U.S. patent application number 11/072293 was filed with the patent office on 2005-09-08 for insulated cargo containers.
This patent application is currently assigned to Martin Marietta Materials, Inc.. Invention is credited to Seiter, Joseph A., Zupancich, Ronald J..
Application Number | 20050194381 11/072293 |
Document ID | / |
Family ID | 34915146 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050194381 |
Kind Code |
A1 |
Zupancich, Ronald J. ; et
al. |
September 8, 2005 |
Insulated cargo containers
Abstract
The prevention discloses an insulated cargo container. In one
implementation, the insulated cargo container includes at least one
insulating panel applied on an exterior surface of the side walls,
end walls, roof, or doors of the cargo container. In another
implementation, the floor of the cargo container is also modified
to improve the thermal efficiency of the cargo container.
Inventors: |
Zupancich, Ronald J.;
(Clayton, NC) ; Seiter, Joseph A.; (Raleigh,
NC) |
Correspondence
Address: |
FINNEGAN, HENDERSON, FARABOW, GARRETT & DUNNER
LLP
901 NEW YORK AVENUE, NW
WASHINGTON
DC
20001-4413
US
|
Assignee: |
Martin Marietta Materials,
Inc.
|
Family ID: |
34915146 |
Appl. No.: |
11/072293 |
Filed: |
March 7, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60549929 |
Mar 5, 2004 |
|
|
|
Current U.S.
Class: |
220/1.5 |
Current CPC
Class: |
B65D 88/121 20130101;
B61D 27/0081 20130101; Y02T 30/42 20130101; B61D 17/18 20130101;
Y02T 30/00 20130101; B65D 90/06 20130101 |
Class at
Publication: |
220/001.5 |
International
Class: |
B65D 088/00 |
Claims
What is claimed is:
1. A cargo container comprising: an underframe having a top and
bottom surface; a floor connected to the top surface of the
underframe; first and second side walls having exterior surfaces;
first and second end walls having exterior surfaces, a roof having
an exterior surface, the underframe, floor, first and second side
walls; first and second end walls, and roof being connect to form
an enclosure; and at least one insulating panel comprising an
insulating layer and at least one outer skin located on at least
one face of the insulating layer, the at least one insulating panel
located on the exterior surface of at least one of the first side
wall, second side wall, first end wall, second end wall, or
roof.
2. The cargo container of claim 1, wherein the at least one outer
skin of the at least one insulating panel comprises
fiber-reinforced plastics and wherein the insulating layer
comprises urethane foam.
3. The cargo container of claim 1, wherein the at least one outer
skin of the at least one insulating panel comprises metal and
wherein the insulating layer comprises urethane foam.
4. The cargo container of claim 1, wherein the at least one outer
skin of the at least one insulating panel comprises
fiber-reinforced plastics and wherein the insulating layer
comprises a vacuum insulated panel.
5. The cargo container of claim 1, wherein the at least one outer
skin of the at least one insulating panel comprises metal and
wherein the insulating layer comprises a vacuum insulated
panel.
6. The cargo container of claim 1, wherein the at least one
insulating panel substantially covers the exterior surface of the
side wall, end wall, or roof to which it is applied.
7. The cargo container of claim 1, further comprising: at least one
corner piece joining the at least one insulating panel located on
the exterior surface of the first side wall, second side wall,
first end wall, second end wall, or roof to a second insulating
panel located on the exterior surface of an adjacent generally
perpendicularly disposed side wall, end wall, or roof.
8. The cargo container of claim 7, wherein the at least one
insulating panel and the at least one corner piece substantially
cover the exterior surfaces of the first side wall, second side
wall, first end wall, second end wall, and roof.
9. The cargo container of claim 1, wherein at least two insulating
panels are located on the exterior surfaces of the first side wall,
second side wall, first end wall, second end wall, and roof; and
wherein each insulating panel is connected to at least one other
insulating panel located on the same exterior surface.
10. The cargo container of claim 9, wherein each insulating panel
comprises a latch designed to engage a catch on another insulating
panel and a catch to be engaged by a latch on another insulating
panel.
11. The cargo container of claim 1, further comprising: at least
one insulating member located between the underframe and the
floor.
