U.S. patent application number 14/581383 was filed with the patent office on 2015-04-23 for lower frame assembly for a collapsible container.
This patent application is currently assigned to ROBERT J. KRAFT. The applicant listed for this patent is JOSHUA J. KRAFT, ROBERT J. KRAFT. Invention is credited to JOSHUA J. KRAFT, ROBERT J. KRAFT.
Application Number | 20150108121 14/581383 |
Document ID | / |
Family ID | 52825250 |
Filed Date | 2015-04-23 |
United States Patent
Application |
20150108121 |
Kind Code |
A1 |
KRAFT; JOSHUA J. ; et
al. |
April 23, 2015 |
LOWER FRAME ASSEMBLY FOR A COLLAPSIBLE CONTAINER
Abstract
The present invention discloses a novel apparatus for improving
the structural integrity of a folding shipping container in order
to improve safety and durability of the shipping container. A
foldable shipping container is provided having an improved lower
frame assembly.
Inventors: |
KRAFT; JOSHUA J.; (TEQUESTA,
FL) ; KRAFT; ROBERT J.; (TEQUESTA, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KRAFT; JOSHUA J.
KRAFT; ROBERT J. |
TEQUESTA
TEQUESTA |
FL
FL |
US
US |
|
|
Assignee: |
KRAFT; ROBERT J.
TEQUESTA
FL
KRAFT; JOSHUA J.
TEQUESTA
FL
|
Family ID: |
52825250 |
Appl. No.: |
14/581383 |
Filed: |
December 23, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13815638 |
Mar 13, 2013 |
|
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14581383 |
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Current U.S.
Class: |
220/7 ;
220/1.5 |
Current CPC
Class: |
B65D 88/522
20130101 |
Class at
Publication: |
220/7 ;
220/1.5 |
International
Class: |
B65D 88/52 20060101
B65D088/52; B65D 88/10 20060101 B65D088/10 |
Claims
1. A supporting frame assembly for a collapsible container
comprising: a first lower base beam extending from a front of the
container to a rear of the container; a second lower base beam
generally parallel to the first lower base beam and spaced a
distance from the first lower base beam, the second lower base beam
extending from the front of the container to the rear of the
container; and, a plurality of cross members secured to and
extending between the first lower base beam and the second lower
base beam, the plurality of cross members comprising: a vertical
member; a first leg extending in a generally perpendicular
direction from a first end of the vertical member; and, a second
leg extending from a second end of the vertical member, the second
leg extending towards the first leg.
2. The supporting frame assembly of claim 1, wherein the first
lower base beam and the second lower base beam each have a
generally c-shaped cross section.
3. The supporting frame assembly of claim 1, wherein the plurality
of cross members have a vertical height comparable to that of the
first and second lower base beams.
4. The supporting frame assembly of claim 1, wherein the cross
members are located from proximate the rear of the container
through at least a midpoint of the first lower base beam and the
second lower base beam.
5. The supporting frame assembly of claim 4, wherein the cross
members are spaced at an equal axial distance from each other.
6. The supporting frame assembly of claim 4 further comprising a
recessed portion formed in part by a first axial beam and a second
axial beam extending from the front of the container a distance
towards the midpoint of the first lower base beam and the second
lower base beam and parallel to the first lower base beam and
second lower base beam.
7. The supporting frame assembly of claim 6 further comprising a
plurality of c-shaped cross members extending between the first
axial beam and the first lower base beam and the second axial beam
and the second lower base beam.
8. The supporting frame assembly of claim 1 further comprising a
torsional spring in the first lower base beam and the second lower
base beam.
9. A preloaded supporting frame assembly for a collapsible shipping
container comprising: a first lower base beam having a first length
extending from a front of the container to a rear of the container,
the first lower base beam having an arc-shaped profile along the
first length; a second lower base beam having a second length
extending generally parallel to the first lower base beam and
spaced a distance from the first lower base beam, the second lower
base beam extending from the front of the container to the rear of
the container and having an arc-shaped profile along the second
length; and, a plurality of cross members extending between the
first lower base beam and the second lower base beam, and from the
rear of the container forward a predetermined distance, the
plurality of cross members comprising: a vertical member; a first
leg extending in a generally perpendicular direction from a first
end of the vertical member; and, a second leg extending from a
second end of the vertical member, the second leg extending towards
the first leg; wherein the first lower base beam and the second
lower base beam are formed so as to have a maximum deflection at a
midpoint along the first lower base beam and the second lower base
beam.
10. The preloaded supporting frame assembly of claim 9, wherein the
deflection is formed by hydraulic pressure applied to the first
lower base beam and the second lower base beam.
11. The preloaded supporting frame assembly of claim 9 further
comprising a recessed portion adjacent the front of the container
formed in part by a first axial beam and a second axial beam and a
plurality of c-shaped cross members extending from the first axial
beam to the first lower base beam and from the second axial beam to
the second lower base beam.
12. The supporting frame assembly of claim 9, wherein the first
lower base beam and the second lower base beam each have a
generally c-shaped cross section.
13. The supporting frame assembly of claim 12, wherein the
plurality of cross members have a vertical height comparable to
that of the first and second lower base beams.
14. The supporting frame assembly of claim 9, wherein the
arc-shaped profile tapers from a front or rear of the container to
the midpoint.
15. The supporting frame assembly of claim 9, wherein upon a
mechanical loading of the supporting frame assembly, the deflection
of the first lower base beam and second lower base beam is
reduced.
16. The supporting frame assembly of claim 9, wherein the maximum
deflection of the first lower base beam and second lower base beam
is approximately 10 mm.
17. A cross beam member of a frame assembly comprising: a vertical
member; a first leg extending in a generally perpendicular
direction from a first end of the vertical member; and, a second
leg extending from a second end of the vertical member, the second
leg extending towards the first leg.
18. The cross beam member of claim 17, wherein the cross beam is
positioned between and secured to a first lower base beam and a
second lower base beam to form a frame assembly.
19. The cross beam member of claim 18, wherein the cross beam is
oriented perpendicular to the first lower base beam and the second
lower base beam.
20. The cross beam member of claim 17, wherein the cross beam
member extending between the first lower base beam and the second
lower base beam proximate a midpoint of the first lower base beam
and the second lower base beam is deflected a distance of
approximately 10 mm at the midpoint along the first lower base beam
and the second lower base beam.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 13/815,638, filed on Mar. 13, 2013.
TECHNICAL FIELD
[0002] The present invention relates generally to a shipping
container. More specifically the present invention relates to
improvements in a supporting frame assembly for a collapsible
shipping container.
BACKGROUND OF THE INVENTION
[0003] The shipping industry uses large cargo containers to ship
cargo from one location to another in domestic and global commerce.
Such containers are designed to be conveniently moved from one mode
of transport to another across the land by road or on rail or over
the sea. Such containers are sometimes referred to as "intermodal
shipping containers". The use of such containers has essentially
eliminated the need for manually transferring cargo from one vessel
to another, or from one vehicle or railcar to another in the effort
to deliver the cargo to its final destination.
[0004] Today, cargo containers are generally standardized by
internationally recognized standards, and by national domestic
standards with respect to dimensions and structure. Thus, the
standard containers can be securely arranged in vertical stacks in
side-by-side and end-to-end relationship with each other, and can
be handled most effectively when transferring from one mode of
transport to another.
[0005] Often, these containers must be transported empty from one
delivery point to the next location where cargo is available for
shipment. Transport of empty containers costs the shipper money and
erodes profits since transport of each such container incurs
handling cost and occupies valuable space which could otherwise be
used to ship a revenue producing container loaded with cargo.
Additionally, the shipping of both loaded and empty containers
creates problems such as how to arrange the lighter, empty
containers and the heavier, loaded containers aboard ships in such
a manner that the safety of the ships is not compromised. Beyond
safety issues, the shipment of empty containers causes monetary
losses for shippers, losses which result in either substantial
financial impact on the shipper, or increased charges to customers
for the handling and transport of loaded containers. Similar cost
disadvantages apply when shipping empty containers over road or by
rail.
[0006] Long ago shippers recognized that significant economic
savings in shipping could be realized if empty containers could be
"folded" so as to occupy a substantially smaller space, so that
less space need be sacrificed in the transporting of empty
containers. Such an effort presently exists only for the "open
frame" or flat rack type containers. To that end, the prior art
proposed many foldable or nesting cargo containers of the enclosed
types intended to reduce the space required for their shipment when
empty. While such prior art foldable containers have been proposed,
the market has not embraced the prior art containers as a
substitute for the standard, non-foldable cargo containers.
[0007] One common shortcoming in most foldable container designs is
that structural features are incorporated in them which render the
designs nearly incompatible for use in combination with existing,
standard cargo containers. Accordingly, if these cargo containers
were to become a part of the norm, they could not be used with
existing standard containers, making the cost of implementation of
these designs impractical, if not prohibitive.
[0008] Another shortcoming of foldable containers of the prior art
is the lack of structural designs which enable or facilitate the
folding and un-folding of such containers in a simple and effective
manner with commonly available equipment.
OBJECTS OF THE PRESENT INVENTION
[0009] An object of this invention is to provide a novel, foldable,
enclosed shipping container which is compatible with existing
standard non-foldable containers.
[0010] It is another object of this invention to provide a
container which does not require assembly and disassembly of loose
parts of the container in its normal use.
[0011] Another object and feature of the present invention is to
provide a foldable shipping container which includes flat,
horizontal, rigid unitary roof and base panels and vertical side
panels hingedly connected to adjacent edges of the base panel
whereby the side panels can pivot laterally inwardly relative to
the roof and base panels during the process of folding the
container from an unfolded condition to a folded condition in which
the roof panel and base panel end up in close parallel relationship
with each other.
[0012] Yet another object of this invention is to provide a
container structure of the general character referred to above
which includes normally vertical end walls to maintain the roof,
base and side panels in their normal positions.
[0013] Still another object of this invention is to provide a
container which includes vertical posts at the four corners of the
container but which allow for free movement of the panels and their
related parts while folding or unfolding the container.
[0014] The foregoing and other objects and features of this
invention will be fully understood from the following detailed
description of one typical preferred embodiment of the invention
throughout which description reference is made to the accompanying
drawings.
SUMMARY
[0015] The present invention discloses a system for collapsible
shipping containers. More specifically, in an embodiment of the
present invention, a supporting frame assembly for a collapsible
container is provided. The supporting frame assembly comprises a
first lower base beam and second lower base beam extending from a
front to the rear of the container. A plurality cross members
extend between the lower base beams with the cross members having a
vertical member, a first leg perpendicular to the vertical member
and a second member extending from the vertical member, but in a
direction towards the first leg.
[0016] In an alternate embodiment of the present invention, a
preloaded supporting frame assembly for a collapsible shipping
container is disclosed. The preloaded supporting frame assembly
comprises a first lower base beam having an arc-shaped profile
along its length and a second lower base beam having an arc-shaped
profile along its length. A plurality of cross members extend
between the lower base beams with the cross members having a
vertical member, a first leg perpendicular to the vertical member
and a second member extending from the vertical member, but in a
direction towards the first leg. The preloaded supporting frame
assembly is cambered a predetermined distance in order to comply
with shipping regulations when in a loaded condition.
[0017] In an alternate embodiment of the present invention, a cross
beam member of a frame assembly is provided. The cross beam member
has a vertical member, a first leg perpendicular to the vertical
member and a second member extending from the vertical member, but
in a direction towards the first leg.
[0018] Additional advantages and features of the present invention
will be set forth in part in a description which follows, and in
part will become apparent to those skilled in the art upon
examination of the following, or may be learned from practice of
the invention. The instant invention will now be described with
particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] The present invention is described in detail below with
reference to the attached drawing figures, wherein:
[0020] FIG. 1 is a view of the present invention viewing the door
panel and the right side panel.
[0021] FIG. 2 is a view of the present invention viewing the door
panel and the left side panel.
[0022] FIG. 3 a view of the present invention viewing the front
panel and the left side panel.
[0023] FIG. 4 is a plan view of the top of the roof panel.
[0024] FIG. 5 is a perspective view of the underside of the roof
panel.
[0025] FIG. 6 is a view of the inside of the front panel taken
along line A-A of FIG. 1.
[0026] FIG. 7 is an enlarged view of section B-B of FIG. 6.
[0027] FIG. 8 is an enlarged view of section C-C of FIG. 6.
[0028] FIG. 9 is a cross sectional view of the front panel taken
along line D-D of FIG. 3.
[0029] FIG. 10 is a partial view of the underside of the front end
of the roof panel.
[0030] FIGS. 11A and 11B are plan views of the front first hinge
members.
[0031] FIG. 12 is a plan view of the front end of the roof
panel.
[0032] FIG. 13 is a plan view of the door end of the roof
panel.
[0033] FIG. 14 is a partial view of the underside of the door end
of the roof panel.
[0034] FIG. 15 is a plan view of the door first hinge members.
[0035] FIG. 16 is a perspective view of the upper side of the left
side of the base panel.
[0036] FIG. 17 is a perspective view of the upper side of the right
side of the base panel.
[0037] FIG. 18 is a plan view of the front end of the base
panel.
[0038] FIGS. 19, 20 and 21 are views of base front tangs.
[0039] FIG. 22 is a plan view of the door end of the base
panel.
[0040] FIG. 23 is a plan view of the right side door interlock.
[0041] FIG. 24 is a plan view of the left side door interlock.
[0042] FIG. 25 is a view of the base panel hammer locking mechanism
and right door interlock.
[0043] FIG. 26 is a view of the base panel hammer locking mechanism
and left door interlock.
[0044] FIG. 27 is a plan view of the underside of the base
panel.
[0045] FIG. 28 is a plan view of the upper side of the base
panel.
[0046] FIG. 29 is a plan view of the external surface of the right
side panel.
[0047] FIG. 30 is a cross sectional view of the flanges at the
front edge of the right side panel.
[0048] FIG. 31 is a cross sectional view of the flanges at the door
edge of the right side panel.
[0049] FIG. 32 is a plan view of the internal surface of the right
side panel.
[0050] FIG. 33 is a cross sectional view of a linear spring
assembly.
[0051] FIG. 34 is a cross sectional view of the upper end of a
linear spring assembly.
[0052] FIG. 35 is a cross sectional view of the lower end of a
linear spring assembly.
[0053] FIG. 36 is a plan view of a locking rod assembly in
isolation.
[0054] FIG. 37 is a plan view of the external surface of the left
side panel.
[0055] FIG. 38 is a cross sectional view of the flanges at the door
edge of the left side panel.
[0056] FIG. 39 is a cross sectional view of the flanges at the
front.
[0057] FIG. 40 is a plan view of the internal surface of the left
side panel.
[0058] FIGS. 41A and 41B are plan views of the side hinge
members.
[0059] FIG. 42 is a plan view of the external surface of the front
panel.
