1. The Technical Field
The present invention is directed generally to collapsible containers and more particularly to collapsible shipping and storage containers and methods of using same.
2. The Prior Art
Known shipping and storage containers typically have fixed dimensions and occupy the same physical volume whether full or empty. Although this shortcoming is tolerable when the containers are in use, it adversely affects the cost of storing or transporting the containers when empty. Prior attempts to reduce the volume of an unused container typically involve dismantling the container by removing the sides, ends, and top, and stacking these pieces on the bottom. Such dismantling is labor intensive and time consuming, requires substantial rigging, and yields a number of easily lost and essential loose parts, e.g., the fasteners used in assembling the sides, ends, top, and bottom of the container. As such, there is a need for containers that are sufficiently robust to handle the rigors of shipping and storing voluminous and/or heavy cargo but can be easily and quickly broken down to a self-contained, compact form for storage or transport when empty.
Front end 22 typically is configured to provide access to the interior of container 10. Preferably, container 10 includes overhead door 26 that can be moved between a first, deployed position wherein door 26 closes an opening defined by front end 22 of container 10 and a second, retracted position wherein door 26 nests with or within roof 12, as will be described further below. In preferred embodiments, door 26 is made from roll-formed metal sheeting as would be used to make a conventional metal roll-up door. Such doors are commonly used on the rear of delivery trucks and in connection with concession service windows at sports stadiums. In alternate embodiments, door 26 can be a conventional single- or multi-panel overhead door (not shown) that may or may not include a swinging service door (not shown), as would be known to one skilled in the art. In other alternate embodiments, door 26 can retract into floor 12. Front end 22 and door 26 can be embodied in other forms as well, as would be apparent to one skilled in the art. Means (not shown), such as an integral locking mechanism or hasp for receiving a padlock, can be provided for securing door 26 in a “closed” position to preclude unauthorized access to the interior of container 10.
Floor frame 32 typically includes a perimeter rim defining the sides and ends of floor frame 32. In the illustrated embodiment, the perimeter rim is defined by side rails 44 and joists 46 spanning the ends of side rails 44 crosswise. Additional joists 46 are shown spanning side rails 44 intermediate the ends of side rails 44. In other embodiments, joists 46 can span a pair of end rails lengthwise. Stiffeners, braces, and the like (not shown) can be provided to strengthen floor frame 32, as would be known to one skilled in the art. Decking 28 is installed on floor frame 32 to provide a loadable floor inside container 10. Decking 28 typically is made of a suitable grade and thickness of plywood, but decking 28 could be made of other materials, as well, as would be known to one skilled in the art.
Roof frame 34 typically includes perimeter rim 48 defining the sides and ends of roof frame 34 and rafters 50 spanning and connected to perimeter rim 48. Roof frame 34 also can include stiffeners or braces 52 and/or other structural members connected to one or more of perimeter rim 48, rafters 50, and/or other structural members to provide strength to roof frame 34, as would be known to one skilled in the art. Preferably, roof frame 34 also includes a second perimeter rim 48A parallel to and offset from perimeter rim 48 by means of short columns 49. See
In preferred embodiments, roof frame 34 includes overhead door tracks 54 which receive the side edge portions of door 26 when door 26 is located in and moved to and from the retracted position. See
Each of upper side wall frames 36U,38U preferably includes a perimeter rim 58U defining the top, bottom, and ends of the respective upper side wall frame. Typically, perimeter rim 58U includes a bottom member 60U, a top member 62U, and a pair of columns 64U spanning the ends of the bottom and top members. Additional columns 64U may be provided intermediate the columns 64U spanning the ends of bottom member 60U and top member 62U, as shown in
Upper side wall frames 36U,38U are hinged to roof frame 34 so that upper side wall frames 36U,38U can be folded inwardly and substantially flatly against the bottom of roof frame 34 when container 10 is in the collapsed state and unfolded such that upper side wall frames 36U,38U are substantially perpendicular to roof frame 34 when container 10 is in the deployed state. In the preferred embodiment, one or more conventional hinges 66 are used to connect upper side wall frames 36U,38U to roof frame 34. Alternative embodiments can use any other suitable hinge mechanism, as would be known to one skilled in the art.