12. A cargo container comprising: an underframe having a top and
bottom surface; a liner having a top surface and located on the top
surface of the underframe; a floor located on the top surface of
the liner; first and second side walls having exterior surfaces;
first and second end walls having exterior surfaces, a roof having
an exterior surface, the underframe, floor, first and second side
walls; first and second end walls, and roof being connected to form
an enclosure; and at least one insulating panel comprising an
insulating layer and at least one outer skin located on at least
one face of the insulating layer, the at least one insulating panel
being located on the exterior surface of at least one of the first
side wall, second side wall, first end wall, second end wall, or
roof.
13. The cargo container of claim 12, further comprising: at least
one insulating member located between the liner and the floor.
14. The cargo container of claim 13, further comprising: at least
two insulating members located between the liner and the floor; and
a layer of insulation on the liner in an area between the at least
two insulating members.
15. The cargo container of claim 13, wherein the floor is
constructed of a nailable material.
16. The cargo container of claim 13, wherein the at least one outer
skin of the at least one insulating panel comprises
fiber-reinforced plastics and wherein the insulating layer
comprises urethane foam.
17. The cargo container of claim 13, wherein the at least one outer
skin of the at least one insulating panel comprises metal and
wherein the insulating layer comprises urethane foam.
18. The cargo container of claim 13, wherein the at least one outer
skin of the at least one insulating panel comprises
fiber-reinforced plastics and wherein the insulating layer
comprises a vacuum insulated panel.
19. The cargo container of claim 13, wherein the at least one outer
skin of the at least one insulating panel comprises metal and
wherein the insulating layer comprises a vacuum insulated
panel.
20. A cargo container comprising: an underframe having a top and
bottom surface; a liner having a top surface and located on the top
surface of the underframe; at least one insulating member on the
top surface of the liner; a floor located on the at least one
insulating member; first and second side walls having exterior
surfaces; first and second end walls having exterior surfaces, a
roof having an exterior surface, the underframe, floor, first and
second side walls; first and second end walls, and roof being
connected to form an enclosure; and at least two insulating panels
comprising an insulating layer and at least one outer skin located
on at least one face of the insulating layer, the at least two
insulating panels being located on the exterior surface of at least
one of the first side wall, second side wall, first end wall,
second end wall, or roof; wherein each insulating panel is
connected to at least one other insulating panel located on the
same exterior surface.
Description
I. CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/549,929, filed Mar. 5, 2004, by Ronald J.
Zupancich and Joseph A. Seiter and titled Insulated Cargo
Containers, the disclosure of which is expressly incorporated
herein by reference.
II. BACKGROUND
[0002] A. Technical Field
[0003] The present invention relates to a method of insulating a
cargo container and an insulated or refrigerated cargo container.
In one embodiment, the cargo container is a railroad boxcar.
[0004] B. Related Art
[0005] Currently, many shippers utilize insulated or refrigerated
large cargo containers (such as boxcars) to transport items that
require the maintenance of specified temperatures during transit.
Because these containers are required to maintain certain
temperatures, the thermal efficiency of these containers is an
important feature. Thermal efficiency is characterized by the
thermal conductivity of a particular component or its inverse, its
resistance to heat transfer commonly referred to as an R value.
[0006] In the past, large cargo containers were typically
constructed of a combination of wood and metal members. Because
members of this type typically possessed a low R-value, insulation,
such as foam insulation, was often installed in these cargo
containers to increase their thermal efficiency. Even with the use
of insulation; however, the thermal efficiency of cargo containers
of this type has not been as high as desired by users of these
cargo containers. Therefore, there is a need for methods of
constructing cargo containers with improved thermal efficiency.
[0007] One such existing method has involved placing additional
insulating materials on the interior of the container. One drawback
of this method is that placing additional insulating materials on
the interior of the container reduces the interior dimensions of
the cargo container. In turn, reducing the interior dimensions of
the cargo container reduces the amount of space available for
cargo. In addition, insulating materials located on the interior of
a cargo container can also be subject to damage from the placement
of cargo in the containers. This also reduces the thermal
efficiency of the cargo container. Therefore, there is a need for
methods of constructing cargo containers with improved thermal
efficiency without substantially reducing the interior dimensions
of the car and making the insulating panels less susceptible to
loading damage.
