 104, which may be at least partially threaded. A cap 106 is disposed to an upper end of the fastener 104. In one embodiment, the cap 106 is a discrete component that is secured to the fastener 104. In another embodiment, the cap 106 is integrally formed with the fastener 104 (e.g., as a fastener head that is integrally formed with a fastener shank). A spring 110 is disposed about the fastener 104 between an upper surface of the base flange 102 and a lower surface of the cap 106. In this way, the spring 110 acts to bias the fastener 104, via the cap 106, in a first axial direction (e.g., generally upward and forward). A nut 112 is secured to the threaded portion of the fastener 104 such that axial movement of the fastener 104 in the first axial direction is inhibited when the nut 112 engages a bottom surface of the base flange 102 (e.g., due to the biasing force of the spring 110). The nut 112 may be adjustable along the threaded portion of the fastener 104 to adjust a resting position of the lift frame 16, as discussed in greater detail below. In use, the cap 106 receives a member of the lift frame 16 on an upper surface of the cap 106. The spring 110 may be selected or tuned such that the weight of the lift frame 16 does not compress the spring 110 when the lift frame 16 is in the resting position, as shown in FIG.5. When an operator lifts the lifting frame 16 (e.g., via handlebar 84), the lifting frame 16 pivots forwardly about the pivot axis 98. Pivoting of the lift frame 16 in the forward direction is inhibited when the bottom surface of the engagement protuberance 90 (e.g., the bottom surface of the protuberance base 92) engages a forward surface of a forward support rail 52, as depicted in FIG.6. When an operator lowers the lifting frame 16 (e.g., via handlebar 84), the lifting frame 16 pivots rearwardly about the pivot axis 98. Pivoting of the lift frame 16 in the rearward direction moves the lifting frame 16 back to the resting position of FIG.5. When an operator further urges the lift frame 16 in a downward direction, the spring 110 compresses to allow axial movement of the fastener 104, cap 106, and nut 112 in an axial direction that is generally downward and rearward (e.g., opposite the first axial direction). Pivoting of the lift frame 16 in the reward direction is inhibited or prevented when the spring 110 fully compresses, and continued movement of the cap 106 toward the base flange 102 is inhibited or prevented by the spring 110. In some embodiments, the lift frame 16 may pivot through a range of motion of 30° to 90°, 50° to 70°, or about 60°. In some embodiments, the spring is engaged through a range of 2° to 10°, 4° to 8°, or about 6° at the low end of the range of motion of the handle 84, which corresponds to the high end of the range of motion of the extensions 94. In some embodiments, the tool is made of mild steel, alone or in combination with other materials, and has a weight of 10 to 30 kg., 15 to 25 kg., or about 20 kg. In some embodiments, the tool is capable of stably supporting a wall weighing up to 30 kg. In some embodiments, the tool may have a lower or higher capacity, and be lighter heavier in weight. Referring to FIG. 7, a shipping container 200 capable of carrying cargo is shown. The shipping container 200 includes a base 202 and one or more removable walls 204 that extend upwardly from the base 202 and that may be removed from the base 202. The removable walls 204 may include a front wall 206, a rear wall 208, and side walls 210, 212. One or more of the removable walls 204 may include planar wall portions 214 and one or more support rails 216 that provide increased structural rigidity for the planar wall portions 214. The removable walls 204 may be removed when the shipping container 200 is fully loaded to facilitate access to cargo loaded on the base 202. Examples of cargo that may be transported within the shipping container 200 may include solid materials (e.g., natural or synthetic rubber materials) and/or liquids or other flowable materials (e.g., tomato paste). When the walls are oriented vertically, each removable wall 204 includes a horizontal structural member which may be in the form of a transverse upper frame member 220 adjacent a vertical panel portion 222. A downwardly-facing bottom surface of a lip interface 230 of the transverse upper frame member 220 extends outwardly (e.g., horizontally in the X direction) from the vertical panel portion 222 to a bottom outer edge 224 of the frame member 220, thus forming a concavity or interior corner between the panel 222 and bottom surface of the lip interface 230 for receiving the protuberance extensions 94 after the wall has been tilted outward. The shipping container 200 includes locking mechanisms 240 for maintaining the removable walls 204 in an upright, assembled configuration. The locking mechanisms 240 may be provided at the upper edges of the side walls 210, 212 adjacent to the front wall 206 and the rear wall 208. Each of the locking mechanisms 240 may include a handle 242 that is pivotable between a locked position (e.g., “lowered”) and an unlocked or open position (e.g., “raised”). When the handles 242 are all in the locked