Lightweight metallic shipping container

Abstract

A lightweight shipping container includes two parallel side walls each having a top rail and secured on the opposite side to bottom rails of a floor frame, both bottom rails being coupled to one another by a floor, which is secured to and resting on a multiplicity of cross-beam members of the floor frame. A front end assembly is secured to one end of the top and bottom side rails and a door end assembly opposite the front end assembly is secured to an opposite end of the top and bottom side rails. The container further includes a roof secured to respective ones of the top rails of each of the two side walls. The floor includes a metallic cellular sandwich panel formed by a frame defining an interior portion of the panel and including a metallic cellular core of a multiplicity of metallic polygonal cells, and a skin covering both the frame and the metallic cellular core.

Claims

1. A lightweight metallic container comprising: two parallel elongated side walls each having a top rail at one side and each being secured on an opposite side to a corresponding bottom rail of a floor frame, each bottom rail being coupled to one another by a floor secured to and resting on a multiplicity of cross-beam members of the floor frame, wherein the side walls each comprise a multiplicity of vertically continuous steel corrugated panels of two different thicknesses arranged in multiple alternating sequences of panels of greater thickness and panels of lesser thickness; a front end assembly secured to one end of each of the top rails and to one end of each of the bottom rails over respective corner castings; a door end assembly opposite the front end assembly and secured to an opposite end of each of the top rails and to an opposite end of each of the bottom side over respective corner castings, and a roof secured to respective ones of the top rails of each of the two side walls and comprising a multiplicity of horizontally continuous steel corrugated panels of a single uniform thickness of equal to or less than 1.6 mm in thickness, the floor comprising at least one metallic cellular sandwich panel formed by a frame defining an interior portion of the panel, the interior portion including a cellular core of a multiplicity of metallic polygonal cells, and a skin covering both the frame and the metallic cellular core.

2. The container of claim 1, wherein the two different thicknesses comprise 1.6 mm and 2.0 mm.

3. The container of claim 1, wherein the front end panel comprises a multiplicity of vertically continuous steel corrugated panels of two different thicknesses arranged in multiple alternating sequences of panels of greater thickness and panels of lesser thickness.

4. The container of claim 3, wherein the two different thicknesses comprise 1.6 mm and 2.0 mm.

5. The container of claim 1, wherein the roof comprises a multiplicity of horizontally continuous steel corrugated panels of two different thicknesses arranged in multiple alternating sequences of panels of greater thickness and panels of lesser thickness.

6. The container of claim 5, wherein the two different thicknesses comprise 1.6 mm and 2.0 mm.

7. The container of claim 5, further comprising a roof panel stiffener assembly supporting the roof and coupled to a door end beam and extending longitudinally to a front end beam.

8. The container of claim 1, further comprising a roof panel stiffener assembly supporting the roof and coupled to a door end beam and extending longitudinally to a front end beam.

9. The container of claim 7, wherein the assembly comprises two symmetrical corrugated L stiffeners joined to one another.

10. The container of claim 9, further comprising two additional L stiffeners disposed at opposite sides of the assembly and extending longitudinally from the door end beam to the front end beam.

11. The container of claim 1, wherein the bottom rail of each side wall comprises a multiplicity of stiffening ribs welded to the bottom rail.

12. The container of claim 1, wherein the top rail of each side wall comprises a pair of opposing stiffeners, one of the stiffeners extending horizontally from a top portion of the top rail upon which the roof rests, and a perpendicularly oriented one of the stiffeners extending downwardly from an interior side portion of the top rail outside of which one of the side panels rests.

