CONTAINER ASSEMBLY

TECHNICAL FIELD

The present invention relates to a container assembly, an intermodal container insulating assembly and a refrigerated shipping container.

BACKGROUND

Intermodal containers, in particular shipping containers, may include insulation to insulate an interior of the container.

SUMMARY

According to a first aspect of the present invention, there is provided a container assembly comprising: an intermodal container; and an insulating structure comprising an aerogel, wherein the insulating structure is removably secured to an interior of the intermodal container, and wherein the insulating structure comprises an interior for receiving goods.

In some container assemblies, for example refrigerated containers, insulation is permanently attached to the interior of the container. Due to the structure of the container assemblies, the insulation may also be needed to provide structural rigidity to the container assemblies. As such, when the thermal efficiency of the insulation decreases beyond a desired level (through, for example, degradation of the insulation), the entire container assembly will need to be replaced. The present invention provides an insulating structure that is removable from the internal volume of an intermodal container, such that the insulating structure may be removed for servicing or repair, or may be removed when insulation is not required. This may help to increase the lifespan of the insulating structure as the insulating structure may be inserted into a new intermodal container when the old one is worn-out. The worn-out intermodal container may then be recycled while the insulating structure re-used. The use of an aerogel to provide insulation may also allow the insulating material to be thinner than when the insulating material is polyurethane (PU). This may increase the overall useable internal volume that may be used to store goods. As such, fewer containers may be needed to store and transport the same number of goods, which may help to reduce the environmental impact of the transport of the goods. As aerogel does not degrade over time in the same way as PU, the aerogel may have a longer lifespan and may need to be replaced less often than other insulation materials. As degradation of the aerogel is reduced as compared to PU, this may also reduce the power required for a refrigeration unit to keep the interior of the insulating structure cool. This may reduce the load on the refrigeration unit and may also reduce the environmental impact of cooling the interior of the insulating structure. Optionally, the aerogel comprises an Oryza aerogel or a Spacetherm aerogel

Optionally, the insulating structure comprises a plurality of layers and at least one of the layers may comprise the aerogel. This may allow the aerogel to be covered by another layer of material, which may help to protect the aerogel. Optionally, multiple layers of the plurality of layers comprise the aerogel. This may provide increased insulation over the use of a single layer of aerogel. Optionally, at least one layer of the plurality of layers is the aerogel.

Optionally, the insulating structure comprises a polymer blown plastic, stainless steel, or other alloy or composite material. Optionally, the insulating structure comprises two layers of steel, such as stainless steel, and the aerogel is disposed between the two layers of steel. The steel layers may help to protect the aerogel from damage and may provide further structural rigidity to the insulating structure. Moreover, the steel layers may prevent or restrict UV light from reaching the aerogel, which may otherwise damage the aerogel.

Optionally, the insulating structure is substantially free of polyurethane, such as polyurethane foam. This may increase the lifetime of the insulating structure as compared to using polyurethane, as polyurethane degrades over time. For example, bubbles in polyurethane foam may pop over time, which may decrease the efficiency of the polyurethane foam. Avoiding the use of polyurethane may help to overcome this problem. Optionally, the insulating structure comprises the aerogel and polyurethane. This may provide improved insulation over using polyurethane alone. Optionally, a first of the plurality of layers comprises the aerogel and a second of the plurality of layers comprises polyurethane. Optionally, the first of the plurality of layers is the aerogel and the second of the plurality of layers is polyurethane.

Optionally, the insulating structure comprises an inner surface defining the interior of the insulating structure, and the inner surface comprises a groove to direct a fluid flow through the interior. The groove directs a fluid flow, such as an airflow, along the surface and through the interior. This may help to improve the thermal efficiency of the container assembly. In some examples, the groove may direct a flow of water (which may be a result of condensation in the interior) along the surface and out of the interior. This may improve the sanitation of the container assembly. Optionally, the inner surface comprises a plurality of grooves.

