Shipping container insulation panel and installation method

Abstract

An insulation system is configured for mounting to corrugated walls such as the walls of a shipping container. A first end has a first coupling surface and a second end opposite the first end has a second complementary coupling surface. Mating alignment portions are on a top surface of the panel and on a bottom surface of the panel. The second face includes a corrugated surface with a protruding first surface parallel to the first face, a recessed second surface spaced apart from and parallel to the first surface, and third and fourth surfaces extending between the first surface and the second surface, the third and fourth surfaces being orthogonal to the first and second surfaces.

Claims

1. An insulation panel comprising: a first face; a second face; a first end having a first coupling surface; a second end opposite the first end, the second end having a second coupling surface configured to mate with the first coupling surface; a first alignment portion on a top surface of the panel and a second alignment portion on a bottom surface of the panel, the second alignment portion being complementary to the first alignment portion; the second face having a corrugated surface, the corrugated surface comprising a first planar surface parallel to the first face, a recessed second planar surface spaced apart from and parallel to the first planar surface, and third and fourth planar surfaces extending between the first planar surface and the second planar surface, the third and fourth planar surfaces being oblique to the first and second planar surfaces.

2. An insulation panel according to claim 1, wherein the panel comprises a planar panel.

3. An insulation panel according to claim 1, further comprising a vertical passage extending through the panel.

4. An insulation panel according to claim 3, wherein the vertical passage is located intermediate the third and fourth planar surfaces.

5. An insulation panel according to claim 1, wherein the panel comprises a water impervious foam panel.

6. An insulation panel according to claim 1, further comprising a support embedded in the panel.

7. An insulation panel according to claim 1, wherein the first planar surface forms an obtuse angle with each of the third and fourth planar surfaces and the second planar surface forms an obtuse angle with each of the third and fourth planar surfaces.

8. An insulation panel according to claim 1, wherein each of the first planar surface, the second planar surface, the third planar surface and the fourth planar surface has a width greater than a distance between a plane of the first planar surface and a plane of the second planar surface.

9. An insulated shipping container comprising: a container, the container comprising: a base; a roof; walls extending between the base and the roof, at least one of the walls having a corrugated surface; a door; a plurality of insulation panels, each of the insulation panels comprising: a first face; a second face; a first end having a first coupling surface; a second end opposite the first end, the second end having a second coupling surface configured to mate with the first coupling surface; a first alignment portion on a top surface of the panel and a second alignment portion on a bottom surface of the panel, the second alignment portion being complementary to the first alignment portion; the second face having a corrugated surface, the corrugated surface comprising a first planar surface parallel to the first face, a second planar surface spaced apart from and parallel to the first planar surface, and third and fourth planar surfaces extending between the first planar surface and the second planar surface, the third and fourth planar surfaces being oblique to the first and second planar surfaces.

10. A shipping container according to claim 9, the corrugated surface of the second face of the insulation panels being complementary to the corrugated surface of the walls.

11. A shipping container according to claim 9, wherein the shipping container comprises an interior and wherein the insulation panels are mounted to the interior of the at least one wall.

12. A shipping container according to claim 9, further comprising a support embedded in the panel.

13. A shipping container according to claim 9, wherein the first planar surface forms an obtuse angle with each of the third and fourth planar surfaces and the second planar surface forms an obtuse angle with each of the third and fourth planar surfaces.

14. A shipping container according to claim 9, wherein each of the first planar surface, the second planar surface, the third planar surface and the fourth planar surface has a width greater than a distance between a plane of the first planar surface and a plane of the second planar surface.

15. A method of insulating a shipping container including a base, a roof, walls extending between the base and the roof, at least one of the walls having a corrugated surface, and a door; the method comprising: providing a plurality of insulation panels, each of the insulation panels comprising: a first face; a second face; an insert embedded in the panel; a first end having a first coupling surface; a second end opposite the first end, the second end having a second coupling surface configured to mate with the first coupling surface; a first alignment portion on a top surface of the panel and a second alignment portion on a bottom surface of the panel, the second alignment portion being complementary to the first alignment portion; the second face having a corrugated surface, the corrugated surface comprising a first planar surface parallel to the first face, a planar second surface spaced apart from and parallel to the first planar surface, and third and fourth planar surfaces extending between the first planar surface and the second planar surface, the third and fourth planar surfaces being oblique to the first and second planar surfaces; mounting a plurality of the insulation panels to the walls of the container so complementary portions of the corrugated surface of each panel engage the corrugated surface of at least one of the walls; aligning and engaging the first alignment portion with the second alignment portion of a vertically adjacent panel; and aligning and mating the first and second ends of laterally adjacent ones of the panels.

16. A method according to claim 15, wherein the shipping container comprises an interior and wherein the insulation panels are mounted to the interior of the at least one wall.

17. A method according to claim 15, wherein the shipping container comprises an exterior and wherein the insulation panels are mounted to the exterior of the at least one wall.

18. A method according to claim 15, wherein the shipping container comprises an interior and an exterior, and wherein the insulation panels are mounted to the interior of the at least one wall and are mounted to the exterior of the at least one wall.

19. A method according to claim 15, wherein the first planar surface forms an obtuse angle with each of the third and fourth planar surfaces and the second planar surface forms an obtuse angle with each of the third and fourth planar surfaces.

20. A method according to claim 15, wherein each of the first planar surface, the second planar surface, the third planar surface and the fourth planar surface has a width greater than a distance between a plane of the first planar surface and a plane of the second planar surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:

(2) FIG. 1 is a perspective view of a shipping container with portions removed for clarity and with a portion of one wall covered with an insulation system according to the principles of the present invention;

(3) FIG. 2 is a front perspective view of an insulation panel according to the principles of the present invention;

(4) FIG. 3 is a rear elevational view of the insulation panel shown in FIG. 2;

(5) FIG. 4 is a front elevational view of the insulation panel shown in FIG. 2;

(6) FIG. 5 is a rear elevational view of the insulation panel shown in FIG. 2;

(7) FIG. 6 is a right side elevational view of the insulation panel shown in FIG. 2;

(8) FIG. 7 is a top plan view of the insulation panel shown in FIG. 2;

(9) FIG. 8 is a bottom plan view of the insulation panel shown in FIG. 2;

(10) FIG. 9 is a perspective view of mounting element embedded in the panel shown in FIG. 2;

(11) FIG. 10 is a side elevational view of the mounting element shown in FIG. 9;

(12) FIG. 11 is an end elevational view of the mounting element shown in FIG. 9;

(13) FIG. 12 is a sectional view taken through a wall of the shipping container shown in FIG. 1 with insulation panels installed;

(14) FIG. 13 is an elevational view of an inner wall of the shipping container shown in FIG. 1 with insulation panels installed on a portion of the wall;

(15) FIG. 14 is a perspective view of a shipping container with portions removed for clarity and with a portion of one outer wall covered with an insulation system according to the principles of the present invention;

(16) FIG. 15 is an elevational view of an outer wall of the shipping container shown in FIG. 1 with insulation panels installed on a portion of the outer wall;

(17) FIG. 16 is a sectional view taken through a wall of the shipping container shown in FIG. 1 with insulation panels installed on an exterior face of the wall and the interior face of the wall;

(18) FIG. 17 is a perspective view of a shipping container with portions removed for clarity and with a portion of one outer wall and a portion of the inner wall covered with an insulation system according to the principles of the present invention;

(19) FIG. 18 is a sectional view taken through a wall of the shipping container shown in FIG. 1 with insulation panels installed on an interior face and an exterior face of the wall;

(20) FIG. 19 is a sectional view taken through a side wall of the shipping container shown in FIG. 1; and

(21) FIG. 20 is a sectional view taken through an end wall of the shipping container shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(22) Referring now to the drawings and in particular to FIG. 1, there is shown a wall insulating system, generally designated 100. The insulating system 100 is especially suited for mounting to a shipping container, generally designated 1000. It can be appreciated however that the system 100 of the present invention may be adapted to other types of applications with a complementary non-planar mounting surface.

(23) Shipping containers 1000 are generally rectangular with a floor 1002, side walls 1004, doors 1006, an end wall 1008 and a roof 1010. A standard container is typically 40 feet or 20 feet long, 8 feet 6 inches high and 8 feet wide. Shipping containers are generally made of metal with at least the side walls 1004 and the end wall 1008 configured with a corrugated cross-section to increase the strength of the walls. The corrugations typically have a depth of 1.25 inches up to 2 inches. Corner posts 1012 provide added support for the container 1000 and sufficient support for lifting the container. Bottom frame members 1014 may include openings 1016 for forklift tines or straps.

(24) The insulating system 100 is formed of interconnected panels 120, described hereinafter, that mount to the walls 1004 with glue or conventional fasteners. A finishing layer, such as paneling, drywall or other finishing treatments mounts with fasteners, glue or other conventional mounting techniques to the insulating panels 120. For some applications, a coating such as paint, wallpaper or other final, exposed material that is visible may cover certain finishing layers, such as drywall. The system of the present invention provides for elimination of the conventional stud framing and roll-type insulation being added to a shipping container 1000 and provides improved R-value in a thinner layer, adding floor space and volume to the finished interior of a shipping container. In addition, the present invention is less expensive and easier to install than prior conventional building systems and techniques.

(25) The insulating system 100 is formed from interconnected rectangular insulating panels 120 mounted in an edge-to-edge relationship. As shown in FIGS. 2-8, the panels 120 are generally rectangular and include tongues 140 and complementary grooves 142, such as shown most clearly in FIGS. 2 and 4, along the top and bottom surface and the ends of the panel 120. The tongues and grooves 140 and 142 provide for alignment and connection along both the horizontal and vertical edges so that the panels 120 may be connected to extend horizontally and vertically in a continuous insulating layer. The panels 120 also include alignment tabs 144 and complementary notches 146 along the top and bottom edges that aid in aligning the panels for final orientation. In one embodiment, the panels 120 are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder. Although a vapor barrier may also be added to the system, it can be appreciated that with the insulating layer 104 made of a water impervious material and with interlocking edges, the need for a separate vapor barrier used in many applications may be eliminated.

(26) Referring again to FIGS. 2-6, each of the panels 120 includes a generally planar outer face 122 having a series of parallel passages 128 that may serve as wiring chases or for running tubing, fiber optics or other elements through the insulating layer without requiring cutting into the panels 120. Indicator lines 124 are aligned with the passages 128 and a centerline 125 acts as a cutting line for cutting the panels 120 into even halves. The passages 128 also allow for water to drain. When the panels 120 are attached, horizontally extending channels 126 are formed. The horizontal channels 126 bypass the vertical passages 128 so that utilities may be run in both directions without intersecting. The vertical passages 128 provide for easy insertion and routing of wiring, tubing and other elements that are typically placed inside walls. In some embodiments, the small section of panel foam between the horizontal channel 126 and the vertical passage 128 may be removed so the channels 126 and the passages 128 connect. A cutting guide may provide for trimming the panels 120 to a common size and provides a guide for forming a straight edge. It can be appreciated that in one embodiment, the panels are approximately 44 inches wide and 24 inches high (12261 cm). A typical depth for a panel 120 is two inches (5 cm) at the narrower section and about 3.25 inches at the deepest depth of a corrugation. Such a size provides for standard alignment and easily transporting the panels 120 down narrow staircases such as often lead to a basement.

(27) The panels 120 also include mounting elements 150 that serve as studs embedded into the panels. In one embodiment, each panel 120 includes two embedded mounting elements 150. The mounting elements 150 extend vertically when the panels 120 are installed. The mounting elements 150 may be placed at conventional spacing such as at 16 inch (41 cm) centers or varying on center spacing such as approximately 22 inch centers as is typical with wood stud construction. The mounting elements 150 extend to a first face of the panels 120 and provide a surface for gluing as well as receiving conventional fasteners such as bolts, screws and/or nails. The mounting elements 150 are lightweight, but provide rigidity and strength to the panels 120.

(28) As shown in FIGS. 9-11, each mounting element 150 is a substantially elongate, molded plastic element with a generally H shaped cross-sectional profile. The mounting element 150 includes a first mounting portion 152, a second opposed mounting portion 160, and a series of central ribs 154 connecting the first portion 152 and the second portion 160. The first portion 152 extends laterally outward from the ribs 154 at a generally right angle. The ribs 154 may also be configured with portions extending generally diagonally in tension or compression between the first portion 152 and the second portion 160 to aid in transferring loads between the faces. A first face of the first portion 152 includes a glue channel 153 or glue channels transverse to the longitudinal direction. The second mounting portion 160 extends from either side of the center ribs 154. The second portion 160 also includes transverse channels 156 on an outer face and substantially extending transverse to the longitudinal axis of the mounting element 150. The outer channels 156 may also serve as glue channels for mounting.

(29) Referring again to FIGS. 2-8, to mount to corrugated walls, such as side walls 1004 of a shipping container, an inner mounting face 130 of each panel 120 has a corrugated surface that is complementary to the corrugated surface of the side walls 1004. The corrugated mounting surface 130 includes protruding portions 132 alternating with recesses 134. The protruding portions 132 include a planar face 136 and tapering connection surfaces 138 that lead from the protruding planar face 136 to the planar face of the inner recess 134 and are orthogonal to the faces 134 and 136. The inner recessed surface 134 and the planar faces 136 of the protruding portions 132 are generally parallel to one another and to the exposed surface on the opposite side of each panel 120. The protruding portions 132, the recesses 134 and the connection surfaces extend generally vertically to align with the complementary portions of the corrugated walls of the shipping container 1000. The configuration of the panels 120 provides a tight fit against the corrugated walls 1004 without gaps as shown in FIGS. 12 and 16-18.

(30) As shown in FIGS. 19 and 20, the side walls 1004 and the end walls 1008 may have a different corrugation pattern with slightly different dimensions and angles for the protruding portions and the recesses. The panels 120 may be configured with a mounting surface that fits the particular corrugation pattern of the wall to which it is mounted. Moreover, as the walls 1004 are symmetrical, the panels 120 may mount to either the interior or the exterior surface of a corrugated wall 1004.

(31) The mounting elements 150 are spaced apart generally at common intervals such as 8 inches, 12 inches or 16 inches, or at 11 inches or 22 inches or other standard spacing for shipping container corrugations, and provide a lightweight yet durable surface for receiving mounting hardware, as discussed above. The mounting elements 150 are also lightweight and molded and impervious to water for durable and inexpensive construction. It can be appreciated that the system of the present invention reduces the likelihood for water damage, mold and other problems that conventional systems are prone to, especially when the shipping container 1004 is in a damp environment. It can further be appreciated that the present invention provides for easy trimming and cutting with a hand saw or simple knife. The materials used are not irritating to skin or eyes and do not require special gloves for handling as is needed for fiberglass systems. The materials are lightweight and of a size that is easier to handle than typical long wood studs and 4 feet by 8 feet sheets of drywall. Drywall does not need to be aligned with studs as is required with conventional techniques. Installation is much quicker and does not require special skills or tools.

(32) The insulating system 100 of the present invention is also easy to install. Little preparation is needed but drain tile, if necessary, is installed before the system is in place. A bead of construction adhesive is placed in the gluing channels 153 on the studs 150 on each panel 120. Installation generally starts in a lower corner of the wall 1004 with the panel 120 simply pressed onto the inner face of a side wall 1004 or end wall 1008. The panel 120 is then secured with an adhesive or conventional mounting hardware. Installation continues with the panels 120 until a level of panels 120 is completed. The panels 120 of an adjacent level are aligned with vertically extending tongues 140 inserting into corresponding grooves 142 until a bottom row of panels 120 extends across the wall. The panels 120 of the next row are generally offset from the previous row and placed starting along one edge and working along the row in a similar manner. The mounting elements 150 are aligned by the alignment tabs 144 inserting into the corresponding notches 146. The panels 120 are configured so that the passages 128 must align. Construction continues along horizontal rows until the entire surface of a wall is covered. The corners are accommodated by cutting off the tongues and/or grooves and butting the panels 120 together.

(33) Spaces for receiving electrical boxes can be cut into the panels 120 using a standard drywall keyhole saw. Wiring and other elements can be run through the insulation system panels 120 by leading the wiring through the passages 128 and the channels 126. When the panels 120 have been installed, the glue is generally allowed to dry for a period of time such as 24 hours. Once the glue sets, the drywall can be applied to the planar outer face 122 by using standard drywall screws attaching to the mounting elements 150. The insulation system 100 is finished in the same manner as conventional walls with mud and tape used with the drywall and an inner layer such as paint or wallpaper applied over the drywall. In some applications, paneling or other materials may be used rather than drywall. The method is typically faster and easier with less skill and fewer tools required than conventional construction techniques.

(34) It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.