[0060] FIGS. 43A and 43B are plan views of the right and left front
access panels.
[0061] FIG. 44 is a plan view of the internal surface of the front
panel.
[0062] FIGS. 45A, 45B, 45C and 45D are views of the front pivot
hinge.
[0063] FIG. 46 is an internal view of the front end panel and right
access panel.
[0064] FIG. 47 is an enlarged view of section E-E of FIG. 46.
[0065] FIG. 48 is an internal view of the front end panel and left
access panel.
[0066] FIG. 49 is an enlarged view of section F-F of FIG. 48.
[0067] FIGS. 50, 51 and 52 are horizontal cross sectional views of
the front panel interlocks.
[0068] FIG. 53 is a cross sectional view taken along line H-H of
FIG. 50.
[0069] FIG. 54 is a cross sectional view of the right side
interlock of the front panel.
[0070] FIG. 55 is a cross sectional view taken along line I-I of
FIG. 50.
[0071] FIG. 56 is a cross sectional view of the left side interlock
of the front panel.
[0072] FIG. 57 is a perspective view of the right interlock of the
front panel.
[0073] FIG. 58 is an inside view of the right interlock of the
front panel.
[0074] FIG. 59 is an external view of the roller arm cover plate of
the front right post.
[0075] FIG. 60 is a perspective view of the roller arm cover plate
of the front right post.
[0076] FIG. 61 is an end view of the roller arm cover plate of the
front right post.
[0077] FIG. 62 is a perspective view of the left interlock of the
front panel.
[0078] FIG. 63 is an inside view of the left interlock of the front
panel.
[0079] FIG. 64 is an external view of the roller arm cover plate of
the front left post.
[0080] FIG. 65 is a perspective view of the roller arm cover plate
of the front left post.
[0081] FIG. 66 is an end view of the roller arm cover plate of the
front left post.
[0082] FIG. 67 is a perspective view of the front panel and right
and left access panels.
[0083] FIG. 68 is a view of a front right access panel hinge.
[0084] FIG. 69 is a plan view of the inner surface of the front
right access panel.
[0085] FIG. 70 is a cross sectional view of the front right access
panel.
[0086] FIG. 71 is an enlarged view of section K-K of FIG. 70.
[0087] FIG. 72 is a view of the slide locking mechanism of the
front right access panel.
[0088] FIG. 73 is a perspective view of the upper cap plate of the
front right access panel.
[0089] FIG. 74 is a perspective view of the front panel and right
and left access panels.
[0090] FIG. 75 is a view of a front left access panel hinge.
[0091] FIG. 76 is a plan view of the inner surface of the front
left access panel.
[0092] FIG. 77 is a cross sectional view of the front left access
panel.
[0093] FIG. 78 is an enlarged view of section M-M of FIG. 77.
[0094] FIG. 79 is a view of the slide locking mechanism of the
front left access panel.
[0095] FIG. 80 is a perspective view of the upper cap plate of the
front left access panel.
[0096] FIG. 81 is a plan view of the external surface of the door
panel.
[0097] FIG. 82 is a top view of the locking bar on the door
panel.
[0098] FIG. 83 is a plan view of the locking bar on the door
panel.
[0099] FIG. 84 is an internal view of the door end panel and right
access panel.
[0100] FIG. 85 is an enlarged view of section P-P of FIG. 84.
[0101] FIG. 86 is an internal view of the door end panel and left
access panel.
[0102] FIG. 87 is an enlarged view of section Q-Q of FIG. 86.
[0103] FIGS. 88A, 88B and 88C are views of the door pivot
hinge.
[0104] FIG. 89 is a perspective view of the door panel and right
and left access panels.
[0105] FIG. 90 is a perspective view of the door panel and right
and left access panels.
[0106] FIG. 91 is a plan view of the external surface of the door
right access panel.
[0107] FIG. 92 is a plan view of the external surface of the door
left access panel.
[0108] FIG. 93 is a view of the front face of the door right post
locking tang.
[0109] FIG. 94 is a view of the door face of the door right post
locking tang.
[0110] FIG. 95 is a view of the front face of the door left post
locking tang.
[0111] FIG. 96 is a view of the door face of the door left post
locking tang.
[0112] FIG. 97 is a view of the door right post roller arm.
[0113] FIG. 98 is a view of the door left post roller arm.
[0114] FIG. 99 is a plan view of the inner surface of the door
right access panel.
[0115] FIG. 100 is a cross sectional view of the door right access
panel.
[0116] FIG. 101 is an enlarged view of section T-T of FIG. 100.
[0117] FIG. 102 is a view of a door right access panel hinge.
[0118] FIG. 103 is a view of the slide locking mechanism of the
door right access panel.
[0119] FIG. 104 is a perspective view of the upper cap plate of the
door right access panel.
[0120] FIG. 105 is a plan view of the inner surface of the door
left access panel.
[0121] FIG. 106 is a cross sectional view of the door left access
panel.
[0122] FIG. 107 is an enlarged view of section V-V of FIG. 106.
[0123] FIG. 108 is a view of a door left access panel hinge.
[0124] FIG. 109 is a view of the slide locking mechanism of the
door left access panel.
[0125] FIG. 110 is a perspective view of the upper cap plate of the
door left access panel.
[0126] FIG. 111 is a perspective view of the front end of the
folded container.
[0127] FIG. 112 is a perspective view of the door end of the folded
container.
[0128] FIG. 113 is a schematic plan view showing the base panel
with the side panels folded down and laying on top of it.
[0129] FIG. 114 is schematic cross sectional view taken along line
114-114 of FIG. 113.
[0130] FIG. 115 shows a schematic side view of the base panel with
the side panels in an unfolded position.
[0131] FIG. 116 is a schematic transverse cross-sectional view
through the base panel and the side panels adjacent one of the side
hinge members and linear spring assemblies.
[0132] FIG. 117 is a view of one of the hinge pin torsion spring
assemblies secured to the base panel and a side panel.
[0133] FIG. 118 is a view of a hinge pin of one of the hinge pin
torsion spring assemblies.
[0134] FIG. 119 is a view of a Torsion spring of one of the hinge
pin torsion spring assemblies.
[0135] FIG. 120 is a view of a hinge pin torsion spring fully
assembled.
[0136] FIG. 121 is a view showing a hinge pin of a hinge pin
torsion spring received within a hole in a base hinge member.
[0137] FIG. 122 is a view showing a hinge pin of a hinge pin
torsion spring received within a hole in another base hinge
member.
[0138] FIG. 123 is a perspective view of a supporting frame
assembly in accordance with an embodiment of the present
invention.
[0139] FIG. 124 is a top elevation view of the supporting frame
assembly of FIG. 123 in accordance with an embodiment of the
present invention.
[0140] FIG. 125 is a cross section view taken through the
supporting frame assembly of FIG. 123 in accordance with an
embodiment of the present invention.
[0141] FIG. 126 is an alternate cross section view taken through
the supporting frame assembly of FIG. 123 in accordance with an
embodiment of the present invention.
[0142] FIG. 127 is a perspective view of a cross member in
accordance with an embodiment of the present invention.
[0143] FIG. 128 is a cross section view of the cross member of FIG.
126 in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0144] As shown in FIG. 1 the preferred embodiment of the foldable
container 10 of the present invention includes a roof panel 11, a
door panel, and a right side panel 14, and as shown in FIG. 2 the
foldable container 10 further includes a left side panel 16.
Collectively, the right side panel 14 and the left side panel 16
may be referred to herein as the "side panels", or individually
either may be referred to as a "side panel". As shown in FIG. 3,
the foldable container further includes a base panel 17, and a
front panel 12 opposite the door panel 18.
[0145] Referring back to FIG. 1, the roof panel 11 includes a roof
right edge 19, a roof left edge 20, a roof door edge 21, and a roof
front edge 22. As shown in FIGS. 1 and 3, the roof panel 11
includes four standard corner fittings 36a, 36b, 36c, 36d of the
type known in the art for lifting the foldable container 10 (as
with a spreader), or for securing the foldable container 10 to
another container which may be stacked on top of it. One corner
fitting 36a, 36b, 36c, 36d is located on the roof panel 11 adjacent
each end 13a, 13b of the roof front edge 22, and adjacent each end
15a, 15b of the roof door edge 21 thereof, in accordance with the
international standards.
[0146] As shown in FIGS. 4 & 5, a hollow, rectangular roof
right beam 600 extends along the right edge 19 of the roof panel 11
from the corner fitting 36a on the front edge 22 adjacent the roof
right edge 19 of the roof panel 11 to the corner fitting 36b on the
roof door edge 21 adjacent the roof right edge 19 of the roof panel
11. The roof right beam 600 is continuous except for the
interruptions where the roof lifting beams 606, 607 pass through
the roof right beam 600. The end 601 of the roof right beam 600
adjacent the roof front edge 22 is rigidly attached to the adjacent
corner fitting 36a, preferably by welding, and the end 602 of the
roof right beam 600 adjacent the roof door edge 21 is rigidly
attached to the adjacent corner fitting 36b, preferably by welding.
Likewise, the roof right beam 600 is preferably welded to the roof
lifting beams 606, 607 where they pass through the roof right beam
600. As shown in FIGS. 6&7, the roof right beam 600 is hollow
and extends downwardly from the roof right edge 19 a distance of
about four inches.
[0147] As shown in FIGS. 4 & 8, a hollow, rectangular roof left
beam 603 extends along the roof left edge 20 of the roof panel 11
from the corner fitting 36c on the front edge 22 adjacent the roof
left edge 20 of the roof panel 11 to the corner fitting 36d on the
roof door edge 21 adjacent the roof left edge 20 of the roof panel
11. The roof left beam 603 is continuous except for the
interruptions where the roof lifting beams 606, 607 pass through
the roof left beam 603. The end 604 of the roof left beam 603
adjacent the roof front edge 22 is rigidly attached to the adjacent
corner fitting 36c, preferably by welding, and the end 605 of the
roof left beam 603 adjacent the roof door edge 21 is rigidly
attached to the adjacent corner fitting 36d, preferably by welding.
Likewise, the roof left beam 603 is preferably welded to the roof
lifting beams 606, 607 where they pass through the roof left beam
603. The roof left beam 603 is hollow and extends downwardly from
the roof left edge 20 a distance of about four inches. The lower
face 608 of the roof right beam 600 and the lower face 609 of the
roof left beam 603 each contain a plurality of locking bolt holes
610, the purpose of which is described below.
[0148] As shown in FIG. 1, along the roof right edge 19 of the roof
panel 11, a right skirt 23 extends downwardly therefrom a length of
about twelve inches, and as shown in FIG. 2, along the roof left
edge 20 of the roof panel 11, a left skirt 24 also extends
downwardly therefrom a length of about twelve inches.
[0149] The upper exterior surface 25 of the roof panel 11 is made
from corrugated metal, preferably CorTen.RTM. steel. As shown in
FIGS. 3 & 9, the roof panel 11 includes a hollow, rectangular
roof front beam 1000 that has one end 611 adjacent the roof right
edge 19 and another end 612 adjacent the roof left edge 20. The
roof front beam 1000 extends along the roof front edge 22 of the
roof panel 11, and extends downwardly therefrom a distance of about
four inches. More specifically, the rectangular roof front beam
1000 extends from the corner fitting 36a on the roof front edge 22
to the other corner fitting 36c on the roof front edge 22. The end
611 of the front beam 1000 adjacent the corner fitting 36a is
rigidly attached thereto, preferably by welding, and the end 612 of
the roof front beam 1000 adjacent the corner fitting 36c is rigidly
attached thereto, also preferably by welding. As shown in FIG. 10,
the roof panel 11 further includes two front first hinge sets 613,
614. The front first hinge set 613 includes two front first hinge
members 31a, 31b, each rigidly connected to the lower surface 615
of the corner fitting 36a adjacent the roof front edge 22 and the
roof right edge 19, preferably by welding. The front first hinge
set 614 likewise includes two front first hinge members 31c, 31d,
each rigidly connected to the lower surface 616 of the corner
fitting 36c adjacent the roof front edge 22 and the roof left edge
20, preferably by welding. The front first hinge members 31a, 31b,
of the front first hinge set 613 adjacent the roof right edge 19
are fixed in spaced relation to each other for receiving a front
hinge pivot 617, as described in greater detail below, and the
front first hinge members 31c, 31d, of the front first hinge set
614 adjacent the roof left edge 20 are fixed in spaced relation to
each other for receiving another front hinge pivot 618, as
described in greater detail below. A representative front first
hinge member 31 is shown in isolation in FIGS. 11A and 11B. Each
front first hinge member has a front hinge edge 622, front pivot
hole 619, a front bolt hole 620, and a lug receiving slot 621. The
purpose of each of these features is described in greater detail
below.
[0150] As shown in FIG. 5, a front hinge plate 623, 624, having a
length substantially equal to the length of the front hinge edge
622 of the first hinge members 31a, 31b, 31c, 31d, is fixedly
secured between immediately adjacent first hinge members 31a, 31b,
and 31c, 31d, preferably by welding along the length of each front
hinge edge 622. The combination of front hinge plate 623 and the
first front hinge members 31a, 31b secured to it, form a roof front
interlock 625 adjacent the roof right edge 19 of the roof panel 11,
and the combination of front hinge plate 624 and the first front
hinge members secured to it 31c, 31d, form a roof front interlock
626 secured to the corner fitting 36c adjacent the roof left edge
20 of the roof panel 11. Each front roof interlock 625, 626 has a
lower slot 627, 628 for receiving a large tang extending from the
base panel 17 when the folding container 10 is in its fully folded
condition, as described below.
[0151] Referring again to FIG. 5, a front shelf beam 629 extends
between the front first hinge sets 613, 614, and the end 630 of the
front shelf beam 629 adjacent the roof right edge 19 is fixedly
secured to the inward front first hinge member 31b, preferably by
welding, such that the lower edge 632 of the front shelf beam 629
is approximately aligned with the lower edge 633 of the front hinge
plate 623. Likewise, the end 631 of the front shelf beam 629
adjacent the roof left edge 20 is fixedly secured to the inward
front first hinge member 31d, preferably by welding, such that the
lower edge 632 of the front shelf beam 629 is approximately aligned
with the lower edge 634 of the front hinge plate 624. As shown in
FIG. 12, mounted to the front shelf beam 629 adjacent each roof
front interlock 625, 626, and aligned with the bolt holes 620
therein, are hammer lock retainers 76, 77. A hammer locking
mechanism 78, 79, including a slide hammer 80, 81, and a hammer
locking bolt 82, 83 is slideably secured to each of the hammer lock
retainers 76, 77, such that each hammer locking mechanism 78, 79 is
positionable by use of one of the slide hammers 80, 81, slideably
mounted on one of the hammer locking bolts 82, 83, between an
unlocked position in which the respective hammer locking bolt 82,
83, is in a retracted position substantially outside of the roof
front interlock 625, 626, immediately adjacent thereto, and a
locked position in which the respective hammer locking bolt 82, 83
extends through the bolt holes 620 of the roof front interlock 625,
626 immediately adjacent thereto.