Optionally, the insulating structure substantially fills the interior of the intermodal container. Substantially filling the interior of the intermodal container may increase the rigidity of the container assembly and may help to reduce twisting (otherwise known as racking) of the intermodal container. In some examples, the insulating structure fills at least 40% of the interior of the intermodal container. In some examples, the insulating structure fills at least 60% of the interior of the intermodal container. In some examples, the insulating structure fills at least 80% of the interior of the intermodal container.

Optionally, the insulating structure comprises a ceiling portion, a floor portion and at least two opposing side wall portions, wherein a thickness of the roof portion is different to a thickness of the floor portion and/or the side wall portions. This may allow the thickness of the insulating structure to be tailored. For example, a thicker section of the insulating structure may be required at the floor portion to allow for goods to be stored on the floor portion. Optionally, the aerogel has a thickness of around 10 mm to 20 mm. Optionally, the insulating structure has a thickness of around 60 mm to 100 mm.

Optionally, the ceiling portion, the floor portion and the two side wall portions each comprise a plurality of smaller panels which, when combined together, form the ceiling portion, the floor portion and the two side wall portions. This may allow the portions of the insulating structure to be more easily interchangeable between containers of different sizes. For example, when located within a 40 ft container, the ceiling portion may comprise four equally sized panels which together form the ceiling portion, whereas the ceiling portion may comprise two of the same equally sized panels when located in a 20 ft container. Optionally, the ceiling portion, the floor portion and the two side wall portions each comprise a single panel. This may simplify the insulating structure by reducing the total number of parts compared to the ceiling portion, the floor portion and the two side wall portions each comprising multiple panels.

Optionally, the insulating structure comprises a support assembly to support the ceiling portion. The support assembly comprises a locking bar which extends from a first edge of the ceiling portion to a second opposing edge of the ceiling portion. The support assembly may help to hold the ceiling portion in place and may provide additional structural rigidity to the insulating structure.

Optionally, the intermodal container comprises a recessed floor to accommodate the floor portion of the insulating structure. This may help to avoid the insulating structure interfering with loading and unloading of the intermodal container.

Optionally, the insulating structure is removably secured to the intermodal container by a securing arrangement comprising a securing member which extends through a hole in the insulating structure and is received by an engagement portion of the intermodal container. The hole in the insulating structure may be a hole in one of the plurality of layers. The securing member may comprise a first end portion which is shaped to engage with the insulating structure when the securing member passes through the hole in the insulating structure, and a second end portion (the second end portion opposite the first end portion) which is shaped so as to allow the second end portion to pass into the engagement portion when the securing member is in a first orientation, and to restrict passage of the second end portion into and out of the engagement portion when the securing member is in a second orientation. To secure the insulating structure to the intermodal container, the securing member, while in the first orientation, may pass through the hole in the insulating structure such that the first end portion engages with the insulating structure and the second end portion is received by the engagement portion. The securing member may then be switched to the second orientation, which restricts movement of the securing member out of the engagement portion, and secures the insulating structure to the intermodal container. To remove the securing member, the securing member may be switched to the first orientation, which may allow the second end portion of the securing member to be removed from the engagement portion, and the securing member may then be removed. This may allow the securing member to be removed from the insulating structure, without causing structural damage to the insulating structure, to allow the insulating structure to be removed from the intermodal container.

Optionally, the intermodal container comprises a refrigeration unit. The refrigeration unit may be configured to provide cooling to the interior of the insulating structure. Optionally, the refrigeration unit is disposed within the insulating structure. This may allow the refrigeration unit to be easily removed from the intermodal container along with the insulating structure.

Optionally, the intermodal container is a shipping container. Optionally, the intermodal container is a refrigerated shipping container. Optionally, the intermodal container is a container complying with ISO 668 and ISO 1496-2 requirements.

