STACKABLE FLAT-PACK SHIPPING CONTAINER WITH SEGMENTED ROOF

FIELD OF THE INVENTION

The present invention relates to shipping containers generally used to ship and store articles of freight. More particularly, the invention relates to a stackable storage container which may be transported in a flat-pack configuration.

BACKGROUND OF THE INVENTION

Rigid shipping containers are frequently used to ship and to store freight at warehouses, wharves, and similar locations. Such containers typically consist of rectangularly-shaped box-like structures which are constructed from rectangularly-shaped metal panels that are fastened together to form the container. These containers are generally 20-foot or 40-foot steel boxes, and are often referred to as intermodal containers, ISO containers, or Container Express (ConEx) boxes. Similar styles of container are often used for storage purposes.

Regardless of the specifications and dimensions, shipping containers are generally made from corrugated steel panels that are fastened together and welded together. Most containers comprise one or more doors which may be open on vertical axes to allow access to the interior space of the container-even when stacked.

It will be apparent that shipping containers of the type noted above are relatively bulky, and as such shipping empty containers is expensive. It would therefore be advantageous to have a shipping or storage container that could be shipped in a compact, collapsed, configuration that occupies significantly less volume than a fully assembled container.

Furthermore, roof panels are generally too large to pack with components of the container in the flat-packed configuration-especially when roof overhangs are taken into consideration. This is exacerbated by containers having widths greater than 7.7 feet, as these containers, in their flat-packed state, won't fit into ISO containers for shipping. ISO containers have standardized dimensions, and one such dimension is the external dimension of 8 feet in width, and having an internal dimension of only 7.7 feet. Items having a width and length greater than 7.7 ft. in each dimension cannot fit into an ISO container rectilinearly. Furthermore, shoebox style roofs, being superior to other styles of roofs for weather tightness, are generally made of a single unit, and certainly will not rectilinearly fit in an ISO container when the width of the roof is 10 ft, for example. The internal height dimension of an ISO container is 7.9 ft (8.9 ft. for a High Cube container), so this is a similar constraint, and would dictate that any portion of a flat-packed article greater than 7.7 ft and less than 8.9 ft must be loaded vertically for a High Cube container. For a standard ISO container, any portion of a flat-packed article greater than 7.7 ft but less than 7.9 ft must be loaded vertically. Diagonally loading flat-packed articles defeats the purpose of flat-packing, as container space use is not efficient and prohibitively expensive.

Accordingly, there is a need for an improved over-sized portable shipping and storage container having an oversized width (greater than 7.7 or 7.9 ft, depending on the container) that can be disassembled into a configuration having a relatively small flat-packable volume such that it can fit into an ISO container.

While modular roofs are known in the art, the present embodiments provide improvements for ensuring weather tightness, both at the junction(s) between roof panels and with regard to the container as a whole.

Accordingly, there is a need for an improved over-size portable shipping and storage container that can be folded or disassembled into a configuration having a relatively small flat-packable volume while also having a modular shoebox-style roof that is weather tight, while also being stackable in a fully assembled state.

SUMMARY

A modular container is provided that comprises a base. A plurality of panels is coupled to the base to form an enclosure having an internal volume, wherein the plurality of panels substantially defines an outer perimeter of the modular container, and substantially defines a top circumferential edge of the modular container. At least one door provides access to the internal volume. A roof is coupled to the plurality of panels, wherein the roof comprises a shoebox flange that downwardly protrudes from a top of the roof and circumscribes the roof and defines the outer perimeter of the roof, and wherein the shoebox flange fits over the top circumferential edge of the modular container. The roof comprises a plurality of individual roof panels that are fastenable together. The modular container is at least one of horizontally and vertically flat-packable in an ISO container when in a disassembled state. The modular container, when in a disassembled and flat-packed state, fits at least one of horizontally and vertically in an ISO container.

A method of assembling a flat-packable modular container is provided. The method comprises coupling a plurality of base members to form a base, and coupling a plurality of panels and/or support panels to the base. The adjacent panels and/or support panels are coupled to each other. At least one crossmember is coupled to any two of the panels and/or the support panels such that the at least one crossmember is disposed to be under a seam defined by a roof. The roof is formed by coupling a plurality of roof members together. The roof is coupled to a top circumferential edge defined by the plurality of panels and/or support panels. A u-channel is coupled to a junction formed between the coupled roof members. At least one door is installed in an opening defined by the plurality of panels and/or support panels.