[0008] The present invention provides a method of constructing
cargo containers with improved thermal efficiency without reducing
the interior dimensions of the car.
II. SUMMARY OF THE INVENTION
[0009] An apparatus consistent with the present invention provides
a cargo container including an underframe having a top and bottom
surface; a floor connected to the underframe; first and second side
walls having exterior surfaces; first and second end walls having
exterior surfaces, and a roof having an exterior surface. The
underframe, floor, first and second side walls; first and second
end walls, and roof form an enclosure. The cargo container also
includes at least one insulating panel comprising an insulating
layer and at least one outer skin located on at least one face of
the insulating layer. The at least one insulated panel is located
on the exterior surface of at least one of the first side wall,
second side wall, first end wall, second end wall, or roof.
[0010] Another apparatus consistent with the present invention
provides a cargo container including an underframe having a top and
bottom surface; a liner having a top surface and located on the top
surface of the underframe; and a floor located on the top surface
of the liner. The cargo container also includes first and second
side walls having exterior surfaces; first and second end walls
having exterior surfaces, and a roof having an exterior surface.
The underframe, floor, first and second side walls; first and
second end walls, and roof form an enclosure. The cargo container
also includes at least one insulating panel comprising an
insulating layer and at least one outer skin located on at least
one face of the insulating layer. The at least one insulated panel
is located on the exterior surface of at least one of the first
side wall, second side wall, first end wall, second end wall, or
roof.
[0011] Another apparatus consistent with the present invention
provides a cargo container including an underframe having a top and
bottom surface; a liner having a top surface and located on the top
surface of the underframe; at least one insulating member on the
top surface of the liner; and a floor located on the at least one
insulating member. The cargo container also includes first and
second side walls having exterior surfaces; first and second end
walls having exterior surfaces, and a roof having an exterior
surface. The underframe, floor, first and second side walls; first
and second end walls, and roof form an enclosure. The cargo
container further includes at least two insulating panels
comprising an insulating layer and at least one outer skin located
on at least one face of the insulating layer. The at least two
insulating panels are located on the exterior surface of at least
one of the first side wall, second side wall, first end wall,
second end wall, or roof. In addition, each insulating panel is
connected to at least one other insulating panel located on the
same exterior surface.
[0012] Additional objects and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
of the invention. The objects and advantages of the invention will
be realized and attained by means of the elements and combinations
particularly pointed out in the appended claims.
[0013] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
[0014] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention and together with the description,
serve to explain the principles of the invention.
III. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A is a perspective view of a boxcar;
[0016] FIG. 1B is a side view of a boxcar;
[0017] FIG. 2 is a perspective view of an insulated panel
consistent with one embodiment of the invention;
[0018] FIG. 3 is a perspective view of a boxcar with insulated
panels installed consistent with one embodiment of the
invention;
[0019] FIG. 4A illustrates two insulated panels with connectors
consistent with one embodiment of the invention;
[0020] FIG. 4B is a cut-away illustration of a portion of two
insulated panels with connectors consistent with one embodiment of
the invention; and
[0021] FIG. 5 illustrates a modified floor consistent with one
embodiment of the invention.
IV. DESCRIPTION OF THE EMBODIMENTS
[0022] A. Introduction
[0023] As described below, methods and apparatus consistent with
the present invention will now be described with respect to the
modification of one embodiment of an existing cargo container: a
boxcar. The invention as claimed, however, is broader than boxcars
and extends to the modification of other large insulated cargo
containers, such as, shipping containers used on seagoing container
vessels, truck trailers, straight trucks, refrigerated buildings,
or the like.
[0024] B. Apparatus and Methods
[0025] FIGS. 1A-1B illustrate two views of a boxcar, one type of
cargo container. A boxcar is an enclosed rail car used to transport
freight. As shown in FIGS. 1A-1B, a boxcar 100 includes side walls
110, a roof 120, a floor 130, end walls 140, and a door opening
150. Wall panels 110, roof 120, floor 130, and end walls 140
combine to form an enclosure 160. Door opening 150 provides access
to enclosure 160. Enclosure 160 can be used to store articles at
specified temperatures. As shown in FIG. 1B, boxcar 100 may also
include doors 170.