According to a second aspect of the present invention, there is provided an intermodal container insulating assembly comprising: a plurality of walls defining an internal volume, the plurality of walls comprising an insulating material; a securing arrangement for removably securing the insulating assembly to an interior of an intermodal container; and a connector to connect to a refrigeration unit such that the internal volume is in fluid communication with the refrigeration unit.

By providing an insulating assembly that is separate to the intermodal container and removably securable to the container, the insulating assembly may be retrofitted into existing containers. Moreover, the insulating assembly can be removed to be replaced and/or serviced without also having to dispose of the intermodal container, which may help to reduced waste. The connection of the refrigeration unit may allow cooled air from the refrigeration unit to be passed into the internal volume of the intermodal container insulating assembly, so as to cool the internal volume of the intermodal container insulating assembly.

Optionally, the insulating assembly is configured to fill between about 40% and 95% of the interior of the intermodal container when secured to the interior of the intermodal container. Optionally, the insulating assembly is configured to fill between about 60% and 90% of the interior of the intermodal container when secured to the interior of the intermodal container. Optionally, the insulating assembly is configured to fill between about 70% and 85% of the interior of the intermodal container when secured to the interior of the intermodal container. This may help to provide structural rigidity to the intermodal container.

Optionally, the insulating material comprises an aerogel. An aerogel may provide increased thermal efficiency over other insulating materials, such as polyurethane. Moreover, a thinner layer of aerogel may be used as compared to polyurethane, which may increase the internal usable capacity of the intermodal container.

Optionally, each of the plurality of walls comprises a plurality of layers and at least one of the layers comprises the aerogel. This may allow the aerogel to be sandwiched between other layers of material, which may help to protect the aerogel. Optionally, multiple layers of the plurality of layers may comprise the aerogel. This may provide increased insulation over the use of a single layer of aerogel. Optionally, at least one layer of the plurality of layers is the aerogel.

Optionally, an inner surface of the plurality of walls comprises a groove to direct a fluid flow through the internal volume. The groove directs a fluid flow, such as an airflow, along the surface and through the internal volume. This may help to improve the thermal efficiency of the container assembly. In some examples, the groove may direct a flow of water (which may be a result of condensation in the internal volume) along the surface and out of the interior. This may improve the sanitation of the intermodal container insulating assembly. Optionally, the inner surface comprises a plurality of grooves.

Optionally, the plurality of walls have different thicknesses. This may allow the plurality of walls to have different characteristics depending on their respective thicknesses. For example, a thicker wall may allow goods to be stored on said wall.

Optionally, the intermodal container insulating assembly has a length of between around 5 m to 12 m, a width of between around 1.8 m to 2.5 m and a height of between around 2 m and 3 m.

According to a third aspect of the present invention there is provided an intermodal container comprising insulation removably attached to an interior of the intermodal container, wherein the insulation comprises an aerogel.

The use of an aerogel may provide improved thermal efficiency over other insulation materials (such as polyurethane). Moreover, a smaller amount of aerogel may be required compared to polyurethane, which may result in an increased internal capacity of the intermodal container. As the insulation is removably attached to the interior of the intermodal container, the insulation may be removed with causing structural damage to the insulation, to allow the insulation to be replaced. Optionally, the intermodal container comprises a refrigerated shipping container.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a schematic side view of a container ship;

FIG. 2 shows a schematic isometric view of a shipping container;

FIG. 3 shows an exploded schematic view of the shipping container and an insulating structure;

FIG. 4 shows a schematic cross-sectional view of a floor of the shipping container;

FIG. 5 shows a schematic cross-sectional view of a part of the insulating structure;

FIG. 6 shows a schematic cross-sectional view of a surface of the insulating structure;

FIG. 7 shows a schematic cross-sectional view of the shipping container and the insulating structure;

FIG. 8 shows a schematic cross-sectional side view of the shipping container of FIG. 3;

FIGS. 9 and 10 show schematic cross-sectional views of example securing arrangements; and

FIG. 11 shows a schematic cross-sectional view of a further shipping container.