A method of disassembling a modular container is provided. An assembled flat-packable modular container is provided. At least one door disposed in at least one opening defined by a plurality of panels and/or support panels is uninstalled. A u-channel is uncoupled from a junction formed between at least two coupled roof members that define a roof. The roof is uncoupled from a top circumferential edge defined by the plurality of panels and/or support panels. At least two coupled roof members are uncoupled. A crossmember is uncoupled from any two of the panels and/or the support panels to which the crossmember is coupled. Adjacent panels and/or support panels are uncoupled from each other. The plurality of panels and/or support panels are uncoupled from a base that comprises a plurality of base members. The plurality of base members is uncoupled.

Aspects

According to an embodiment, a modular container is provided that comprises a base. A plurality of panels is coupled to the base to form an enclosure having an internal volume, wherein the plurality of panels substantially defines an outer perimeter of the modular container, and substantially defines a top circumferential edge of the modular container. At least one door provides access to the internal volume. A roof is coupled to the plurality of panels, wherein the roof comprises a shoebox flange that downwardly protrudes from a top of the roof and circumscribes the roof and defines the outer perimeter of the roof, and wherein the shoebox flange fits over the top circumferential edge of the modular container. The roof comprises a plurality of individual roof panels that are fastenable together. The modular container, when in a disassembled and flat-packed state, fits at least one of horizontally and vertically in an ISO container.

Preferably, the modular container comprises a plurality of connection flanges on the roof, wherein each individual roof panel comprises at least one connection flange proximate an outer edge of the roof panel, and wherein the individual roof panels are fastenable to each other by securing the connection flanges together.

Preferably, each outer edge of each roof panel comprises either a connection flange or a shoebox flange.

Preferably, the modular container comprises a gasket placed between the connection flanges of the plurality of individual roof panels.

Preferably, the modular container comprises a u-channel that is fastened to a junction defined by adjacent flanges of adjacent roof panels, wherein the junction between adjacent panels and the gasket are substantially shielded from external factors by the u-channel.

Preferably, the u-channel comprises a plate attached to each end of the u-channel.

Preferably, the u-channel comprises a plate attached to each end of the u-channel, and each plate is attachable to a portion of the modular container proximate the shoebox flange.

Preferably, the modular container comprises a crossmember installed to a portion of the modular container, being disposed beneath a junction defined by adjacent connection flanges of adjacent roof panels, wherein the crossmember comprises a main support that is adjacent to the roof when the roof is installed.

Preferably, the main support comprises attachment blocks that are received by a portion of at least one of the panels, support panels, or other support member, and couplable thereto.

Preferably, the base comprises at least one split that defines a junction between at least two base portions being couplable to each other at the junction.

Preferably, the split of the base comprises a split through at least one of a length of the modular container, a width of the modular container, and both the length and the width of the modular container.

Preferably, a split of the roof comprises a split through the length of the modular container or the width of the modular container or both the length and width of the container.

Preferably, the modular container comprises a plurality of floor panels, each having a size and dimension that allows the floor panels to fit into an ISO container when at least one of horizontally and vertically flat-packed.

Preferably, the base portions are at least one of horizontally and vertically flat packable to fit in an ISO container.

Preferably, the modular container a width greater than 7.7 feet and a length greater than 7.7 feet when in an assembled state.

Preferably, every component of the modular container, when in a disassembled state, is flat-packable and comprises at least one of a horizontally and vertically flat-packed width of less than or equal to 7.7 feet.

Preferably, at least one of the plurality of panels is hingedly attached to another portion of the modular container.

According to an embodiment, a method of assembling a flat-packable modular container is provided. The method comprises coupling a plurality of base members to form a base, and coupling a plurality of panels and/or support panels to the base. The adjacent panels and/or support panels are coupled to each other. At least one crossmember is coupled to any two of the panels and/or the support panels such that the at least one crossmember is disposed to be under a seam defined by a roof. The roof is formed by coupling a plurality of roof members together. The roof is coupled to a top circumferential edge defined by the plurality of panels and/or support panels. A u-channel is coupled to a junction formed between the coupled roof members. At least one door is installed in an opening defined by the plurality of panels and/or support panels.

According to an embodiment, a method of disassembling a modular container is provided. An assembled flat-packable modular container is provided. At least one door disposed in at least one opening defined by a plurality of panels and/or support panels is uninstalled. A u-channel is uncoupled from a junction formed between at least two coupled roof members that define a roof. The roof is uncoupled from a top circumferential edge defined by the plurality of panels and/or support panels. At least two coupled roof members are uncoupled. A crossmember is uncoupled from any two of the panels and/or the support panels to which the crossmember is coupled. Adjacent panels and/or support panels are uncoupled from each other. The plurality of panels and/or support panels are uncoupled from a base that comprises a plurality of base members. The plurality of base members is uncoupled.

