PROFILE FOR A CONTAINER, METHODS FOR MANUFACTURING A PROFILE, BASE STRUCTURE FOR A CONTAINER AND CONTAINER

Abstract

The invention relates to a profile in a container, where a profile (5, 6, 7, 8, 101) comprising a cross section where at least a part of the cross section over a length of the profile is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the critical buckling load for zones abutting the crumple zone. The invention further relates to a method of manufacturing a profile for a container, where one or more profiles (5, 6, 7, 8, 101) in the container (1) is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the rest of the profile (5, 6, 7, 8, 101). The invention also relates to abase structure for a container, comprising a pair of bottom side rails, a front sill (4) in one end and a door end in an opposite end, a number of crossmembers (8) placed in parallel with the front sill (4) and door end and extending from a bottom side rail (2) in one side of the container (1) to a bottom side rail (2) at the other side of the container (1), wherein the crossmember (8) comprises a cross-section, where at least a part of the cross section over a length of the profile (5, 6, 7, 8, 101) is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the critical buckling load for zones abutting the crumple zone.

Claims

1. A profile for a container, the profile comprising a cross-section, wherein at least a part of the cross-section over a length of the profile is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the critical buckling load of zones abutting the crumple zone.

2. The profile according to claim 1, wherein the crumple zone is provided in or by a sidewall/body of the profile.

3. The profile according to claim 2, wherein the sidewall/body is provided with a material thickness smaller than the thickness of the abutting zones.

4. The profile according to claim 2, wherein the sidewall/body is provided with a material strength lower than the material strength of the abutting zones.

5. The profile according to claim 1, wherein the profile comprises a bottom flange, which bottom flange is provided with a greater material thickness by one or more additional layers of metal sheets being secured to the bottom flange.

6. The profile according to claim 1, wherein the profile comprises a bottom flange, which bottom flange is provided with a greater material strength by a combined mix of materials, said materials being steel, high strength steel, polymers, or carbon fibers.

7. The profile according to claim 5, wherein a width of the one or more additional layers of metal sheets secured to the bottom flange corresponds to the width of the bottom flange.

8. The profile according to claim 5, wherein a width of the one or more additional layers of metal sheets secured to the bottom flange, for at least a part of a length of the bottom flange (11), are narrower than the width of the bottom flange.

9. The profile according to claim 1, wherein the crumple zone is provided by means of longitudinal bends in the sidewall/body, which longitudinal bends predefine place and shape of deformations in the crumple zone.

10. A method for manufacturing a profile for a container, wherein the method comprises providing a crumple zone by increasing material thickness in zones of the profile abutting the crumple zone.

11. The method according to claim 10, wherein the method further comprises providing the crumple zone in a sidewall/body of the profile by laminating a bottom flange of the profile with one or more metal sheets.

12. The method according to claim 11, wherein the one or more metal sheets are laminated to the bottom flange of the profile by a thermal joining process, said thermal joining process being welding, stitch welding, or spot welding.

13. The method according to claim 11, wherein the one or more metal sheets are laminated to the bottom flange of the profile by a bonding process, said bonding process being gluing or vulcanizing.

14. The method according to claim 11, wherein the one or more metal sheets are laminated to the bottom flange of the profile by rivets or bolts.

15. The method according to claim 11, wherein the method comprises forming longitudinal bends by bending, roll forming, embossing, or stamping the sidewall/body.

16. A container comprising one or more profiles according to claim 1.

17. A base structure for a container, which base structure comprises a pair of bottom side rails, a front sill in one end and a door end in an opposite end, a number of crossmembers placed in parallel with the front sill and door end and extending from a bottom side rail in one side of the container to a bottom side rail at the other side of the container, wherein the crossmember comprises a cross-section, wherein at least a part of the cross-section over a length of the crossmember is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the critical buckling load for zones abutting the crumple zone.

Description

[0073] The above and other features and advantages of the present invention will become readily apparent to those skilled in the art by the following detailed description of exemplary embodiments thereof with reference to the attached drawings, in which:

[0074] FIG. 1 shows a schematic view of an underside of a container;

[0075] FIG. 2 shows a schematic side view of a crossmember of a container;

[0076] FIG. 2A shows schematically an enlarged side view of an end of the crossmember shown on FIG. 2;

[0077] FIG. 3 shows schematically an enlarged end view of the crossmember of FIG. 2;

[0078] FIG. 4 shows a perspective view of the crossmember of FIG. 2;

[0079] FIG. 5 shows a perspective view of a profile of a prior art crossmember of a container;

[0080] FIG. 6 shows a cross section of the prior art profile shown in FIG. 5;

[0081] FIG. 7 shows an example of a normal static load situation on a crossmember of a loaded container;

[0082] FIG. 8 schematically shows an abnormal static load situation on a cross member of loaded container, for example placed on the ground with a stone or similar obstacle projecting above ground level;

[0083] FIG. 9 schematically shows an abnormal impact load situation on a cross member of loaded container, for example when hitting an object during handling of the container;

[0084] FIG. 10 shows a top view of an embodiment of a crossmember of a container;

[0085] FIG. 10B shows a an enlarged cross section along a line B-B of the crossmember shown in FIG. 10;

[0086] FIG. 10C shows a cross section along a line C-C of the crossmember shown in FIG. 10;

[0087] FIG. 10D shows a cross section along a line D-D of the crossmember shown in FIG. 10;

[0088] FIG. 11 shows a top view of an embodiment of a crossmember of a container, which crossmember is provided with reinforcement members;

[0089] FIG. 12 shows a side view of the crossmember of FIG. 11;

[0090] FIG. 13 shows a longitudinal cross section of the crossmember of FIG. 11 along line A-A;

[0091] FIG. 13B shows a cut-out of the cross section marked B in the crossmember shown in FIG. 13;

[0092] FIG. 13C shows a cut-out of the cross section marked C in the crossmember shown in FIG. 13;

[0093] FIG. 13D shows a cut-out of the cross section marked D in the crossmember shown in FIG. 13;

[0094] FIG. 13E shows a cut-out of the cross section marked E in the crossmember shown in FIG. 13;

[0095] FIG. 14 shows a perspective view of a profile of a middle section of another embodiment of a crossmember of a container;

[0096] FIG. 15 shows a cross section or end view of the profile shown in FIG. 14;

[0097] FIG. 16 schematically shows a side view of a container indicating cross sectional views A-A and C-C;

[0098] FIG. 16A shows a cross sectional view along line A-A;

[0099] FIG. 16C shows a cross sectional view along line C-C;

[0100] FIG. 17 is a cutout from FIG. 16A showing a lower corner assembly where a crossmember joins a side of the container; and

[0101] FIG. 18 is a cutout from FIG. 16C showing a lower corner assembly where a crossmember joins a side of the container.

[0102] Various embodiments are described hereinafter with reference to the figures. Like reference numerals refer to like elements throughout. Like elements will, thus, not be described in detail with respect to the description of each figure.

[0103] It should also be noted that the figures are only intended to facilitate the description of the embodiments.

[0104] They are not intended as an exhaustive description of the claimed invention or as a limitation on the scope of the claimed invention. In addition, an illustrated embodiment needs not have all the aspects or advantages shown.

[0105] An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated, or if not so explicitly described.

[0106] Throughout, the same reference numerals are used for identical or corresponding parts.

[0107] A base frame construction of a railway container, an intermodal container or a shipping container 1 shown in FIG. 1, comprises a floor section 10 provided by a pair of bottom side rails 2, a gooseneck tunnel 3 placed in an end of the container pointing away from an end provided with one or more doors (not shown) for access to an inner side of the container 1. The gooseneck tunnel 3 is normally defined by a front sill 4, a pair of gooseneck side rails 5 at each side of the gooseneck tunnel 3 and a bolster 6. The bolster forms a transition between a gooseneck end of the container 1 and an opposite end of the container 1, comprising the door end or rear end.

[0108] A number of outriggers 7 are distributed between the front sill 4 and the bolster 6 and being parallel to the front sill 4 and the bolster 6. The outriggers extends from a bottom side rail 2 to a gooseneck side rail 5 and are provided at both sides of the gooseneck tunnel 3.

[0109] In a simple embodiment, the base frame structure comprises a floor section 10 provided by a pair of bottom side rails 2, a front sill 4 in one end and a door sill in an opposite end.

[0110] At a part of the container 1 running from the bolster 6 to the door end or rear end, a number of crossmembers 8 are placed in parallel with the bolster 6 and extending from a bottom side rail 2 in one side of the container 1 to a bottom side rail 2 at the other side of the container 1.

[0111] Within the container 1 a floor (not shown) is placed and fastened on top of the floor section 10.

[0112] The crossmembers 8, being part of the floor section 10 contributes to the strength of the base frame of the container 1 and to the strength of the container as a whole.

[0113] The crossmember 8 of the container 1 is in principle a simply supported beam, which takes the load across the beam and transfer these forces to two end supports being the bottom side rails 2 of the container 1.

[0114] There are however other similar load cases in the container structure, where geometries, characteristics and functionalities of the crossmember 8 according to the invention is beneficial and bring improvements to the mechanical properties of the container.

[0115] In the front part of the base structure 10 of the container 1 there are no crossmembers 8 mounted as these will collide with the gooseneck tunnel 3, which is in the container 1 to make space for a connection point between trailer and truck. In this area of the gooseneck tunnel 3, the loads of cargo and forklift truck is supported by the bolster 6 and the gooseneck rails 5. The bolster 6 is similar to the crossmembers 8 mounted across the container and transfer the forces to the bottom side rails 2, and the gooseneck side rails 5 in similar way transfer the forces to the bolster 6 in one end and to a bottom front rail or front sill 4 in a front end of the container 1.

[0116] In sidewalls 100 of a container 1 there is mounted beams, named sideposts 101 in between bottom side rail 2 and top side rail 102, or in between scuff and top side rail, these beams 101 being part of a sidewall structure comprising side linings and foam similar to the floor structure. Scuff is a protection plate of the lower part of the inner side of the container wall. In this case the load on the sidewall 100 is related to an over-/under pressure in the container, the pressure being a result of temperature differences and/or changes in temperature inside and outside the container 1, or related to changes in atmospheric pressure or wind load outside the container 1.

[0117] Variation of moment of inertia in a lengthwise direction of the crossmember 8 according to an embodiment is established by lamination of one or more layers of sheet metal 15, resulting in total higher thickness of the laminated area causing a higher moment of inertia at the center (between ends) of the crossmember 8 and center of the container 1 and lower moment of inertia at the zone near the ends of the crossmember 8 and near the sides of the container 1.

[0118] This variation of moment of inertia in the lengthwise direction of the crossmember 8 can also be established by a variation of width of the sheets 15, 16, 17, so at the center of the crossmember 8 at the center of the container 1 the highest moment of inertia is established by having the highest width of the sheets of metal laminated, and the moment of inertia is reduced in the zone near the ends of the crossmember 8 near the side of the container 1 by reduced width of the sheets of metal laminated. In this embodiment, the sheet 15, 16, 17 at least along a part of its length, is narrower than the bottom flange 11.

[0119] The crossmember 8 according to the invention comprises a bottom flange 11 and a pair of sidewalls 12 forming a body of the crossmember 8. The sidewalls/body 12 each extend from a side of the bottom flange to a side of the top flange in such a way that the top flanges 13 are placed in a plane parallel to a plane through the bottom flange and pointing away from each other. Each top flange 13 can be provided with a kind of skirt 14. In an embodiment, the skirt 14 can be straight and in another embodiment, the skirt can be bended. Bending the skirt can provide the skirt 14 with enhanced strength or stiffness.

[0120] The bottom flange 11 is provided with a greater thickness than the sidewalls/body 12, the top flanges 13 and the skirt 14 (if any).

[0121] In an embodiment, the greater thickness is provided by placing and securing a sheet 15 on the bottom flange 11.

[0122] In an embodiment, the sheet 15 extend in full length of the bottom flange 11.

[0123] In an embodiment, the moment of inertia in the lengthwise direction of the crossmember 8 can be varied by placing and securing one or more sheets 15, 16, 17 on the bottom flange 11 of the crossmember 8.

[0124] In an embodiment, the same effect can be achieved with a sheet having Here a first sheet 15 extends in a full length of the bottom flange 11, a second sheet 16 extends from an area B to an area E in FIG. 13 and a third sheet 17 extends from an area C to an area D

[0125] In an embodiment the variation of moment of inertia in the lengthwise direction of the crossmember 8 can be established by a variation of width of the sheets 15, 16, 17 so at the center of the crossmember 8 at the center of the container 1 the highest moment of inertia is established by having the highest width of the sheets 15, 16, 17 of metal laminated, and the moment of inertia is reduced in the zone near the ends of the crossmember 8 near the side of the container 1 by reduced width of the sheets 15, 16, 17 of metal laminated. In this embodiment, the sheet 15 or sheetsl5, 16, 17 only along a part of the length, is of the same width as the bottom flange 11.