DETAILED DESCRIPTION

FIG. 1 shows a schematic side view of a marine vessel in the form of a container ship 1. A plurality of shipping containers 2 are stacked above a deck of the container ship 1. A bridge 3 is located on the container ship 1 from which operation of the container ship 1 may be controlled. The bridge 3 includes displays for displaying various details about the container ship 1 and/or the containers 2 along with inputs for controlling the container ship 1 and/or the containers 2.

FIGS. 2 to 11 show schematic views of the shipping container 2, and an insulating structure 10 located within the shipping container 2, in more detail.

A container assembly 100 comprising the shipping container 2 and the insulating structure 10 is shown in an exploded schematic view in FIG. 3. The shipping container 2 is a dry-cargo shipping container which complies with ISO 668 and ISO 1496-2 requirements. The container 2 has a length of around 40 ft (12.2 m), a width of around 8 ft (2.4 m) and a height around of 9 ft 6 in (2.9 m). The container 2 comprises a pair of doors 4, first and second pairs of hinges 5, a pair of door bars 7 and a lock 6. The doors 4 are generally planar in form and are attached to the container 2 by a respective one of the pairs of hinges 5. The door bars 7 and the lock 6 act to secure the doors 4 in a closed position. The shipping container also comprises a roof 101, a floor 102, two side walls 103 and an end wall 104 which, together with the doors 4, define an interior of the shipping container 2.

The floor 102 of the container 2 comprises a plurality of channels 42 extending in a direction substantially parallel to a longitudinal axis of the container 2 (i.e. in a direction parallel to a longest edge of the container 2), with the plurality of channels 42 illustrated in the schematic cross-sectional view of FIG. 4. The floor 102 comprises a plurality of platforms 41 between which the channels 42 are located. The channels 42 have a partially circular cross-sectional shape. The channels 42 allow a flow of air (or other fluid flow) to pass around the insulating structure and towards the doors 4 of the container 2. A section of the floor 102 of the container 2 is recessed to accommodate the insulating structure 10 (as shown in FIG. 8).

Each of the side walls 103 of the container 2 comprises an engagement portion 23 which is configured to receive an end of a securing member 20 passing through a portion of the insulating structure 10, as discussed later with reference to FIG. 9.

The roof 101 of the container 2 comprises a pin 25 which extends into the interior of the container 2. The pin 25 is configured to engage with the insulating structure 10, as discussed later with reference to FIG. 10.

The insulating structure 10 comprises a ceiling portion 11, a floor portion 12, an end wall portion 52, two door portions 53 and two side wall portions 13. Goods are received within an interior 14 of the insulating structure 10 and the insulating structure 10 insulates the interior 14 from an external environment.

The ceiling portion 11, the floor portion 12, the two side wall portions 13, the end wall portion 52 and the door portion 53 (also referred to as “the portions”) of the insulating structure 10 each comprise three layers 15, 16, 17, which are each around 20 mm thick. The structure of the layers 15, 16, 17 is shown schematically in FIG. 5. An aerogel layer 16 is located between two steel layers 15, 17. The steel layers 15, 17 comprise stainless steel and the aerogel layer 16 comprises an Oryza aerogel.

The insulating structure 10 is free of any blown polyurethane foam. Aerogel typically has a thermal efficiency of around 9 to 48 W/K, as compared to polyurethane foam which has a thermal efficiency of around 42 W/K. As such, a layer of aerogel may be much thinner than a layer of polyurethane providing an equivalent level of insulation. In FIG. 5, the layer 16 of aerogel is around 20 mm thick. To provide an equivalent level of insulation with a layer of blown polyurethane foam would require the layer of blown polyurethane to be around 70 mm thick. Therefore, the portions of the insulating structure 10 may be thinner, and take up less of the interior of the container 2, when aerogel is used compared to blown polyurethane.