[0026] As described above, the thermal efficiency of boxcar 100
depends, in part, on the construction of side walls 110, roof 120,
floor 130, end walls 140, and doors 170. The present invention
provides a method for increasing the thermal efficiency of a cargo
container, such as boxcar 100, by attaching insulated panels to the
exterior surfaces of the cargo container and, in one
implementation, by modifying floor 130. For example, in one
implementation, insulated panels are attached to one or more of the
exterior surfaces of side walls 110, roof 120, end walls 140, and
doors 170. In some cases, however, insulation may also be applied
to the interior side of the doors. These implementations are merely
exemplary and other implementations may also be used.
[0027] FIG. 2 is a perspective view of an insulated panel
consistent with one embodiment of the invention. As discussed
above, insulated panels will be attached to exterior surfaces of
boxcar 100 to improve the thermal efficiency of boxcar 100. As
shown in FIG. 2, in one implementation, an insulated panel 200 is
constructed of an outer skin 210 located on at least one face of an
insulating layer 220. In the implementation of FIG. 2, outer skin
210 is located on opposing faces of insulating layer 220. These
implementations are merely exemplary, and other implementations may
also be used including having multiple and different types of outer
skins.
[0028] In one implementation, the outer skin 210 is constructed of
galvanized steel, aluminum, stainless steel, fiber-reinforced
plastics, removable plastic films or some combination of these
materials. Because insulated panel 200 will be attached to an
existing surface that provides structural support to the boxcar,
insulated panel 200 need not be constructed of materials capable of
providing such support. Therefore, in another implementation,
lighter and more thermally efficient composite materials may be
used to form outer skin 210. These implementations are merely
exemplary, and other implementations may also be used.
[0029] Insulating layer 220 may be constructed from any insulating
material that will increase the thermal efficiency of the
insulating panel 200. In one implementation, insulating layer 220
comprises a closed-cell polymer foam, such as urethane. In another
implementation, insulating layer 220 comprises a vacuum insulated
panel. Vacuum insulated panels are constructed of an intermediate
film or laminate providing a barrier to passage of air into an
interior porous insulating material that has been evacuated to
increase its insulating value. In one implementation, the interior
porous insulating material comprises a micro-cellular open-cell
foam core material. In one implementation, the diameter of the
cells is on the order of 10.sup.-6 in. A one inch thick sheet of
such a material may have a R-value (evacuated) of approximately 28.
A micro-cellular, open-cell polystyrene foam, such as Instill.TM.
available from Dow Chemicals may be used in such an implementation.
In yet another implementation, the porous insulating material is a
fine fiberglass web core material. In one implementation, each fine
fiberglass strand will have a diameter of approximately 0.001 in. A
one inch thick sheet of such a material may have a R-value
(evacuated) of approximately 40. A fine fiberglass web core
material such as Threshold.TM. available from Thermal Visions may
be used in such an implementation. In another implementation,
insulation layer 220 comprises a combination of foam and vacuum
insulated panels. These implementations are merely exemplary, and
other implementations may be used.
[0030] As indicated above, insulated panels are intended for
installation on the exterior surfaces of the boxcar. Therefore, in
one implementation, insulated panels are constructed in a shape
such that they may be overlaid on the exterior surfaces of the
sidewalls of a boxcar. For example, as shown in FIG. 1A, side walls
110 of boxcar 100 contains protrusions, such as protrusion 180 on
boxcar 100. Therefore, in one implementation, insulated panels
include indentations so that insulated panels can fit over the
protrusions on the exterior portion of the boxcar. Insulated panels
may be constructed from any of several well-known methods. In one
implementation, insulated panels will be constructed using
composite extrusion to create a single panel. These implementations
are merely exemplary, and other implementations may also be
used.
[0031] The insulated panels may be applied to boxcar 100 using any
of several well-known application methods. In one implementation,
insulated panels will be applied to boxcar 100 using a structural
adhesive, such as Pliogrip 7700 available from Ashland Specialty
Chemical Company. In another implementation, mechanical fasteners
or welding may be used. In yet another implementation, a
combination of adhesives and mechanical fasteners may be used.
These implementations are merely exemplary, and other
implementations may also be used.
[0032] FIG. 3 is a perspective view of a boxcar with insulated
panels installed consistent with one embodiment of the invention.
As shown in FIG. 3, in one implementation, side wall insulated
panels 300, roof insulated panels 310, end wall insulated panels
320, and door insulated panels 330 are applied to the exterior of
boxcar 350 to improve the thermal efficiency of boxcar 350. Side
wall insulated panels 300, roof insulated panels 310, end wall
insulated panels 320, and door insulated panels 330 are insulated
panels of the construction described above and are designed to fit
over the exterior surfaces of the side walls, roof, end walls, and
doors respectively. In addition, side wall insulated panels 300,
roof insulated panels 310, end wall insulated panels 320, and door
insulated panels 330 are attached to boxcar 350 using one of the
methods described above. Any number of insulated panels may be
applied to a boxcar including any combination of side wall
insulated panels 300, roof insulated panels 310, end wall insulated
panels 320, and door insulated panels 330. These implementations
are merely exemplary, and other implementations may also be
used.
[0033] In one implementation, corner pieces may also be used at the
intersection of various insulated panels. Corner pieces may be made
of FRP composites or any other suitable material which are designed
to fit at the intersection of other composite panels. Insulation
may be added to the corner piece or flashing. As here embodied and
shown in FIG. 3, corner pieces 340 may be installed at the
intersection of a side wall insulated panel 300 and a roof
insulated panel 310 or at the intersection of a side wall insulated
panel 300 with an end wall insulated panel 310. In one
implementation, corner pieces may be connected to the other
insulated panels using one of the methods described below. These
implementations are merely exemplary, and other implementations may
also be used.
[0034] In one implementation, if multiple insulated panels are
used, the insulated panels will interconnect with one another. In
another implementation, the insulated panels will interconnect to
form a single structure. Any suitable method of interconnecting the
insulated panels may be used, such as adhesives, mechanical
fasteners, or welding. In one implementation, the insulated panels
may be connected prior to application of the panels to the boxcar.
In another implementation, the insulated panels may be connected
when during application of the panels to the boxcar. These
implementations are merely exemplary, and other implementations may
also be used.
[0035] In one implementation, insulated panels will be
interconnected using a connector such as that disclosed in U.S.
Pat. No. 3,353,314, the disclosure of which is expressly
incorporated herein. FIG. 4A illustrates two insulated panels with
connectors of this type consistent with one embodiment of the
invention. As shown in FIG. 4A, in one implementation, insulated
panels 400 and 410 have slots 412 and 414 and 416 and 418,
respectively. Slots 412, 414, 416, and 418 are positioned on the
edges of insulated panels 400 and 410 such that when insulated
panels 400 and 410 are aligned with one another, slots 412 and 416
are approximately aligned and slots 414 and 418 are approximately
aligned. In this implementation, each edge of a insulated panel has
two slots, however, any number of slots may be used. In this
implementation, each pair of aligned slots includes a mechanism to
connect insulated panel 400 to insulated panel 410. This mechanism
is further described in FIG. 4B. This implementation is merely
exemplary, and other implementations may also be used.
[0036] FIG. 4B is a cut-away illustration of a portion of two
insulated panels consistent with one embodiment of the invention.
As shown in FIG. 4B, in one implementation, slot 416 includes a
hook 422 and corresponding slot 412 includes a pin 424. In order to
connect two insulated panels, hook 422 engages pin 424. In one
implementation, hook 422 is joined to a rod 426. Rotation of rod
426 allows hook 422 to be rotated so as to either engage with pin
424 or disengage from pin 424. In this implementation, rod 426
extends through outer skin 430 of the insulated panel, as shown in
FIG. 4A. This design allows hook 422 to be rotated without having
to access the interior of the insulated panel. In one
implementation, rod 426 is designed such that it can be turned with
a wrench. These implementations are merely exemplary, and other
implementations may also be used.
[0037] In another implementation, the insulated panels will be
connected using a clip. In this implementation, each insulated
panel will include either a clip or a slot to receive the clip. In
order to connect the insulated panels, the clip will slide into the
slot and lock into place. Any suitable clip may be used in this
implementation. This implementation is merely exemplary, and other
implementations may also be used.
[0038] In one implementation, all insulated panels attached to the
exterior of a boxcar will include a connector such as that shown in
FIG. 4A-4B. In this implementation, the connection of all the
insulated panels will result in the panels forming a single
structure. This implementation is merely exemplary, and other
implementations may also be used.
[0039] Where the cargo container may not be readily insulated by
adding a panel to an exterior surface, such as the floor of a
boxcar, the interior may also be modified to improve the thermal
efficiency of the boxcar without significantly reducing the
interior dimensions of the boxcar. In one implementation, the
interior of the floor of the boxcar may be modified to improve the
thermal efficiency.
[0040] FIG. 5 illustrates a modified floor consistent with one
embodiment of the invention. As shown in FIG. 5, insulated floor
500 includes an underframe 510, which would typically be the
existing underframe of the boxcar. Underframe 510 may also include
structural members, such as center sill 530, side sills 520, or
stringers (not shown).
[0041] In order to improve the thermal efficiency of the floor 500,
a liner 537 is first applied to underframe 510 of a boxcar. Liner
537 may be constructed of sheet material of wood, polymers, metal
or laminates and combinations thereof. In one implementation, sheet
steel is used. In one implementation, the dimensions of liner 537
will be substantially the same as the length and width of the
boxcar. Liner 537 may be attached to underframe 510 using any
suitable method, such as adhesives, fasteners, or welding. These
implementations are merely exemplary, and other implementations may
also be used.
[0042] In this implementation, composite structural members 540 are
then installed on the top surface of liner 537. In one
implementation, as shown in FIG. 5, composite structural members
540 are fiber reinforced polymer structures having a square cross
section that extend substantially the length of the boxcar.
Composite structural members 540 may be applied to liner 537 using
any suitable method, such as adhesives or fasteners. In one
implementation, a structural adhesive, such as Pliogrip 7700
available from Ashland Specialty Chemical Company is used. This
implementation is merely exemplary, and other implementations may
also be used.
[0043] In this implementation, as shown in FIG. 5, insulation 570
is then installed on liner 537 in the areas between composite
structural members 540. In one implementation, insulation 570 is
urethane foam. In another implementation, insulation 570 is a
vacuum insulated panel, such as those described above. In still
another implementation, insulation 570 includes a combination of
urethane foam and vacuum insulated panels. These implementations
are merely exemplary and other implementations may also be
used.
[0044] In this implementation, a top plate 550 is then applied on
top of the composite structural members 540. Top plate 550 may be
constructed of sheet material of wood, polymers, metal or laminates
and combinations thereof. In one implementation, as shown in FIG.
5, supports 535 may also be included to provide additional support
for top plate 550. In this implementation, supports 535 may be
attached to side sills 520. This implementation is merely exemplary
and other implementations may also be used.
[0045] In one implementation, top plate 550 forms the floor of the
boxcar. In another implementation, as shown in FIG. 5, a nailable
floor 560 is applied on top plate 550. Nailable floor 560 is floor
constructed in such a manner that nails may be driven into the
floor to attach cargo to the floor. Nailable floor 560 may be
constructed of wood, polymers, metal or laminates and combinations
thereof. These implementations are merely exemplary and other
implementations may also be used.
[0046] It should be understood that the result of modifying a
boxcar as described above including the use of insulated panels on
the exterior of the car and modifying the floor will improve the
thermal efficiency of the boxcar. It should also be understood that
the increase in these insulating properties has been achieved
without having to construct an entirely new boxcar. As indicated
above, the method of the invention may be applied to other cargo
containers, besides boxcars.
[0047] Other embodiments of the invention will be apparent to those
skilled in the art from consideration of the specification and
practice of the invention disclosed herein. It is intended that the
specification and examples be considered as exemplary only, with a
true scope and spirit of the invention being indicated by the
following claims.
* * * * *