position, the locking mechanisms 240 can maintain the removable walls 204 in an upright, locked configuration, as shown in FIG.7. To release the front wall 206 from locked engagement with adjacent side walls 210, 212, an operator pivots the handle 242A of side wall 210 to the unlocked position. The operator also pivots the handle 242B (not visible) of side wall 212 to the unlocked position. With both handles 242A, 242B in the unlocked positions, the front wall 206 is mechanically released from the adjacent side walls 210, 212, and may pivot outward to the position shown in FIG. 8. The rear wall 208 may similarly be released from, and pivot outwardly. With the front and rear walls 206, 208 released, the side walls 210, 212 may also pivot outward. In the outwardly-pivoted positions, lower portions of the walls 204 are supported at a predetermined angled orientation (which may be, for example, approximately 15 degrees off vertical). Referring now to FIGS.8-11, a method for removing a wall from a shipping container 200 will be described. As shown in FIG. 8, the tool 10 may be pushed or otherwise transported into close proximity with the container, then into contact with a container wall as shown in Fig.9, with the lifter 16 pivoted manually or otherwise to a position shown in Figs.6 and 9 by raising the handle 84. With the lift frame 16 in this position, the tool is moved forward so that the extensions 94 contact the frame member bottom surface 230 and panel 222 at their intersection. Due to the outward tilt of the wall, the panel 222 is inclined upward and outward from the base, and bottom surface 230 slopes upward toward the panel 222 from its outer edge 224, and the intersection or interior corner formed by the bottom surface 230 and panel 222 thus can receive the extensions 94 in stable equilibrium. More particularly, the lip interface 230 receives the engagement protuberances 90 therein. Referring to FIG. 10, the operator may then manually pivot the lift frame 16 by applying a downward lifting force to the handle 84 of the lift frame 16. Downward pivoting of the lift frame 16 causes the extensions 94 to lift the front wall 206. In this way, the tool 10 supports the weight of the front wall 206. More particularly, the tool 10 supports the front wall 206 at the engagement protuberances of the lift frame 16 and at a forward-facing abutment surface of the forward support frame 52. Referring to FIG.11, upon lifting the front wall 206 with the lift frame 16, the operator may pivot the front wall 206 laterally (e.g., along a vertical axis) such that one side (e.g., the left side) of the front wall 206 is pulled away from the base 202 while the opposite side remains partially engaged with the base 202. Such pivoting causes a pivot pin located at a lower region of the left side of the front wall 206 to be displaced laterally outward through a slot in the base 202. A pivot pin at a lower region of the right side of the front wall 206 may then be disengaged from the base 202, thereby releasing the front wall 206 from the base 202. Upon release of the front wall 206, the tool 10 supports the front wall 206 in stable equilibrium, and the operator may transport the front wall 206 away from the base 202. This removal process may be repeated for one or more of the rear wall 208, side wall 210, and side wall 212. Removal of one or more of the walls may facilitate access to the contents of shipping container 200 and/or may facilitate storage of one or more components of the shipping container 200. The tool 10 may also facilitate assembly (or reassembly) of a shipping container 200. As such, the above-described method may be generally performed in reverse order. For example, an operator may load the front wall 206 onto the tool 10 by engaging the engagement protuberances 90 with the lip interface 230 of the front wall 206. The operator may then lift the front wall 206 to an installation position by pivoting the lift frame 16 to a lowered position (e.g., the lowered position depicted in FIG. 11). With the lift frame 16 of the tool 10 in the lowered position, the operator may then position a lower portion of the front wall 206 relative to the base 202 (e.g., as positioned in FIG. 10). Upon positioning, the operator may raise the lift frame 16 to a raised position (e.g., the raised position depicted in FIG. 9) to thereby lower the front wall 206 into an engagement position with the base 202. In the engagement position, base 202 maintains the front wall 206 in the outwardly-pivoted position depicted in FIG. 9. Upon positioning the front wall 206 in the engagement position, the operator may back the tool 10 away from the shipping container 200 to disengage the engagement protuberances 90 from the lip interface 230 of the front wall 206. This assembly (or reassembly) process may be repeated for one or more of the rear wall 208, side wall 210, and side wall 212. With the walls in the outwardly-pivoted position, the side walls 210, 212 may be moved to vertical positions. The front wall 206 may then be raised into the vertical position, and handles 242A, 242B may be moved from unlocked positions to locked positions to secure to the front wall 