[0152] As shown in FIG. 13, the roof panel 11 includes a hollow,
rectangular roof door beam 635 that extends along the roof door
edge 21 of the roof panel 11, and extends downwardly therefrom a
distance of about four inches. The hollow, rectangular roof door
beam 635 extends from the corner fitting 36b on the roof door edge
21 adjacent the roof right edge 19 to the corner fitting 36d on the
roof door edge 21 adjacent the roof left edge 20. The end 636 of
the roof door beam 635 adjacent the roof right edge 19 is rigidly
attached to the corner fitting 36b adjacent the roof right edge 19,
preferably by welding, and the end 637 of the roof door beam 635
adjacent the roof left edge 20 is rigidly attached to the corner
fitting 36d adjacent the roof left edge 20, preferably by welding.
The exterior vertical face 638 of the rectangular roof door beam
635 includes a plurality of lock hasps 90, preferably four, rigidly
secured thereto for receiving the upper ends 91 of each of the
locking rods 92 of the door latch assembly 639 as described below.
The roof panel 11 further includes a pair of locking straps 640,
removably secured thereto adjacent the lock hasps 90. Each locking
strap 640 is preferably made of steel, and has a shape of similar
to that of an "I". Adjacent each end of each locking strap 640 is a
bolt hole 645, 646, for receiving one of the strap bolts 647 that
are used to removably secure the locking strap 640 to the container
10 when the container 10 is in its folded, and unfolded, condition,
as described below. When the container 10 is in its unfolded
condition, the strap bolts 647 are received within stored strap
bolt holes 648, not shown, that secure the locking strap 640 to the
roof panel 11. The roof panel 11 also includes two upper active
strap bolt holes 649, not shown, for use when the container 10 is
in its folded condition, as described below. A plurality, and
preferably four (4), pairs of upper door stop receivers 650 are
welded to the exterior vertical face 638 of the rectangular roof
door beam 635 adjacent the lock hasps 90, the upper door stop
receivers 650 of each such pair being in spaced relation to each
other. Each of the upper active strap bolt holes 649 is aligned
with one pair of upper door stop receivers 650. As those skilled in
the art will readily appreciate, when a locking strap 640 is
secured by a strap bolt 647 to one of the upper active strap bolt
holes 649, the "T" at one end 645 of the locking strap 640 rests on
one pair of the door stop receivers when the locking strap 640 is
supporting a load. Accordingly, the thickness of the each locking
strap 640, and the load carrying ability of the upper door stop
receivers 650 on which the locking strap 640 rests, must be
sufficient to support, at a minimum, a weight equal to that of the
entire container 10 when the container 10 is empty, which, in turn,
depends on the material from which the container 10, the locking
straps 640, and the upper door stop receivers 650 are made, as well
as the strength of the welds securing the upper door stop receivers
650 to the roof door beam 635.
[0153] As shown in FIG. 14, the roof panel 11 further includes two
door first hinge sets 651, 652. The door first hinge set 651
includes two door first hinge members 653a, 653b, each rigidly
connected to the lower surface 654 of the corner fitting 36b
adjacent the roof door edge 21 and the roof right edge 19,
preferably by welding. The door first hinge set 652 likewise
includes two door first hinge members 653c, 653d, each rigidly
connected to the lower surface 655 of the corner fitting 36d
adjacent the roof door edge 21 and the roof left edge 20,
preferably by welding. The door first hinge members 653a, 653b, of
the door first hinge set 651 adjacent the roof right edge 19 are
fixed in spaced relation to each other for receiving a door hinge
pivot 656, as described in greater detail below, and the door first
hinge members 653c, 653d, of the door first hinge set 652 adjacent
the roof left edge 20 are fixed in spaced relation to each other
for receiving a front hinge pivot 666, as described in greater
detail below. A representative door first hinge member 653 is shown
in isolation in FIG. 15. Each door first hinge member 653 has a
door hinge edge 667, door pivot hole 668, and a door lug receiving
slot 669. The purpose of each of these features is described in
greater detail below.
[0154] Referring again to FIG. 13, a door hinge plate 670, 671,
having a length substantially equal to the length of the door hinge
edge 667 of the door first hinge members 653a, 653b, 653c, 653d, is
fixedly secured between immediately adjacent door first hinge
members 653a, 653b, 653c, 653d, preferably by welding along the
length of each door hinge edge 667.
[0155] As shown in FIGS. 16 & 17, the base panel 17 includes a
base right edge 99, a base left edge 100, a base front edge 101,
and a base door edge 102. The base panel 17 includes four standard
corner fittings 36e, 36f, 36g, 36h of the type known in the art for
securing the container 10 to another container on which it may be
stacked. One corner fitting 36e, 36f, 36g, 36h is located on the
base panel 17 adjacent each end of the base front edge 101, and
adjacent each end of the base door edge 102, in accordance with the
international standards.
[0156] As shown in FIG. 17, a hollow, rectangular base right beam
672 extends along the base right edge 99 of the base panel 17 from
the corner fitting 36e on the base front edge 101 adjacent the base
right edge 99 of the base panel 17 to the corner fitting 36f on the
door edge 102 adjacent the right edge 99 of the base panel 17. Each
end 673, 674 of the base right beam 672 is rigidly attached to the
adjacent corner fitting 36e, 36f, preferably by welding. The base
right beam 672 comprises base right beam lower portions 675, 676
which extend upwardly from the base right edge 99 a distance of
about eight inches, and a base right beam upper portion 677 that
extends further up from the base right edge 99 to a height of about
twelve inches. Referring again to FIG. 16, a plurality of cable
anchors 679, the purpose of which is described in greater detail
below, are secured to base right beam 672 in spaced relation to
each other adjacent the upper edge 680 of the base right beam upper
portion 677. Sloped right transition portions 103a, 103b, extend
between each end 681, 682 of the base right beam upper portion 677
to the base right beam lower portions 675, 676 adjacent thereto.
The top edge 683, 684 of each of the base right beam lower portions
675, 676, is capped with a guide rail 401, 402, preferably made of
stainless steel. The purpose of the guide rails 401, 402, and the
purpose of the base right beam lower portions 675, 676 of the base
right beam 672, are discussed below.
[0157] As shown in FIG. 16, a hollow, rectangular base left beam
685 extends along the base left edge 100 of the base panel 17 from
the corner fitting 36g on the base front edge 101 adjacent the base
left edge 100 of the base panel 17 to the corner fitting 36h on the
door edge 102 adjacent the left edge 100 of the base panel 17. Each
end 686, 687 of the base left beam 685 is rigidly attached to the
adjacent corner fitting 36g, 36h, preferably by welding. The base
left beam 685 comprises base left beam lower portions 688, 689
which extend upwardly from the base left edge 100 a distance of
about eight inches, and a base left beam upper portion 690 that
extends further up from the base left edge 100 to a height of about
twelve inches. Referring again to FIG. 17, a plurality of cable
anchors 691, the purpose of which is described in greater detail
below, are secured to base left beam 685 in spaced relation to each
other adjacent the upper edge 692 of the base right beam upper
portion 690. Sloped left transition portions 104a, 104b, extend
between each end 693, 694 of the base left beam upper portion 690
to the base left beam lower portions 688, 689 adjacent thereto. The
top edge 695, 696 of each of the base left beam lower portions 688,
689, is capped with a guide rail 403, 404, preferably made of
stainless steel. The purposes of the guide rails 403, 404, and the
purpose of the base left beam lower portions 688, 689 of the base
left beam 685, are discussed below.
[0158] As shown in FIG. 18, extending upward from each corner
fitting 36e, 36g on the base panel 17 adjacent the front edge 101
is a base front tang 108a, 108b. A representative base front tang
108 is shown in FIGS. 19-21. Each of the base front tang 108 has a
rectangular base portion 700, and a locking portion 702 extending
therefrom. The locking portion 702 of each base front tang 108
includes an upper tapered locking hole 110 and a lower tapered
locking hole 704, each of which is substantially parallel to the
front edge 101 of the base panel 17, and each of which is sized and
located so as to be able to receive therein one of the hammer
locking bolts of the front panel 12, as discussed below.
[0159] Referring back to FIG. 18, the base portion 700 of each base
front tang 108a, 108b is fixedly secured to the corner fitting 36e,
36g it extends from, preferably by welding. The base panel 17
includes a hollow, rectangular base front beam 706 that extends
between the base portions 700 of the base front tangs 108a, 108b.
Each end 707, 708 of the base front beam 706 is rigidly attached to
the base portion 700 of the base front tang 108a, 108b immediately
adjacent thereto, preferably by welding.
[0160] As shown in FIG. 22, the base panel 17 includes a hollow,
rectangular base door beam 709 that extends along the door edge 102
of the base panel 17, and extends upwardly therefrom a distance of
about four inches. The base door beam 109 extends from the corner
fitting 36f on the door edge 102 adjacent the right edge 99 of the
base panel 17 to the corner fitting 36h on the door edge 102
adjacent the left edge 100 of the base panel 17. Each end 710,711
of the base door beam 709 is rigidly attached to the adjacent
corner fitting 36f, 36h, preferably by welding. The exterior
vertical face 712 of the base door beam 709 includes a plurality of
lock hasps 90b, preferably four, rigidly secured thereto for
receiving lower end 713 of each of the locking rods 92 of the door
latch assembly as described below. The door end of the base panel
17 further includes at least two pairs of lower door stop receivers
714 that are welded to the exterior vertical face 712 of the
rectangular base door beam 709 adjacent the lock hasps 90b closest
to the corner fittings 36f, 36h, the lower door stop receivers 714
of each such pair being in spaced relation to each other. A lower
active strap bolt hole 715 is aligned with each pair of lower door
stop receivers 714. As those skilled in the art will readily
appreciate, when a locking strap 640 is secured by a strap bolt 647
to one of the lower active strap bolt holes 715, the inverted "T"
at one end of the locking strap 640 supports the load placed on it
by the pair of door stop receivers 714 within which the locking
strap 640 is received. Accordingly, the load carrying ability of
the lower door stop receivers 714 which rest on the locking strap
640 must be sufficient to support, at a minimum, a weight equal to
that of the entire container 10 when the container 10 is empty,
which, in addition to those factors previously stated, depends on
the material from which the lower door stop receivers 714 are made,
as well as the strength of the welds securing the lower door stop
receivers 714 to the base door beam 709.
[0161] Extending upwardly from each of the corner fittings 36f, 36h
on the door edge 102 of the base panel 17 is a door interlock 116,
117. As shown in FIGS. 23 & 24, each door interlock 116, 117
has four walls: a door wall 718, 719 which faces the door edge 102
of the base panel 17, a front wall 720, 721 which faces the front
edge 101 of the base panel 17 and is parallel to, and in spaced
relation with, the door wall 718, 719, an inner wall 722, 723 that
is perpendicular to the door wall 718, 719 and the front wall 720,
721 and faces the inner wall 720, 721 of the other door interlock
116, 117, and an outer wall 724, 725 which is parallel to, and in
spaced relation with, the inner wall 720, 721. The door interlock
116 extending from the corner fitting 36f on the door edge 102
adjacent the base right beam 672 is rigidly attached to that corner
fitting 36f and the door end 674 of the base right beam 672,
preferably by welding. Likewise, the door interlock 117 extending
from the corner fitting 36h on the door edge 102 adjacent the base
left beam 685 is rigidly attached to that corner fitting 36h and
the door end 687 of the base left beam 685, also preferably by
welding.
[0162] Each door interlock 116, 117 has a first bolt hole 726, 727
in the door wall 718, 719 thereof, and a second bolt hole 728, 729
in the front wall 720, 721 thereof aligned with the first bolt hole
726, 727 of the same door interlock 116, 117. The diameter of the
second bolt holes 728, 729 is preferably slightly larger than the
diameter of the first bolt holes 726, 727 for reasons discussed
below.
[0163] As shown in FIGS. 16 & 17, the lower portion 676 of the
base right beam 672 and the lower portion 689 of the base left beam
685 each include a recessed portion 730, 731 immediately adjacent
the door edge 102 of the base panel 17. As shown in greater detail
in FIG. 25, hammer lock retainers 732 are mounted in the recessed
portion 730 of the lower portion 676 of the base right beam 672
adjacent the door interlock 116 and aligned with the bolt holes
726, 728 therein. Likewise, as shown in greater detail in FIG. 26,
hammer lock retainers 733 are mounted in the recessed portion 731
of the lower portion 689 of the base left beam 685 adjacent the
door interlock 117 and aligned with the bolt holes 727, 729
therein. As shown in FIG. 25, a hammer locking mechanism 78 is
slideably secured to the hammer lock retainers 732 in the recessed
portion 730 of the lower portion of the base right beam 676. The
hammer locking mechanism 78 therein includes a slide hammer 79
slideably mounted on a hammer locking bolt 80. As those skilled in
the art will readily appreciate, by sliding the slide hammer 79
against one of the hammer stops 734, 735, the hammer locking bolt
80 can be selectively positioned at an unlocked position in which
the hammer locking bolt 80 is in a retracted position substantially
outside of the interlock 116 immediately adjacent thereto, and a
locked position in which the locking bolt 80 extends through the
bolt holes 726, 728 of the interlock 116 immediately adjacent
thereto.
[0164] Likewise, as shown in FIG. 26, a hammer locking mechanism
736 is slideably secured to the hammer lock retainers 733 in the
recessed portion 731 of the lower portion of the base left beam
689. The hammer locking mechanism 736 therein includes a slide
hammer 737 slideably mounted on a hammer locking bolt 738. As those
skilled in the art will readily appreciate, by sliding the slide
hammer 737 against one of the hammer stops 739, 740, the hammer
locking bolt 738 can be selectively positioned at an unlocked
position in which the hammer locking bolt 738 is in a retracted
position substantially outside of the interlock 117 immediately
adjacent thereto, and a locked position in which the locking bolt
738 extends through the bolt holes 727, 729 of the interlock 117
immediately adjacent thereto.
[0165] Referring again to FIG. 16, the base right beam 672 includes
a plurality of right hinge recesses 741 in spaced relation to each
other along the length of the base right beam 672, and a base right
hinge member 106 is fixedly secured within each of the right hinge
recesses 741. A close-up view exemplary of a base right hinge
member 106 is shown in FIG. 41. Additionally, the base right beam
672 preferably includes a plurality of small recesses 742 spaced
along the length thereof, within which tie-down bars 743 are
rigidly mounted for receiving tie-down straps of the type known in
the art for securing the contents of the container 10 during
shipping.
