U.S. patent application number 11/516875 was filed with the patent office on 2007-05-17 for foldable container.
Invention is credited to Christopher Krohn, Gerd Krohn, Daniel Major, Dave Revelia, Ed Sajdak, Peter S. Warhurst.
Application Number | 20070108204 11/516875 |
Document ID | / |
Family ID | 37546713 |
Filed Date | 2007-05-17 |
United States Patent
Application |
20070108204 |
Kind Code |
A1 |
Warhurst; Peter S. ; et
al. |
May 17, 2007 |
Foldable container
Abstract
A container includes side walls and end walls that can be folded
to collapse the container for transport and storage. The end walls
are hinged to, and can be folded against, the container floor. The
side walls are articulated so that they can be folded in half. A
sliding coupling secures the side walls in the unfolded position.
The side walls also are hinged to, and can be folded against, the
container floor and roof. One end forms an opening that can be
closed with a door.
Inventors: |
Warhurst; Peter S.;
(Belleair, FL) ; Revelia; Dave; (New Port Richey,
FL) ; Sajdak; Ed; (Largo, FL) ; Krohn;
Gerd; (Knoxville, TN) ; Krohn; Christopher;
(Calhoun, GA) ; Major; Daniel; (Knoxville,
GA) |
Correspondence
Address: |
JENNER & BLOCK, LLP
ONE IBM PLAZA
CHICAGO
IL
60611
US
|
Family ID: |
37546713 |
Appl. No.: |
11/516875 |
Filed: |
September 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60714756 |
Sep 6, 2005 |
|
|
|
Current U.S.
Class: |
220/6 |
Current CPC
Class: |
B65D 2519/00452
20130101; B65D 2519/00502 20130101; B65D 2519/00208 20130101; B65D
2519/00532 20130101; B65D 19/06 20130101; B65D 2519/00164 20130101;
B65D 2519/00273 20130101; B65D 90/0086 20130101; B65D 2519/00333
20130101; B65D 2519/00731 20130101; B65D 2519/00059 20130101; B65D
7/26 20130101; B65D 2519/00233 20130101; B65D 2519/00656 20130101;
B65D 88/524 20130101; B65D 2519/00323 20130101; B65D 2519/00805
20130101; B65D 90/021 20130101; B65D 2519/00641 20130101; B65D
2519/00129 20130101; B65D 2519/00562 20130101; B65D 2519/00611
20130101; B65D 2519/00174 20130101; B65D 2519/00029 20130101; B65D
2519/00925 20130101 |
Class at
Publication: |
220/006 |
International
Class: |
B65D 6/00 20060101
B65D006/00 |
Claims
1. A collapsible container comprising: a top frame portion, a
bottom frame portion, a pair of opposing side frame portions, a
rear frame portion and a front frame portion; each of said side
frame portions comprising a lower side frame portion and an upper
side frame portion, said lower side frame portion hingedly attached
to said bottom frame portion, said upper side frame portion
hingedly attached to said top frame portion, and said lower side
frame portion hingedly attached to said upper side frame portion
whereby said side frame portion is movable between first position
wherein said side wall frame is substantially perpendicular to said
bottom portion and said top portion and a second position wherein
each of said upper side frame portion and said lower side frame
portion is substantially parallel to said bottom frame portion and
said top frame portion; said rear frame portion hingedly attached
to said bottom frame portion and movable between a first position
wherein said rear frame portion is substantially perpendicular to
said bottom frame portion and a second position wherein said rear
frame portion is substantially parallel to said bottom frame
portion; and said front frame portion hingedly attached to said
bottom frame portion and movable between a first position wherein
said front frame portion is substantially perpendicular to said
bottom frame portion and a second position wherein said front frame
portion is substantially parallel to said bottom frame portion.
2. The container of claim 1 further comprising a coupling
associated with at least one of said side frame portions, said
coupling being movable between a first position wherein said
coupling engages with both of the upper and lower side frame
portions comprising said side frame portion and a second position
wherein said coupling does not engage with both of the upper and
lower side frame portions comprising said side frame portion.
3. The container of claim 1 further comprising at least one
removable fastener securing at least one of said top frame portion,
said pair of opposing side frame portions, said rear frame portion
and said front frame portion to another of said top frame portion,
said pair of opposing side frame portions, said rear frame portion
and said front frame portion.