206 to the side walls 210, 212. This process is then performed at the back wall 208 to full assemble the shipping container 200 in an erected configuration. Referring to FIGS. 12-15, a second cart or mobile tool 300 for handling walls of a shipping container is shown. The tool 300 includes one or more frames, including a carriage or base frame 302, a support frame 304 that extends upwardly from the base frame 302, and a lifter or lift frame 306 that is pivotably connected to the support frame 304. The base frame 302 may include a forward rail 310, a rear rail 312, and side rails 314 that connect to the forward rail 310 and the rear rail 312. The side rails 314 may extend forwardly beyond the forward rail 310. The side rails 314 may also or instead extend rearwardly beyond the rear rail 312. Casters 320 are secured at or near each of the four corners of the base frame 302 to facilitate movement of the tool 300 along a floor surface. A forward caster 320 may be secured (e.g., welded or mechanically fastened) to the forward rail 310, to a side rail 314, or to both the forward rail 310 and a side rail 314. Similarly, a rearward caster 320 may be secured to the rear rail 312, to a side rail 314, or to both the rear rail 312 and a side rail 314. Each caster 320 may include one or more wheels or rollers such that the tool 300 may be a rollable tool 300. One or more of the casters 320 may include a brake or locking mechanism (not shown) for providing resistance to rotation, or for locking the wheel(s) of the caster 320, to thereby slow, impede or inhibit movement of the tool 300. The tool 300 is configured to facilitate manual operation, with a worker pushing and pulling the tool 300 as necessary to move, position, and stop the tool during operation. In some embodiments, one or more drive mechanisms may be provided to reduce or eliminate the need for manual forces to be applied. In some embodiments, the drive mechanism(s) may be controlled by a manually operated or autonomous electronic controller on the tool, or by a remote control hard-wired or wirelessly connected to the tool, or by other means. In some embodiments, the tool may operate as a robotic unit. The tool 300 includes one or more lower support bumper members 330 disposed at a lower forward face of the tool 300. For example, the tool 300 may include a cross bar 332 that extends laterally across a lower forward face of the tool 300. The cross bar 332 may be secured to lower portions of tool 300 via a mounting fame 334, which may be welded or mechanically fastened to lower portions of the support frame 304. end faces of the side rails 314. The cross bar 332 may extend above (e.g., in the Z direction) at least a portion of the side rails 314. The tool 300 may also, or may instead, include one or more bumpers 336, which may include a generally planar forward face. The bumpers 336 may be disposed, for example, at forward edges of the side rails 314. As discussed below, when a removable wall 204 of a shipping container 200 is carried by the tool 300, the planar wall portion(s) 214 of a removable wall 204 rest on and are supported by the bumpers 336, and the support rail(s) 216 of the removable wall 204 rest on and are supported by the cross bar 332. The support frame 304 extends generally upwardly (e.g., in the Z direction) from the base frame 302. More particularly, the support frame 304 may include opposing side frames 340, with each side frame 340 extending generally upwardly from a respective side rail 314. In the approach shown, a side frame 340 includes a forward support rail 342 that extends generally upwardly from a forward portion of a side rail 314, and a rear support rail 344 that extends generally upwardly from a rear portion of a side rail 314. The rear support rails 344 may cooperate to form a rear support frame 344^ (also referred to herein as a rear support). Lower ends of the forward support rails 342 and the rear support rails 344 may be secured (e.g., welded or mechanically fastened) to the side rails 314. In one approach, the upper end of a forward support rail 342 is secured to the upper end of a rear support rail 344. In another approach, a side frame 340 includes integrally-formed forward and rear support rail portions. In either approach, a side frame 340 may generally define an A-frame structure. Other shapes, which may include intermediary rails, connectors, etc., are also contemplated. Similar to the forward support rail 52 of the tool 10 shown in FIG.2, a forward support rail 342 may extend generally upwardly and rearwardly (e.g., toward a rear support rail 344) from a side rail 314 such that a forward support rail 342 forms an angle 350 (FIG.12) with the side rail 314. In one approach, the angle is an oblique angle, such as an acute angle within the range of approximately 70 degrees to approximately 89 degrees, and more particularly, in the range of approximately 75 degrees to approximately 85 degrees, and even more particularly, approximately 77 degrees or approximately 83 degrees. The forward support rails 342 may cooperate to form a forward support frame 342^ (also referred to herein as a front support). In a similar manner, a rear support rail 