[0166] As shown in FIG. 17, the base left beam 685 includes a
plurality of left hinge recesses 744 in spaced relation to each
other along the length of the base left beam 685, and a base left
hinge member 745 is fixedly secured within each of the left hinge
recesses 744. The base left hinge member 745 is similar in design
and function to the base right hinge member 106 shown in FIG. 41.
Additionally, the base left beam 685 preferably includes a
plurality of small recesses 746 spaced along the length thereof,
within which tie-down bars 747 are rigidly mounted for receiving
tie-down straps of the type known in the art for securing the
contents of the container 10 during shipping.
[0167] As shown in FIGS. 3, 27 & 28, a plurality of base
support beams 748 are secured to the base right beam 672 and the
base left beam 685 and span therebetween to add structural rigidity
to the floor 749 of the base panel 17. Adjacent the base front edge
101, the base panel 17 includes a "gooseneck tunnel" 750 of the
type known in the art. As shown in FIG. 3, a pair of hollow, base
lifting beams 751, 752 are secured to the base right beam 672 and
the base left beam 685, preferably by welding, and span
therebetween to add structural rigidity to the base panel 17 and to
provide means for lifting the foldable container 10 by use of a
fork lift if desired. The floor 749 of the base panel 17 is
preferably made of a sheet of Cor-Ten steel extending from the base
right beam 672 to the base left beam 685, and from the base front
beam 706 to the base door beam 709. The floor 749 is welded about
its entire periphery to the right beam 672, the base left beam 685,
the base front beam 706 and the base door beam 709, to make the
base panel 17 watertight with respect to the floor 749. The floor
749 is also welded to the base support beams 748 and the base
lifting beams 751, 752 for structural purposes. Preferably, the
floor 749 is covered with plywood, or a similarly suitable flooring
material.
[0168] As shown in FIG. 29, the right side panel 14 includes a top
edge 118, a bottom edge 119, a front edge 120 and a door edge 121.
Extending along the top edge 118 of the right side panel 14 along
the length thereof is a right upper cap plate 122 having a front
end 754, a door end 755, and a right roof flange 756 extending from
the front end 754 to the door end 755. Extending along the bottom
edge 119 of the right side panel 14 along the length thereof is a
right compound beam 757 that has a front end 758 and a door end
759. The right compound beam 757 comprises a right upper horizontal
beam 123c rigidly connected to two right lower horizontal beams
123a, 123b, preferably by welding. As shown in FIGS. 16 & 29,
the lower edge 760 of the right compound beam 757 has a profile
that matches the profile formed by the upper edge 680 of the base
right beam upper portion 677, the top edges 683, 684 of the base
right beam lower portions 675, 676, and the sloped right transition
portions 103a, 103b of the base panel 17, to provide mating sealing
surfaces when the container 10 is in its unfolded condition.
[0169] As shown in FIG. 29, a right front member 761 extends from
the front end 754 of the right upper cap plate 122 to the front end
758 of the right compound beam 757, and is fixedly secured to the
front ends 754, 758, preferably by welding. As shown in FIG. 30,
the right front member 761 includes a long flange 762 and a short
flange 763, each of which extends along the length of the right
front member 761 and towards the front edge 101 of the base panel
17. As shown in FIG. 29, a right door member 764 extends from the
door end 755 of the right upper cap plate 122 to the door end 759
of the right compound beam 757, and is fixedly secured to the door
ends 755, 759, preferably by welding. The right door member 764
includes a long flange 765 and a short flange 766, each of which
extends along the length of the right door member 764 and towards
the door edge 102 of the base panel 17, as shown in FIG. 31. The
right front member 761 and the right door member 764 each have a
plurality, and preferably three, right side bolt holes 767, 768 for
receiving locking bolts as described in greater detail below.
[0170] Referring again to FIG. 29, corrugated sheet metal 769
extends from the right upper cap plate 122 to the right compound
beam 757 along the entire length thereof, and from the right front
member 761 to the right door member 764 along the entire length
thereof. The corrugated sheet metal 769 is welded along its entire
perimeter to the immediately adjacent right upper cap plate 122,
right front member 761, right compound beam 757, and right door
member 764. As shown in FIG. 1, the corrugated sheet metal 769 is
welded to the right front member 761 and the right door member 764
such that the long flanges 762, 765 are visible from the exterior
of the container 10 in its unfolded condition.
[0171] As shown in FIG. 29, extending downwardly from the bottom
edge 119 of the right side panel 14 are a plurality of right side
hinge members 125, each of which is fixedly secured to the right
compound beam 757. Each right side hinge member 125 is rotatably
connected to one of the base right hinge members 106 of the base
panel 17 by one or more hinge pins 770, so as to allow the right
side panel 14 to rotate relative to the base panel 17. As shown in
FIG. 32, a plurality of linear spring assemblies 771 are mounted to
the right side panel 14 within corrugations 772 of the corrugated
sheet metal 769, as are a plurality of locking bolt assemblies
773.
[0172] As shown in FIGS. 33-35, each right side linear spring
assembly 771, includes a tube 802 fixedly secured to a tube base
803 mounted within the right upper horizontal beam 123c. A
compression spring 804, cable 805, and plunger 806 are received
within each tube 802. The upper end of the cable 805 is secured to
the plunger 806. Each plunger 806 has a plunger foot 808 which is
in contact with the upper end 807 of the compression spring 804,
and each plunger foot 808 has a diameter 809 that is at least as
large as the inner diameter 810 of the compression spring 804 to
prevent the plunger 806 from sliding through the compression spring
804. Referring again to FIG. 32, a tube shield 811 secured to the
corrugated sheet metal 769 retains and protects the upper end 811a
of each tube 802, as well as the plunger 806 attached thereto,
during use of the container 10.
[0173] As shown in FIG. 35, each tube base 803 includes a cable
channel 812 within which is rotatably mounted a cable pulley 813
adjacent the lower edge 814 thereof. The upper end 815 of each tube
base 803 has a diameter 816 that is at least as large as the inner
diameter 810 of the compression spring 804 to support the
compression spring 804 against the force applied by the plunger
foot 808 at the upper end 807 of the compression spring 804. In
addition, the upper end 815 of each tube base 803 has an opening
817 through which the cable 805 passes, and the opening 817 has a
diameter 818 that is smaller than the inner diameter 810 of the
compression spring 804 to prevent the compression spring 804 from
sliding therethrough. The lower end 819 of each cable 805 is
attached to one of the cable anchors 679 secured to the base right
beam upper portion 677 adjacent the upper edge 680 thereof. It is
to be understood that when the container 10 is in the unfolded
condition, each cable anchor 679 is vertically aligned with the
tube 802 that contains the cable 805 that is attached to such cable
anchor 679.
[0174] As shown in FIG. 32, the plurality of locking bolt
assemblies 773 are mounted to the right side panel 14 within the
corrugations 772 of the corrugated sheet metal 769. As shown in
FIGS. 32 & 36, each locking bolt assembly 773 includes a pivot
anchor 820, a positioning lever 821 with a handle 822 attached
thereto, a locking bolt 823, a locking bolt guide 824, and a pair
of links 825 pivotably connecting the lower end 826 of the locking
bolt 823 to the positioning lever 821. Each of the locking bolt
guides 824 includes a guide tube 827 that extends through, and is
fixedly secured to the right upper cap plate 122, and one locking
bolt 823 is slideably received within each of the guide tubes 827.
Each pivot anchor 820 is fixedly secured to the corrugated sheet
metal 769, and each positioning lever 821 is pivotably connected to
one of the pivot anchors 820.
[0175] As those skilled in the art will readily appreciate, each of
the locking bolt assemblies 773 so described is selectively
positionable between a first position in which the locking bolt 823
is received within one of the locking bolt holes 610 in the lower
face 608 of the roof right beam 600, when the container 10 is in
the unfolded condition, and a second position in which the locking
bolt 823 is fully withdrawn from that locking bolt hole 610.
[0176] As shown in FIG. 37, the left side panel 16 includes a top
edge 774, a bottom edge 775, a front edge 776 and a door edge 777.
Extending along the top edge 774 of the left side panel 16 along
the length thereof is a left upper cap plate 778 having a front end
779, a door end 780a, and a left roof flange 780b extending from
the front end 779 to the door end 780. Extending along the bottom
edge 775 of the left side panel 16 along the length thereof is a
left compound beam 781 that has a front end 782 and a door end 783.
The left compound beam 781 comprises a left upper horizontal beam
784 rigidly connected to two left lower horizontal beams 785, 786,
preferably by welding. As shown in FIGS. 17 & 37, the lower
edge 787 of the left compound beam 781 has a profile that matches
the profile formed by the upper edge 692 of the base left beam
upper portion 677, the top edges 695, 696 of the base left beam
lower portions 688, 689, and the sloped left transition portions
104a, 104b of the base panel 17, to provide mating sealing surfaces
when the container 10 is in its unfolded condition.
[0177] As shown in FIG. 37, a left front member 788 extends from
the front end 779 of the left upper cap plate 778 to the front end
782 of the left compound beam 781, and is fixedly secured to the
front ends 779, 782, preferably by welding. As shown in FIG. 38,
the left front member 788 includes a long flange 789 and a short
flange 790, each of which extends along the length of the left
front member 788 and towards the front edge 101 of the base panel
17. Referring again to FIG. 37, a left door member 791 extends from
the door end 780a of the left upper cap plate 778 to the door end
783 of the left compound beam 781, and is fixedly secured to the
door ends 780, 783, preferably by welding. As shown in FIG. 39, the
left door member 791 includes a long flange 792 and a short flange
793, each of which extends along the length of the left door member
791 and towards the door edge 102 of the base panel 17. The left
front member 788 and the left door member 791 each have a
plurality, and preferably three, left side bolt holes 794, 795 for
receiving locking bolts as described in greater detail below.
[0178] As shown in FIG. 40, corrugated sheet metal 796 extends from
the left upper cap plate 778 to the left compound beam 781 along
the entire length thereof, and from the left front member 788 to
the right door member 791 along the entire length thereof. The
corrugated sheet metal 796 is welded along its entire perimeter to
the immediately adjacent left upper cap plate 778, left front
member 788, left compound beam 781, and left door member 791. As
shown in FIG. 2, the corrugated sheet metal 796 is welded to the
left front member 788 and the left door member 791 such that the
long flanges 789, 792 are visible from the exterior of the
container 10 in its unfolded condition.
[0179] As shown in FIG. 37, extending downwardly from the bottom
edge 775 of the left side panel 16 are a plurality of left side
hinge members 797, each of which is fixedly secured to the left
compound beam 781. Each left side hinge member 797 is rotatably
connected to one of the base right hinge members 745 of the base
panel 17 by one or more hinge pins 798, so as to allow the left
side panel 16 to rotate relative to the base panel 17. The hinge
member 797 is shown in isolation, and in greater detail, in FIGS.
41A and 41B. The design and function of hinge member 797 is the
same as that of hinge member 125 on right side panel 14.
[0180] As shown in FIG. 40, a plurality of linear spring assemblies
799 are mounted to the left side panel 16 within corrugations 800
of the corrugated sheet metal 796, as are a plurality of locking
bolt assemblies 801. The construction of the linear spring
assemblies 799 is the same as those described with respect to the
right side panel 14, except that each tube base 803 is mounted
within the left upper horizontal beam 784, each tube shield 811 is
secured to the corrugated sheet metal 796 of the left side panel
16, and the lower end 819 of each cable 805 is attached to one of
the cable anchors 691 secured to the base left beam upper portion
690 adjacent the upper edge 692 thereof. It is to be understood
that when the container 10 is in the unfolded condition, each cable
anchor 691 is vertically aligned with the tube 802 that contains
the cable 805 that is attached to such cable anchor 691.
[0181] Likewise, the construction of the locking bolt assemblies
801 is the same as those described with respect to the right side
panel 14, except that each pivot anchor 820 is fixedly secured to
the corrugated sheet metal 796 of the left side panel 16, and each
guide tube 827 extends through, and is fixedly secured to, the left
upper cap plate 778. As those skilled in the art will readily
appreciate, each of the locking bolt assemblies 801 so described is
selectively positionable between a first position in which the
locking bolt 823 is received within one of the locking bolt holes
610 in the lower face 609 of the roof left beam 603, when the
container 10 is in the unfolded condition, and a second position in
which the locking bolt 823 is fully withdrawn from that locking
bolt hole 610.
[0182] Referring now to FIGS. 42, 43A and 43B, the front panel 12
includes a front main panel 828, a front right access panel 829,
and a front left access panel 830. The front main panel 828
includes a top edge 56, a bottom edge 57, a right edge 58, and a
left edge 59. Extending along the top edge 56 of the front main
panel 828 is a header 60 and along the bottom edge 57 is a sill
panel 61, in spaced relation to the header 60. A right front post
62, hollow and rectangular in cross section, extends along the
right edge 58 of the front main panel 828, and a left front post
63, also hollow and rectangular in cross section, extends along the
left edge 59 of the front main panel 828. Lateral support for the
front main panel 828 is provided by corrugated sheet metal which
extends between the two front posts 62, 63 along the entire length
thereof, and is welded around its periphery to the immediately
adjacent sill panel 61, header 60, the right front post 62, and the
left front post 63.
[0183] As shown in FIGS. 42, 43A, 43B and 44, extending upwardly
from each of the front posts 62, 63 adjacent the top edge 56 of the
front panel 828 is a front hinge pivot 617, 618. When assembled to
the roof panel 11, each front hinge pivot 617, 618 is rotatably
connected to one of the sets 613, 614 of front first hinge members
31a, 31b, 31c, 31d located adjacent the front edge 22 of the roof
panel 11 by means of a hinge pin 52, so as to allow the front panel
12 to rotate relative to the roof panel 11.
[0184] The front hinge pivot 617 adjacent the right edge 58 of the
front main panel 828, and the front hinge pivot 618 adjacent the
left edge 59 of the front main panel 828 are identical, and a
representative front hinge pivot 617 is shown in isolation in FIGS.
45A, 45B, 45C, and 45D. As shown in FIGS. 45A, 45B, 45C, and 45D,
each front hinge pivot 617 has a pivot hinge pin hole 831 extending
therethrough, and a cylindrical lug hole 832 extending therethrough
as well. As shown in FIGS. 42 and 44, a cylindrical lug 833 extends
through each cylindrical lug hole 832 and protrudes from each side
of the front hinge pivots 617. Each cylindrical lug 833 has a
diameter that is only slightly less than the height 834b of the
front lug receiving slot 621 on each of the front first hinge
members 31a, 31b, 31c and 31d of the roof panel 11. When
incorporated into the present invention, the hinge pin 52 extends
through the front pivot hole 619 of one of the front first hinge
members 31a, 31c, through the pivot hinge pin hole 831 of one of
the front hinge pivots 617, and through the front pivot hole 619 of
another one of the front first hinge members 31b, 31d adjacent to
the other front first hinge member 31a, 31c to allow for rotation
between the front panel 12 and the roof panel 11. As those skilled
in the art will readily appreciate, when the front hinge pivots 617
are rotatably secured between two of the front first hinge members
31a, 31b, 31c and 31d by a hinge pin 52, rotation of the
cylindrical lugs 833 into the lug receiving slots 621 of the
immediately adjacent front first hinge members 31a, 31b, 31c and
31d, shifts much of the load carried by the front hinge pivots 617
from the hinge pins 52 to the cylindrical lugs 833, allowing each
of the front hinge pivots 617 to support more weight than either
could carry on the hinge pin 52 alone. The construction and
function of the front hinge pivot 618 adjacent the left edge 59 of
the front main panel 828 is the same as that described for the
front hinge pivot 617 adjacent the right edge 58, except that the
front hinge pivot 618 is received between the front first hinge
members 31c, 31d adjacent the left edge 19 of the roof panel 11.