13. The container of claim 1, wherein the door end assembly comprises two doors each comprising a frame defining an interior portion of the door, the interior portion including a metallic cellular core of a multiplicity of metallic polygonal cells, and an aluminum skin covering both the frame and the metallic cellular core.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:

(2) FIG. 1 is a perspective view of a lightweight metallic container with an exploded portion illustrating one cross member beam secured to a bottom rail of a side wall of the container;

(3) FIG. 2 is a perspective view of the lightweight metallic container of FIG. 1 with an exploded portion illustrating a floor of the container including at least one metallic cellular sandwich panel;

(4) FIG. 3 is a perspective view of the lightweight metallic container of FIG. 1 with an exploded portion illustrating placement of stiffening ribs about the bottom rail;

(5) FIG. 4A is a perspective view of the lightweight metallic container of FIG. 1 with an exploded portion illustrating the side walls of the container;

(6) FIG. 4B is a perspective view of the lightweight metallic container of FIG. 1 detailing a front end panel of the container;

(7) FIG. 5A is a perspective view of the lightweight metallic container of FIG. 1 with an exploded portion illustrating a roof of the container with a stiffener assembly;

(8) FIG. 5B is a perspective view of the lightweight metallic container of FIG. 1 detailing the roof of the container;

(9) FIG. 6 is a perspective view of a door end assembly of the lightweight metallic container of FIG. 1 with an exploded portion illustrating a door of the container including at least one metallic cellular sandwich panel; and,

(10) FIG. 7 is a perspective view of a side wall of the lightweight metallic container of FIG. 1 with an exploded portion illustrating different stiffeners affixed to the top rail of each of the side panels.

DETAILED DESCRIPTION OF THE INVENTION

(11) Embodiments of the invention provide for a lightweight metallic container and a process for the fabrication thereof. A lightweight metallic container includes two parallel elongated side walls, each with a top rail at one side and secured on an opposite side to a bottom rail of a floor frame, both bottom rails being coupled to one another by a floor, which is secured to and resting on a multiplicity of cross-beam members of the floor frame. The side walls additionally are coupled to one another by a front end assembly secured to one end of the top and bottom rails of each of the two side walls over respective corner castings, and also by a door end assembly opposite the front end assembly and secured to an opposite end of the top and bottom rails of each of the two side walls over respective corner castings, and by a roof secured to respective top rails of each of the two side walls. Importantly, the floor includes at least one metallic cellular sandwich panel formed by a frame defining an interior portion of the panel, the interior portion including a metallic cellular core of a multiplicity of polygonal cells, and a skin covering both the frame and the metallic cellular core.

(12) In further illustration, FIG. 1 is a perspective view of a lightweight metallic container with an exploded portion illustrating one cross member beam secured to a bottom rail of a side wall of the container. As shown in FIG. 1, a lightweight shipping container 100 includes two parallel bottom rails 110 and two parallel top rails 120, each of the bottom rails 110 being secured to a corresponding one of the top rails 120 over respective corner castings (not shown) by a door end post 130A and a front end post 130B. As well, the top rails 120 are secured to one another by door end beam 140A and front end beam 140B. As will be recognized by one of skill in the art, each of the top rails 120 when secured to a corresponding one of the bottom rails 110 by the door end post 130A and the front end post 130B defines a frame for a corresponding elongated side wall (not shown). As well, the door end posts 130A and the door end beams 140A and 170A define a door end frame (not shown), while the front end posts 130B and the front end beams 140B and 170B define a front end frame (not shown).

(13) Of importance, the elongated side walls are coupled to one another by the floor secured and resting on the floor frame, which includes a multiplicity of cross-beam members 150, as well as smaller C-beam members 160 interspersed between the cross-beam members 150, all joining the bottom rail 110 of each of the two side walls. Optionally, stiffening ribs 310 may be dispersed along the bottom rails 110 and welded thereto as shown in FIG. 3. As well, in reference to FIG. 7, different stiffeners may be secured to the top rail 120 of each of the side panels in the roof plane and side wall plane, respectively, as shown in FIG. 7. In this regard, the stiffeners may include an inwardly extending horizontal metallic extension 710 of a top portion of the top rail 120 upon which a roof is placed, and also a downwardly extending metallic extension 720 outside of which one of the side walls is placed.