BRIEF DESCRIPTION OF THE DRAWINGS

The same reference number represents the same element on all drawings. The drawings are not necessarily to scale.

FIG. 1A illustrates a folding container according to an embodiment;

FIG. 1B illustrates a folding container according to an embodiment with the side panels and roof removed for clarity;

FIG. 2 illustrates the folding container with a rear panel in a folded position;

FIG. 3 illustrates the folding container with a rear panel and front panel both in a folded position;

FIG. 4 illustrates the folding container with a rear panel and front panel both in a folded position in addition to a side panel a folded position;

FIG. 5 illustrates the folding container with a rear panel and front panel both in a folded position in addition to both side panels in folded positions; and

FIG. 6 illustrates a detailed view of a portion of the folding container according to an embodiment.

FIG. 7A illustrates a modular flat-pack container according to an embodiment;

FIG. 7B illustrates a modular flat-pack container according to an embodiment;

FIG. 8 illustrates a modular flat-pack container according to another embodiment;

FIG. 9 illustrates details of a base and floor portions of a modular flat-pack container according to an embodiment.

FIG. 10 illustrates a roof assembly according to an embodiment;

FIG. 11 illustrates a roof assembly according to an embodiment;

FIG. 12 illustrates assembly details of a roof assembly according to an embodiment;

FIG. 13 illustrates assembly details of a roof assembly according to an embodiment;

FIG. 14 illustrates assembly details of a roof assembly according to an embodiment;

FIG. 15 illustrates assembly details of a roof assembly according to an embodiment;

FIG. 16 illustrates a portion of a modular flat-pack container according to an embodiment;

FIG. 17 illustrates a crossmember assembly and a roof-securing bracket, according to an embodiment;

FIG. 18 illustrates a crossmember according to an embodiment;

FIG. 19 illustrates a plurality of disassembled modular containers on a skid, according to an embodiment;

FIG. 20 illustrates a modular flat-pack container stacked upon another modular flat-pack container; and

FIG. 21 is a flow chart illustrating a method of assembling a flat-packable container according to an embodiment.

DETAILED DESCRIPTION

Referring first to FIGS. 1A-6, a folding container 100 according to the present embodiments comprises a plurality of generally flat, rectangularly-shaped panels which are foldably fastened together so to form a cuboid-shaped enclosure having an internal volume configured for storage and/or transport when the folding container 100 is in an unfolded state.

The folding container 100 comprises a base 102, side panels 104, 104′, a rear panel 106, front panel 108, and roof panel 110. The side panels 104 may comprise one or more doors. The rear panel 106 may comprise a one or more rear doors 107, and the front panel 108 may comprise one or more front doors 109. Doors may be vertically hinged, horizontally hinges, rolling doors, removable panels, other door types known in the art, and combinations thereof. In the embodiments illustrated, the panels 106, 108 each comprise support members 106′, 108′ that support their respective doors 107, 109.

In general, all sides, doors, and/or insert panels of the folding container 100 may be fabricated from rectangularly-shaped corrugated sheet at least partially bounded by corners/members. Corrugated sheets may be substituted with door assemblies. Alternatively, corrugated sheets may comprise door or window assemblies. Combinations of folding container 100 panels may include any combination of sheet panels, doors, and/or panels comprising doors. Although corrugated sheet is common, non-corrugated panel material is contemplated. Metals, such as steel, are contemplated for door, panel, corner, braces, and any other structural members. However, other materials, such as wood, plastics, polymers, and composites may be used alone or in conjunction with metals.

The base 102 is preferably constructed from hollow tubing, angle stock, U-stock, sheet stock, and/or combinations thereof. The general plan view of the base is that of a substantially square or rectangular structure, and is generally rectilinear in nature. However, other polygonal or even rounded/arced portions may be present. Support members (not shown) of the base may traverse under the floor 112 to provide structural support thereto. Edge rails 114 provide perimeter support for the base 102, and provide anchor points for the support members. Lift points 116 provide space for forklift fork access.

The front and rear panels 108, 106 are hingedly or pivotably fastened to the base 102. The rear panel 106 comprises rear hinges 118 (visible in FIG. 1B) that are disposed at or below the level of the floor 112. The rear hinges 118 are attached to the base 102 and rear support members 106′. The rear panel 106 thus may hingedly fold such that the inward-facing surface 120 thereof may be made to contact the floor 112 when the rear panel is in a “folded” or horizontal position. The front panel 108, however, comprises front hinges 122 (See FIG. 6) that are disposed on a plane higher than the level of the top plane of the floor 112. The distance the front hinge 122 is positioned from the floor 112 is based on the thickness of the rear panel. The distance the front hinge 122 is positioned from the floor 112 is so that the font panel 108 may hingedly fold such that the inward-facing surface 124 of the front panel may be made to contact the outward-facing surface 126 of the rear panel 106 when both panels 108, 106 are in the folded position. The front hinges 122 are thus attached to the front support members 108′ and corresponding hinge block 119. At least two hinges are associated with each panel 108, 106, each pair having colinear hinge axes.