Front hinge pivot 617 is shown assembled to the front first hinge
members 31a, 31b of the roof panel 11 in perspective in FIG. 46,
and in greater detail in FIG. 47. Likewise, front hinge pivot 618
is shown assembled to the front first hinge members 31c, 31d of the
roof panel 11 in perspective in FIG. 48, and in greater detail in
FIG. 49.
[0185] As shown in FIGS. 50-56, incorporated into the lower end
portion 834, 835 of each of the front posts 62, 63 on the front
panel 12 is a front panel interlock 836, 837. Each front panel
interlock 836, 837 has a door wall 838, 839 which faces the door
panel 18, a front wall 840, 841 that is parallel to, and in spaced
relation with, the door wall 838, 839, an inner wall 842, 843 that
is perpendicular to the front wall 840, 841, and the door wall 838,
839 and faces the inner wall 842, 843 of the other front panel
interlock, and an outer wall 844, 845 which is parallel to, and in
spaced relation with, the inner wall 842, 843.
[0186] Each front panel interlock 836, 837 has a first bolt hole
846, 847 in the outer wall 844, 845, and a second bolt hole 848,
849 in the inner wall 842, 843. The diameters of the second bolt
holes 848, 849 are slightly larger than the diameters of the first
bolt holes 846, 847, and the first bolt holes 846, 847 and the
second bolt holes 848, 849 are located on the inner walls 842, 843
and the outer walls 844, 845 of the front panel interlocks 836,
837, such that when one of the base front tangs 108a, 108b of the
base panel 17 is received therein, the upper tapered locking hole
110a, 110b in the base front tang 108a, 108b is aligned with the
first bolt hole 846, 847 and the second bolt hole 848, 849 of the
respective front panel interlock 836, 837, such that the first bolt
hole 846, 847 is immediately adjacent the smaller diameter end of
the upper tapered locking hole 110a, 110b, and the second bolt hole
848, 849 is immediately adjacent the larger diameter end of the
upper tapered locking hole 110a, 110b.
[0187] Referring now to FIGS. 44, 50, 53 and 55, the sill panel 61
includes a lower sill beam 850 and an upper sill beam 851, each of
which extends between the fronts posts 62, 63 adjacent the lower
end portions 834, 835 thereof. Each end 853, 854 of the lower sill
beam 850 is fixedly secured to the inner wall 842, 843 of the front
panel interlock 836, 837 immediately adjacent thereto, preferably
by welding, such that the lower edge 855 of the lower sill beam 850
is approximately aligned with the lower ends 856, 857 of the front
posts 62, 63. Each end 858, 859 of the upper sill beam 851 is
likewise fixedly secured to the inner wall 842, 843 of the front
panel interlock 836, 837 immediately adjacent thereto, preferably
by welding, such that upper sill beam 851 is parallel, and in
spaced relation, to the lower sill beam 850. A sill plate 860,
which is substantially aligned with the front walls 840, 841 of the
front panel interlocks, extends from the upper sill beam 851 to the
lower sill beam 850, and from front left post 63 to the front right
post 62, and is welded about its periphery to the upper sill beam
851, the lower sill beam 850, the front left post 63, and the front
right post 62.
[0188] Adjacent each front panel interlock 836, 837, and aligned
with the bolt holes 846, 848, 847, 849 therein, are hammer lock
retainers 861, 862 mounted to the sill panel 61. As shown in FIGS.
46, 48, 53 and 55, a hammer locking mechanism 863, 864, including a
slide hammer 865, 866, and a hammer locking bolt 867, 868, is
slideably secured to each of the hammer lock retainers 861, 862,
within the sill panel 61 such that each hammer locking mechanism
863, 864 is positionable by use of one of the slide hammers 865,
866 slideably mounted on one of the hammer locking bolts 867, 868,
between an unlocked position in which the respective hammer locking
bolt 867, 868, is in a retracted position substantially outside of
the front panel interlock 836, 837, and a locked position in which
the respective hammer locking bolt 867, 868 extends through the
bolt holes 846, 848, 847, 849 of the front panel interlock 836, 837
immediately adjacent thereto.
[0189] As shown in FIGS. 57-66, a front roller arm 869, 870 is
fixedly secured to the door wall 838, 839 of each of the front
interlocks 836, 837, and extends downward therefrom, and the outer
wall 844, 845 of each of the front interlocks 836, 837 includes a
roller recess 871, 872. A roller cover plate 873, 874 is removably
secured to the outer wall 844, 845 of each of the front interlocks
836, 837, preferably with bolts 875, 876. The upper edge 877, 878
of each roller cover plate 873, 874 extends upward along the outer
wall 844, 845 to which it is attached so as to cover the roller
recess 871, 872 immediately adjacent thereto, and the lower edge
879, 880 of each roller cover plate 873, 874 extends downward along
the outer wall 844, 845 to which it is attached about 2 inches
below the lower end 881, 882 of the immediately adjacent front
roller arm 869, 870. A first front roller 883, 884 is rotatably
attached to each of the front roller arms 869, 870 adjacent the
lower end thereof, and is secured in place by an axel pin 885, 886
that extends between each roller arm 869, 870 and the roller cover
plate 873, 874 immediately adjacent thereto. Likewise, a second
front roller 887, 888 is rotatably attached to each of the outer
walls 844, 845 of the front interlocks 836, 837 within the roller
recess 871, 872 therein, and is secured in place by an axel pin
889, 890 that extends between the outer wall 844, 845 of the
respective front interlock 836, 837 and the roller cover plate 873,
874 immediately adjacent thereto. Each of the first front rollers
883, 884 and the second front rollers 887, 888 is aligned with one
of the rails 401, 403 of the base panel 17 and rides on such rails
401, 403 during the folding, and unfolding, of the container 10 as
described in more detail below.
[0190] Referring to FIGS. 67, 68 and 74, the front right post 62
includes a front right hinge plate 891 that extends towards the
door edge 21 of the roof panel 11 when the container 10 is in the
unfolded condition. Attached to the inward surface 892 of the front
right hinge plate 891, in spaced relation to each other, are a
plurality of, and preferably four, first front right hinge members
893. Each of the first front right hinge members 893 is fixedly
secured to the inward surface 892 of the front right hinge plate
891, preferably by welding.
[0191] As shown in FIG. 67, a front right access panel 894 is
pivotably attached to the front right post 62, and as shown in FIG.
69, the front right access panel 894 includes a top edge 214, a
bottom edge 216, a front edge 218, and a door edge 220. Extending
along the top edge 214 of the front right access panel 894 along
the length thereof is a front right upper cap plate 895 having a
front end 896, a door end 897, and preferably, as shown in FIGS. 67
and 74, a front right roof flange 898 extends from the front end
896 to the door end 897. Extending along the bottom edge 216 of the
front right access panel 894 along the length thereof is a front
right beam 900 that has a front end 901 and a door end 902.
[0192] As shown in FIG. 69, a first front right access member 903
extends from the front end 896 of the front right upper cap plate
895 to the front end 901 of the front right beam 900, and is
fixedly secured to the front ends 896, 901, preferably by welding.
As shown in FIG. 69, a second front right access member 906 extends
from the door end 897 of the front right upper cap plate 895 to the
door end 902 of the front right beam 900, and is fixedly secured to
the door ends 897, 902, preferably by welding. As shown in FIGS.
69, 70 and 71, the second front right access member 906 includes a
long flange 907 and a short flange 908, each of which extends along
the length of the second front right access member 906 and towards
the door edge 21 of the roof panel 11 when the container 10 is in
the unfolded condition. Located between the long flange 907 and the
short flange 908 are a plurality of locking bolt holes 909,
preferably three, that extend through the second front right access
member 906. When the container 10 is in the unfolded condition, the
locking bolt holes 909 are aligned with the right side bolt holes
767 of the right side panel 14
[0193] Referring again to FIG. 69, corrugated sheet metal 910
extends from the front right upper cap plate 895 to the front right
beam 900 along the entire length thereof, and from the first front
right access member 903 to the second front right access member 906
along the entire length thereof. The corrugated sheet metal 910 is
welded all along its entire perimeter to the immediately adjacent
front right upper cap plate 895, first front right access member
903, front right beam 900, and second front right access member
906. As those skilled in the art will readily appreciate, the
second front right access member 906 is welded to the corrugated
sheet metal 910 such that the long flange 907 is visible from the
interior of the container 10 when the container 10 is in its
unfolded condition. As shown in FIGS. 67-69, attached to the inward
surface 911 of the first front right access member 903 in spaced
relation to each other, are a plurality of second front right hinge
members 912. As shown in FIG. 68, each of the second front right
hinge members 912 is rotatably secured to one of the first front
right hinge members 893 by a hinge pin 913 so as to allow the front
right access panel 894 to swing relative to the front main panel
828.
[0194] Referring again to FIG. 69, immediately adjacent each of the
locking bolt holes 909 in the second front right access member 906
is a recess 914 in the corrugated sheet metal 910, and within each
recess 914 and aligned with the locking bolt holes 909 in the
second front right access member 906 are slide lock retainers 915.
As shown in FIGS. 69 and 72, a slide locking mechanism 916,
including a slide lock lever 917, and a slide locking bolt 918, is
slideably secured to each of the slide lock retainers 915 within
the recesses 914 such that each slide locking mechanism 916 is
positionable by use of one of the slide lock levers 917 between an
unlocked position in which the respective slide locking bolt 918 is
in a retracted position outside of the right side bolt holes 767 of
the right side panel 14, and a locked position in which the
respective slide locking bolt 918 extends through the immediately
adjacent locking bolt hole 909 of the second front right access
member 906 and one of the right side bolt holes 767 of the right
side panel 14.
[0195] Referring again to FIGS. 67 and 69, at least one locking
bolt assembly 919 is mounted to the front right access panel 894
within corrugations 920 of the corrugated sheet metal 910. The
construction of the locking bolt assembly 919 is the same as those
described with respect to the right side panel 14, except that each
pivot anchor 820 is fixedly secured to the corrugated sheet metal
910 of the front right access panel 894, and each guide tube 827
extends through, and is fixedly secured to, the front right upper
cap plate 895, as shown in FIG. 73. As those skilled in the art
will readily appreciate, each of the locking bolt assemblies 919 so
described is selectively positionable between a first position in
which the locking bolt 823 is received within one of the locking
bolt holes 610 in the lower face 608 of the roof right beam 600
when the container 10 is in the unfolded condition, and a second
position in which the locking bolt 823 is fully withdrawn from that
locking bolt hole 610.
[0196] As shown in FIGS. 67, 74 and 75, the front left post 63
includes a front left hinge plate 2891 that extends towards the
door edge 21 of the roof panel 11 when the container 10 is in the
unfolded condition. Attached to the inward surface 2892 of the
front left hinge plate 2891, in spaced relation to each other, are
a plurality of, and preferably four, first front left hinge members
2893. Each of the first front left hinge members 2893 is fixedly
secured to the inward surface 2892 of the front left hinge plate
2891, preferably by welding.
[0197] As shown in FIG. 74, a front left access panel 2894 is
pivotably attached to the front left post 63, and as shown in FIG.
76, the front left access panel 2894 includes a top edge 2214, a
bottom edge 2216, a front edge 2218, and a door edge 2220.
Extending along the top edge 2214 of the front left access panel
2894 along the length thereof is a front left upper cap plate 2895
having a front end 2896, a door end 2897, and preferably as shown
in FIGS. 67 & 74 a front left roof flange 2898 extends from the
front end 2896 to the door end 2897. Extending along the bottom
edge 2216 of the front left access panel 2894 along the length
thereof is a front left beam 2900 that has a front end 2901 and a
door end 2902.
[0198] As shown in FIG. 76, a first front left access member 2903
extends from the front end 2896 of the front left upper cap plate
2895 to the front end 2901 of the front left beam 2900, and is
fixedly secured to the front ends 2896, 2901, preferably by
welding. As shown in FIG. 76, a second front left access member
2906 extends from the door end 2897 of the front left upper cap
plate 2895 to the door end 2902 of the front left beam 2900, and is
fixedly secured to the door ends 2897, 2902, preferably by welding.
As shown in FIGS. 76, 77 and 78, the second front left access
member 2906 includes a long flange 2907 and a short flange 2908,
each of which extends along the length of the second front left
access member 2906 and towards the door edge 21 of the roof panel
11 when the container 10 is in the unfolded condition. Located
between the long flange 2907 and the short flange 2908 are a
plurality of locking bolt holes 2909, preferably three, that extend
through the second front left access member 2906. When the
container 10 is in the unfolded condition, the locking bolt holes
2909 are aligned with the left side bolt holes 794 of the left side
panel 16
[0199] Referring again to FIG. 76, corrugated sheet metal 2910
extends from the front left upper cap plate 2895 to the front left
beam 2900 along the entire length thereof, and from the first front
left access member 2903 to the second front left access member 2906
along the entire length thereof. The corrugated sheet metal 2910 is
welded all along its entire perimeter to the immediately adjacent
front left upper cap plate 2895, first front left access member
2903, front left beam 2900, and second front left access member
2906. As those skilled in the art will readily appreciate, the
second front left access member 2906 is welded to the corrugated
sheet metal 2910 such that the long flange 2907 is visible from the
interior of the container 10 when the container 10 is in its
unfolded condition. As shown in FIGS. 74-76, attached to the inward
surface 2911 of the first front left access member 2903 in spaced
relation to each other, are a plurality of second front left hinge
members 2912. Each of the second front left hinge members 2912 is
rotatably secured to one of the first front left hinge members 2893
by a hinge pin 2913 so as to allow the front left access panel 2894
to swing relative to the front main panel 828.