Similarly, each of lower side wall frames 36L,38L preferably includes a perimeter rim 58L defining the top, bottom, and ends of the respective lower side wall frame. Typically, perimeter rim 58L includes a bottom member 60L, a top member 62L, and a pair of columns 64L spanning the ends of the bottom and top members. Additional columns 64L may be provided intermediate the columns 64L spanning the ends of bottom member 60L and top member 62L, as shown in
Lower side wall frames 36L,38L are hinged to floor frame 32 so that lower side frames 36L,38L can be folded inwardly and substantially flatly against the top of floor frame 32 when container 10 is in the collapsed state and unfolded such that lower side wall frames 36L,38L are substantially perpendicular to floor frame 32 when container 10 is in the deployed state. In the preferred embodiment, one or more conventional hinges 68 are used to connect lower side wall frames 36L,38L to floor frame 32. Alternative embodiments can use any other suitable hinge mechanism, as would be known to one skilled in the art.
Upper side wall frames 36U,38U are hinged to corresponding lower side wall frames 36L,38L so that upper side wall frames 36U,38U can be folded substantially flatly against corresponding lower side wall frames 36L,38L when container 10 is in the collapsed state. When container 10 in the deployed state, upper side wall frames 36U,38U and lower side wall frames 36L,38L are substantially coextensive such that each pair of corresponding upper side wall frames 36U,38U and lower side wall frames 36L,38L defines a substantially planar side wall 16,18. In the preferred embodiment, one or more conventional hinges 70 are used to connect upper side wall frames 36U,38U to lower side wall frames 36L,38L. Alternative embodiments can use any other suitable hinge mechanism, as would be known to one skilled in the art.
Rear wall frame 40 includes a perimeter rim 86 that defines the top, bottom, and sides of rear wall frame 40. Perimeter rim 86 includes a bottom member 88, a top member 90, and a pair of columns 92 spanning the ends of bottom and top members, 88,90, respectively. Rear wall frame 40 can include additional columns (not shown) intermediate the columns 92 spanning the ends of bottom and top members, 88,90, a cross-member 94, and additional braces and/or stiffeners (not shown) for strength, as would be known to one skilled in the art.
Rear wall frame 40 preferably is hinged to floor frame 32 so that rear wall frame 40 can be folded inwardly and substantially flatly against the top of floor frame 32 when container 10 is in the collapsed state and unfolded so that rear frame 40 is substantially perpendicular to each of floor frame 32, roof frame 34, and side wall frames 36,38 when container 10 is in the deployed state. In the illustrated embodiment, hinge pins 72 are used to connect rear wall frame 40 to floor frame 32. Alternative embodiments can use any other suitable hinge mechanism, for example, conventional leaf-type hinges, as would be known to one skilled in the art.
Front end frame 42 includes a perimeter rim 96 that defines the top and sides of front end frame 42. Perimeter rim 96 includes top member 98 and a pair of columns 100 extending from top member 98. Front end frame 42 can further include one or more cross-members (not shown) and braces and/or stiffeners (not shown) for strength, as would be known to one skilled in the art. Any such additional members preferably are located so as to not impede access to the interior of, or create a trip hazard within or near the entry of, container 10.
Front end frame 42 preferably is hinged to floor frame 32 so that front end frame 42 can be folded inwardly and substantially flatly against the top of floor frame 32 when container 10 is in the collapsed state and unfolded so that front end frame 42 is substantially perpendicular to floor frame 32, roof frame 34, and side wall frames 36,38 when container 10 is in the deployed state. In the preferred embodiment, hinge pins 74 are used to connect the lower ends of columns 100 of front end frame 42 to floor frame 32. Alternative embodiments can use any other suitable hinge mechanism, as would be known to one skilled in the art. In preferred embodiments, front end frame 42 includes door tracks 76 (see
In preferred embodiments, stop plates 104 are provided at both ends of framework 30 in connection with roof frame 34 and the upper and lower portions of side wall frames 36,38 to prevent rotation of rear wall frame 40 and front end frame 42 more than about 90 degrees from the collapsed position against floor 12 so that rear wall frame 40 and front end frame 42 can be easily indexed to their respective deployed positions. In such embodiments, stop plates 104 preferably are connected to columns 64 defining the ends of the upper and lower portions of side wall frames 36,38 and the ends of perimeter rim 48 of roof frame 34. Gasket material (not shown), for example, conventional weatherstrip, can be provided in connection with stop plates 104 to provide a form of seal between roof frame 34, side wall frames 36,38, rear wall frame 40 and front end frame 42. Gasket material (not shown) also can be provided in connection with the joints between floor 12 and rear wall frame 40, floor 12 and lower side wall frames 36L,38L, lower side wall frames 36L,38L and upper side wall frames 36U,38U, and upper side wall frames 36U,38U and roof frame 34. Further, gasket material (not shown) can be provided at the bottom of door 26, adjacent the side of door 26 and door tracks 76, and along top member 98 of front end frame 42 to form a seal between door 26, floor 12, front end frame 42, and side walls 16,18 when door 26 is in the closed position.