[0126] The moment of inertia can be tailored to the crossmember 8 by selecting a specified length of the one or more sheets 15, 16, 17. FIGS. 11-13 illustrates an example where three sheets of different lengths are placed and secured on the bottom flange 11 of a crossmember 8. Here a first sheet 15 extends in a full length of the bottom flange 11, a second sheet 16 extends from an area B to an area E in FIG. 13 and a third sheet 17 extends from an area C to an area D. The second sheet 16 being shorter than the first sheet 15 and the third sheet 17 being shorter that the second sheet 16.

[0127] In an embodiment, the first sheet 15 can be omitted, leaving the ends of the crossmember 8 with its own material thickness.

[0128] In an embodiment, the same effect as enforcing the bottom with two or three sheets can be achieved with a sheet having different thicknesses along the length of the sheet. Here a first thickness is provided to the sheet 15 from one end of the bottom flange 11 to the area B, a second (thicker than the first thickness) thickness of the sheet 15 extends from the area B to the area C, a third (thicker than the second thickness) thickness extends from the area C to the area D, a second (thicker than the first thickness) thickness of the sheet 15 extends from the area D to the area E, and a first thickness of the sheet 15 extends from the area E to another end of the bottom flange 11. FIG. 13 is used as an illustrative example.

[0129] Securing the one or more sheets 15, 16, 17 to the bottom flange 11 can be done by welding to an inner side of the crossmember 8.

[0130] In an embodiment the bottom flange 11 and the top flanges 13 are provided with a greater thickness than the sidewalls/body 12 and the skirt 14 (if any).

[0131] The sidewalls/body 12 in the above mentioned embodiments can extend straight from each side of the bottom flange 11 to the top flanges 13 or the sidewalls/body 12 can be provided with one or more bends 18. Also the sidewalls/body 12 can be perpendicular to the bottom flange 11 or the sidewalls/body 12 can incline away from each other in an upwards direction.

[0132] The bottom flange 11 having a greater thickness than the sidewalls/body 12, meaning in other words, that the sidewalls/body 12 have a less thickness than the bottom flange 11 leading to less strength of the sidewalls/body 12 compared to the bottom flange 11. In case of an intense impact on the underside of the crossmember 8, the sidewalls/body 12 will start to deform or crumple. The same will occur if the sidewalls/body are bend, for example as illustrated in FIG. 15.

[0133] Selecting distances from top or bottom of the sidewall/body 12 being 1/3 of a height of the sidewall/body 12 for placing the bends 18 will enhance the possibility for the sidewall/body 12 to collapse in a controlled manner in the bends 18, when exposed to an intense impact.

[0134] The design of the impact absorbing crossmember 8 according to the invention can also be applied to the bolster 6 and to the gooseneck side rails 5 and bring similar benefits regarding absorption of energy related to impact accidents, benefits regarding reduction of tare weight of the container 1 and benefits related to reduction of metal material used for manufacturing the container 1.

[0135] The solution is also achieved by a method of manufacturing of a container e.g.

[0136] a railway container, an intermodal container, a reefer container or a shipping container, where one or more profiles 5, 6, 7, 8, 101 in the container 1 is provided with a crumple zone according to embodiments mentioned above.

[0137] The solution is also achieved by a container, e.g. a railway container, an intermodal container, a reefer container or a shipping container comprising side and end walls, a ceiling, a floor section, a door opening, the floor section comprising profiled elements placed in a lengthwise or crosswise direction in relation to a lengthwise direction of the container, comprising a profile (5, 6, 7, 8, 101) having a cross section where at least a part of the cross section over a length of the profile (5, 6, 7, 8, 101) is provided with a crumple zone according to embodiments mentioned above.

[0138] The solution is further achieved by a base structure of a container, e.g. a railway container, an intermodal container, a reefer container or a shipping container, which base structure comprises a floor section 10 provided by a pair of bottom side rails 2, a gooseneck tunnel 3 placed in a front end of the container 1, a bolster 6 extending at an end of the gooseneck tunnel 3 from one bottom side rail 2 to another 2, the floor section further comprising at a part of the container base structure running from the bolster 6 to a door end or rear end, a number of crossmembers 8 placed in parallel with the bolster 6 and extending from a bottom side rail 2 in one side of the container 1 to a bottom side rail 2 at the other side of the container 1, where the crossmember 8 comprises a cross section, where at least a part of the cross section over a length of the crossmember 8 is provided with a crumple zone, which crumple zone has a critical buckling load being smaller than the critical buckling load for zones abutting the crumple zone.