[0200] Referring again to FIGS. 74 & 76, immediately adjacent
each of the locking bolt holes 2909 in the second front left access
member 2906 is a recess 2914 in the corrugated sheet metal 2910,
and within each recess 2914 and aligned with the locking bolt holes
2909 in the second front left access member 2906 are slide lock
retainers 2915. As shown in FIGS. 76 and 79, a slide locking
mechanism 2916, including a lock lever 2917, and a slide locking
bolt 2918, is slideably secured to each of the slide lock retainers
2915 within the recesses 2914 such that each slide locking
mechanism 2916 is positionable by use of one of the slide lock
levers 2917 between an unlocked position in which the respective
slide locking bolt 2918 is in a retracted position outside of the
left side bolt holes 794 of the left side panel 16, and a locked
position in which the respective slide locking bolt 2918 extends
through the immediately adjacent locking bolt hole 2909 of the
second front left access member 2906 and one of the left side bolt
holes 794 of the left side panel 16.
[0201] Referring again to FIG. 76, at least one locking bolt
assembly 2919 is mounted to the front left access panel 2894 within
corrugations 2920 of the corrugated sheet metal 2910. The
construction of the locking bolt assembly 2919 is the same as those
described with respect to the right side panel 14, except that each
pivot anchor 820 is fixedly secured to the corrugated sheet metal
2910 of the front left access panel 2894, and each guide tube 827
extends through, and is fixedly secured to, the front left upper
cap plate 2895, as shown in FIG. 80. As those skilled in the art
will readily appreciate, each of the locking bolt assemblies 2919
so described is selectively positionable between a first position
in which the locking bolt 823 is received within one of the locking
bolt holes 610 in the lower face 609 of the roof left beam 603 when
the container 10 is in the unfolded condition, and a second
position in which the locking bolt 823 is fully withdrawn from that
locking bolt hole 610.
[0202] As shown in FIGS. 81, 84 and 86, the door panel 18 includes
a door main panel 921, a door right access panel 922, and a door
left access panel 923. The door main panel 921 includes a top edge
928, a bottom edge 929, a right edge 930, a left edge 931, two door
posts 924, 925, and two doors 926, 927. The right door post 924,
hollow and rectangular in cross section, extends along the right
edge 930 of the door main panel 921, and a left door post 925, also
hollow and rectangular in cross section, extends along the left
edge 931 of the door main panel 921.
[0203] Referring again to FIG. 81, each door 926, 927 is of the
type known in the shipping container art, and is hinged to one of
the door posts 924, 925 by a plurality of door hinges 932 so as to
be rotatable between a first position in which such door 926, 927
is closed, and a second position in which such door 926, 927 is
open. Each door 926, 927 has a door latch assembly 639 attached
thereto, and each door latch assembly preferably includes two
locking rods 92 rotatably attached to the outer surface 934, 935 of
such door 926, 927 by rod guides 933. The locking rods 933 of the
present invention are of the type known in the art and commonly
used on shipping containers. Such locking rods 92 have knuckles 940
at the upper ends 91 thereof, and knuckles 941 at the lower ends
713 thereof, and each locking rod 92 has a handle 936 attached
thereto to rotate such locking rod 92 approximately 180 degrees. As
those skilled in the art will readily appreciate, when the
container 10 is in the unfolded condition and the doors 926, 927
are closed, rotating each of the locking rods 92 by means of the
handles 936 attached thereto causes the knuckles 940 at the upper
ends 91 of such locking rods 92 to rotate into one of the lock
hasps 90a on the roof panel 11 while simultaneously causing the
knuckles 941 at the lower ends 713 of such locking rods 92 to
rotate into one of the lock hasps 90b on the base panel 11, thereby
securing the doors 926, 927 in the closed position.
[0204] As shown in FIGS. 82 and 83, a locking bar 943 is pivotably
connected at one end 944 to one of the locking rods 92 of the right
door 926, and a locking block 945 is fixedly secured to the left
door 927 at a location that is aligned with the locking bar 943
when both of the doors 926, 927 are closed. The locking bar 943
further includes a lock pin hole 946 that extends vertically
through the locking bar 943, and the locking bar 943 has a locking
rod recess 947 adjacent the distal end 948 of the locking bar 943.
The locking block 945 has an upper flange 949 and a lower flange
950 in spaced relation to each other for receiving the locking bar
943, and a pin receiving hole 951 that is the same diameter as the
lock pin hole 946 extends vertically through the upper flange 949
and lower flange 950. The lock pin hole 946 is located on the
locking bar 943 such that, when the locking bar 943 is received
within the flanges 949, 950 of the locking block 945 and a locking
rod 92 on the left door 927 is received within the locking rod
recess 947 (the "locked position"), the lock pin hole 946 of the
locking bar 943 and pin receiving hole 951 of the locking block 945
are substantially coaxial, so as to allow a locking pin 952 to be
inserted through the pin receiving hole 951 of the upper flange
949, through the lock pin hole 946 of the locking bar 945, and into
the pin receiving hole 951 of the lower flange 950.
[0205] As shown in FIG. 81, extending upwardly from each of the
door posts 924, 925 adjacent the top edge 928 of the door main
panel 921 is a door hinge pivot 953, 954, and as shown in FIGS.
84-87, each door hinge pivot 953, 954 is rotatably connected to one
of the sets 651, 652 of door first hinge members 653a, 653b, 653c,
653d located adjacent the door edge 21 of the roof panel 11. Each
door hinge pivot 953, 954 has a hinge pin 955, as shown in FIG. 81,
that extends through one of the door hinge pivots 953, 954 and the
door pivot holes 668 of the immediately adjacent door first hinge
members 653a, 653b, 653c and 653d so as to allow the door panel 12
to rotate relative to the roof panel 11.
[0206] The door hinge pivot 953 adjacent the right edge 930 of the
door main panel 921 and the door hinge pivot 954 adjacent the left
edge 931 of the door main panel 921 are identical, and a
representative door hinge pivot is shown in isolation in FIGS.
88A-88C. Each door hinge pivot 953, 954 has a pivot hinge pin hole
956 extending therethrough, and a cylindrical lug hole 957
extending therethrough as well. As shown in FIG. 81, a cylindrical
lug 958 extends through each cylindrical lug hole 957 and protrudes
from each side of the door hinge pivots 953, 954. Each cylindrical
lug 958 has a diameter that is only slightly less than the height
959 of the door lug receiving slot 669 on each of the door first
hinge members 653a, 653b, 653c, 653d of the roof panel 11. When
incorporated into the present invention, the hinge pin 955 extends
through the door pivot hole 668 of one of the door first hinge
members 653a, 653c through the pivot hinge pin hole 956 of the door
hinge pivot 953, and through the door pivot hole 668 of another one
of the door first hinge members 653b, 653d adjacent to the other
door first hinge member 653a, 653c to allow for rotation between
the door panel 18 and the roof panel 11. As those skilled in the
art will readily appreciate, when the door hinge pivots 953, 954
are rotatably secured between two of the door first hinge members
653a, 653b, 653c, 653d by a hinge pin 955, rotation of the
cylindrical lugs 958 into the lug receiving slots 669 of the
immediately adjacent door first hinge members 653a, 653b, 653c,
653d, shifts much of the load carried by the door hinge pivots 953,
954 from the hinge pins 955 to the cylindrical lugs 958, allowing
the door hinge pivots 953, 954 to support more weight than either
could carry on the hinge pins 955 alone. The construction and
function of the door hinge pivot 954 adjacent the left edge 931 of
the door main panel 921 is the same as that described for the door
hinge pivot 953 adjacent the right edge 930, except that the door
hinge pivot 954 is received between the door first hinge members
653c, 653d adjacent the left edge 20 of the roof panel 11.
[0207] As shown in FIGS. 89-92, at the lower end 960, 961 of each
of the door posts 924, 925 of the door panel 18 is a tang 962, 963.
Each door tang 962, 963 has a front face 964, 965 which faces the
front panel 12, and a door face 966, 967 which faces away from the
front panel 12. As shown in greater detail in FIGS. 93 and 94, the
door tang 962 attached to the door right post 924 includes a hole
968, which extends from the front face 964 to the door face 966 of
the door tang 962, and the hole 968 tapers from a first diameter at
the front face 964 to a slightly smaller diameter at the door face
966. As shown in FIGS. 95 and 96, the construction of the door tang
963 attached to the door left post 925 is the same as that for the
tang 962 attached to the door right post 924, except that the hole
968 extends from the front face 965 of the door tang 963 attached
to the door left post 925 to the door face 967 of the door tang 963
attached to the door left post 925.
[0208] As shown in FIGS. 93-96, each of the door posts 924, 925 has
a door roller arm 969, 970 fixedly secured thereto adjacent the
lower end thereof 960, 961, and each door roller arm 969, 970
extends downward along the immediately adjacent tang 962, 963, but
in spaced relation thereto. The lower end 971, 972 of each door
roller arm 969, 970 extends about two inches below the lower end
973, 974 of the immediately adjacent door tang.
[0209] As shown in FIGS. 93-98, a spacer 975, 976 is secured to
each door roller arm 969, 970 adjacent the lower end 971, 972
thereof, and each spacer 975, 976 has a roller cover plate 977, 978
removably secured thereto in spaced relation to the immediately
adjacent door roller arm 969, 970. The lower edge 979, 980 of each
roller cover plate 977, 978 extends downward along the immediately
adjacent door roller arm 969, 970 and then about half an inch to an
inch below the lower end 973, 974 thereof. A door roller 981, 982
is rotatably attached to each of the roller arms 969, 970 adjacent
the lower end 973, 974 thereof, and is secured in place by an axel
pin 983, 984 that extends between the door roller arm 969, 970 and
the roller cover plate 977, 978 immediately adjacent thereto. Each
of the door rollers 981, 982 is aligned with one of the rails 402,
404 of the base panel 17 and rides on such rails 402, 404 during
the folding, and unfolding, of the container 10 as described in
more detail below.
[0210] Referring back to FIGS. 89 and 90, the door right post 924
includes a door right hinge plate 3891 that extends towards the
front edge 22 of the roof panel 11 when the container 10 is in the
unfolded condition. Attached to the inward surface 3892 of the door
right hinge plate 3891, in spaced relation to each other, are a
plurality of, and preferably four, first door right hinge members
3893. Each of the first door right hinge members 3893 is fixedly
secured to the inward surface 3892 of the door right hinge plate
3891, preferably by welding.
[0211] A door right access panel 3894 is pivotably attached to the
door right post 924, and as shown in FIGS. 99 and 105, the door
right access panel 3894 includes a top edge 3214, a bottom edge
3216, a front edge 3218, and a door edge 3220. Extending along the
top edge 3214 of the door right access panel 3894 along the length
thereof is a door right upper cap plate 3895 having a front end
3896, a door end 3897, and preferably as shown in FIG. 90, a door
right roof flange 3898 extends from the front end 3896 to the door
end 3897. Extending along the bottom edge 3216 of the door right
access panel 3894 along the length thereof is a front right beam
3900 that has a front end 3901 and a door end 3902.
[0212] As shown in FIG. 99, a first door right access member 3903
extends from the door end 3897 of the door right upper cap plate
3895 to the door end 3902 of the door right beam 3900, and is
fixedly secured to the door ends 3897, 3902, preferably by welding.
As shown in FIGS. 91 and 99, a second door right access member 3906
extends from the front end 3896 of the door right upper cap plate
3895 to the front end 3901 of the door right beam 3900, and is
fixedly secured to the front ends 3896, 3901, preferably by
welding. As shown in FIGS. 99-101, the second door right access
member 3906 includes a long flange 3907 and a short flange 3908,
each of which extends along the length of the second door right
access member 3906 and towards the door edge 21 of the roof panel
11 when the container 10 is in the unfolded condition. Located
between the long flange 3907 and the short flange 3908 are a
plurality of locking bolt holes 3909, preferably three, that extend
through the second door right access member 3906. When the
container 10 is in the unfolded condition, the locking bolt holes
3909 are aligned with the right side bolt holes 768 of the right
side panel 14
[0213] Referring again to FIG. 99, corrugated sheet metal 3910
extends from the door right upper cap plate 3895 to the door right
beam 3900 along the entire length thereof, and from the first door
right access member 3903 to the second door right access member
3906 along the entire length thereof. The corrugated sheet metal
3910 is welded all along its entire perimeter to the immediately
adjacent door right upper cap plate 3895, first door right access
member 3903, door right beam 3900, and second door right access
member 3906. As those skilled in the art will readily appreciate,
the second door right access member 3906 is welded to the
corrugated sheet metal 3910 such that the long flange 3907 is
visible from the interior of the container 10 when the container 10
is in its unfolded condition. As shown in FIGS. 89, 99 and 102,
attached to the inward surface 3911 of the door right access panel
3894 and the first door right access member 3903 in spaced relation
to each other, are a plurality of second door right hinge members
3912. Each of the second door right hinge members 3912 is rotatably
secured to one of the first door right hinge members 3893 by a
hinge pin 3913 so as to allow the door right access panel 3894 to
swing relative to the door main panel 921.
[0214] Immediately adjacent each of the locking bolt holes 3909 in
the second door right access member 3906 is a recess 3914 in the
corrugated sheet metal 3910, and within each recess 3914 and
aligned with the locking bolt holes 3909 in the second door right
access member 3906 are slide lock retainers 3915. As shown in FIGS.
99 and 103, a slide locking mechanism 3916, including a lock lever
3917, and a slide locking bolt 3918, is slideably secured to each
of the slide lock retainers 3915 within the recesses 3914 such that
each slide locking mechanism 3916 is positionable by use of one of
the slide lock levers 3917 between an unlocked position in which
the respective slide locking bolt 3918 is in a retracted position
outside of the right side bolt holes 768 of the right side panel
14, and a locked position in which the respective slide locking
bolt 3918 extends through the immediately adjacent locking bolt
hole 3909 of the second door right access member 3906 and one of
the right side bolt holes 768 of the right side panel 14.
[0215] Referring again to FIG. 99, at least one locking bolt
assembly 3919 is mounted to the door right access panel 3894 within
corrugations 3920 of the corrugated sheet metal 3910. The
construction of the locking bolt assembly 3919 is the same as those
described with respect to the right side panel 14, except that each
pivot anchor 820 is fixedly secured to the corrugated sheet metal
3910 of the door right access panel 3894, and each guide tube 827
extends through, and is fixedly secured to, the front right upper
cap plate 3895, as shown in FIG. 104. As those skilled in the art
will readily appreciate, each of the locking bolt assemblies 3919
so described is selectively positionable between a first position
in which the locking bolt 823 is received within one of the locking
bolt holes 610 in the lower face 608 of the roof right beam 600
when the container 10 is in the unfolded condition, and a second
position in which the locking bolt 823 is fully withdrawn from that
locking bolt hole 610.
[0216] Referring back to FIGS. 89 and 90, the door left post 925
includes a door left hinge plate 4891 that extends towards the
front edge 22 of the roof panel 11 when the container 10 is in the
unfolded condition. Attached to the inward surface 4892 of the door
left hinge plate 4891, in spaced relation to each other, are a
plurality of, and preferably four, first door left hinge members
4893. Each of the first door left hinge members 4893 is fixedly
secured to the inward surface 4892 of the door left hinge plate
4891, preferably by welding.