In prior art containers, a riser rib is provided to enable a first panel to overlie a second panel. This unfortunately yields a container that has a riser rib that spans an entire edge of a container. In cases where doors are provided on a panel having a riser rib, the riser rib blocks access through the doors, and necessitates the lifting of cargo over the riser rib, thus hindering rolling carts, dollies, or lifts from accessing the interior space of the container.

FIGS. 2-6 illustrate the details of the folding mechanisms, and of the front panel 108 in particular. A front panel 108 comprising a front door 109 is shown. In the embodiments illustrated, it is the rear panel 106 that folds first, and front panel 108 that folds from a “deployed” or vertical position down to a folded position second, and ultimately rests upon the rear panel 106 when in the folded position. For the front door panel 108 to not bind on the rear panel 106 and to instead lay flat, the front hinges 122 are attached to hinge blocks 119 which place the fulcrum axis of the front hinges 122 in a position approximately coplanar with the outward-facing surface 2 of the rear panel 106 when the rear panel 106 is in the folded position.

A bottom region of the front door 109 extends past where a typical door would otherwise extend, so to facilitate proper sealing when the front door 109 is closed. FIG. 6 illustrates the extension region 128 of the front door 109 that passes past the topmost plane of the floor 112 when the front panel 108 is deployed. When the front panel is deployed, the extension region 128 of the front door 109 mates with a recess 130 defined by the base 102. The recess 130 serves as a limit stop for the front door 109 and also provides a bottom seal region for the doors that helps to prevent intrusion of the elements and debris. Furthermore, by providing an inward door travel limit, security is improved, as the door is resistant to being forcibly inwardly opened.

A method of folding the folding container 100 is provided. From a fully assembled state, illustrated in FIG. 1, hardware that attaches the roof panel 110 and hardware that attaches the rear panel 106 to the side panels 104, 104′ is removed. The rear panel 106 is hingedly folded from a vertically deployed position until it is resting horizontally on the floor 112 in a folded position, as is illustrated in FIG. 2. FIG. 3 illustrates folding the front panel 108 from a vertically deployed position until it is resting horizontally on the rear panel 106 in a folded position. It will be understood that any hardware that attaches the front panel 108 to the side panels 104, 104′ is removed or unengaged before this operation. FIG. 4 illustrates folding a side panel 104 from a vertically deployed position until it is resting horizontally on the front panel 108 in a folded position. Likewise, FIG. 5 illustrates folding the opposing side panel 104′ from a vertically deployed position until it is resting horizontally on the side panel 104 that was folded immediately prior. It will be clear to those skilled in the art that to assemble the folding container 100 from a folded position that the steps outlined above will be carried out in the reverse order.

At least one hinge 105, 105′ is respectively attached to each of the side panels 104, 104′. In FIG. 4 it is illustrated that two hinges 105′ are disposed somewhat inboard from the edges 134′ of side panel 104′. Hinges 105′ are attached to both the side panel 104′ and a riser 132′. The hinges 105 on side panel 104 are illustrated in FIG. 4 as being disposed proximate the edges 134 of side panel 104. Hinges 105 are attached to both the side panel 104 and a riser 132. It should be noted that in embodiments, the distance a hinge 105, 105′ is from an edge of a side panel 134, 134′ may be different within a particular side panel and/or between side panels. It should be noted that in embodiments, the distance a hinge 105, 105′ is from an edge of a side panel 134, 134′ may be the same within a particular side panel and/or between side panels.

It should be noted that the height of the fulcrum axes of the various hinges for the different side panels 104, 104′, with respect to the floor 112, are different to accommodate the panels folded down in steps prior. For example, the first side panel folded 104 rests on both the front 108 and rear 106 panels, when in a folded position. Therefore, the height of the riser 132 immediately below this side panel 104 is such that the fulcrum axis of the hinges 105 is approximately coplanar with the outward-facing surface 125 of the front panel 108 when the front panel 108 is in the folded position. Furthermore, the last side panel folded 104′ rests on both the front 108 and rear 106 panels as well as the opposing side panel 104, when in a folded position. Therefore, the height of the riser 132′ immediately below this side panel 104′ is such that the fulcrum axis of the hinges 105′ are approximately coplanar with the outward-facing surface 136 of side panel 104 when this side panel 104 is in the folded position.

