WO2001040064A1

WO2001040064A1 - Collapsible shipping containers and methods for collapsing the same

Info

Publication number: WO2001040064A1
Application number: PCT/US2000/042422
Authority: WO
Inventors: Andrew Christoffersen
Original assignee: Arrow Dynamics, Inc.
Priority date: 1999-12-02
Filing date: 2000-11-30
Publication date: 2001-06-07
Also published as: AU3971801A

Abstract

Collapsible shipping containers (2) and methods for making the same. To collapse the containers (2) of the present invention, the roof (14) of the shipping container (2) is removed, the end walls (10, 12) of the shipping containers ae removed and placed on the floor (4) of the container, the side walls (6, 8) are then folded down on top of the end walls (10, 12) and the roof (14) is placed over the side walls (6, 8). By folding in such a manner, there are few loose pieces and connections, the collapsed container has one-fourth of the vertical height of the container in its uncollapsed state.

Description

COLLAPSIBLE SHIPPING CONTAINERS AND METHODS FOR COLLAPSING THE SAME

FIELD OF THE INVENTION

The present invention relates to containers used in the shipping industry to transport various products. Specifically, the present invention relates to shipping containers that are easily collapsed and assembled. BACKGROUND OF THE INVENTION As long as companies have shipped products, they have faced the problem of what to do with the shipping container once the product has been received. Once the products are removed from the shipping container, it is typically either discarded or shipped back to the manufacture. When the shipping container is discarded, it not only increases the load on an already overburdened landfill system, but also causes temporary storage and related labor costs.

On the other hand, transporting empty containers, along with the associated handling and storage, imposes several problems on the shipping industry. First, it adds significantly to shipping and freight costs since expenses are incurred in transporting empty containers as their volume does not differ from full. Second, it can result in stability and safety complications. Third, it can congest loading and unloading facilities, thus adding to the time necessary for shipping. However, should the shipping container be transported back to the original shipper, additional costs are incurred with regard to return shipping.

Thus, it has been a goal in the shipping industry to have a desirable return ration, e.g., a ratio reflecting as great a difference as possible between the assembled and collapsed volume of the shipping container. Therefore, the shipping industry would like containers which can be collapsed when empty and returned in the collapsed condition. To this end, many collapsible shipping containers have been proposed recently. See, for example, U.S. Patent Nos. 4,506,798, 4,715,508, 5,056,667, 5,161 ,709, 5,190,179, 5,253,763, 5,419,448, 5,501 ,333, 5,601 ,202, 5,725,119, and 5,86,5334, the disclosures of which are incorporated herein by reference.

These known containers have the drawback that although collapsible, they do not have sufficient structural strength to meet the ISO structural requirements, such as those listed in ISO Standard 668 and ISO Standard 1496. Accordingly, the commercial success of such containers has been quite limited.

SUMMARY OF THE INVENTION The present invention provides collapsible shipping containers and methods for making the same. To collapse the containers of the present invention, the roof of the shipping container is removed, the end walls of the shipping containers are removed and placed on the floor of the container, the side walls are then folded down on top of the end walls, and the roof is placed over the side walls. By folding in such a manner, there are few loose pieces and connections, the collapsed container has one-fourth of the vertical height of the container in its un-collapsed state.

The present invention includes collapsible shipping containers having a base with a plurality of structural members, a top with a plurality of structural members, a pair of end walls with each end wall having edge structural members mating with at least one of the top structural members and at least one of the base structural members, with the end walls detachable from the top and the base, and a pair of side walls with each side wall having at least one structural member with the bottom thereof integral with at least one of the base structural members and the top thereof mating with at least one of the top structural members, the side walls detachable from the top and pivotally mounted to the base. The base structural members may include members located at corners of the base. The base may include a floor and sides extending upwardly from the base and perpendicular to the floor. The base structural members can extend upwardly from the base to substantially the same height as the sides. The top structural members can include members located at the corners of the top and the structural members can extend downwardly from the top. The bottom of the top structural members, the bottom of the end wall structural members, and the bottom of the side wall structural members can have a substantially similar diameter. The top of the base structural members, the top of the end wall structural members, and the top of the side wall structural members can have a substantially similar diameter. The present invention also includes methods for collapsing such containers by removing the top, removing the end walls and placing them on the base, pivoting the side walls to a substantially horizontal position overlying the end walls, and placing the top so it rests on the base with the base structural members mating with the top structural members. The present invention includes collapsed shipping containers having a base with a plurality of structural members, a top with a plurality of structural members, a pair of end walls detached from the top and the base, a pair of side walls detached from the top and pivotally mounted to the base, an interior enclosed by the base and top, wherein the top rests on the base with the base structural members mating with the top structural members and the end walls and side walls located in the interior. The base structural members may include members located at corners of the base. The base may include a floor and sides extending upwardly from the base and perpendicular to the floor. The base structural members can extend upwardly from the base to substantially the same height as the sides. The top structural members can include members located at the corners of the top and the structural members can extend downwardly from the top.