As aerogels have a much longer lifespan than polyurethane foam, the insulating structure 10 may need to be replaced less often than if polyurethane foam was used. Moreover, as degradation over time of the aerogel is much lower than polyurethane foam, this may also reduce the power required for a refrigeration unit 50 (shown in FIG. 8) to keep the interior of the insulating structure 10 cool. This may reduce the load on the refrigeration unit 50 and may also reduce the environmental impact of cooling the interior 14 of the insulating structure 10.

An inner surface 54 of the ceiling portion 11 of the insulating structure 10 (i.e. the part of the ceiling portion facing the interior 14 of the insulating structure 10) is shown schematically in FIG. 6, and comprises grooves 57 to direct a flow of air from the refrigeration unit 50 through the interior 14 of the insulating structure 10. The inner surface 54 comprises a series of peaks 55 and troughs 56 which form the grooves 57 in the inner surface 54. The profile of the inner surface 54 is such that air flowing along the inner surface 54 is directed towards the doors 4 of the container 2.

The end wall portion 52 comprises a connector 51 to connect the refrigeration unit 50 to the interior 14 of the insulating structure 10. The connector 51 comprises a tube which extends through the end wall portion 52, is open at a first end to the interior 14 of the insulating structure 10, and is connectable at a second end, opposite the first end, to the refrigeration unit 50.

Each of the side wall portions 13 comprise a hole 21 which extends through the respective side wall portion 13. The holes 21 are configured to receive a part of the securing member 20 to secure the side wall portions 13 to the container 2, as discussed later with reference to FIG. 9.

The ceiling portion 11 comprises an engagement portion 27 which is configured to engage with the pin 25 of the roof 101 to secure the ceiling portion 11 to the container 2, as discussed later with reference to FIG. 10.

The floor portion 12 is thicker than the ceiling portion 11 and the two side wall portions 13, and the ceiling portion 11 is thinner than the two side wall portions 13 and the floor portion 12. A support member 18 extends along the ceiling portion 11 between the two side wall portions 13, to support the ceiling portion 11 when installed within the container 2.

The portions of the insulating structure 10 are provided as separate components, which are then individually inserted into the interior of the container 2 to form the insulating structure 10 within the container 2. In use, each of the portions of the insulating structure 10 are inserted into the interior of the shipping container 2 through the doors 4 of the container 2. FIGS. 7 and 8 show schematic cross-sectional views of the container 2 when the insulating structure 10 is located within the container 2. When located within the container 2, the insulating structure 10 substantially fills the container 2. The floor portion 12 abuts against the floor 102 of the container 2, the ceiling portion 11 abuts against the roof 101 of the container 2, and the two side wall portions 13 abut against the opposing side walls 103 of the container 2. The door portions 53 are attached to respective doors 4 of the shipping container 2. The ceiling portion 11, the floor portion 12, the side wall portions 13, the end wall portion 52 and the door portion 53 abut against each other to define the interior 14 of the insulating structure 10.

The refrigeration unit 50 is located at an end of the shipping container 2, opposite the doors 4 of the shipping container 2, between the end wall 104 and the end wall portion 52. The refrigeration unit 50 is fluidically connected to the interior 14 of the insulating structure 10 via the connector 51. In use, the refrigeration unit 50 provides a cooled airflow to the interior 14 of the insulating structure 10 via the connector 51. This cooled airflow is used to control the temperature within the insulating structure 10 so that it remains below a predetermined value. The predetermined value may vary depending on the good being stored and/or transported in the container 2.

When located within the insulating structure 10, the portions are removably secured to the shipping container 2 using securing members 20, as shown in more detail in FIGS. 9 and 10. As the insulating structure 10 is removably secured to the shipping container 2, this may allow the insulating structure 10 to be removed for servicing or repair, or to be removed when insulation is not required. This may help to increase the lifespan of the insulating structure 10 as the insulating structure 10 may be inserted into a new shipping container 2 when the old one is worn-out. The worn-out container may then be recycled while the insulating structure 10 is re-used.

The securing member 20 shown in FIG. 9 extends through the hole 21 in the side wall portion 13 of the insulating structure 10. The securing member 20 has a barbed end 22 which passes through the hole 21 and engages with the engagement portion 23 of the side wall 103 of the container 2. When in a first orientation relative to the engagement portion 23, the securing member 20 can move freely into and out of the engagement potion 23. When the barbed end 22 engages with the engagement portion 23, the securing member 20 is rotated to a second orientation relative to the engagement portion 23. In the second orientation, the barbed portion is retained within the engagement portion 23 and is prevented from being removed from the engagement portion 23. The securing member 20 also comprises an end cap 24 which has a diameter larger than a diameter of the hole 21. As such, the end cap 24 of the securing member 20 prevented from passing through the hole 21. Therefore, once the barbed end 22 is received by the engagement portion 23, and the securing member 20 is rotated to the second orientation, the side wall portion 13 is held in place relative to the side wall 103. To enable the side wall portion 13 of the insulating structure 10 to be removed from the side wall 103, the securing member 20 is rotated back to the first orientation, to allow the securing member 20 to be removed from the engagement portion 23.

A further securing member 20 for securing the ceiling portion 11 to the roof 101 of the container 2 is shown in FIG. 10. The securing member 20 comprises the pin 25 which extends from the roof 101 of the container 2. The pin 25 comprises an end portion 26 which is received by the engagement portion 27 of the ceiling portion 11. Once the end portion 26 is received by the engagement portion 27, the engagement portion 27 can be rotated from a first orientation relative to the roof 101 to a second orientation relative to the roof 101, such that the engagement portion 27 engages with the end portion 26 to prevent removal of the end portion 26 from the engagement portion 27. To remove the ceiling portion 11 from the roof 101 of the container 2, the engagement portion 27 is rotated from the second orientation back to the first orientation, which releases the end portion 26 of the pin 25 and allows the ceiling portion 11 to be removed without causing structural damage to the ceiling portion 11 or the container 2.

FIG. 11 shows an alternative example of a shipping container 2 comprising the insulated structure 10. In the example of FIG. 11, the ceiling portion 11, floor portion 12 and wall portions 13 of the insulated structure 10 are not secured to the container 2 using the securing members 20 discussed above but are instead held in place relative to the container 2 by brackets 31 provided between adjacent portions of the insulating structure 10. The brackets 31 have a substantially arcuate shape and are provided in corners of the interior 14 of the insulating structure, between the ceiling portion 11 and the two side wall portions 13, and between the floor portion 12 and the two side wall portions 13. The brackets 31 are removably secured to the respective insulating structure 10 portions, to allow the brackets 31 to be removed without causing structural damage to the insulating structure 10. Each bracket 31 is secured on a first side to one of the ceiling portion 11 or the floor portion 12 and a second side to a respective one of the side wall portions 13. The brackets 31 allow the insulating structure 10 to have structural rigidity, without requiring the portions of the insulating structure 10 to be directly secured to the container 2. As such, any forces which the container 2 may be subject to (e.g. such as racking/twisting of the container 10) will not immediately affect the insulating structure 10. This may protect the insulating structure 10 from being damaged by forces applied to the container 2.

Although in the above-described examples, the portions of the insulating structure 10 are assembled within the container 2, in some examples the portions of the insulating structure 10 are constructed into the insulating structure 10 external to the container 2 (i.e. before being inserted into the container 2). The entire insulating structure 10 may then slide into the container 2 and be secured to the container 2, which may allow the entire insulating structure 10 to be easily inserted and removed from the container 2.

Example embodiments of the present invention have been discussed, with particular reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made without departing from the scope of the invention as defined by the appended claims. Although the above is discussed in relation to a shipping container, in other examples the container is another type of intermodal container, such as a freight container.

	Number	Date	Country
Parent	PCT/DK2023/050205	Aug 2023	WO
Child	19053057		US

CONTAINER ASSEMBLY

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Abstract

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CROSS-REFERENCE TO RELATED APPLICATIONS

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