[0217] A door left access panel 4894 is pivotably attached to the
door left post 925, and as shown in FIG. 105, the door left access
panel 4894 includes a top edge 4214, a bottom edge 4216, a front
edge 4218, and a door edge 4220. Extending along the top edge 4214
of the door left access panel 4894 along the length thereof is a
door left upper cap plate 4895 having a front end 4896, a door end
4897, and preferably as shown in FIG. 89, a door left roof flange
4898 extends from the front end 4896 to the door end 4897.
Extending along the bottom edge 4216 of the front left access panel
4894 along the length thereof is a door left beam 4900 that has a
front end 4901 and a door end 4902.
[0218] As shown in FIG. 105, a first door left access member 4903
extends from the door end 4897 of the door left upper cap plate
4895 to the door end 4902 of the door left beam 4900, and is
fixedly secured to the door ends 4897, 4902, preferably by welding.
As shown in FIGS. 92 and 105, a second door left access member 4906
extends from the front end 4896 of the door left upper cap plate
4895 to the front end 4901 of the door left beam 4900, and is
fixedly secured to the front ends 4896, 4901, preferably by
welding. As shown in FIGS. 105-107, the second door left access
member 4906 includes a long flange 4907 and a short flange 4908,
each of which extends along the length of the second front left
access member 4906 and towards the front edge 22 of the roof panel
11 when the container 10 is in the unfolded condition. Located
between the long flange 4907 and the short flange 4908 are a
plurality of locking bolt holes 4909, preferably three, that extend
through the second front left access member 4906. When the
container 10 is in the unfolded condition, the locking bolt holes
4909 are aligned with the left side bolt holes 795 of the left side
panel 16
[0219] Referring again to FIG. 105, corrugated sheet metal 4910
extends from the door left upper cap plate 4895 to the door left
beam 4900 along the entire length thereof, and from the first door
left access member 4903 to the second door left access member 4906
along the entire length thereof. The corrugated sheet metal 4910 is
welded all along its entire perimeter to the immediately adjacent
door left upper cap plate 4895, first door left access member 4903,
door left beam 4900, and second door left access member 4906. As
those skilled in the art will readily appreciate, the second door
left access member 4906 is welded to the corrugated sheet metal
4910 such that the long flange 4907 is visible from the interior of
the container 10 when the container 10 is in its unfolded
condition. As shown in FIGS. 90, 105 and 108, attached to the
inward surface 4911 of the door left access panel 4894 and the
first door left access member 4903 in spaced relation to each
other, are a plurality of second door left hinge members 4912. Each
of the second door left hinge members 4912 is rotatably secured to
one of the first door left hinge members 4893 by a hinge pin 4913
so as to allow the door left access panel 4894 to swing relative to
the door main panel 921.
[0220] Immediately adjacent each of the locking bolt holes 3909 in
the second door left access member 4906 is a recess 4914 in the
corrugated sheet metal 4910, and within each recess 4914 and
aligned with the locking bolt holes 4909 in the second front left
access member 4906 are slide lock retainers 4915. As shown in FIGS.
105 and 109, a slide locking mechanism 4916, including a slide lock
lever 4917, and a slide locking bolt 4918, is slideably secured to
each of the slide lock retainers 4915 within the recesses 4914 such
that each slide locking mechanism 4916 is positionable by use of
one of the slide lock levers 4917 between an unlocked position in
which the respective slide locking bolt 4918 is in a retracted
position outside of the left side bolt holes 795 of the left side
panel 16, and a locked position in which the respective slide
locking bolt 4918 extends through the immediately adjacent locking
bolt hole 4909 of the second door left access member 4906 and one
of the left side bolt holes 795 of the left side panel 16.
[0221] As shown in FIG. 105, at least one locking bolt assembly
4919 is mounted to the door left access panel 4894 within
corrugations 4920 of the corrugated sheet metal 4910. The
construction of the locking bolt assembly 4919 is the same as those
described with respect to the right side panel 14, except that each
pivot anchor 820 is fixedly secured to the corrugated sheet metal
4910 of the door left access panel 4894, and each guide tube 827
extends through, and is fixedly secured to, the door left upper cap
plate 4895, as shown in FIG. 110. As those skilled in the art will
readily appreciate, each of the locking bolt assemblies 4919 so
described is selectively positionable between a first position in
which the locking bolt 823 is received within one of the locking
bolt holes 610 in the lower face 609 of the roof left beam 603 when
the container 10 is in the unfolded condition, and a second
position in which the locking bolt 823 is fully withdrawn from that
locking bolt hole 610.
[0222] As those skilled in the art will readily appreciate, further
embodiments can be incorporated to reduce cost and weight. One of
these embodiments includes elimination of the access panels,
replacing the side hinge members and linear spring assemblies with
a torsion pin hinge, and increasing the height of the side panels
to provide more strength to the base panel and reduction of weight
from the top panel.
[0223] The primary function of the access panels is to minimize the
side panel section height near the door panel and the front panel
to give access thereto. FIG. 113 is a schematic view plan view
looking down on the base 17, showing the side panels folded down on
the base 17. The area marked by the "X" 5000, shows the area
occupied by the side panels when they are folded down. The two
areas 5001, 5002, immediately adjacent the side panels are areas
that are not occupied by the side panels because in this view the
access panels are folded into the front panel or the door panel. A
side view of the base 17 shown in FIG. 113 is shown in FIG. 114,
which shows that since the side panels do not extend the entire
length of the base, notched areas 5003, 5004 are formed at the ends
of each side panel, because the stacked-up height 5005 of the base
17 and the side panels is substantially greater than the height
5006 of the base panel 17 at the two areas 5001, 5002, immediately
adjacent the side panels. As shown by the curved arrows 5007, 5008,
these notched areas 5003, 5004 allow the door panel and the front
panel to clear the folded-down side panels as they swing along the
paths shown by the curved arrows 5007, 5008 during the folding
process. Unfortunately, inherent in this notched design are
surfaces that may be difficult to seal effectively, and structural
issues require additional weight in to achieve desirable rigidity
of the container. This further embodiment eliminates the access
panels all together by extending the side panels the entire length
of the base. This eliminates the sealing requirements between the
access panels and the side panels, reduces cost, and also
significantly improves the structural aspects of the container.
[0224] FIG. 115 shows a schematic side view of the base 17 with the
side panels erect. As previously described, the side panels are
structurally tied to the base panel 17 by side hinge members that
provide both a hinge function for the side panels, and shear load
capability for the container in its unfolded condition. While this
design may perform satisfactorily, it incorporates structural
features that may not be desirable in certain applications.
Unfortunately, the side panels, which provide 80% of the load
carrying capability of the base panel 17 (by effectively increasing
the beam-height from a structural point of view), do not extend all
the way to the ends of the base panel 17 where the right and left
side door interlocks, and the right and left side front interlocks
take all of the vertical loading. Consequently, stress is
concentrated at the points 5009, 5010, where the ends of the side
panels meet the base panel 17. By extending the side panels the
full length of the base panel 17, to the end of the beam, this
stress concentration can be eliminated.
[0225] FIG. 116 shows schematically a transverse cross-sectional
view through the base panel 17 and the side panels adjacent one of
the side hinge members and linear spring assemblies. As the left
side panel is rotated down from its vertical position (as shown by
the dashed lines) the spring mechanism in the linear spring
assembly (not shown) is compressed, developing a tensile force in
the cable 5045 which is preferably adjusted to provide the
appropriate force to counter-balance the weight of the left side
panel as it is folded down. Unfortunately, this design requires
that the right side panel be shortened by a distance "D" 5011. As a
result, the right side skirt, which extends down from the top
panel, must be longer to compensate for the shortened height of the
right side panel, as compared to if the right side panel height did
not have to be shortened by a distance "D" 5011 to accommodate the
cable 5045. As those skilled in the art will readily appreciate,
since the right and left side skirts are less rigid than the rest
of the top panel from which they extend, the distance which the
side skirts extend down from the top panel should preferably be as
short as possible, and the side panels should be as tall as
possible, to maximize the structural rigidity of the container.
[0226] A further embodiment significant improvement to this
arrangement is the use of hinge pin torsion spring assemblies, an
example of which is shown in FIG. 117, instead of the linear spring
assemblies and side hinge members attached to the right and left
side panels described in the preferred embodiment. The hinge pin
torsion spring replaces the "pin" in FIG. 116 torsion feature
interior to the bottom beam. Preferably, each hinge pin torsion
spring assembly 5000 includes a side panel hinge member 5020, base
hinge members 5021, 5022, and a hinge pin torsion spring 5023.
Although the hinge pin torsion spring assembly shown in FIG. 117 is
shown and described attached to the to the left side panel, it is
to be understood that the hinge pin torsion spring assemblies used
on the right side panel are similar.
[0227] The hinge pin torsion spring 5023, as shown in FIG. 118,
includes a hinge pin 5024 having a cylindrical main section 5025, a
non-cylindrical section 5026, preferably hexagonal in
cross-section, at one end of the hinge pin, and a pin ratcheting
feature 5027 at the end opposite the non-cylindrical section 5026.
The pin ratcheting feature 5027, which is preferably a cylindrical
disk, includes a plurality of gear teeth 5028 which face the
non-cylindrical section 5026 and which are all canted in the same
circumferential direction. The non-cylindrical section 5026 and the
pin ratcheting feature 5027 are integral with the cylindrical main
section 5025, so that rotation of the non-cylindrical section 5026
necessarily causes the pin ratcheting feature 5027 to rotate in the
same direction.
[0228] As shown in FIG. 119, the torsion spring 5029 of the hinge
pin torsion spring 5023 includes a coil spring 5030, an attachment
ring 5031, a spring ratcheting feature 5032, and a spring shield
5033. The attachment ring 5031 and the spring ratcheting feature
5032 each have an inner bore having a diameter that is greater than
the outer diameter of the cylindrical main section 5025 of the
hinge pin 5024 to allow the cylindrical main section 5025 of the
hinge pin 5024 to slide therethrough without binding. Likewise, the
inner diameter of the coil spring 5030 is greater than the outer
diameter of the cylindrical main section 5025 of the hinge pin 5024
to avoid binding between the cylindrical main section 5025 of the
hinge pin 5024 and the coil spring 5030 at all operating positions
of the hinge pin torsion spring 5023. The attachment ring 5031 is
fixedly attached, preferably by welding, to one end of the coil
spring 5030, and the spring ratcheting feature 5032 is fixedly
attached, preferably by welding, to the opposite end of the of the
coil spring 5030. The spring ratcheting feature 5030, which is
preferably generally cylindrical, includes a plurality of gear
teeth 5034 which face away from the attachment ring 5031 and which
are all canted in the same circumferential direction, which is
opposite the direction in which the gear teeth 5028 of the pin
ratcheting feature are canted. The spring ratcheting feature 5032
includes a non-cylindrical portion 5035, which is preferably
hexagonal in cross section, the purpose of which is described
below. The spring shield 5033 which is tubular and may be
cylindrical or non-cylindrical, fits loosely around, and protects,
the coil spring 5030.
[0229] The hinge pin torsion spring 5023 is shown in FIG. 120 fully
assembled, with the hinge pin 5024 inserted into the torsion spring
5029. As those skilled in the art will readily appreciate, in this
assembled condition, the gear teeth 5028 of the pin ratcheting
feature 5027 are interlocked with the gear teeth 5034 of the spring
ratcheting feature 5032, and due to the canted nature of the gear
teeth 5028, 5034, can only be rotated in one direction, and the
gear teeth 5028, 5034 will lock together if rotation in the
opposite direction is attempted.
[0230] As shown in FIG. 121 the hinge pin 5024 of the hinge pin
torsion spring 5023 is received within a hole 5036 in base hinge
member 5022. The hole 5036 is slightly larger than the outer
diameter of the cylindrical main portion 5025 of the hinge pin 5024
so as to allow the hinge pin to rotate freely therein. In addition,
the attachment ring 5031, is fixedly attached to the base hinge
member 5022, either by welding or by some other attachment method
that prevents rotation between the attachment ring 5031 and base
hinge member 5022. Base hinge member 5022 is welded to the base
left beam 685 along the vertical edge 5037 immediately adjacent
thereto, and to the base left beam 685 along the horizontal edge
5038 immediately adjacent thereto.
[0231] As shown in FIG. 122 the hinge pin 5024 of the hinge pin
torsion spring 5023 is received within a hole 5039 in base hinge
member 5021. The hole 5039 is slightly larger than the outer
diameter of the cylindrical main portion 5025 of the hinge pin 5024
so as to allow the hinge pin to rotate freely therein. Base hinge
member 5021 is welded to the base left beam 685 along the vertical
edge 5040 immediately adjacent thereto, and to the base left beam
685 along the horizontal edge 5041 immediately adjacent
thereto.
[0232] Referring again to FIG. 117, the hexagonal portion 5026 of
the hinge pin 5024 is received within a hexagonal hole 5042 in side
panel hinge member 5020. The hexagonal portion 5026 of the hinge
pin 5024 welded, or otherwise fixedly secured to side panel hinge
member 5020 to prevent the hinge pin 5024 from inadvertently
sliding out of the torsion spring 5029. Side panel hinge member
5020 is welded to the left side panel 16 along the vertical edge
5043 immediately adjacent thereto, and if desired, may include a
stop 5044 to insure that the side panel 16 stops rotating once the
side panel 16 is vertical to prevent it from rotating past the
vertical position.
[0233] As those skilled in the art will readily appreciate, in the
fully assembled condition shown in FIG. 117, an open-end wrench can
be used on the hexagonal portion 5035 of the spring ratcheting
feature 5032 to rotate the spring ratcheting feature 5032, thereby
increasing the torque on the hinge pin 5024 and increasing the
counterbalancing effect of the coil spring 5030 on the side panel
16. Once the torque has been so set, the hinge pin torsion springs
provide torque to the side panels as they are rotated down, thereby
counterbalancing the weight of the side panels.
[0234] The hinge pin torsion spring assembly 5000 eliminates the
need for the step up in height from height 5006 to height 5005 in
FIG. 114, eliminates the requirement that either side panel 14, 16
be shortened to provide clearance for the cable 5045 from the
linear spring assembly. Each hinge pin torsion spring assembly 5000
replaces a pin, cable and linear spring, among others. With no need
to shorten the side panels to accommodate the cables, the height of
the side panels can be increased to minimize the distance that the
right and left skirts 23, 24 extend down from the roof panel,
simplifying sealing in this area. With the elimination of the cable
5045, the risk that this cable, which is exposed and always under
tension, may get caught on something and break, or injure someone,
is eliminated as well. Likewise, elimination of the access panels
allows each side panel to span the full length of the container,
and the use of the hinge pin torsion springs allows height of each
side panel to be maximized, resulting in a container that is
lighter in weight and more rigid than a container incorporating
access panels and linear spring assemblies with cables.