4. The container of claim 3 wherein said at least one of said top
frame portion, said pair of opposing side frame portions, said rear
frame portion and said front frame portion and said another of said
top frame portion, said pair of opposing side frame portions, said
rear frame portion and said front frame portion define a pair of
corresponding apertures for receiving said removable fastener.
5. The container of claim 3 further comprising at least one captive
nut for receiving said at least one removable fastener.
6. The container of claim 1 wherein at least one of said rear frame
portion, when in said first position, and said front frame portion,
when in said first position, engages with at least one of said top
frame portion and said pair of opposing side frame portions.
7. The container of claim 1 further comprising a floor deck
associated with said bottom frame portion.
8. The container of claim 1 further comprising a skin associated
with at least one of said top frame portion, said pair of opposing
side frame portions, said rear frame portion.
9. The container of claim 1 further comprising a door associated
with said front frame.
10. The container of claim 9 wherein said door is movable between a
first position wherein said door is associated with, and closes an
opening in, said front frame portion and a second position wherein
said door is associated with said top frame portion.
11. The container of claim 10 further comprising at least one guide
roller associated with said door.
12. The container of claim 11 wherein said at least one guide
roller is connected to said top frame portion by a bracket, said
bracket being movable between a first position and a second
position.
13. The container of claim 9 further comprising means for locking
said door.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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.
BACKGROUND OF THE INVENTION
[0002] 1. The Technical Field
[0003] The present invention is directed generally to collapsible
containers and more particularly to collapsible shipping and
storage containers and methods of using same.
[0004] 2. The Prior Art
[0005] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front perspective view of a foldable container
in a deployed state according to the present invention;
[0007] FIG. 2 is a front perspective view of a foldable container
in a partially-collapsed state according to the present
invention;
[0008] FIG. 3 is a perspective view of a foldable container in a
collapsed state according to the present invention;
[0009] FIG. 4 is a rear perspective view of the framework of a
foldable container in a partially deployed state according to the
present invention;
[0010] FIG. 5 is a rear perspective view of the framework of a
foldable container in a deployed state according to the present
invention;
[0011] FIG. 6 is an exploded view of the framework of a foldable
container according to the present invention;
[0012] FIG. 6A is a detail view of a portion of the framework of a
foldable container according to the present invention;
[0013] FIG. 6B is a detail view of a portion of the framework of a
foldable container according to the present invention;
[0014] FIG. 6C is a detail view of a portion of the framework of a
foldable container according to the present invention; and
[0015] FIG. 6D is a detail view of a portion of the framework of a
foldable container according to the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0016] FIGS. 1-3 illustrate a foldable container according to a
preferred embodiment of the present invention in deployed,
partially-collapsed, and collapsed states, respectively. Foldable
container 10 includes floor 12, roof 14, side walls 16,18, rear
wall 20, and front end 22. Each of side walls 16,18 typically
includes an upper portion 16U,18U and a lower portion 16L,18L.
Preferably, upper side walls 16U,18U define the upper half of side
walls 16,18 and lower side walls 16L,18L define the lower half of
side walls 16,18. Roof 14, side walls 16,18, and rear wall 20
typically include a skin 24R,24SW,24RW, respectively, that protects
the contents of container 10 from the elements and provides a
barrier to unauthorized access to the interior of container 10.
[0017] 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.
[0018] FIGS. 4-6 illustrate the framework 30 of container 10 in
partially-deployed and deployed states, respectively, according to
a preferred embodiment of the present invention. In this
embodiment, framework 30 includes floor frame 32, roof frame 34,
side wall frames 36,38, rear wall frame 40, and front end frame 42.
Each of side wall frames 36,38 includes an upper portion 36U,38U
and a lower portion 36L,38L.
[0019] 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.
[0020] 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 FIG. 6 (where a
portion of perimeter member 48A has been cut away for clarity).
This design provides additional volume (compared to embodiments
lacking second perimeter rim 48A and short columns 49) within roof
frame 34 for receiving door 26 and enclosing and protecting related
components, as will be discussed further below.