344 may extend generally upwardly and forwardly (e.g., toward a forward support rail 342) from a side rail 314 such that a rear support rail 344 forms an angle 352 (FIG. 13) with the side rail 314. In one approach, the angle is an oblique angle, such as an acute angle within the range of approximately 70 degrees to approximately 89 degrees, and more particularly, in the range of approximately 75 degrees to approximately 85 degrees, and even more particularly, approximately 77 degrees or approximately 83 degrees. The support frame 304 (and more particularly, the forward support frame 342^) may include a forward support rod 360 that extends between opposing forward support rails 342. The support frame 304 may also, or may instead, include a rear support rod 362 that extends between opposing rear support rails 344. The forward support rod 360 and rear support rod 362 may be secured (e.g., welded or mechanically fastened) at opposing ends to forward support rails 342 and rear support rails 344, respectively. The lift frame 306 includes a pivot bar 370 and opposing lift rails 372 that extend from the pivot bar 370. One or more mechanical fasteners 386 may be provided to pivotably connect the lift frame 306 to the support frame 304. For example, screws or bolts may pivotably connect forward ends of the lift rails 372 (or both the lift rails 372 and the pivot bar 370) to upper ends of respective forward support rails 342. In this way, the mechanical fasteners 386 may function as a fulcrum about which the lift rails 372 (or both the lift rails 372 and the pivot bar 370) may pivot. Use of mechanical fasteners here and elsewhere may also provide an advantage with respect to enabling tool components to be transported prior to assembly in a compact arrangement, e.g., as a kit, to a warehouse or other location where the tool is to be used, then assembled at the warehouse or other location. The lift rails 372 of the lift frame 306 are nonlinear. More specifically, they include multiple segments that are non-colinear. For example, a lift rail 372 may include a first segment such as load segment 373, and a second segment such as effort segment 375 that extends from the load segment 373. The effort segment 375 extends from the load segment 373 such that the load segment 373 and the effort segment 375 form an angle 377 therebetween. In one approach, the angle 377 is an oblique angle, such as an obtuse angle within the range of 95 degrees to approximately 175 degrees, and more particularly, in the range of 120 degrees to 150 degrees, and even more particularly, approximately 135 degrees. In this way, the multiple segments of a lift rail 372 may cooperate to form an angled lift rail 372. Angled lift rails 372 may improve the ergonomics of the tool 300 during lifting, lowering and/or transport of walls. The lift frame 306 further includes a handlebar 374 that extends between the lift rails 372. The handlebar 374 extends along a direction parallel to a pivot axis 388 of the lift frame 306. An upper support rod 376 also extends between the lift rails 372 and is disposed generally between the pivot bar 370 and the handlebar 374. In use, an operator may pivot the lift frame 306 relative to the support frame 304 and base frame 302 by lifting and lowering the handlebar 374 to pivot the lift rails 372 about the pivot axis 388. The lift frame 306 further includes at least one, and preferably two, engagement protuberances 380. The engagement protuberances 380 are disposed at or near a forwardmost end of the lift frame 306 proximate the forward support rails 342. First and second engagement protuberances 380 may be aligned along an axis parallel to the pivot axis 388 of the lift frame 306. With respect to FIGS.7 and 16, an engagement protuberance 380 may comprise a piece of angle iron having a length or horizontal dimension of 1 to 3 in. that includes a protuberance base 382 that is secured (e.g., welded) to a forward end of a lift rail 372 (e.g., at a forward end of the load segment 373. The protuberance base 382 may have a surface that is parallel with an upper surface of the load segment 373. An engagement protuberance 380 may further includes a protuberance extension or flange 384 that extends upward and forward from the protuberance base 382. In the approach shown, the flange 384 extends orthogonally from protuberance base 382, and as such, extends orthogonally from the load segment 373. In some embodiments, the flange 384 has a length or horizontal dimension of about 1.5 in. and extends between 0.125 in. and 1.5 in., or about 0.75 in., from the base. In other embodiments, the flange may have other dimensions. Other protuberance extension shapes are also contemplated. The tool 300 may include means to cushion certain impact loads or the like that may be transmitted to and/or from the lifter, comprising a stop assembly 390. As the lifter is actuated to lift a wall, as the lifter approaches the end of its lifting motion, the stop assembly may act to slow the lifting motion and bring the lifter to a gradual stop. Also, the stop may help to dissipate loads experienced by the tool during transportation of a wall on the tool, e.g., loads associated with