Referring to FIGS. 7-21, a modular flat-pack container 200 (or simply modular container 200) according to the present embodiments comprises a plurality of generally flat panels (e.g. sides, floor, roof) which are fastened together so to form an enclosure having an internal volume configured for storage and/or transport when the modular container 200 is in an assembled state. In an embodiment, the generally flat panels are rectangularly-shaped, and are fastened together so to form a cuboid-shaped enclosure. The plurality of panels also aids in defining the external faces of the modular container 200. When disassembled, the panels are stackable, horizontally and/or vertically flat-packable, and easily transported in bulk, such that a plurality of flat-packed containers 200 will fit into standard ISO containers. Panels are also packable in a combination of horizontal and vertical orientation. In embodiments, when in a disassembled and flat-packed state, the width of the flat-pack is 7.7 ft or less. This allows the flat-pack to fit inside an ISO container, that can only accommodate items with a width of 7.7 ft. or less. When in an assembled state, the modular container 200 comprises a length and width each greater than 7.7 ft. The width, when in a disassembled and flat-packed state, may be less than 8.9 ft. for a High Cube container. When in an assembled state, the modular container 200 comprises a length or width greater than 8.9 ft for a High Cube container.

The modular container 200 may comprise many of the elements of the foldable container 100 noted above. It is contemplated that the modular container 200 have some foldable portions described above, and also non-foldable panels that are attachable and detachable to form the structure of the modular container 200.

Referring first to FIGS. 7A, 7B, and 8, in an embodiment, a modular container 200 according to the present embodiments comprises a plurality of generally flat, square or rectangularly-shaped panels which are fastenable together so to form a cuboid-shaped enclosure having an internal volume configured for storage and/or transport when the modular container 200 is in an assembled state.

The modular container 200 comprises a base 202 and panels 204. The number of panels is dictated by the size of the modular container 200. The number of doors may vary between 1 and 12 or even greater, depending on the application. Windows and other openings are also contemplated. Doors 211 may be present on the ends 270 or sides 272 of the container. A rear panel, front panel, and roof 210 may be present. As illustrated, panels 204 may comprise openings a for doors (comprising support panels e) or panels without doors. Sides 272 of the container may comprise one or more panels having one or more doors 211. Ends 270 of the container may comprise panels having one or more doors 211. Doors 211 may be vertically hinged, horizontally hinged, rolling doors, removable panels, other door types of doors known in the art, and combinations thereof. In the embodiments illustrated, panels 204 may comprise support panels 204A that support their respective doors 211.

Modular container 200 panels 204 may include any combination of sheet panels, doors, and/or panels comprising windows or any other opening. Although corrugated sheet is common, non-corrugated panel material is contemplated. Metals, such as steel, are contemplated for door, panel, corner, braces, and any other structural members. However, other materials, such as wood, plastics, polymers, and composites may be used alone or in conjunction with metals. In an embodiment, the roof is galvanized steel.

The base 202 is preferably constructed from hollow tubing, angle stock, U-stock, sheet stock, and/or combinations thereof. In an embodiment, the plan view of the base is that of a substantially square or rectangular structure, and is generally rectilinear in nature. However, other polygonal or even rounded/arced portions may be present. Support members (not visible) of the base may traverse under the floor 209 to provide structural support thereto. Edge rails 214 provide perimeter support for the base 202 and provide anchor points for the panels 204, support panels 204A, and corner members 294. Lift points 216 provide pockets for a forklift fork or any other lifting mechanism engagable to the lift points 216. Lift points 216 may be on any of the ends and/or sides of the base 202.

Anchor points 217 provide a point to fasten the base 202 to another object. The anchor points 217 may comprise rings, D-rings, bed bolts, grab hooks, bolts, and any other mechanical anchor known in the art. The anchor points 217 may be welded, attached with fasteners, or both. The anchor points 217 provide points to attach the base 202 and/or the assembled or partly assembled modular container 200 to a flatbed, a trailer, a skid, a pallet, decking, a floor, the ground, other anchor points, and/or another modular container 200.