In other embodiments, either or both of rear wall frame 40 and front end frame 42 can be completely detachable from floor frame 32, and hinge pins 72 and/or hinge pins 74 (or other, alternate hinge means) can be omitted. In such embodiments, rear wall frame 40 and front end frame 42 can be connected to floor frame 32, roof frame 34, and/or side wall frames 36,38 by threaded fasteners or other suitable means when container 10 is in the deployed state and stored against floor 12 when container 10 is in the collapsed state.
One or more lifting lugs 106 can be provided to facilitate deployment and collapsing of container 10 using a crane or other lifting mechanism (not shown). Such lifting lugs preferably would be attached to roof frame portion 34 using fasteners or welded connections but, alternatively, could be attached to other portions of framework 30 by any suitable means.
The detailed design of container 10 and framework 30 as illustrated in the drawings and discussed above is representative, but by no means limiting. One skilled in the art would recognize that that the detailed design for a particular collapsible container according to the present invention is a function of, among other factors, the size of and intended use for the container. One skilled in the art would know how to size and arrange the members (e.g., perimeter rims, joists, rafters, columns, stiffeners, braces, etc.) used to build the various frame portions, select appropriate materials (e.g., tube steel, angle iron, and steel channel) for such members, specify connection details (e.g., brackets, hinge mechanisms, etc.), and specify connection methods (i.e., bolting, welding, etc.).
With container 10 in the deployed state, as shown in
In preferred embodiments, as best shown in
Preferably, bolts 80 engage with captive nuts 82 associated with one aperture 78 of each of such corresponding pairs of apertures 78. Loose nuts (not shown) can be used in lieu of captive nuts 82, but captive nuts 82 are preferred because they are permanently affixed, for example, welded as bridge weld nuts, to framework 30 and thus do not contribute to the inventory of loose parts (including, e.g., certain bolts 80) that must be controlled when container 10 is in the collapsed state. Apertures 78 can be configured so that bolts 80 are inserted through members to be joined in their entirety. For example, as shown in
Although threaded fasteners are preferred for the foregoing mechanical connections, various other forms of fasteners, including quick release fasteners, can be used in lieu of threaded fasteners in certain embodiments, as would be known to one skilled in the art.
Preferred embodiments also include a coupling associated with pairs of corresponding columns 64U,64L of upper and lower side wall frames 36U,38U and 36L,38L, respectively, which helps to secure the upper and lower side wall frames 36,38 in the deployed position.
In preferred embodiments, coupling 84 includes a handle 85 that extends through slot 89 in column 64L. Preferably, handle 85 is a bolt threaded into and staked to a threaded aperture 87 in coupling 84 (or a bolt inserted through an unthreaded aperture in coupling 84 and threaded into and staked to a captive nut attached to coupling 84) so that handle 85 cannot be inadvertently removed from coupling 85. Slot 89 and handle 85 interact to define the extent to which coupling 84 can slide within columns 64L,64U.
In preferred embodiments, coupling 84 includes a number of apertures 91 and corresponding captive nuts 83, and columns 64U,64L include a number of apertures 78 that align with apertures 91 in coupling 84 when coupling 84 is in the deployed position. Coupling 84 can be secured in the deployed position by inserting bolts 80 through apertures 78 in columns 64U,64L and apertures 91 in coupling 84 and threading them into captive nuts 83. Preferably, columns 64U,64L also include a number of apertures 78 that align with apertures 91 in coupling 84 when coupling 84 is in the retracted position. Coupling 84 can be secured in the retracted position by inserting bolts 80 through such apertures 78 in columns 64U,64L and apertures 91 in coupling 84 and threading them into captive nuts 83. One skilled in the art would recognize that coupling 84 and the means for securing coupling 84 to columns 64U,64L could be modified in many ways. For example, apertures 91 in coupling 84 could be threaded and captive nuts 83 could be omitted. Apertures could provided to allow bolts 80 to extend through columns 64U,64L in their entirety and captive nuts could be provided with columns 64U,64L to secure bolts 80 thereto. Alternatively, coupling 84 could be external to columns 64U,64L.
With container 10 in the deployed state, door 26 can be readily moved between the retracted position, wherein door 26 nests within roof frame 34, and the deployed position wherein door 26 closes the opening defined by front end 22. Guide rollers 56 help door 26 transition between a substantially vertical orientation defined by door tracks 76 attached to front end frame 42 and a substantially horizontal orientation defined by door tracks 54 attached to roof frame 34.
Roof skin 24R preferably takes the form of a fiberglass shell overlying and connected to the exterior of roof frame 34, as shown in the drawings. Side wall skin 24SW and rear wall skin 24RW preferably take the form of rigid or semi-rigid panels, preferably made of high molecular weight polyethylene, the edges of which are received by channels 108 associated with the members comprising at least portions of side wall frames 36,38 and rear wall frame 40. Alternatively, skins 24R,24SW,24RW can be made of any suitable rigid, semi-rigid, or flexible material and attached to the inside or outside of the corresponding frame portion using any suitable means, for example, adhesives, rivets, threaded fasteners, etc.
Preferably, one or more portions of side wall perimeter rim 58 and rear wall perimeter rim 86 are removable to allow replacement of sections of side wall skin 24SW and rear wall skin 24RW should they become damaged. For example, upper side wall frame 36U preferably is configured so that top member 62 can be removed to allow replacement of corresponding side wall skin 24SW by sliding such skin in and out of channels 108. Preferably, top member 62 is attached to columns 64U using brackets (not shown) that are riveted to one of top member 62 and columns 64U and welded or otherwise attached to the other of top member 62 and columns 64U. Alternatively, such brackets can be riveted to both of top member 62 and columns 64U. Should side wall skin 24SW need replacement, such rivets (not shown) could be easily drilled out and replaced. Rear wall frame 40 and corresponding skin 24R can be similarly configured.
A preferred procedure for placing container 10 into the deployed state from the collapsed state involves attaching suitable rigging to lifting lugs 106 and a suitable lifting mechanism, for example, a crane or fork lift. The lifting mechanism then raises roof 14, causing upper and lower side walls 16U,18U,16L,18L to unfold from positions adjacent and substantially parallel to the bottom of roof 14 and top of floor 12, respectively, to form substantially planar and vertical walls 16,18. Couplings 84 are then moved from a retracted position within column 64L to a deployed position within both of columns 64L and 64U. Bolts 80 are inserted through apertures 91 in coupling 84 and apertures 78 in corresponding portions of columns 64L and 64U and secured to captive nuts 83. Rear wall frame 40 and front end frame 42 are then unfolded from positions adjacent and substantially parallel to the top of floor 12 to positions substantially perpendicular to each of floor 12, roof 14, and side walls 16,18. As discussed above, stop plates 104 prevent over-rotation of rear wall frame 40 and front end frame 40 and help to index rear wall frame 40 and front end frame 40 to the desired orientation relative to 12, roof 14, and side walls 16,18. Bolts 80 are inserted through corresponding pairs of apertures in the foregoing frame sections and fastened to captive nuts 82. The rigging can be safely removed once couplings 84 have been deployed and secured, but preferably remains in place until the previous step has been completed. If container 10 includes foldable guide roller brackets 57, such brackets are moved to the deployed position. Door 26 then can be moved between its open and closed positions, traveling over guide rollers 56.
A preferred procedure for collapsing container 10 essentially reverses the steps of the foregoing deployment procedure. That is, door 26 typically would be placed in the stored position within roof frame 34 and guide roller brackets 57, if foldable, then would be placed in the stored position. Next, bolts 80 would be removed from apertures 78, except those apertures 78 through which bolts 80 are secured to couplings 84. Next, rear wall frame 40 and front wall frame 42 would be folded against floor 12. Bolts 80 securing rear wall frame 40 and front wall frame 42 to side wall frames 36,38 and roof frame 34 could then be reinstalled in the apertures 78 from which they were removed and threaded into captive nuts 82 to reduce the risk of losing such bolts 80. Rigging would be installed before the next step, which involves loosening or removing bolts 80 securing couplings 84, as necessary, to allow couplings 84 to be moved to the retracted position within the corresponding columns 64L. Such bolts 80 then could be used to secure coupling 84 in the retracted position. Roof 14 then would be lowered by slackening the rigging connected to lifting lugs 106. It may be necessary to exert an inward force near hinges 70 joining upper and lower side wall frames 16U,16L and 18U,18L to initiate the folding of walls 16,18.
This disclosure illustrates and describes one or more particular embodiments preferred by the inventors. One skilled in the art would recognize that various modifications could be made to embodiment(s) disclosed herein without departing from the scope of the invention, which is limited only by the following claims.
This application claims priority from, and incorporates by reference the disclosure of, U.S. Provisional Patent Application No. 60/714,756, which was filed on Sep. 6, 2005.
Number | Date | Country | |
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60714756 | Sep 2005 | US |