INTERMODAL CONTAINER HANDLING SYSTEM

Abstract

An intermodal container handling system for collapsing a collapsible intermodal container including a pair of opposing side walls each hingedly connected to a roof and a floor respectively, wherein said walls remain substantially parallel to one another whilst the collapsible container is collapsed from an expanded configuration to a collapsed configuration, said handling system comprising: a docking assembly adapted for docking of the collapsible intermodal container in the expanded configuration; a collapsing assembly operatively coupled to the docking assembly via a transit assembly adapted to releasably engage the docked collapsible container to facilitate movement of said collapsible container between the docking assembly and the collapsing assembly; a folding sub-assembly associated with the collapsing assembly, said folding sub-assembly adapted for releasable engagement with a first of the pair of opposing side walls wherein movement of the folding sub-assembly and the associated first side wall relative to a second of the opposing side walls collapses said container between the expanded configuration and the collapsed configuration; a stacking assembly operatively coupled to the collapsing assembly via the transit assembly adapted to facilitate movement of the container between the collapsing assembly and the stacking assembly for stacking in a vertical orientation with a further collapsible intermodal container in a collapsed configuration and vertical orientation.

Claims

1. An intermodal container handling system for collapsing and/or expanding a collapsible intermodal container including a pair of opposing side walls each hingedly connected to a roof and a floor respectively, wherein said walls remain substantially parallel to one another whilst the collapsible container is moved between an expanded configuration and a collapsed configuration, said handling system comprising: a docking assembly adapted for docking of the collapsible intermodal container; a collapsing assembly operatively coupled to the docking assembly via a transit assembly adapted to releasably engage the docked collapsible container to facilitate movement of said collapsible container between the docking assembly and the collapsing assembly; a folding sub-assembly associated with the collapsing assembly, said folding sub-assembly adapted for releasable engagement with a first of the pair of opposing side walls wherein movement of the folding sub-assembly and the associated first side wall relative to a second of the opposing side walls moves said container between the expanded configuration and the collapsed configuration; a stacking assembly operatively coupled to the collapsing assembly via the transit assembly adapted to facilitate movement of the container in the collapsed configuration between the collapsing assembly and the stacking assembly for stacking or unstacking the container in a vertical orientation with a further collapsible intermodal container in a collapsed configuration and vertical orientation.

2. The intermodal container handling system as claimed in claim 1, wherein the transit assembly includes a pair of parallel conveyors along which the collapsible intermodal container moves from the docking assembly to the collapsing assembly and in turn to the stacking assembly.

3. The intermodal container handling system as claimed in claim 2, wherein the pair of parallel conveyors are separated a distance less than a length dimension of the collapsible container wherein both of said conveyors maintain contact with the floor of said container.

4. (canceled)

5. The intermodal container handling system of claim 1, also comprising an anchoring sub-assembly associated with the folding sub-assembly and adapted for releasable engagement with the second side wall, said anchoring sub-assembly being effective in anchoring the second side wall during movement of the first side wall toward the second side wall via the folding sub-assembly.

6. The intermodal container handling system as claimed in claim 5, also comprising a structural framework associated with the collapsing assembly, said framework including an upper framework assembly and a lower framework assembly.

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. The intermodal container handling system of claim 1, also comprising roof and floor lock activators associated with the collapsing assembly and adapted to release roof and floor locks associated with the roof and the first wall, and the floor and the second wall, respectively, thereby permitting collapsing of the collapsible container via the folding sub-assembly.

12. The intermodal container handling system of claim 5, wherein the anchoring sub-assembly includes upper and lower pin sub-assemblies fixed stationary to the upper and lower framework assemblies, respectively.

13. The intermodal container handling system of claim 7, wherein the upper and the lower car of the folding sub-assembly are slidably mounted to the upper and lower framework assemblies, respectively, thereby permitting movement of the first side wall toward the second side wall during movement of the folding sub-assembly and the engaged first side wall toward the anchored second side wall.

14. The intermodal container handling system of claim 7, wherein the collapsing assembly further includes roof and floor support arrangements adapted for releasable contact with respective of the roof and the floor to support them during movement of the folding sub-assembly, and the consequential collapsing of the collapsible container from the expanded configuration to the collapsed configuration.

15. The intermodal container handling system of claim 9, wherein the roof support arrangement is mounted to the upper framework assembly and includes a magnetic coupling adapted for magnetic retention of the roof to support it during collapsing of the collapsible container.

16. (canceled)

17. The intermodal container handling system of claim 9, wherein the collapsing assembly also includes a swing assembly adapted to releasably engage each of a pair of opposing end frames of the collapsible container in the expanded configuration, said swing assembly being rotated outward of said container for opening of the pair of end frames into an open position wherein said end frames are disposed substantially parallel to and alongside an outer-facing surface of the first side wall.

18. The intermodal container handling system of claim 11, wherein the folding sub-assembly includes one or more end frame lock actuators adapted to actuate respective of end frame locks associated with each of the end frames, said end frame locks being actuated with said end frames in the open position for retention of said end frames in the open position with the collapsible container in the expanded configuration.

19. The intermodal container handling system of claim 11, wherein the swing assembly includes a swing arm at one end pivotally mounted to the lower framework assembly and at an opposite end mounted to a retractable swing pin sub-assembly adapted for releasable engagement with the end frame wherein rotation of the swing arm, with said swing pin sub-assembly engaged with the end frame, effects opening of the end frame between a closed position and the open position.

20. The intermodal container handling system of claim 13, wherein the swing arm is extendible thereby enabling adjustment of the length of said arm.

21. (canceled)

22. (canceled)

23. The intermodal container handling system of claim 1, wherein the transit assembly includes a lower carriage sub-assembly mounted to the lower framework assembly and adapted for releasable engagement with the collapsible container for its movement between the docking, collapsing, and stacking assemblies.

24. The intermodal container handling system of claim 15, wherein the transit assembly also includes an upper carriage sub-assembly mounted to the upper framework assembly and adapted for releasable engagement with the collapsible container for its movement in concert with the lower carriage sub-assembly between the collapsing and stacking assemblies.

25. The intermodal container handling system of claim 16, wherein the upper carriage sub-assembly and the lower carriage sub-assembly each include a plurality of upper and lower retractable pins arranged for releasable engagement with both the first and the second side walls of the collapsible container for its movement whilst being retained via said retractable pins in either the expanded or the collapsed configurations; and wherein the plurality of lower and upper retractable pins of the respective lower and upper carriage sub-assemblies are adapted for engagement with the lower and the upper beams of the first and second side walls of both the collapsible container and the further collapsible container for their movement in the packaged configuration from the collapsing assembly to the stacking assembly.

26. (canceled)

27. The intermodal container handling system of claim 16, wherein the upper and lower carriage sub-assemblies together enable movement of the collapsible containers in the packaged configuration from the collapsing assembly to the stacking assembly and thereafter movement via the lower carriage sub-assembly alone to another docking assembly for subsequent removal and transportation in the packaged configuration; and wherein the plurality of upper retractable pins of the upper carriage sub-assemblies are adapted for release from the upper beams of the side walls of the collapsible and the further collapsible containers in the packaged configuration to permit their movement from the stacking assembly to the other docking assembly under the influence of the lower carriage sub-assembly alone.

28. (canceled)

29. The intermodal container handling system of claim 2, wherein the docking assembly includes a shunt assembly adapted for longitudinal shunting of the collapsible container in its expanded configuration for alignment with the collapsing assembly prior to placement of the aligned collapsible container on the pair of parallel conveyors for movement between the docking and collapsing assemblies.

30. The intermodal container handling system of claim 19, wherein the shunt assembly includes a pair of nudge sub-assemblies located at the docking assembly and adapted to contact the collapsible container at respective of its opposite ends for longitudinal and lateral alignment of said container relative to the pair of parallel conveyors; and wherein the pair of nudge sub-assemblies each include an end nudge plate and a side nudge plate adapted to contact respective of the end frame and either the first or second side wall thereby nudging the container for the required longitudinal and lateral alignment.

31. (canceled)

32. A method of handling a collapsible intermodal container including a pair of opposing side walls each hingedly connected to respective of a roof and a floor wherein said walls remain substantially parallel to one another whilst the collapsible container is collapsed from an expanded configuration to a collapsed configuration, said method comprising: docking the collapsible intermodal container in the expanded configuration at a docking assembly; moving the docked collapsible container in the expanded configuration from the docking assembly to a collapsing assembly via a transit assembly configured for releasable engagement of the collapsible container; collapsing the collapsible container at the collapsing assembly by (a) releasably engaging a folding sub-assembly with a first of said opposing side walls, (b) moving the folding sub-assembly and the associated first side wall toward a second of the opposing walls wherein said container is collapsed from its expanded configuration to the collapsed configuration; moving the collapsible container in the collapsed configuration from the collapsing assembly to a stacking assembly via the transit assembly for stacking in a vertical orientation with a further collapsible intermodal container in a collapsed configuration and vertical orientation.

33-46. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0063] In order to achieve a better understanding of the nature of the present invention a preferred embodiment of an intermodal container handling system together with other aspects of the technology will now be described, by way of example only, with reference to the accompanying drawings in which:

[0064] FIG. 1A and 1B are isometric and detailed views of an intermodal container handing system of a preferred embodiment of a first aspect of the invention shown together with a collapsible intermodal container in its expanded configuration;

[0065] FIG. 2 is an isometric view of the intermodal container handling system of the preferred embodiment of FIG. 1 shown without the collapsible intermodal container and associated equipment;

[0066] FIG. 3 is a plan view of the intermodal container handling system of the preferred embodiment of FIG. 2;

[0067] FIGS. 4A to 4C are isometric and detailed views of a transit assembly taken from the container handling system of the preferred embodiment of the preceding figures;

[0068] FIGS. 5A and 5B are isometric and detailed views of the lower and upper folding sub-assemblies taken from the collapsing assembly of the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0069] FIGS. 6A to 6D are isometric and detailed views of the upper folding sub-assembly and carriage sub-assembly taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0070] FIGS. 7A to 7D are isometric views of carriage sub-assemblies of the transit assembly, and folding sub-assemblies of the collapsing assembly of the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0071] FIGS. 8A and 8B are isometric and detailed views of a floor support arrangement taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0072] FIGS. 9A to 9C are isometric and detailed views of a roof support arrangement taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0073] FIGS. 10A and 10B are isometric and detailed view of a swing assembly of the collapsing assembly taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0074] FIGS. 11A and 11B are isometric and plan view of a stacking assembly and its associated collapsing tines taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0075] FIGS. 12A to 12D are isometric and detailed views of a shunt assembly and associated sub-assemblies taken from the container handling system of the preferred embodiment of FIGS. 1 to 3;

[0076] FIGS. 13 to 27 are isometric and elevational views of a method of handling a collapsible intermodal container according to a preferred embodiment of a second aspect of the invention showing sequential steps in collapsing an intermodal container together with at least one further collapsible intermodal container in a packaged configuration;

[0077] FIG. 28 is a schematic illustration of an intermodal container handling system and associated method for unpacking a collapsible intermodal container and at least one further collapsible intermodal container in their packaged configuration according to preferred embodiments of third and fourth aspects of the invention.

DETAILED DESCRIPTION

[0078] As seen in FIGS. 1 to 3, there is an intermodal container handling system 10 of a preferred embodiment of a first aspect of the invention configured for collapsing an intermodal container 11a. The collapsible intermodal container 11a of this implementation includes a pair of opposing side walls 13aa and 13ab each hingedly connected to respective of a floor 17a and a roof 15a wherein said walls 13aa/ab remain substantially parallel to one another whilst the collapsible container 11a is moved between an expanded configuration and a collapsed configuration. It is to be understood that the collapsible container 11a is otherwise constructed in accordance with the applicant's co-pending Australian provisional patent application no. 2022901112. The disclosures of the specification of this Australian provisional patent application are to be understood as included herein in their entirety by way of this reference.

[0079] The intermodal container handling system 10 of the preferred embodiment of the first aspect broadly comprises: [0080] a docking assembly 12 adapted for docking of the collapsible intermodal container 11a in the expanded configuration; [0081] a collapsing assembly 14 including a folding sub-assembly 16 adapted for collapsing the container 11a from its expanded configuration to the collapsed configuration; [0082] a stacking assembly 18 arranged for stacking of the collapsed collapsible container 11a in a vertical orientation alongside a further collapsible intermodal container (not shown) also in a collapsed configuration and vertical orientation.

[0083] In this embodiment, the intermodal container handling system 10 also comprises a transit assembly 20 operatively coupled to the docking assembly 12, the collapsing assembly 14, and the stacking assembly 18 to facilitate movement of the collapsible container such as 11a between said assemblies Dec. 14, 2018. The transit assembly 20 includes a pair of parallel conveyors 22a and 22b along which the collapsible container 11a moves from the docking assembly 12 to the collapsible assembly 14 and in turn to the stacking assembly 18. The parallel conveyors 22a/b are separated a distance less than a length dimension of the collapsible container 11a wherein both of said conveyors 22a/b maintain contact with the container 11a. As best seen in FIG. 1B, the pair of conveyors 22a/b each include a plurality of rollers such as 24aa and 24ab equally spaced a distance less than a sectional width of a floor frame (not designated) of the floor 17a. This spacing ensures that at least two of the plurality of rollers such as 22aa/ab contact the floor frame during movement of the container 11a between, for example, the docking assembly 12 and the collapsing assembly 14.

[0084] In this embodiment, the intermodal container handling system also comprises a structural framework depicted generally at 26 including an upper framework assembly 28 and a lower framework assembly 30. As seen in FIG. 2, the upper and lower framework assemblies 28/30 are each fabricated from multiple relatively large section structural members each being of a maximum length capable of being housed and transported in a 40-foot container. This demountable-style construction requires prefabricated joint brackets such as 27a for rigid joining of adjacent of the structural members such as 25a and 25b. The pair of parallel conveyors 22a/b of the transit assembly 20 are mounted to the lower framework assembly 30. The transit assembly 20 also includes a lower carriage sub-assembly depicted at 32a and 32b mounted to the lower framework assembly 30, and an upper carriage sub-assembly depicted at 34a and 34b mounted to the upper framework assembly 28.

[0085] As seen in FIGS. 4 to 7, the lower carriage sub-assembly 32a/b includes a pair of lower carriages 36a/b slidably mounted to respective of a pair of lower conveyor rails 40a/b. Likewise, the upper carriage sub-assembly 34a/b includes a pair of upper carriages 38a/b slidably mounted to respective of a pair of upper conveyor rails 42a/b. The lower conveyor rails 40a/b are mounted to the lower framework assembly 30 alongside the pair of parallel conveyors 22a/b, and the upper conveyor rails 42a/b are mounted to the upper framework structure 28 wherein one of the pair of upper carriages 38a is in vertical alignment with a corresponding of the pair of lower carriages 36a and the other of the pair of upper carriages 38b aligns vertically with the other of the pair of lower carriages 36b.

[0086] In this embodiment, each of the lower and upper carriages 36a/b and 38a/b include a plurality of lower and upper retractable pins such as 44aa to 44ah and 46aa to 46ah arranged for releasable engagement with the collapsible container 11a for its movement along the pair of parallel conveyors 22a/b. As seen in FIG. 1B, the outermost of the retractable pins such as 44aa and 44ah are arranged for releasable engagement with the first and second side walls 13aa and 13ab of the collapsible container 11a in its expanded configuration for movement from the docking assembly 12 to the collapsing assembly 14. In this embodiment the retractable pins such as 44aa and 46aa incorporate self-lubricating linear bearings 31aa and 33aa, see FIGS. 7A and 7B. As seen in FIGS. 6C and 6D, in the collapsed configuration of the collapsible container 11a, neighbouring of the upper retractable pins such as 46bg and 46bh of the upper carriage such as 38b are arranged for releasable engagement with the first and second side walls 13aa/ab of said container 11a. Likewise, neighbouring of the lower retractable pins such as 44bg and 44bh of the lower carriage such as 36b are arranged for releasable engagement with the first and second side walls 13aa/ab of said container 11a. The container 11a in the collapsed configuration can thus be moved between the collapsing and the stacking assemblies 14 and 18 via the lower and upper carriage sub-assemblies 32a/b and 34a/b.

[0087] It will be understood that the lower and upper carriages 36a/b and 38a/b of the lower and upper carriage sub-assemblies 32a/b and 34a/b of the transit assembly 20 are thus effective in both moving the collapsible container 11a and retaining it in either the expanded or collapsed configurations. In this example, the lower and upper retractable pins such as 44aa to 44ah and 46aa to 46ah are adapted for engagement with respective of the lower and the upper beams (not designated) of the first and second side walls 13aa and 13ab of the collapsible container 11a. As best seen in FIG. 6, the lower and upper carriages 36a/b and 38a/b are driven for sliding movement along the lower and upper conveyor rails 40a/b and 42a/b via respective of lower and upper endless conveyor drive belts 37a/b and 39a/b. The upper conveyor drive belt such as 39b is driven at one end of the upper conveyor rail 42b via conveyor drive motor 41b connected to an associated conveyor drive pulley 43b. An opposite end of said upper rail 42b includes a driving conveyor pulley 45b which is engaged by said drive belt 39b. It is to be understood that the lower carriage sub-assembly 32a/b is of similar construction including a lower conveyor drive belt such as 47a which extends the full length of the lower framework assembly 30 and includes a conveyor drive motor 49aa/ab and associated pulley 51aa/ab at both ends of the lower conveyor rail 40a and 40b.

[0088] In this embodiment, the folding sub-assembly 16 of the collapsing assembly 14 includes four (4) lower cars and four (4) upper cars of substantially identical construction. For simplicity, the folding sub-assembly 16 is described and designated as a lower pair of cars 48a and 48b and an upper pair of cars 50a and 50b adapted for releasable engagement with the first side wall 13aa of the collapsible container 11a. The handling system 10 also comprises an anchoring sub-assembly including four (4) lower pin sub-assemblies and four (4) upper pin sub-assemblies but for simplicity is described and designated as lower pin sub-assemblies 52a and 52b and upper pin sub-assemblies 54a and 54b fixed stationary to the lower and upper framework assemblies 30 and 28, respectively. The lower cars 48a/b of the folding sub-assembly 16 each include a retractable lower car pin 56a/b adapted to releasably engage a lower beam of the first side wall 13aa whereas the upper cars 50a/b each include a retractable upper car pin 58a/b adapted to releasably engage an upper beam of the first side wall 13aa of said container 11a. The lower and upper cars 48a/b and 50a/b are slidably mounted to lower and upper pairs of glide rails 60a/b and 62a/b mounted to the lower and upper frame assemblies 30 and 28, respectively. In this embodiment the lower and upper pin assemblies 52a/b and 54a/b are fixed stationary to respective of the lower and upper glide rails 60a/b and 62a/b and adapted to releasably engage lower and upper beams of the second side wall 13ab of the container 11a. The lower and upper cars 48a/b and 50a/b are operatively coupled to lower and upper car drive motors 53a/b and 55a/b mounted to respective of the stationary lower and upper pin assemblies 60a/b and 62a/b. Each of the drive motors such as 53a/b is actuated for sliding movement of the lower car 48a/b back and forth along the corresponding glide rail 60a/b.

[0089] It will be understood that collapsing of the collapsible container 11a is effected at the collapsing assembly 14 via operation of the folding sub-assembly 16. In this embodiment, the lower and upper cars 48a/b and 50a/b releasably engage the lower and upper beams of the first side wall 13aa, and the lower and upper pin sub-assemblies 52a/b and 54a/b releasably engage the second side wall 13ab. Thereafter, it will be understood that movement of the lower and upper cars 48a/b and 50a/b and the associated first side wall 13aa toward the second of the side walls 13ab collapses the container 11a from its expanded to the collapsed configurations. The second side wall 13ab is, during this collapsing operation, anchored at the collapsing assembly 14 via the lower and upper pin sub-assemblies 52a/b and 54a/b. In this embodiment, the upper retractable car pins 58a/b for each of the upper cars 50a/b together with the lower pin sub-assemblies 52a/b of the anchoring sub-assembly serve a secondary function of releasing roof and floor locks (see FIG. 5B). The floor and roof locks are constructed in accordance with the disclosures of the applicant's co-pending Australian provisional patent application no. 2022901112.

[0090] As seen in FIGS. 8 and 9, the collapsing assembly 14 further includes floor and roof support arrangements 57 and 59 adapted for releasable contact with respective of the floor 17a and the roof 15a to support them during collapsing of the collapsible container 11a. The roof support arrangement 59 is mounted to the upper framework assembly 28 and includes a magnetic coupling 61 for magnetic retention of the roof 15a to support it. The floor support arrangement 57 is mounted to the lower framework assembly 30 and includes one or more wheels such as 66 adapted to contact the floor 17a to support it during collapsing of the collapsible container 11a. The roof support arrangement 59 includes a telescopic strut 68 about which the magnetic coupling 61 rocks to accommodate tilting of the roof 15a during collapsing of the collapsible container 11a. The retractable strut 68 is mounted to an upper carriage support 70 configured to traverse the upper framework structure 28 during collapsing of the collapsible container 11a. The floor support arrangement 62 includes a pivoting arm 72 having the wheel 66 mounted at its distal end. The pivoting arm 72 pivots about a lower support beam 74 mounted to the lower framework structure 30. The floor support arrangement 57 also includes a hydraulic actuator 76 pivotally anchored to the lower support beam 74 with its associated reciprocating rod 78 fixed to the pivoting arm 72 about midway along its length. The pivoting arm 72 is thus pivoted about the floor beam 74 under the action of the hydraulic actuator 76 which rocks within the beam 74 whilst driving the pivoting arm 72 upward or downward as required.

[0091] As seen in FIG. 10, the collapsing assembly 14 also includes a swing assembly 80 mounted to the lower framework assembly 30. The swing assembly 80 is effectively duplicated at each end of the collapsing assembly 14 and adapted to releasably engage each of a pair of opposing end frames 19aa and 19ab of the collapsible container 11a in the expanded configuration. The swing assembly 80 is designed to rotate outward of the collapsible container such as 11a for opening of the pair of end frames 19aa/ab into an open position where they are disposed substantially parallel to and alongside an outer-facing surface of the first side wall 13aa. In this embodiment the swing assembly 80 includes a swing arm 82 at one end including a turntable 84 pivotally mounted to a base plate 86 associated with the lower framework assembly 30. The swing arm 82 at an opposite end is mounted to a retractable swing pin sub-assembly 88 adapted for releasable engagement with the corresponding end frame such as 19ab wherein rotation of the swing arm 82 effects opening of the end frame 19aa between a closed position and the open position. The swing assembly 80 further includes a swing motor 90 mounted to the base plate 86 and operatively coupled to the turntable 84 to effect its rotation. In this embodiment the swing arm 82 is extendible being of a telescopic construction thereby enabling adjustment of the length of said arm 82 to, if required, vary its length during opening or closing of the end frame 19aa/ab.

[0092] As seen in FIG. 11, the stacking assembly 18 of this embodiment includes a series of collapsing tines 92aa to 92ea and its opposing pair 92ab to 92eb each being independently movable between upright and collapsed positions. It is to be understood that neighbouring tines such as 92aa/ba and 92ab/bb are spaced and adapted to support the collapsible container such as 11a in its collapsed configuration in the vertical orientation. Likewise, neighbouring tines of the opposing pair 92da/ea and 92db/eb are separated and adapted to support a further collapsible container 11d in its collapsed configuration in the vertical orientation. In this embodiment, the collapsible container 11a and the further collapsible container 11d are separated via the series of collapsing tines 92aa to 92ea and 92ab to 92eb a predetermined lateral spacing which permits rotation of the end frames 19da and 19db of the further collapsible container 11d from the open position to the closed position. It will be understood that the end frames 19da/db in the closed position align with the second side wall 13ab of the collapsible container 11a for engagement with it thereby retaining said container 11a and the further collapsible container 11 in the packaged configuration.

[0093] As seen in FIG. 12, the docking assembly 12 of this embodiment includes a shunt assembly 96 mounted to the lower framework structure 30 and adapted for longitudinal shunting of the collapsible container such as 11a in its expanded configuration at the docking assembly 12. This longitudinal shunting of the collapsible container 11a is intended to align the collapsible container 11a with the collapsing assembly 14 prior to final placement of the aligned collapsible container 11a on the pair of parallel conveyors 22a/b for movement between the docking and collapsing assemblies 12 and 14. In this example, the shunt assembly 96 includes a pair of nudge sub-assemblies 98a and 98b which are effectively a mirror image of one another including a pair of opposing walls 99aa/ab and 99ba/bb, one of said walls such as 99ba being fixed and the other wall 99bb being hinged about the lower framework assembly 30. The nudge sub-assembly 98a/b also includes an end wall 99ac/bc located between corresponding ends of the opposing walls 99aa/ab and 99ba/bb and hinged about the lower framework structure 30. Each of the nudge sub-assemblies 98a/b thus surround respective of opposing ends of the collapsible container such as 11a to nudge it for placement at the docking assembly 12. Each of the opposing and end walls such as 99ba/bb/bc have upper inclined faces 101ba/bb/bc for sliding contact with the collapsible container 11a during its placement at the docking assembly 12. Each of the inclined faces such as 101bc include a plurality of wear plates such as 102bc which in this example are fabricated from high-density polyethylene (HDPE). The opposing and end walls such as 99ba/bb/bc also each include rollers 103ba/bb/bc mounted within an upright and inward facing surface 105ba/bb/bc of the nudge sub-assembly 98b for rolling contact with corresponding faces of the collapsible container 11a. The hinged and adjacent walls such as 99ab and 99ac are each hinged for lowering or raising via actuator rods such as 104ab and 104ac.

[0094] As best seen in FIG. 12D, the shunt assembly 96 of this embodiment also includes four (4) support roller arrangements 106a to 106d oriented parallel to the longitudinal dimension of the collapsible container 11a and mounted to the lower framework assembly 30 in opposing pairs. One pair of the roller lift arrangements such as 106a and 106b contacts a lower beam of the first side wall 13aa of said container 11a whereas the other pair of the roller lift arrangements 106c and 106d contacts a lower beam of the second wall 13ab of the container 11a. Each of the roller lift arrangements such as 106a include a series of adjacent rollers 108a to 108h located alongside and parallel to one another within an upper lift housing 110a. The upper lift housing 110a is coupled to a lower lift housing 112a via lift shafts 114aa and 114ab. The lift arrangement such as 106a also includes a hydraulic lift 116a located between the lift shafts 114aa/ab and designed for raising and lowering the upper housing 110a and its associated rollers 108a to 108h relative to the lower housing 112a. The lower housing 112a to 112h is mounted to the lower framework structure 30 wherein independent operation of the lift arrangements 106a to 106d facilitates alignment of the container such as 11a under the influence of the shunt assembly 96.

[0095] As seen in FIGS. 13 to 27, there is a method of handling a collapsible intermodal container of a preferred embodiment of a second aspect of the invention. In this embodiment, the collapsible container 11a is substantially identical to the intermodal container of the exemplary deployment of the intermodal container handling system 10 of the first aspect of the invention. Similarly, the intermodal container handling system 10 of the preferred embodiment of the first aspect of the invention is utilised in implementation of the preferred method of the second aspect of the invention. The component reference numbers for the preferred embodiment of the first aspect are thus the same as the component reference numbers for the method of the preferred embodiment of the second aspect of the invention.

[0096] The method of handling the collapsible intermodal container 11a of the preferred embodiment of the second aspect broadly comprises: [0097] docking the collapsible intermodal container 11a in the expanded configuration at a docking assembly 12 (see FIG. 13); [0098] moving the docked collapsible container 11a in the expanded configuration from the docking assembly 12 to a collapsing assembly 14 via a transit assembly 20 configured for releasable engagement of the collapsible container 11a (see FIG. 14); [0099] collapsing the collapsible container 11a at the collapsing assembly 14 by (a) releasably engaging a folding sub-assembly 34a and 34b with a first of the opposing side walls 13aa/ab of the container 11a, (b) moving the folding sub-assembly 34a/b and the associated first side wall 13aa toward a second of the opposing side walls 13aa/ab wherein said container 11a is collapsed from its expanded configuration to the collapsed configuration (see FIG. 15 to FIG. 19); [0100] moving the collapsible container 11a in the collapsed configuration from the collapsing assembly 14 to a stacking assembly 18 via the transit assembly 20 for stacking in a vertical orientation with a further collapsible intermodal container 11d in a collapsed configuration and vertical orientation (see FIG. 20).

[0101] In relation to step 1, the collapsible container 11a is lowered into the docking assembly 12 wherein the rollers such as 103ba provide rolling movement on the side wall 13aa of the container 11a, and level pads of the upper inclined faces such as 101bb protect the side walls such as 13ab during positioning (see FIGS. 12B and 12C). Typically, lifting and lowering of the container 11a into the docking assembly 12 is effected via a forklift (not shown). The collapsible container 11a is placed on the opposing pair of roller lift arrangements such as 106a and 106b which in operation adjust (i) the relative height of the container 11a in preparation for lowering it onto the pair of roller conveyors 22a/b, and (ii) the effective length of the container 11a on the roller conveyor 22a/b. It will be understood that the nudge sub-assemblies 98a/b are actuated for movement of the expanded container 11a across the roller lift arrangement 106a/b for correct positioning of the container 11a at the docking assembly 12 prior to its movement to the collapsing assembly 14.

[0102] In relation to step 2, the hinged walls such as 99ab and 99ac of the nudge sub-assembly 98a are lowered approximately 90 degrees to allow the expanded container 11a to be moved out of the docking assembly 12 (see FIG. 12A). The lower carriage sub-assembly 32a/b of the transit assembly 20 releasably engages opposing side walls 13aa and 13ab of the expanded container 11a via respective of retractable pins such as 44aa and 44ah (see FIGS. 1B and 4A). In this embodiment, all of the retractable pins such as 44aa to 44ah associated with the associated carriage 36a of the carriage sub-assembly 32a move in concert and are driven up and down by independent drive motors. It will be understood that only the outermost of the retractable pins such as 44aa/ah engage the expanded container 11a whereas the intervening retractable pins 44ab to 44ag locate within a channel of the floor 17 between neighbouring floor members (not designated). The lower carriage sub-assembly 32a/b including the conveyor drive motor 49aa/ab and associated pulley 51aa/ab effects movement of the lower carriages 36a/b via a lower conveyor drive belt 47a/b. The container 11a is thus moved out of the docking assembly 12 toward the collapsing assembly 14 along the pair of roller conveyors 22a/b under the action of the lower carriage sub-assembly 32a/b.

[0103] In relation to step 3, prior to collapsing of the collapsible container 11a at the collapsing assembly 14, the method involves a preliminary step of releasably engaging the swing assembly 18 at opposing ends of the collapsing assembly 14 with respective of the pair of opposing end frames 19aa and 19ab of the collapsible container 11a in the expanded configuration (see FIG. 10A). The swing assemblies such as 80 are each rotated outward of the container 11a for opening of the pair of end frames 19aa/ab into the open position. In this embodiment, the retractable swing pin sub-assembly 88 releasably engages the end frame such as 19ab wherein rotation of the swing arm 82 effects opening of the end frame 19ab. The end frames 19aa/ab are thus rotated 270 degrees from the closed to the open positions where they are retained by actuation of an end frame lock pin. It is to be understood that prior to opening of the end frames 19aa/ab, end frame locks associated with an upper beam of each of the end frames 19aa/ab must be actuated via end frame lock actuators such as 51aa and 51ba fixed to the upper framework assembly 28 (see FIGS. 5B and 16B).

[0104] In relation to step 3, prior to collapsing of the collapsible container 11a at the collapsible assembly 14, both the floor support arrangement such as 57 and the roof support arrangements such as 59 contact the floor 17 and the roof 15 to support them (see FIGS. 16B and 16C). It will be understood that the wheel such as 66 of the floor support arrangement 57 contacts floor members of the floor 17, and the magnetic coupling 61 of the roof support arrangement 59 is electronically actuated for magnetic attachment to the roof 15. Roof and floor locks associated with the roof 15 and the floor 17 are released via roof and floor lock actuators which in this embodiment take the form of the upper retractable car pins such as 58a/b and the lower pin sub-assemblies 52a/b (see FIG. 5B). It will be understood that in an alternative embodiment the floor and roof activators may operate and be mounted independent of the folding sub-assembly 16.

[0105] In relation to step 3, the folding sub-assembly 16 having engaged with the associated first side wall 13aa is moved toward the second side wall 13ab wherein the container 11a is progressively collapsed from its expanded configuration to the collapsed configuration (see FIGS. 17 and 18). To permit this collapsing action, the lower carriage sub-assembly 32a/b is first disengaged from the first and second walls 13aa/ab of the collapsible container 11a (see FIGS. 8A and 9A). In this embodiment, the second side wall 13ab is anchored stationary via the anchoring sub-assembly or, in this example, the lower and upper pin sub-assemblies 52/b and 54a/b. It will be understood that the floor and roof support arrangements 57 and 59 support the roof 15a and the floor 17a respectively during collapsing of the container 11a. The lower and upper cars 48a/b and 50a/b of the folding sub-assembly 16 move in concert. The floor and roof support arrangements 57 and 59 coordinate in their movement to ensure support for the floor 17a and the roof 15a is maintained during collapsing of the container 11a. It is to be understood that the floor and roof support arrangements 57 and 59 are to be released from the floor 17a and the roof 15a as the collapsible container 11a approaches its collapsed configuration. The floor and roof support arrangements 57 and 59 are moved clear of the collapsible container 11a to ensure that they do not obstruct collapsing of the container 11a in its final stages (see FIG. 19).

[0106] In relation to step 4, both the lower carriage sub-assembly 32a/b and the upper carriage sub-assembly 34a/b are positioned in the collapsing assembly 14 for releasable engagement with the container 11a in its collapsed configuration (see FIGS. 6C and 6D). It will be understood that the upper carriages 38a/b move across the upper framework assembly 28 via a drive motor, pulley and endless drive belt system which is a similar construction and operates in the same way as the corresponding assembly of the lower carriage sub-assembly 32a/b. The lower and upper retractable pins such as 44ag/ah and 46ag/ah are extended for engagement with the first and second side walls 13aa/ab of the container 11a in its collapsed configuration. With all but one of the opposing pairs of collapsing tines such as 92aa and 92ab of the stacking assembly 18 folded down, the collapsed container 11a is moved via the lower and upper carriage sub-assemblies 32a/b and 34a/b from the collapsing assembly 14 to the stacking assembly 18 (see FIG. 19B). It will be understood that the lower and upper retractable pins 44ag/ah and 46ag/ah of the lower and upper carriage sub-assemblies 32a/b and 34a/b serve the secondary function of retaining the container 11a in its collapsed configuration whilst is moved toward and into the stacking assembly 18. The neighbouring of the collapsing tines 92ba and 92bb is raised to retain the collapsed container 11a in its vertical orientation on release of the lower and upper carriage sub-assemblies 32a/b and 34a/b (see FIG. 20B).

[0107] The method of this embodiment involves repeating the process described in the preceding paragraphs for second, third and fourth collapsible containers 11b, 11c and 11d respectively. In this example the fourth container is to be interpreted as the further container as broadly defined in this specification. The method may alternatively involve collapsing of one or two other containers where the further container is understood to be either the second container 11b or the third container 11c. FIGS. 21 to 27 illustrate additional steps involved in the method of this preferred embodiment of the second aspect of the invention.

[0108] The method of handling a collapsible intermodal container of the preferred embodiment of this second aspect additionally comprises: [0109] moving the collapsed containers 11a to 11d from the stacking assembly 18 to the collapsing assembly 14 via the transit assembly 20 (see FIGS. 21 and 22); [0110] closing the end frames 19da and 19db of the fourth or further collapsible container 11d for engagement with the second side wall 13ab of the first collapsible container 11a thereby retaining it and the further container 11d in a packaged configuration (see FIGS. 23 and 24); [0111] moving the containers 11a to 11d in their packaged configuration from the collapsing assembly 14 to the stacking assembly 18 (see FIG. 25); [0112] moving the containers 11a to 11d from the stacking assembly to another docking assembly via the transit assembly for subsequent removal and transportation in the packaged configuration (see FIGS. 26 and 27).

[0113] In relation to additional step 1, the lower and upper carriage sub-assemblies 32a/b and 34a/b are engaged with the collapsed containers 11a to 11d located at the stacking assembly 18 (see FIGS. 21B and 21C). The lower and upper retractable pins 44aa to 44ah and 46aa to 46ah of the lower and upper carriages 36a/b and 38a/b are extended to engage opposing first and second side walls 13aa to 13da and 13ab to 13db of each of the four (4) containers 11a to 11d. The collapsing tines 92aa to 92ea and their opposing pair of tines 92ab to 92eb are then lowered 90 degrees to allow movement of the collapsed containers 11a to 11d from the stacking assembly 18 to the collapsing assembly 14 (see FIG. 22B).

[0114] In relation to additional step 2, each of the swing assemblies such as 80 engages respective of the end frames such as 19da of the further container 11d to rotate it closed from its current open position (see FIGS. 23B and 23C). Prior to this closure action, the end frame lock between the end frame 19da and the first wall 13da of the further container 11d is disengaged via an end frame lock actuator such as 63A (see FIGS. 5B and 23A). The swing assembly 80 is operated for closure of the end frame such as 19da in the same manner as but reverse direction to its operation for opening of the end frames such as 19aa. The end frames 19da and 19db thus retain the containers 11a to 11d in the packaged configuration with the assistance of the end frame locks, see for example the relevant disclosures of the applicant's co-pending Australian provisional patent application no. 2022901112.

[0115] In relation to additional step 3, the lower and upper carriage sub-assemblies 32a/b and 34a/b engage the containers 11a to 11d in the packaged configuration and move them from the collapsing assembly 14 to the stacking assembly 18 along the pair of conveyor rollers 22a/b (see FIG. 25A). The first of the opposing pair of collapsing tines 92aa and 92ab are raised with the remaining tines lowered wherein the packaged containers 11a to 11d abut the raised pair of tines 92aa/ab on location within the stacking assembly 18. The last of the pair of collapsing tines 92ea and 92eb are then raised wherein the packaged containers 11a to 11d are supported in their vertical orientation between the pairs of raised tines 92aa/ab and 92ea/eb. The upper carriage sub-assembly 34a/b is subsequently released from the containers 11a to 11d (see FIGS. 25B and 25C).

[0116] In relation to additional step 4, the lower carriage sub-assembly 32a/b alone acts to move the packaged containers 11a to 11d from the stacking assembly 18 to a further docking assembly 23 (see FIGS. 26A and 26B). Prior to this movement, the outermost pair of tines 92aa/ab and 92ea/eb are lowered to permit travel of the packaged containers 11a to 11d across the pair of roller conveyors 22a/b. Similarly, neighbouring pair of hinged walls for each of the corresponding nudge sub-assemblies of the further docking assembly 23 are lowered to permit entry of the packaged containers 11a to 11d within the further docking assembly 23. The neighbouring walls of the pair of nudge sub-assemblies are then returned to their vertical disposition to support the packaged containers 11a to 11d in anticipation of their subsequent removal from the further docking assembly 23 (see FIG. 27). The shunt assembly and associated nudge sub-assemblies of the further docking assembly 23 are of substantially the same construction and operation as the shunt assembly 96 and nudge sub-assemblies 98a/b of the preceding docking assembly 12.