The panels 204 are fastened to the base 202. Adjacent panels 204 are also fastened to each other and each panel 204 is fastened to the roof 210. Panels 204 for door support panels may be made of multiple support panels 204A that are fastened together and fastened to the floor 209 and/or base 202 and/or adjacent panels 204 and/or adjacent support panels 204A, depending on the modular container 200 door configuration. Fastening may comprise the use of mechanical fasteners and/or welding. An exterior corner member 294 adds additional structural integrity and also fosters weather tightness. A gasket may be provided beneath the corner member 294 and between the roof 210 and underlying panels 204 and/or support panels 204A. Gaskets may be provided between the floor 209 and the panels 204 and/or support panels 204A. In an embodiment, at least one panel 204 and/or support panel 204A is hingedly attached to another portion of the modular container. In an embodiment, at least one panel 204 and/or support panel 204A is hingedly attached to the base 202. In an embodiment, at least one panel 204 and/or support panel 204A is hingedly attached to another panel 204 and/or support panel 204A.

For the base 202, floor 209, and roof 210, and any other portions of the modular container 200 with width and length dimensions each greater than 7.7 feet to be horizontally and/or vertically flat-packed to fit into an ISO container, these elements each comprise multiple portions. FIG. 19 illustrates flat packing of a flat-packed shipping container, and is further discussed below.

FIGS. 8 and 9 illustrate that the floor 209 comprises multiple panels 209A. It is illustrated in FIG. 8 that the floor 209 is divided into twelve individual floor panels 209A. There could be fewer or greater than twelve panels, and the divisions may vary depending on the length of the container and/or the door configuration. The floor panels 209A may be any size or dimension that allows them to fit into an ISO container when flat-packed with all the other components that comprise the modular container 200.

Since the base 202 may be wider and longer than 7.7 feet in each dimension, the base 202 is comprised of at least two portions 202A that are fastenable to each other at the junction 203 where the at least two portions 202A meet. The base 202 may be split down the length of the modular container 200 or the width of the modular container 200 or both. The junction of the split is where mechanical fasteners couple the at least two portions 202A together.

The roof 210 is also divided into multiple roof panels 210A since the roof is wider and longer than 7.7 feet, for example, in each dimension. The multiple roof panels 210A are fastenable together to comprise the roof 210. The roof 210 may be split down the length of the modular container 200 as illustrated in FIGS. 7A and 8, or the width of the modular container 200, as illustrated in FIGS. 7A, 10, and 11, or both lengthwise and widthwise. Panels 210A are fastenable to each other with at least one connection flange 278 proximate an outer edge 330 of each panel 210A. Panels 210A that are placed between adjacent panels 210A comprise opposing connection flanges 278 that are fastenable to neighboring connection flanges 278 on neighboring panels 210A. A gasket 280 is placed between the connection flanges 278 for weather tightness. Connection flanges 278 define a plurality of holes 284 that are configured to accept fasteners therethrough for the purpose of fastening panels 210A together. Fasteners 282 are tightened such that the gasket is compressed for weather tightness and the connection flanges 278 are tightly abutted together for structural integrity.

Additionally turning to FIGS. 12-14, in an embodiment, upon fastening adjacent panels 210A together via the connection flanges 278, some holes do not yet have a fastener installed therein. These holes are used to fasten a u-channel 286 thereto. The u-channel 286 covers the flange junctions between roof panels 210A. The u-channel 286 provides additional structural integrity, and promotes weather tightness to the roof 210, since the junction between adjacent panels 210A and the gasket 280 acts as a shield from external factors, such as the elements. Holes 284 in the u-channel accept fasteners that pass therethrough and also through the holes 284 of the connection flanges 278. A plate 288 is attached to each end of the u-channel 286. Once the u-channel 286 is attached to the connection flanges 278, the plate 288 is attached to a shoebox flange 290 that circumscribes the assembled roof 210 and defines the outer perimeter of the roof 210, as additionally illustrated in FIGS. 14 and 15. Note that FIG. 15 provides an x-ray portion through the top of the plate 288 to show the underlying connection flanges 278, etc. The fastener 282 illustrated in FIG. 15 is a nut and bolt, and is provided as an example of a fastener. Additional plate fasteners 292 pass through holes in the plate (not visible) to attach to the shoebox flange 290 and any underlying panels 200, 204. This provides additional structural integrity, and also promotes weather tightness to the roof 210 by shielding the junction between adjacent panels 210A at the shoebox flange 290. A gasket (not shown) may be installed behind the plate 288.

The shoebox style roof 210 fits over the top circumferential edge defined by the assembled modular container 200 (minus the roof). The circumferential edge is not visible in the drawings, as the shoebox flange 290 is shown installed in FIGS. 7, 8, 16 and 20, and thus the shoebox flange 290 occludes the top circumferential edge upon which it sits. The reason this is referred to as a shoebox style roof is that the fit of the shoebox flange 290 over the top circumferential edge defined by the assembled modular container 200 is analogous to the way a standard US shoebox lid fits the bottom portion of a shoebox. The downward protrusion of the shoebox flange 290 fits over the outer surface of the panels 204/support panels 204A. This is particularly clear in FIG. 7A, which illustrates the assembled roof 210 attached to the rest of the assembled container 200.