(14) Notably, one or more metallic cellular sandwich panels (not shown) are then secured to a top surface of each of the cross-beam members 150 and C-beam members 160. In further illustration, FIG. 2 is a perspective view of the lightweight metallic container of FIG. 1 illustrating a floor 210 of the container accommodating a gooseneck tunnel adapted to mesh with a gooseneck on a dedicated container semi-trailer. The floor 210 includes at least one metallic cellular sandwich panel, as shown in the exploded portion of the FIG. 2. In this regard, the metallic cellular sandwich panel includes a frame 220 enveloping a metallic cellular core 230 laid and sandwiched between an aluminum skin 240 on opposite sides of the metallic cellular core 230. The metallic cellular core 230 includes a multiplicity of arranged hollow polygonal cells formed of a metal, such as aluminum for instance with a thickness of twenty-six millimeters. By utilizing the metallic cellular sandwich panel instead of wood panels, a lighter weight floor is provided that incorporates the strength provided by the metallic cellular sandwich structure without the weight of a solid material such as wood.

(15) Referring now to FIG. 4A, a perspective view of the lightweight metallic container of FIG. 1 is shown with an exploded portion illustrating the side walls of the container 100 of FIG. 1. The side walls are formed by a multiplicity of vertically continuous steel corrugated panels 410, 420 of two different thicknesses arranged in multiple alternating sequences of panels 420 of greater thickness and panels 410 of lesser thickness. For instance, the two different thicknesses may be 1.6 mm and 2.0 mm. Referring to FIG. 4B, the front end assembly also may include a multiplicity of vertically continuous steel corrugated panels 430, 440 of two different thicknesses arranged in multiple alternating sequences of panels 430 of greater thickness and panels 440 of lesser thickness. Again, the two different thicknesses may include 1.6 mm and 2.0 mm.

(16) Referring now to FIG. 5A, a perspective view of the lightweight metallic container of FIG. 1 is provided with an exploded portion illustrating a roof of the container 100 with a stiffener assembly. In this regard, the roof includes a multiplicity of horizontally continuous steel corrugated panels 510, 520 of two different thicknesses arranged in multiple alternating sequences of panels 520 of greater thickness and panels 510 of lesser thickness, such that the two different thicknesses may be 1.6 mm and 2.0 mm. Alternatively, as shown in FIG. 5B, the roof may include a multiplicity of horizontally continuous steel corrugated panels 550 of a single uniform thickness equal to or less than 1.6 mm in thickness.

(17) Referring again to FIG. 5A, a roof panel stiffener assembly 530 may be provided supporting the roof and which is coupled to a door end beam 140A and extends longitudinally to a front end beam 140B. In one aspect of the embodiment, the roof panel stiffener assembly 530 may include two separate stiffeners abutting one another each including a flat longitudinal strip of metal with a multiplicity of tabs extending upwards perpendicularly at a ninety-degree angle from the flat longitudinal strip with the tabs of each of the separate stiffeners positioned adjacent to one another. In this regard, the assembly may include two symmetrical corrugated L stiffeners joined to one another. As well, two additional L stiffeners 540 may be disposed at opposite sides of the assembly 530 and may extend longitudinally from the door end beam 140A to the front end beam 140B.

(18) A metallic cellular sandwich panel structure also may be incorporated into the door end assembly, though of a different thickness and frame than the floor. In even yet further illustration, FIG. 6 is a perspective view of a door end assembly of the lightweight metallic container of FIG. 1 with an exploded portion illustrating a door of the container including at least one metallic cellular sandwich panel. As shown in FIG. 6, the door end assembly is defined by the door end beam 140A and the door end posts 130A. Double doors 610 are hingedly affixed to the door end posts 130A, each of the double doors 610 including a frame 620 enveloping at least one metallic cellular sandwich core 630. The metallic cellular sandwich core 630 includes a multiplicity of arranged hollow polygonal cells formed of a metal such as aluminum, for instance with a thickness of forty-six millimeters. The frame 620 and the metallic cellular core 630 are covered by an aluminum skin 640. By utilizing the metallic cellular sandwich panel 610 instead of steel, a lighter weight door is provided that incorporates the strength provided by the metallic cellular sandwich structure without the weight of a solid material such as steel.

(19) Finally, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms includes and/or including, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

(20) The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

(21) Having thus described the invention of the present application in detail and by reference to embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims as follows: