FRAMING BRACKETS AND SYSTEMS FOR SHIPPING CONTAINER EXTERIOR

Abstract

A bracket system for use in framing a shipping container exterior, with first brackets having a mounting portion for mounting to a first longitudinal structural member of the shipping container and a first stud retention portion for receipt and retention of a first end of a stud, and second brackets having a mounting portion for mounting to a second longitudinal structural member of the shipping container and a second stud retention portion for receipt and retention of a second end of the stud, so the stud can be used as a framing member. First and second brackets are paired, and they can retain vertical studs as exterior wall framing members and/or horizontal studs as exterior roof framing members. Upper brackets can include both a retention portion for a vertical stud and a retention portion for a horizontal stud.

Claims

1. A bracket system for use in framing an exterior of a shipping container, the system comprising: at least one first bracket comprising: a first bracket mounting portion sized and configured for exteriorly mounting to a first longitudinal structural member of the shipping container; and a first stud retention portion sized and configured for receipt and retention therein of a first end of a stud; and at least one second bracket comprising: a second bracket mounting portion sized and configured for exteriorly mounting to a second longitudinal structural member of the shipping container; and a second stud retention portion sized and configured for receipt and retention therein of a second end of the stud; such that the stud is retained exteriorly to the shipping container as a framing member.

2. The system of claim 1, wherein: the first longitudinal structural member is located adjacent an upper edge of the shipping container, and the first end of the stud is an upper end of the stud; and the second longitudinal structural member is located adjacent a lower edge of the shipping container, and the second end of the stud is a lower end of the stud; such that the stud forms a vertical wall stud for use in framing a wall exterior of the shipping container.

3. The system of claim 1, wherein: the first longitudinal structural member is located adjacent a first upper edge of the shipping container; and the second longitudinal structural member is located adjacent a second and opposed upper edge of the shipping container; such that the stud forms a horizontal roof wall stud between the at least one first bracket and the at least one second bracket exterior of the shipping container.

4. The system of claim 1, wherein the at least one first bracket further comprises an additional stud retention portion sized and configured for receipt and retention therein of a first end of an additional stud, wherein: the first longitudinal structural member is located adjacent an upper edge of the shipping container, and the first end of the stud is an upper end of the stud; and the second longitudinal structural member is located adjacent a lower edge of the shipping container, and the second end of the stud is a lower end of the stud; such that the stud forms a vertical wall stud for use in framing a wall exterior of the shipping container; and such that the additional stud extends horizontally across and exteriorly of an upper surface of the shipping container for use in framing a roof exterior to the shipping container.

5. The system of claim 4, and further comprising: at least one third bracket comprising: a third bracket mounting portion sized and configured for exteriorly mounting to a third longitudinal structural member of the shipping container, the third longitudinal structural member located adjacent the upper edge of the shipping container but positioned on an opposite side of the shipping container from the first longitudinal structural member; a third stud retention portion sized and configured for receipt and retention therein of an upper end of a second vertical wall stud; and an opposed additional stud retention portion sized and configured for receipt therein of a second end of the additional stud; and at least one fourth bracket comprising: a fourth bracket mounting portion sized and configured for exteriorly mounting to a fourth longitudinal structural member of the shipping container, the fourth longitudinal structural member located adjacent the lower edge of the shipping container but positioned on the opposite side of the shipping container from the second longitudinal structural member; and a fourth stud retention portion sized and configured for receipt and retention therein of a lower end of the second vertical wall stud.

6. The system of claim 1, wherein the first bracket mounting portion and the second bracket mounting portion are each sized and configured to be at least partially positioned within a wall corrugation of the exterior of the shipping container.

7. The system of claim 1, wherein the at least one first bracket is a plurality of first mounting brackets and the at least one second bracket is a plurality of second mounting brackets, each of the plurality of first brackets paired with a corresponding one of the plurality of second brackets.

8. The system of claim 1, wherein the first and second longitudinal structural members are composed of steel tubing, such that mounting the at least one bracket and the at least one second bracket respectively thereto does not penetrate into an interior of the shipping container.

9. The system of claim 1, wherein the at least one first bracket and the at least one second bracket are composed of a material selected from the group consisting of metal, plastic, and composite.

10. The system of claim 1, and further comprising a space between the stud and the exterior of the shipping container sized and configured for receipt of an insulating material therein.

11. The system of claim 1, wherein the at least one first bracket and the at least one second bracket comprise holes for mounting the at least one first bracket and the at least one second bracket to the first and second longitudinal structural members, respectively.

12. The system of claim 11, wherein the holes are of different sizes to accommodate different sized mechanical fasteners.

13. The system of claim 11, wherein the holes comprise slots to allow adjustment of the at least one first bracket and the at least one second bracket.

14. The system of claim 9, wherein the at least one first bracket and the at least one second bracket are injection-molded from plastic and further comprise gussets to guide mechanical fasteners therethrough.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In the accompanying drawings, which illustrate exemplary embodiments of the present invention:

[0038] FIG. 1 illustrates bottom and top perspective views of the base bracket of an exemplary exterior framing system.

[0039] FIG. 2 illustrates bottom and top perspective views of the two-way upper bracket of an exemplary exterior framing system.

[0040] FIG. 3A is a perspective view of the exemplary brackets of FIG. 1 and FIG. 2 after installation on a shipping container.

[0041] FIG. 3B is a side elevation view of the embodiment of FIG. 3A.

[0042] FIG. 3C is an end elevation view of the embodiment of FIG. 3A.

[0043] FIG. 3D is a top plan view of the embodiment of FIG. 3A.

[0044] FIG. 4A is a perspective view of the installed position of an exemplary base bracket.

[0045] FIG. 4B is a cross-sectional view of the embodiment of FIG. 4A.

[0046] FIG. 4C is a perspective view of the installed position of the base bracket holding a stud.

[0047] FIG. 5A is a perspective view of the installed position of an exemplary two-way upper bracket.

[0048] FIG. 5B is a cross-sectional view of the embodiment of FIG. 5A.

[0049] FIG. 5C is a perspective view of the installed position of the two-way upper bracket holding studs.

[0050] FIG. 6A is a perspective view of the embodiments of FIG. 1 and FIG. 2 after installation on the container and holding studs.

[0051] FIG. 6B is a side elevation view of the embodiment of FIG. 6A.

[0052] FIG. 6C is an end elevation view of the embodiment of FIG. 6A.

[0053] FIG. 6D is a top plan view of the embodiment of FIG. 6A.

[0054] FIG. 7A is a perspective view of exemplary fork pocket covers installed with two bottom plates.

[0055] FIG. 7B is a front elevation view of the fork pocket covers installed with two bottom plates.

[0056] FIG. 8A is a perspective view of an exemplary truss bracket of an exterior framing system.

[0057] FIG. 8B is a perspective view of the embodiment of FIG. 8A after installation on a shipping container.

[0058] FIG. 8C is a perspective view of the embodiment of FIG. 8A after installation on the container holding studs.

[0059] FIG. 9A illustrates perspective views of an exemplary injection-molded version of a base bracket.

[0060] FIG. 9B illustrates perspective views of an exemplary injection-molded version of a two-way upper bracket.

[0061] Exemplary embodiments will now be described with reference to the accompanying drawings.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0062] Throughout the following description, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. The following description of examples of the invention is not intended to be exhaustive or to limit the invention to the precise form of any exemplary embodiment. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense. The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.

[0063] The present invention is directed to exterior framing brackets and systems for converting shipping containers such as ISO shipping containers into structures that can be framed with traditional wood, metal, composite, specialty, engineered, or other framing members. Exemplary systems consist of various types of brackets, including base brackets (which may be installed at a lower edge of the side walls and end walls of shipping containers and at an upper edge of the end walls of shipping containers), two-way upper brackets (which may be installed at an upper edge of the side walls of shipping containers), fork pocket covers, and truss brackets, which facilitate the attachment of framing members to the container's exterior without the need for extensive welding.

[0064] Embodiments according to the present invention may simplify the conversion process, eliminate extensive welding, and enhance the versatility of container-based construction. Exterior framing brackets according to the present invention are sized and configured to mount on the hollow structural member found on ISO shipping containers, with securing means such as screws occupying the hollow section and not penetrating through the building envelope. This feature helps ensure that the container's inherent structural integrity and the sealed envelope remains uncompromised.

[0065] Referring to FIGS. 1 and 3A, the base bracket (10) is installed on the bottom longitudinal member (38) of the side wall (32) and the bottom longitudinal member (68) of the end wall (34) to hold the studs securely in place on the container (30). The bracket (10) includes multiple fastening holes and offset holes for adjustable positioning, which allows precise alignment and secure attachment of studs (12) or other framing members. This ensures that the exterior planes on the side walls (32) and end wall (34) are precisely defined, providing a reliable foundation for further structural elements.

[0066] FIG. 2 shows the two-way upper bracket (20), which is intended for installation on the hollow longitudinal member (18) located at the top of the container's side walls (32) and the hollow longitudinal member (76) located at the top of the container's end wall (34) to maintain the container's structural integrity without puncturing its envelope. This also facilitates a vertical top plate or flat plate to assist with connecting the end wall (34) framing or provide the option for a cantilever that may be necessary for insulation and subsequent modifications. The top plate (16) (described below) allows for easy installation of various architectural elements, such as cantilevered roof sections.

[0067] FIGS. 3A-3D illustrate the installation process for the base brackets (10) and two-way upper brackets (20). The base brackets (10) are attached to the container's lower longitudinal structural members (38, 68) of the side walls (32) and end walls (34) respectively and the top hollow longitudinal members (76) of the end walls (34) using appropriate fasteners through the provided holes. The two-way upper brackets (20) are similarly installed on the top hollow longitudinal members (18) of the side walls (32).

[0068] Once installed, as shown in FIGS. 4A-4C, with FIG. 4B illustrating a detailed section view (40) of the base bracket (10), the base brackets (10) securely hold the bottom ends of the studs (12), aligning them with the exterior plane of the container's side walls (32) and end walls (34). A bottom plate (22) is shown installed on the bottom longitudinal members (38) of the container side walls (32). This configuration may facilitate the extension of the structure.

[0069] As shown in FIG. 5A-5C, with FIG. 5B illustrating a detailed section view (50) of the two-way upper bracket (20), the two-way upper bracket (20) is installed on the hollow longitudinal member (18) located at the top of the container's side walls (32) without puncturing its envelope. This upper bracket (20) securely holds the upper ends of side wall studs (12), roof studs (14), and top plate (16) aligning them with the exterior plane of the container's side walls. Two-way upper brackets (20) are likewise installed on the hollow longitudinal member (76) of the end walls (34). FIGS. 6A and 6C illustrate the position of the end wall studs (24), the end wall structural member (26), and the top plate (28) on the end wall (64).

[0070] A feature of some embodiments of the present invention is the ability to provide space for spray foam insulation between the studs (12, 42) and the container (30) walls or roof (36), as illustrated in FIG. 4C, FIG. 5C, FIG. 6A, and FIG. 6D. This configuration may help to reduce thermal bridging and improve the energy efficiency of the modified container structure. Batten insulation or a mix of foam and batten insulation can also be used to achieve energy efficiency. This may further reduce the risk of mold growth inside the welded envelope.

[0071] The exterior framing brackets (10, 20) may be sized and configured to accommodate insulation materials, helping to ensure that the container-based structure meets modern building codes and standards for energy efficiency and acoustic standards. This feature may help make the converted containers suitable for residential, commercial, and industrial applications where insulation performance is critical.

[0072] The exterior framing brackets may support a wide range of architectural designs and modifications, as shown in FIG. 6A-D, which illustrate a container (60) comprising a door end (62), an end wall (64) with studs (24), and a roof (66) with studs (42). The brackets may for example allow for the creation of cantilevered roof sections without puncturing the envelope by welding. By defining the exterior planes as shown in FIGS. 4B and 5B and providing a secure attachment for various studs, the brackets may enable architects and builders to incorporate traditional framing techniques into container-based structures. This versatility may thus enhance the overall design flexibility and functionality of the modified containers, making them potentially suitable for a broad spectrum of applications.

[0073] FIGS. 7A and 7B illustrate perspective (70) and side elevation view, showing the fork pocket covers (44), which are installed over the container's fork pockets (74) on the side wall (48) to enable lifting of the framed unit for transport or relocation ensuring that the lifting process does not disturb the installed studs or framing members. These covers (44) are used in conjunction with two bottom plates (22, 46).

[0074] As illustrated in FIGS. 8A-8C, a perspective view (100) is illustrated showing the truss bracket (90) used in scenarios where only roof framing is required. This bracket (90) for example may be installed on the container's top longitudinal structural member (18) on the side walls (32) as illustrated, holding the top plate (72) and roof studs (14) in place and providing the necessary support for roof extensions without side wall framing.

[0075] Embodiments of the present invention may also include injection-molded versions of the base brackets (110) and two-way upper brackets (120), shown in FIGS. 9A and 9B. These versions feature added gussets for enhanced precision in screw placement, ensuring that the screws do not collide and providing robust support for the framing members.

[0076] The exterior framing brackets and systems described herein may provide a robust and adaptable framework for converting ISO shipping containers into traditional framed structures. By removing the need for extensive welding and enabling straightforward attachment of various studs and other framing members, exemplary brackets may enhance design flexibility, simplify construction processes, and improve insulation capabilities. This makes repurposing ISO shipping containers more accessible and adaptable for a range of applications, including residential, commercial, and industrial projects. Additional advantages may include dispensing with the requirement for spray foam, making it more affordable, and removing the need for structural reinforcement of the container around fenestrations, which can be headers framed according to local building codes.

[0077] The foregoing is considered as illustrative only of the principles of the present invention. The scope of the claims should not be limited by the exemplary embodiments set forth in the foregoing, but should be given the broadest interpretation consistent with the specification as a whole.