FIGS. 8 and 16-18 illustrate a crossmember 296. At least one crossmember 296 is installed to portions of the modular container 200 beneath the junctions of the roof panels 210A where the connection flanges 278 meet. The crossmember 296 is coupled to opposing panels 204 and/or support panels 204A. The crossmember 296 provides additional support for the roof 210. The crossmember 296 comprises a main support 298 and attachment blocks 300. The attachment blocks 300 are preferably welded to the crossmember 296. Weld bead 302 is visible in the drawings. The attachment blocks 300 are positioned such that a protrusion 304 is formed that may be received by a receiver 306 in the panels 204 and/or support panels 204A. In an embodiment, the panels 204 and/or support panels 204A comprise a panel crossmember 310 that provides additional structural integrity to the panels 204 and/or support panels 204A, and also provides additional support and/or welding points for the blocks 300. The protrusion 304 engages the receiver 306. A fastening system 308 such that the attachment blocks 300 may be securely attached thereto is present. In an embodiment, the fastening system 308 comprises a mechanical fastener 309, such as a threaded fastener, pin, etc. In FIG. 17, a bolt is shown that passes through the receiver 306 and is secured to the attachment block 300, as an example. The crossmember 296 is positioned such that the top of the main support 298 may be level with the top of the panels 204 and/or support panels 204A, or other support structures, such that when the roof 210 is put in place, it rests upon the both the panels 204 and/or support panels 204A as well as the main support 298 of the crossmember 296.

Turning again to FIGS. 7 and 15, and additionally to FIG. 20, in an embodiment, stack supports 312 are provided with the roof 210. The stack supports 312 are protrusions and/or blocks that are formed by the roof 210 or attached to the roof 210 by well-known attachment means, such as welding or with mechanical fasteners. The stack supports 312 project upwardly from the roof 210. In an embodiment, some or all the stack supports 312 form the highest points on the roof 210. In some embodiments, the stack supports 312 generally project upwardly from the roof 210 so that the tops of each stack support are coplanar. In an embodiment, not every stack support 312 is coplanar with every other stack support 312. In an embodiment, no stack supports 312 are coplanar with other stack supports 312. In each case, the tops of each stack support comprise an elevation profile configured to evenly and securely support another container being stacked thereon. Thus, the base 202 of an upper modular container 200A of a stack 340 rests upon the stack supports 312 of the lower modular container 200B of the stack 340. Additionally, by providing at least some stack support 312 points that are supported by underlying support panels 204A of the lower modular container 200B of a stack, the mass of the upper modular container 200A stacked upon the lower modular container 200 is distributed thereupon such that structural integrity of the lower modular container 200 remains uncompromised.

Turning again to FIG. 17, brackets 314 may be provided to secure the roof to the panels 204 and/or support panels 204A. The brackets 314 may be stationary, may be assemblies of elements, or may comprise a hinge means 324. In an embodiment comprising a hinge means 324, as illustrated in FIG. 17, the hinge means 324 further comprises a pin 316, a knuckle 318, a leaf 320, a hole 322 in the leaf 320, and a receiving portion the roof 210. The roof bracket may be as simple as a roof 210 portion configured to accept a mechanical fastener. The hinge means is fixedly secured to a part 325 of the container by attaching the knuckle 318 to the part 325. The bracket 314 is coupled to the roof 210 by securing the leaf 320 to the roof using a mechanical fastener, such as a bolt, welding/brazing, and/or any other fastening means known to one skilled in the art. The part 325 may comprise a portion of the panels 204 and/or support panels 204A, a block, or any other member of the modular container 200. In some embodiments, the roof is secured to the panels 204 and/or support panels 204A simply by direct attachment with mechanical fasteners and/or welding/brazing without need for a bracket 314.

The hinge means 324 allows the pin 316 to slidingly move through the knuckles 318 to provide adjustability so that the leaf may align with the receiving portion of the roof 210. Additionally, the hole 322 in the knuckle 318 may be elongate to ensure that the leaf 320 aligns with the roof, and there is an unobstructed path to the portion of the roof bracket that may receive a mechanical fastener.

FIG. 19 illustrates a plurality of disassembled modular containers 200 placed into a skid 350. ISO containers have standardized dimensions, and one such dimension is the external dimension of 8 feet in width and an internal width dimension of only 7.7 feet. Items having a width and length greater than 7.7 ft. in each dimension cannot fit into an ISO container, unless loaded diagonally, which would severely limit the number of modular container 200 units that could be shipped in a single container, thus making shipping cost prohibitive. For High Cube ISO containers, the internal width dimension is 7.7 ft, and the internal height dimension is 8.9 ft. In the present embodiments, each modular container 200 comprises a roof 210 divided into a plurality of panels 210A, as well as a base 202 divided into a plurality of portions 202A. This allows portions of the container that were traditionally too large to be efficiently packed into an ISO container to be flat-packed. The skid 350 secures a plurality of disassembled modular containers 200 such that the dimensions do not exceed the maximum width and height limitation of an ISO container. This allows an over-sized portable shipping and storage container having a panel with a width greater than 7.7 ft. that can be disassembled to have dimensions less than the internal dimension limitations of an ISO container to be placed into a configuration having a relatively small flat-packable volume such that it can fit into an ISO container. The skid 350 provides a structure comprising a skid base 352 and support members 354. The skid base 352 may be coupled to some, none, or all the support members 354. Some support members 354 may directly be coupled to each other. The skid 350 aids organizing flat pack assemblies 356 of disassembled modular container 200 units, optimizes space utilizations, and provides for quick loading and unloading of ISO containers. It should be noted that the skid illustrated is provided as an example, and other configurations of flat-packing, with or without a skid, are contemplated. It should also be noted that dimensions for the width and length of roof panels 210 or base portions 202A, may have lengths greater or less than 7.7 ft. All references to the dimensions of the roof panels and baes portions noted herein utilize dimensions of 7.7 ft, 7.9 ft, or 8.9 ft are used merely as examples, as other dimensions, larger or smaller, are contemplated, based upon particular flat-packing constraints.

According to an embodiment, a method 400 of assembling a flat-packable container 200 is provided, as illustrated by FIG. 21.

In step 402, a plurality of base members 202A are coupled to form a base 202.

In step 404, a plurality of panels 204 and support panels 204A are coupled to the base 202. The panels 204 and support panels 204A may be coupled to the edge rails 214. The panels 204 and support panels 204A may be coupled to the floor 209.

In step 406, the adjacent panels 204 and/or support panels 204A are coupled to each other. Corner members may also aid in coupling the panels 204 and/or support panels 204A to each other. One or more openings 274 are defined by the panels 204 and/or support panels 204A.

In step 408, at least one crossmember 298 is installed to provide support for the roof 210. Crossmembers 298 are, in an embodiment, coupled to opposing panels 204 and/or support panels 204A. In an embodiment the crossmembers 298 are coupled to at least two of the panels 204 and/or support panels 204A. However, the crossmembers 298 may be coupled to any appropriate structure of the container 200. Crossmembers are positioned under roof 210 seams.

In step 410, a plurality of roof members 210A is coupled to top edge of panels 204 and/or support panels 204A. The roof members 210A are also coupled to form a roof 210. The roof members 204A may be coupled to each other first and then coupled to the panels 204 and/or support panels 204A. The roof members 204A may be coupled to panels 204 and/or support panels 204A, and then coupled to each other. The shoebox flange 290 is positioned to fit over the top circumferential edge defined by the plurality of the panels 204 and/or support panels 204A of the partly assembled modular container 200 (minus the roof).

In step 412, at least one door 211 is installed in an opening 274.

In step 414, a u-channel 286 is coupled to a junction formed between the roof members 210A.

The method steps noted above may be accomplished in several different orders. For example, any doors 211 may be installed after the u-channel 286 is installed. The u-channel 286 may be installed on the roof members 210A before the roof 210 is installed, in conjunction with step 414. The doors may be installed in conjunction with step 404. These are merely examples, and other permutations of step order are contemplated, as will be understood by those skilled in the art.

For disassembly, the method 400 steps are reversed, and coupling steps become decoupling steps, and installation steps become uninstallation steps. Again, the necessary order of operations for disassembly may not strictly be the reversal of method 400, as multiple permutations of step order are contemplated in a similar vein to the assembly methodology, as will be understood by those skilled in the art.

The present description depicts specific examples to teach those skilled in the art how to make and use the best mode of the invention. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these examples that fall within the scope of the invention.

The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the invention. Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope and teachings of the invention. It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope and teachings of the invention.

Thus, although specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The teachings provided herein may be applied to other embodiments than those described above and shown in the accompanying figures. Accordingly, the scope of the invention is determined from the following claims.

STACKABLE FLAT-PACK SHIPPING CONTAINER WITH SEGMENTED ROOF

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