[0021] 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 FIGS. 6 and 6A. In such embodiments, as would be understood by
one skilled in the art, roof frame 34 also can include guide
rollers 56 to facilitate moving door 26 between the retracted
position wherein door 26 is positioned in door tracks 54 associated
with roof frame 34, as shown in FIG. 4, and the deployed position
wherein door 26 is positioned in door tracks 76 associated with
front end 22, as shown in FIG. 1 and as will be discussed further
below. Guide rollers 56 typically are connected to perimeter member
48 of roof frame 34 by means of brackets 57. Brackets 57 can fixed
to perimeter member 48 or rotatably connected to perimeter member
48 so that bracket 57 and guide rollers 56 can be rotated from a
deployed position wherein guide rollers 56 and portions of brackets
57 may extend outside (and, more particularly, below) the volume
defined by roof frame 34, as discussed above and as shown in FIGS.
6 and 6A, to a stored position (not shown) wherein guide rollers 56
and brackets 57 are more fully enclosed by the volume defined by
roof frame 34.
[0022] 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 FIGS. 4 and 5. Braces and/or stiffeners (not shown) may be
included to provide adequate strength to the upper side wall
frames, as would be known to one skilled in the art.
[0023] 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.
[0024] 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 FIGS. 4 and 5. Braces and/or stiffeners (not shown) may be
included to provide adequate strength to the lower side wall
frames, as would be known to one skilled in the art.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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 FIG.
6; door tracks 76 have been omitted from the other drawings for
clarity) which receive the side edge portions of door 26 when door
26 is positioned in and moved to and from the deployed position, as
shown in FIG. 1.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.).
[0035] With container 10 in the deployed state, as shown in FIGS. 1
and 5, upper and lower side walls 16U,18U and 16L,18L,
respectively, are substantially perpendicular to floor 12 and roof
14 and coextensive with each other. Rear wall 20 and front end 22
are substantially perpendicular to floor 12, roof 14, and side
walls 16,18. Preferably, at least portions of the outer perimeter
of each of rear wall frame 40 and front end frame 42 are at least
loosely engaged with interior portions of roof frame 34 and side
wall frames 36,38, as best shown in FIG. 5, so as to inhibit
collapse of roof 14 and side walls 16,18.
[0036] In preferred embodiments, as best shown in FIG. 6,
corresponding pairs of apertures 78 are provided in adjacent
portions of roof frame 34, upper and lower side wall frames 36U,38U
and 36L,38L, respectively, rear wall frame 40 and front end frame
42 to enable use of fasteners, for example, bolts 80, to
interconnect such frame portions when container 10 is in the
deployed state. (In practice, more or fewer pairs of apertures 78
than shown in FIG. 6 may be provided.) For example, one or more
bolts 80 preferably are inserted through corresponding pairs of
apertures 78 in adjacent portions of the foregoing frame members to
secure perimeter rim 48 of roof frame portion 34 to perimeter rim
58U of upper side frame portions 36U,38U, perimeter rim 86 of rear
frame portion 40, and perimeter rim 96 of front frame portion 42.
Similarly, one or more bolts 80 can be used to secure perimeter rim
56U of upper side frame portions 36U,38U to perimeter rim 56L of
lower side frame portions 36L,38L (see FIG. 6D), and one or more
bolts 80 can be used to secure perimeter rims 56U,56L of upper and
lower side frame portions 36U,36L,38U,38L to perimeter rim 86 of
rear frame portion 40 and perimeter rim 96 of front frame portion
42.
[0037] 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 FIG. 5, bolts 80
extend through the entirety of bottom member 60U of upper side wall
frame 38U and top member 62L of lower side wall frame 38L and are
fastened to captive nuts 82 (or a loose nut) on the bottom surface
of top member 62L of lower side wall frame 38L. In embodiments
where at least one of the members to be fastened together has a
hollow cross-section (e.g., tube steel), captive nuts 82 preferably
are fitted on the inside of such member so that bolt 80 need not
extend through the entirety of such member. In all embodiments,
bolt 80 preferably is installed into the members to be connected
from the interior of container 10 to preclude tampering with bolt
80 from the exterior of container 10.
[0038] 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.
[0039] 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. FIGS. 6, 6B, and 6C illustrate one such embodiment
wherein columns 64U,64L are members, such as tube steel, having
hollow cross sections and coupling 84 is a member, such as steel
bar stock or tube steel, sized to fit within columns 64U,64L in
sliding engagement. Coupling 84 is movable between a first,
retracted position, wherein coupling 84 is engaged with column 64L,
but not column 64U, and a second, deployed position wherein
coupling 84 is engaged with both column 64L and column 64U, thus
inhibiting the collapse of upper and lower side wall frames 36U,38U
and 36L,38L.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
* * * * *