[0117] As schematically seen in FIG. 28, there is an intermodal container handling system and associated method for unpacking a collapsible intermodal container and at least one further collapsible intermodal container in their packaged configuration (not shown) according to third and fourth aspects of the invention. In the preferred embodiment of these aspects of the invention, the collapsible container and further collapsible as well as the container handling system are substantially the same as the containers 11a and 11d and handling system 10 of the preferred embodiment of the first and second aspects of the invention. For this reason the same reference numbers have been used for corresponding components.

[0118] The intermodal container handling system 10 of the preferred embodiment of the third aspect broadly comprises: [0119] a docking assembly 23 adapted for docking of the collapsible container and the further collapsible container in a packaged configuration, end frames of the further collapsible container in the collapsed configuration having been moved to a closed position for engagement with a second of the opposing side walls of the collapsible container in the collapsed configuration thereby retaining said containers in the packaged configuration; [0120] a transit assembly 20 adapted to releasably engage at least one of the collapsible container or the further collapsible container to facilitate movement of the docked containers together in the packaged configuration from the docking assembly 23 to an expanding assembly 14 operatively coupled to the docking assembly 23; [0121] a disengaging sub-assembly 80 associated with the expanding assembly, said disengaging sub-assembly arranged for disengaging the containers in the packaged configuration by (a) releasing engagement of the end frames of the further container with the second side wall of said container, (b) moving said end frames from the closed position to an open position disposed substantially parallel to and alongside an outer-facing surface of a first of the opposing side walls of the further container; [0122] a stacking assembly 18 operatively coupled to the expanding assembly 14 and arranged to receive the disengaged containers from the expanding assembly 14 via the transit assembly 20; [0123] an unfolding sub-assembly 26 associated with the expanding assembly 14 and configured to receive the further collapsible container in the collapsed configuration from the stacking assembly 18 via the transit assembly 20, said unfolding sub-assembly 26 arranged for expanding the further collapsible container at the expanding assembly 14 by (i) releasably engaging the unfolding sub-assembly 26 with the first side wall of the further container, (ii) moving the unfolding sub-assembly 26 and the associated first side wall away from a second of the opposing side walls of the further container wherein said container is expanded from its collapsed configuration to the expanded configuration, (iii) moving the end frames of the further container from the open configuration to the closed configuration for engagement with the second side wall of said further container thereby retaining it in the expanded configuration.

[0124] It is to be understood that the method of handling the collapsible intermodal container and the further collapsible intermodal container of the preferred embodiment of the fourth aspect broadly comprises: [0125] docking the collapsible container and the further collapsible container in a packaged configuration at a docking assembly 23, end frames of the further collapsible container in the collapsed configuration having been moved to a closed position for engagement with a second of the opposing side walls of the collapsible container in the collapsed configuration thereby retaining said containers in the packaged configuration; [0126] moving the docked containers together in the packaged configuration from the docking assembly 23 to an expanding assembly 14 via a transit assembly 20 configured for releasable engagement of at least one of the collapsible container or the further collapsible container; [0127] disengaging the containers in the packaged configuration at the expanding assembly 14 by (a) releasing engagement of the end frames of the further container with the second wall of the container, (b) moving said end frames from the closed position to an open position disposed substantially parallel to and alongside an outer-facing surface of a first of the opposing side walls of the further container; [0128] moving the disengaged containers via the transit assembly 20 from the expanding assembly 14 to a stacking assembly 18; [0129] moving the further collapsible container in the collapsed configuration from the stacking assembly 18 to the expanding assembly 14 via the transit assembly 20; [0130] expanding the further collapsible container at the expanding assembly 14 by (i) releasably engaging an unfolding sub-assembly 26 with the first side wall of the further container, (ii) moving the unfolding sub-assembly 26 and the associated first side wall away from a second of the opposing side walls of the further container wherein said container is expanded from its collapsed configuration to the expanded configuration, (iii) moving the end frames of the further container from the open configuration to the closed configuration for engagement with the second side wall of said container thereby retaining it in the expanded configuration.

[0131] It is to be understood that other steps involved in the preferred embodiment of the fourth aspect generally correspond with steps of the method of the second aspect. In this embodiment, the steps themselves and sequence of steps are typically reversed from the second to the fourth aspects.

[0132] Now that a preferred embodiment of the various aspects of the invention have been described it will be apparent to those skilled in the art that the intermodal container handling system has at least one or more of the following advantages: [0133] the handling system is effective in automated packaging of two or more collapsible intermodal containers; [0134] the handling system and method enable relatively stable and consistent packaging of two or more collapsible containers; [0135] the handling system and method are relatively safe in terms of their construction and operation thereby reducing associated OH&S issues; [0136] the intermodal container handling system is of a modular construction which lends itself to prefabrication off-site for delivery and assembly/commissioning onsite.

[0137] Those skilled in the art will appreciate that the invention as described herein is susceptible to variations and modifications other than those specifically described. The components of the described preferred embodiment of the container handling system may vary provided the core features and functionality are retained. For example, the transit assembly may depart from the preferred embodiment where the pair of roller conveyors is driven to effect movement of the container(s). The folding sub-assembly may depart from the preferred embodiment where the collapsing action is effectively reversed insofar as the first side wall is anchored and the second side wall is moved toward the first side wall. It is also possible for the roof and/or floor support arrangements to function as the folding sub-assembly where one of the opposing side walls of the container is held stationary and the other of said walls is urged toward the stationary wall under the action of the lowering of the roof or raising of the floor which in the preferred construction of the collapsible container is tied to respective of the opposing pair of side walls.

[0138] All such variations and modifications are to be considered within the scope of the present invention the nature of which is to be determined from the foregoing description.