movement of the lifter and/or irregularities in a floor surface over which the tool is rolling, so that such loads are not fully transmitted to the wall. The stop assembly may thus reduce the likelihood of the wall being inadvertently dislodged from the tool. The stop assembly 390 may include a base flange 392 that extends from a rear support rail 344. The base flange 392 includes a through-hole (not visible) for receiving a fastener 394, which may be at least partially threaded. A cap 396 is disposed to an upper end of the fastener 394. In one embodiment, the cap 396 is a discrete component that is secured to the fastener 394. In another embodiment, the cap 396 is integrally formed with the fastener 394 (e.g., as a fastener head that is integrally formed with a fastener shank). A spring 400 is disposed about the fastener 394 between an upper surface of the base flange 392 and a lower surface of the cap 396. In this way, the spring 400 acts to bias the fastener 394, via the cap 396, in a first axial direction (e.g., generally upward and forward). One or more nuts 402 are secured to the threaded portion of the fastener 394 such that axial movement of the fastener 394 in the first axial direction is inhibited when a nut 402 engages a bottom surface of the base flange 392 (e.g., due to the biasing force of the spring 400). The nuts 402 may be adjustable along the threaded portion of the fastener 394 to adjust a resting position of the lift frame 306, as discussed in greater detail below. With reference to FIGS. 12 and 16, the tool 300 may further include a guard 410 that reduces access to the spring 400 to decrease unintentional user contact with the spring 400. The guard 410 may be a three-sided guard having a forward wall 412, a rear wall 414, and a side wall 416 that extends between the forward wall 412 and the rear wall 414. The forward wall 412, rear wall 414, and side wall 416 block access to the spring 400, while an open region opposite the side wall 416 permits user access to the spring 400. The guard 410 may be secured at a lower region of the guard to the base flange 392. An upper region of the guard 410 may be spaced from an adjacent lift rail 372 such that the lift frame 306 may rotate freely relative to the guard 410. In use, the cap 396 receives a member of the lift frame 306 on an upper surface of the cap 396. The spring 400 may be selected or tuned such that the weight of the lift frame 306 does not compress the spring 400 when the lift frame 306 is in the resting position, as shown in FIG.16. When an operator lifts the lifting frame 306 (e.g., via handlebar 374), the lifting frame 306 pivots forwardly about the pivot axis 388. Pivoting of the lift frame 306 in the forward direction is inhibited when the bottom surface of the engagement protuberance 380 (e.g., the bottom surface of the protuberance base 382) engages a forward surface of a forward support rail 342 (similar to the position depicted in FIG. 6). When an operator lowers the lifting frame 306 (e.g., via handlebar 374), the lifting frame 306 pivots rearwardly about the pivot axis 388. Pivoting of the lift frame 306 in the rearward direction moves the lifting frame 306 back to the resting position of FIG.16. When an operator further urges the lift frame 306 in a downward direction, the spring 400 compresses to allow axial movement of the fastener 394, cap 396, and nut 402 in an axial direction that is generally downward and rearward (e.g., opposite the first axial direction). Pivoting of the lift frame 306 in the reward direction is inhibited or prevented when the spring 400 fully compresses, and continued movement of the cap 396 toward the base flange 392 is inhibited or prevented by the spring 400. In some embodiments, the lift frame 306 may pivot through a range of motion of 30° to 90°, 50° to 70°, or about 60°. In some embodiments, the spring is engaged through a range of 2° to 10°, 4° to 8°, or about 6° at the low end of the range of motion of the handlebar 374, which corresponds to the high end of the range of motion of the extensions 384. In some embodiments, the tool is made of mild steel, alone or in combination with other materials, and has a weight of 10 to 30 kg., 15 to 25 kg., or about 20 kg. In some embodiments, the tool is capable of stably supporting a wall weighing up to 30 kg. In some embodiments, the tool may have a lower or higher capacity, and be lighter heavier in weight. Referring to FIG. 17, the tool 300 may be pushed or otherwise transported into close proximity with a shipping container 200, and then into contact with a removable walls 204 so that the engagement protuberances 380 (e.g., the flanges 384) contact a lip interface 230 of the removable wall 204. An operator may then manually pivot the lift frame 306 by applying a downward lifting force to the handlebar 374 of the lift frame 306. Downward pivoting of the lift frame 306 causes the flanges 384 to lift the removable wall 204. As discussed, the lift rails 372 include a user-end effort segment 375 that is angularly offset from a load segment 373 that engages the removable wall 204. When the lift frame 306 is in the resting position shown in FIGS. 12-15, the angled configuration of the lift rails 372 may position the handlebar 374 generally at chest height of an operator. During lifting and transporting of a removable wall 204, the operator may push the lift frame 306 downward from the chest-height position to a waist- height position, shown in FIG. 17. Thus, for many operators, the configuration of the lift rails 372 permits a user to “push” the handlebar 374 downward from the resting position to the lifting position, and may reduce or eliminate a downward “pulling” motion of the lift frame 306. The configuration of the lift rails 372 may therefore allow a user to leverage additional bodyweight above the handlebar 374 when driving the handlebar 374 downward as compared to a “pulldown” motion, thereby improving the ergonomics of the tool 300. In other embodiments, the lift rails may be curved, bent, or otherwise configured to provide similar ergonomic advantages. Upon lifting the removable wall 204, the tool 300 is configured to support the removable wall 204 at the forward support frame 342^ for transporting the removable wall 204. For example, the engagement protuberances 380 retain the removable wall 204 relative to the tool 300 and support the weight of the removable wall 204. Furthermore, the cross bar 332 and bumpers 336 of disposed at a lower forward face of the tool 300 cooperate to maintain the removable wall 204 in an angular orientation. Referring to FIGS. 18-21, the tool 300 may be used to transport the removable walls 204 to a wall stand or rack 500, which may receive and store the removable walls 204 thereon. The rack 500 includes a bifurcated base platform 502 and a generally upright support 504, which may be inclined as discussed below. One or more wheels 510 may be secured to the base platform 502 or the upright support 504 to facilitate movement of the rack 500. In the approach shown, the wheels 510 are secured to a wheel mount 512 that is fixedly secured (e.g., welded) to the upright support 504. The base platform 502 includes a first side support 520 and a second side support 522 that is laterally spaced from the first side support 520. The first and second side supports 520, 522 include spaced apart inner support rails 530 that cooperate to define a channel 540 therebetween. As shown in FIG.21, the inner support rails 530 are spaced such that the tool 300 may pass therebetween. As also shown in FIG. 21, the inner support rails 530 support the removable walls 204 thereon after the removable walls 204 are deposited by the tool 300. In some examples, means to facilitate movement of the removable walls on the inner support rails may be provided. For example, the inner support rails 530 may have low-friction material or rollers thereon. Low-friction material may be provided, e.g., as a length of PTFE or other material shaped as a bead or rod of circular cross-section or other shape, adhered or attached to the entire lengths of the upper surfaces of inner support rails 530 or to portions thereof, or as a coating of all or part of the upper surfaces thereof, or in other forms. The first and second side supports 520, 522 also include outer rollers 532 that are configured to rotate about outer rails (not visible) to facilitate subsequent transporting of the removable walls 204, as discussed below. In one approach, shown in FIG.21, the outer rollers 532 are spaced such that lower portions of the removable walls 204 are received therebetween. In another approach, the outer rollers 532 are spaced such that lower portions of the removable walls 204 are received thereon. The upright support 504 may include one or more bumpers 542 for receiving and supporting removable walls 204. The upright support 504 may be an inclined support that is secured to, and extends from, the base platform 502 such that the upright support 504 forms an oblique angle with the base platform 502, as indicated at 544 in FIG.20. The oblique angle 544 may be, for example, approximately 15 degrees off vertical. In this way, removable walls 204 deposited on the rack 500 and rested against the bumpers 542 in an angled orientation. Referring to FIG. 22, the outer rollers 532 facilitate transportation of the removable walls 204 away from the rack 500, such as to a shipping container 200. For example, a removable wall 204' may be lifted and laterally shifted such that a lower edge of the removable wall 204' rests on an outer roller 532'. With the lower edge of the removable wall 204' on the outer roller 532', an operator may continue to laterally shift the removable wall 204', thereby causing the removable wall 204' to rotate the outer roller 532'. The removable wall 204' may be laterally shifted until it is fully removed from the rack 500 and received within the shipping container 200. The process may be repeated for each removable wall 204 that is supported on the rack 500. When a desired number of removable walls 204 are loaded on shipping container 200, the shipping container 200 may be moved away from the rack 500, or the rack 500 may be moved away from the shipping container 200. While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation. Various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.

Claims

WHAT IS CLAIMED IS: 1. A tool for handling removable walls of a container, the tool comprising: a base frame having wheels connected thereto; a forward support rail extending away from the base frame at an oblique angle; and a lift frame pivotably connected to an upper portion of the forward support rail, the lift frame including an engagement protuberance that moves with the lift frame relative to the forward support rail.

2. The tool of claim 1 wherein the engagement protuberance is disposed at a forwardmost end of the lift frame proximate the forward support rail.

3. The tool of claim 1 wherein at least a portion of the engagement protuberance extends orthogonally from the lift frame.

4. The tool of claim 1 wherein the engagement protuberance is a first engagement protuberance, and wherein the lift frame includes a second engagement protuberance that moves with the lift frame relative to the forward support rail.

5. The tool of claim 4 wherein the first and second engagement protuberances are aligned along an axis parallel to a pivot axis of the lift frame.

6. The tool of claim 1 wherein the lift frame includes a handlebar that extends along a direction parallel to an axis of rotation of the lift frame.

7. The tool of claim 1, further comprising a rear support rail that extends between the base frame and the forward support rail.

8. The tool of claim 7 wherein the base frame, the forward support rail, and the rear support rail generally define a fixed A-frame structure, and wherein the lift frame is pivotable relative to the fixed A-frame structure.

9. The tool of claim 7 wherein the rear support rail includes a stop member configured to limit rotation of the lift frame in a lifting direction when the lift frame engages the stop member.

10. The tool of claim 9 wherein the stop member is adjustable relative to the rear support rail.

11. The tool of claim 1, further comprising a lower support lip disposed proximate a lower region of the forward support rail.

12. The tool of claim 11 wherein the lower support lip includes an inclined surface for supporting a removable wall.

13. The tool of claim 1, further comprising at least one generally planar bumper disposed proximate a forward region of the base frame.

14. The tool of claim 1 wherein the oblique angle is in a range of approximately 75 degrees to approximately 85 degrees.

15. The tool of claim 1 wherein the lift frame includes opposing side lift rails, and wherein at least one of the side lift rails includes a first rail segment that extends obliquely from a second rail segment.

16. The tool of claim 15 wherein the first and second rail segments form an angle of approximately 120 degrees to approximately 150 degrees therebetween.

17. A method of reconfiguring a shipping container having a base and a wall removably connected to the base, the method comprising: releasing a locking mechanism such that the wall is pivotable relative to the base; pivoting the wall outwardly such that the wall is disposed at an oblique angle relative to the base; engaging the wall with a movable tool that includes a base, a forward support frame that extends from the base, and a lift frame that is pivotably connected to the forward support frame and that includes an engagement protuberance, wherein engaging the wall includes engaging a groove of the wall with the engagement protuberance; and pivoting the lift frame relative to the forward support frame to lift the wall away from the base.

18. The method of claim 17 wherein pivoting the lift frame lifts the wall a distance of 15 millimeters to 25 millimeters.

19. The method of claim 17 wherein the wall is a first wall, the method further including: releasing a second locking mechanism such that a second wall is pivotable relative to the base; pivoting the second wall outwardly such that the second wall is disposed at an oblique angle relative to the base; engaging a groove of the second wall with the engagement protuberance; and pivoting the lift frame relative to the forward support frame to lift the second wall away from the base.

20. A tool for handling removable walls tilted upward and outward from a container base at an oblique angle, the tool comprising: a carriage having a front and a rear; a front support extending upward and rearward from the front of the carriage at an oblique angle; and a lifter pivotably mounted on an upper portion of the front support, the lifter having a limited range of motion being capable of engaging a container wall and lifting the container wall to facilitate removal of the container wall from a container base; the tool further being capable of supporting the wall in stable equilibrium for transport, with the both the lifter and the front support engaging and supporting the wall at an oblique angle.

21. The tool of claim 20 wherein the lifter is capable of applying a lifting force to the container wall in response to a manually applied force, and wherein the magnitude of the lifting force is greater than the manually applied force.

22. A method of removing a wall from a shipping container having a base resting on a floor, and a wall removably connected to the base, the wall extending upward and outward from the base at an oblique angle, the method comprising: placing a movable tool on the floor in contact with the wall; the movable tool comprising a carriage facilitating movement of the tool on the floor, and a lever supported on the carriage; lifting the wall by manually applying a downward force to the lever of the movable tool with the movable tool supporting the weight of the wall; and moving the tool laterally away from the shipping container to transport the wall away from the base with the tool supporting the weight of the wall.

23. The method of claim 22 wherein the lever includes a wall engagement end and a handle end, and wherein lifting the wall comprises pivoting the lever about a fulcrum that is closer to the wall engagement end than the handle end.

24. The method of claim 22 wherein the carriage includes a front rail that is positioned forward of the lever to engage a portion of the wall to maintain the wall in an inclined position while it is supported by the tool.

25. A method of removing a wall from a shipping container having a base resting on a floor, and a wall removably connected to the base, the wall extending upward and outward from the base at an oblique angle, the method comprising: placing a movable tool on the floor in contact with the wall; the movable tool comprising a carriage facilitating movement of the tool on the floor, and a lifter supported on the carriage, the lifter having a front portion engaging the wall; using the lifter to elevate the wall; and using the carriage to move the tool laterally away from the shipping container to transport the wall away from the base with the tool supporting the weight of the wall, and with a front rail of the carriage below and forward of the lifter engaging the wall to maintain the wall in an inclined position, leaning rearward relative to the tool.

26. A method of handling a wall of a shipping container having a base resting on a floor, and a wall removably connected to the base, the wall extending upward and outward from the base at an oblique angle, the method comprising: placing a movable tool on the floor in contact with the wall; the movable tool comprising a carriage facilitating movement of the tool on the floor, and a lifter supported on the carriage, the lifter having a front portion engaging the wall; using the lifter to elevate the wall; and using the carriage to move the tool laterally away from the shipping container to transport the wall away from the base with the tool supporting the weight of the wall, and with a front rail of the carriage below and forward of the lifter engaging the wall to maintain the wall in an inclined position, leaning rearward relative to the tool; using the carriage to position the tool and wall in proximity to a storage rack; unloading the tool by lowering the wall onto a support surface of the storage rack so that it is no longer supported by the tool; and moving the tool away from the storage rack.

27. A system for handling walls of a shipping container comprising a movable tool and a storage rack, wherein the tool is capable of lifting a container wall from a container base, transporting it to the storage rack, and placing the wall on the storage rack, and wherein the storage rack has a bifurcated base defining an interior region capable of receiving at least a portion of the movable tool to facilitate cooperation between the tool and the storage rack.