[0235] To fold the container of the present invention, the locking
bolts on the access panels are retracted from their respective bolt
holes in the roof panel, and the slide locking mechanisms in each
of the access panels are used to retract the slide locking bolts
from the bolt holes in the right and left side panels. One of the
access panels on the front panel and one of the access panels on
the at the door panel is then swung toward the interior of the
folding container until they lie substantially flat against the
respective front, or door, main panel. The remaining access panels
are then swung toward the interior of the folding container until
they lie substantially flat against the other access panel. (Of
course, if the embodiment of the present invention is the one which
eliminates the access panels by extending the length of each side
panel to the full length of the container, the foregoing folding
steps related to the access panels do not occur in the folding
process.)
[0236] The doors are then swung closed, but the locking rods are
left in the unlocked position. The locking bar is swung into the
locking block so that it is received between the flanges of the
locking block, and a locking rod on the adjacent door is received
within the locking rod recess of the locking bar. Then a locking
pin is inserted through the pin receiving hole of the upper flange
of the locking block and into the lock pin hole of the locking bar,
thus securing the doors together to prevent the doors from opening
during the folding process.
[0237] Next, the locking bolts on the left and right side panels
are retracted from their respective bolt holes in the roof panel,
thereby freeing the side panels to be rotated inwardly. One of the
side panels is then swung from its vertical position to a position
in which the side panel is resting on the floor of the base panel,
after which the other side panel is then swung from its vertical
position to a position in which it is resting on the other side. As
each of the right and left side panels is rotated inward, the
weight of that side panel is substantially counter balanced by the
spring force provided by the springs in the linear spring
assemblies, or the hinge pin torsion spring assemblies, depending
on which is used, thereby allowing one or two people to safely fold
the left and right side panels from a vertical position to a
horizontal position without additional equipment. At this point, a
spreader attaches to the roof panel at each of the four corner
fittings in the manner similar to lifting typical shipping
containers, so that the roof panel of the container is thus
supported by both the spreader and the posts of the front panel and
the door panel.
[0238] Then the hammer locking mechanisms in the recessed portions
of the base right beam and base left beams adjacent the door main
panel are used to retract the hammer locking bolts from the base
door interlocks, and in doing so the holes in the door tangs at the
lower ends of the right and left door posts, thus freeing the door
panel from the base panel. Then and the hammer locking mechanisms
in the recessed portions of the base right beam and base left beams
adjacent the door main panel are used to retract the hammer locking
bolts from the base door interlocks, and in doing so the holes in
the door tangs at the lower ends of the right and left door posts,
thus unlocking the door panel from the base panel. Likewise, the
hammer locking mechanisms in the sill panel of the front panel are
used to retract the hammer locking bolts from the base front
interlocks, and in doing so the hammer locking bolts retract from
the holes in the base front tangs in the lower ends of the right
and left door posts, thus unlocking the front panel from the base
panel.
[0239] The spreader then lifts the roof panel along with the
attached front panel and door panel until the rollers at the lower
ends of the door posts and front posts are just a little higher
than the guide rails on the base panel immediately adjacent
thereto, at which point the door tangs and base front tangs are in
a position such that they are fully withdrawn from the interlocks
of the door panel and front panel. At this point, the roof panel
has been lifted to the highest point necessary in the folding
process. Then workers push inwardly on the door panel to swing the
bottom edge thereof to be positioned above the base panel well
inward of the door edge of the base panel, while workers
simultaneously push inwardly on the front panel to force the bottom
edge thereof to be positioned above the base panel well inward of
the front edge of the base panel. As the workers are so positioning
the door panel and front panel, the spreader begins to slowly lower
the roof panel until each of the rollers mounted on the lower ends
of the door posts and front posts are resting on the immediately
adjacent guide rails of the base panel.
[0240] Lowering of the roof panel then continues, causing the
rollers of the door panel to roll along the guide rails of the base
panel towards the front panel, guided by the cover plates which
slide along, but outward of, the guide rails to keep the rollers
from sliding off such guide rails. At the same time, lowering of
the roof panel causes the rollers of the front panel to roll along
the guide rails of the base panel towards the door panel, guided by
the cover plates which slide along, but outward of, the guide rails
to keep the rollers from sliding off such guide rails. Further
lowering of the roof panel continues until the front panel and door
panel are substantially parallel to the base panel, the roof panel
is resting on the base panel, and each of the base tangs extending
from the base panel is received within one of the interlocks of the
roof panel. The container is then ready to be locked in its folded
position.
[0241] The hammer locks located on the roof panel adjacent the
front edge thereof are engaged by hammering the locking bolts into
the holes of the interlocks and the holes of the base tangs
received therein, as shown in FIG. 111. This locks the roof panel
to the base panel at the front edges thereof. Then, the pair of
locking straps are removed from their stored position, and then
re-attached to the folded container such that each locking strap is
located between a pair of upper door stop receivers in the roof
panel, and a pair of lower door stop receivers in the base panel.
Each locking strap is secured to the folded container by bolting
the upper end of each locking strap to the roof panel with a bolt
that is threaded into one of the upper active strap bolt holes and
tightened, and by bolting the lower end of each locking strap to
the roof panel with a bolt that is threaded into one of the lower
active strap bolt holes and tightened. In this position, as shown
in FIG. 112, each "T" end of each locking strap is resting against
the upper or lower door stop receivers immediately adjacent
thereto, so that the load carried by the locking straps during
lifting of the folded container is carried by such door stop
receivers rather than the bolts that secure the locking straps to
the roof panel and base panel. At this point, locking of the roof
panel to the base panel has been completed, and the folded
container is ready to be moved, stacked, shipped or stored. At this
point the spreader can lift the folded container to be stacked onto
other folded containers for shipment to the intended
destination.
[0242] Unfolding of the preferred embodiment of the present
invention is essentially the reverse of the folding process,
however when the roof panel has been raised to what was the highest
point in the folding process, workers pull the door panel and front
panel outwardly to properly position the tangs on the door panel
above the interlocks in the base at the door end of the base panel,
while workers position the interlocks at the bottom of the front
posts over the base front tangs. The workers then hold these
positions until the roof panel is lowered and the door tangs and
base front tangs are received within the adjacent interlocks. The
hammer locks located on the base panel adjacent the door end are
then secured by driving each locking bolt through the hole in the
adjacent interlock and into the hole in the door tang received
therein, and the hammer locks located in the sill panel of the
front panel are secured by driving each locking bolt through the
hole in the adjacent interlock and into the hole in the base front
tang received therein. Then the left and right side panels are
lifted to their vertical, unfolded positions (assisted by the
counterbalance provided by the springs in the spring tubes), and
the locking bolts on the side panels are extended into the bolt
holes on the roof panel to lock the left and right side panels to
the roof panel. Then, the access panels are unfolded from the door
panel and front panel so as to be parallel with the side panels,
the slide locking mechanisms in the access panels are used to drive
the slide locking bolts into the bolt holes in the right and left
side panels, and the locking bolts on the access panels are
extended into the bolt holes on the roof panel to lock the access
panels to the roof panel. At this point the container is ready for
use in shipping cargo.
[0243] As those skilled in the art will readily appreciate, the
access panels allow workers to easily enter and exit the container
to assist with the folding and unfolding of the side panels. If
this flexibility is not desired, the side panels could be extended
to span the entire length between the front panel and the door
panel, and locking features could be added to the side panels to
lock the side panels to the front panel and the door panel, thus
eliminating the access panels altogether.
[0244] Referring now to FIGS. 123-128, an alternate embodiment of
the present invention is disclosed. More specifically, an improved
supporting frame assembly 6000 for a collapsible container assembly
is provided. That is, in the improved supporting frame assembly
6000, the beam members are configured so as to provide an improved
structural support and the required operating clearances for a
collapsible shipping container when the collapsible shipping
container is under a mechanical load, such as when carrying goods
being shipped through intermodal means.
[0245] Referring initially to FIG. 123, a supporting frame assembly
6000 is shown in perspective view. The supporting frame assembly
6000 comprises a first lower base beam 6002 extending from a front
6004 of the container to a rear 6006 of the container. A second
lower base beam 6008 is positioned generally parallel to the first
lower base beam 6002 and spaced a distance from the first lower
base beam. The distance the first lower base beam 6002 and the
second lower base beam 6008 are spaced apart establishes a width of
the container. The first lower base beam 6002 and the second lower
base beam 6008 extend from a front 6004 of the container to a rear
6006 of the container to establish its length. Each of the first
lower base beam 6002 and the second lower base beam 6008 have a
generally c-shaped cross section, as shown in FIG. 126. Contained
within the first lower base beam 6002 and the second lower base
beam 6008 is a torsional spring 6020 for aiding in the raising and
lowering of the sidewalls of the collapsible shipping
container.
[0246] As shown in FIGS. 123-125, a plurality of cross members 6010
connect the first lower base beam 6002 and the second lower base
beam 6008. The cross members 6010 are perpendicular to the first
lower base beam 6002 and the second lower base beam 6008, as shown
in FIG. 124, and preferably welded to both the first lower base
beam 6002 and the second lower base beam 6008. Also, the cross
members 6010 are generally equally spaced across a majority of the
axial length of the first lower base beam 6002 and the second lower
base beam 6008, as shown in FIG. 124. The supporting frame assembly
6000 depicted in FIGS. 123 and 124 also comprises a pair of
channels 6012 passing through the width of the supporting frame
assembly 6000. The two channels 6012 provide an opening for
receiving a lifting mechanism, such as the forks of a forklift, for
purposes of lifting and moving the shipping container.
[0247] As one skilled in the art will appreciate, cross members
6010 of the supporting frame assembly 6000 are subject to a
twisting due to the mechanical load applied to the supporting frame
assembly 6000. The plurality of cross members 6010 are uniquely
designed to provide the necessary structural rigidity to account
for this twisting effect. More specifically, and with reference to
FIGS. 125, 127, and 128, the plurality of cross members 6010 have a
unique cross sectional design compared to the first lower base beam
6002 and the second lower base beam 6008. The cross members 6010
are formed from steel plate and comprise a vertical member 6014, a
first leg 6016, and a second leg 6018. In order to fit with the
first and second lower base beams, 6002 and 6008, the height of the
vertical member 6014 is approximately equivalent to that of the
vertical portion of the first and second lower base beams, 6002 and
6008. The first leg 6016 extends generally perpendicular from a
first end 6014A of the vertical member 6014. The second leg 6018
extends from a second end 6014B of the vertical member 6014 and
extends in a direction towards the first leg 6016. That is, the
second leg 6018 is oriented at an acute angle .alpha. relative to
the vertical member 6014. More specifically, for the embodiment
shown in FIGS. 125, 127, and 128, the second leg 6018 is oriented
at an angle of approximately 70 degrees relative to the vertical
member 6014.
[0248] The cross members 6010 have the cross sectional shape
described above to account for twist in the cross member 6010 when
subjected to a mechanical load. This cross member design allows for
a maximum payload without passing a maximum deflection plane, as
dictated by international standards certification requirements for
a forty foot high cube container. For example, a container having a
supporting frame assembly 6000 of the present invention can be
subjected to a loading of twice the maximum payload of 134,400
pounds without deflecting beyond accepted parameters. As one
skilled in the art of shipping container design understands,
shipping containers such as that of the present invention must
undergo extensive testing and certifications prior to being
approved for intermodal transportation. One such approval requires
the container to be load tested simulating two times the full
payload in the container and to measure displacement of the
supporting frame assembly to ensure it is not displaced beyond
industry-adopted safety parameters. Such testing is conducted by
loading concrete blocks into the container until it either reaches
the twice maximum payload level or until the lowest plane passes
six millimeters below the four standard corner fittings 36e, 36f,
36g, 36h, as shown in FIG. 17, of the container.
[0249] In order to compensate for the deflection that occurs under
loading, such as the load testing described above, the supporting
frame assembly 6000 is designed such that the first lower base beam
6002 and the second lower base beam 6008 each have a slight
arc-like shape resulting in a camber to the supporting frame
assembly 6000. The first lower base beam 6002 and the second lower
base beam 6008 have a maximum deflection of approximately 10 mm at
their respective midpoints. This deflection is taken by measuring
the difference between the bottom surface of an end (front 6004 or
rear 6006) compared to the bottom surface of the first lower base
beam 6002 or the bottom of the second lower base beam 6008 at their
respective midpoint. That is, both the front 6004 and rear 6006
will be fixed on the same plane and the midpoint of the first lower
base beam 6002 and second lower base beam 6008 will extend a
maximum height of approximately 10 mm higher than the front and
rear. This preloaded deflection is formed into the supporting frame
assembly 6000 in a sub-assembly stage prior to the flooring being
secured to the supporting frame assembly 6000.
[0250] Referring back to FIGS. 123 and 124, the cross members 6010
are located from proximate the rear 6006 of the container through
at least a midpoint of the first lower base beam 6002 and the
second lower base beam 6008. The geometry of the supporting frame
assembly 6000 changes towards the front 6004 due to other
requirements associated with the collapsible container. For
example, the supporting frame assembly 6000 has a recessed portion
6022 adjacent the front 6004 of the container. This recessed
portion is formed in part by a first axial beam 6026 and a second
axial beam 6028 extending from the front 6004 a distance towards
the rear 6006, as shown in FIGS. 123 and 124. The recessed portion
6022 provides the region for a traditional gooseneck connection for
pulling the container when it is secured to a trailer. In this
configuration, the supporting frame assembly 6000 comprises a
plurality of c-shaped cross members 6024 that extend from the first
axial beam 6026 to the first lower base beam 6002 and from the
second axial beam 6028 to the second lower base beam 6008. The
c-shaped cross members 6024 are of a different cross sectional
geometry than that of the cross members 6010. However, in an
alternate embodiment of the present invention, the c-shaped cross
members 6024 could instead be replaced with cross members 6010
discussed above, such that cross members 6010 extend along the
entire length of the container.
[0251] The above description clearly establishes the advantages
provided by the present invention which need not be explained in
greater detail to those skilled in the art, who will also recognize
that various design modifications and differing components can be
introduced within the scope of the present invention as set forth
below.
[0252] While the invention has been described in what is known as
presently the preferred embodiment, it is to be understood that the
invention is not to be limited to the disclosed embodiment but, on
the contrary, is intended to cover various modifications and
equivalent arrangements within the scope of the following claims.
The present invention has been described in relation to particular
embodiments, which are intended in all respects to be illustrative
rather than restrictive.
[0253] From the foregoing, it will be seen that this invention is
one well adapted to attain all the ends and objects set forth
above, together with other advantages which are obvious and
inherent to the system and method. It will be understood that
certain features and sub-combinations are of utility and may be
employed without reference to other features and sub-combinations.
This is contemplated by and within the scope of the claims.
* * * * *