BRIEF DESCRIPTION OF THE DRAWINGS Figures 1-16 are views of a structural member according to the present invention. Figures 1-16 presented in conjunction with this description are views of only particular — rather than complete — portions of the collapsible shipping container and method of making the same according to the present invention. Figure 1 is a front view of a shipping container according to the present invention.

Figure 2 is a view of a base a shipping container according to the present invention. Figure 3 is a view of a top of a shipping container according to the present invention.

Figures 4 and 5 are views of walls of a shipping container according to the present invention.

Figure 6 is a view of a disassembled shipping container according to the present invention.

Figures 7 and 8 are views of optional doors on the walls of a shipping container according to the present invention.

Figures 9-14 depict various stages with differing views of how the shipping container according to the present invention is collapsed. Figure 15 illustrate a collapsed shipping container according to the present invention.

Figures 16a, 16b, 16c, and 16d depict a view of the posts of a shipping container according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION The following description provides specific details in order to provide a thorough understanding of the present invention. The skilled artisan, however, would understand that the present invention can be practiced without employing these specific details. Indeed, the present invention can be practiced by modifying the illustrated shipping container and method and can be used with apparatus and techniques conventionally used in the industry.

The Figures illustrate one shipping container — a rectangular-shaped container with an eight-foot height — according to the present invention. Other shipping containers with other sizes, shapes, and configurations are not detailed below, but are within the scope of the present invention.

In the Figures, shipping container 2 comprises base 4, side walls 6 and 8, end walls 10 and 12, and top 14. Shipping container 2 can be any suitable shape and size, including the dimensions and sizes dictated by ISO standards, such as the standards for Series 1 freight containers listed in ISO 1496. For example, in Figure 1, the illustrated height of shipping container 2 is 8 feet, the illustrated length is 40 feet, and the illustrated width is 8 feet. The height of shipping container could be configured for 8.5 feet and the length could be configured for 30, and even 20, feet.

The components of shipping container 2 can be made of any suitable materials known in the art, preferably those which have a high strength to weight ratio. In general, the shipping container can be of any construction which maintains sufficient structural rigidity to ensure the integrity of the container during shipment. Thus, the components can be solid, including corrugated or plate steel, or can include a honeycombed structure either alone or in combination with a solid backing. Examples of such materials include metals such as aluminum and steel, metal alloys, various types of plastics such as high density polyethylene, and composites, as well as those known in the art and listed in U.S. Patent No. 5,865,334, the disclosure of which is incorporated herein by reference. Preferably, the shipping container is made of a metal or metal alloy, such as corrugated or plate steel, because of the structural strength of such containers. The structure utilized should take into account the contents which are to be shipped and the possible need for shelter of the contents before, during, or after shipment.

Base 4 of shipping container 2 is preferably, although not necessarily, of a rectangular shape and can be configured for the desired use of the shipping container. Any suitable base known in the art can be employed in the present invention, including those described in U.S. Patent No. 5,190,179, the disclosure of which is incorporated herein by reference. Preferably, base 4 of the shipping container of the present invention comprises base structural members 41 and 42 around the circumference of base 4 and base structural members 43 on the floor of base 4. Base structural members 41 extend along the length of base 4 and base structural members 42 extend the width of base 4. Base structural members 41 and 42 may be of any suitable configuration providing the necessary support to shipping container 2. Preferably, base structural members 41 and 42 are any suitable channel members or tubular members, including hollow or solid tubular members.

Base structural members 43 provide a floor for shipping container 2. Additionally, base structural members 43 support shipping container 2 in combination with base structural members 41 and 42. In Figure 2, base structural members 43 are illustrated as extending along the length of base 4 connecting base structural members 41. Base structural members 43 may also extend along the width of base structural members 41 and connect base structural members 42. In addition, base structural members 43 may extend diagonally in any desired manner across base 4 and connect base structural members 41 and 42. Base structural members 43 may be of any suitable configuration providing the necessary support to shipping container 2. Preferably, base structural members 41 and 42 are any suitable channel members or tubular members, including hollow or solid tubular members. The number of base structural members 43 are selected based on the desired strength and weight characteristics. Optionally, the floor of base 4 can have a covering, such as sheets of plywood or corrugated steel, on its bottom.

The corners of base 4 are provided with base corner components 16 as known in the art. See, for example, U.S. Patent No. 4,506,798, the disclosure of which is incorporated herein by reference. These comer components have standard dimensions (such as 178 x 151 x 110 mm) and they are provided with standard size bores on all their outer sides. These corner components provide a grip for lifting the container with a suitable apparatus, such as a derrick. They also provide a means for fastening two (or more) containers together and for fastening a container to a supporting frame.

Extending upwardly from base corner components 16 are lower corner posts 20. Extending upwardly from base structural members 41 (and optionally base structural members 42) is at least one lower post 18. Also extending upwardly (in a substantially vertical direction) from base structural members 41 and 42 are sides 22 and 24, respectively. These sides are made of any suitable material, such as corrugated steel, in any suitable shape, such as panels or sheets of any desired thickness. Sides 22 and 24 of base 4 include at least one lower post 18.

As shown in Figure 3, top (or roof) 14 of shipping container 2 is similar in size and shape to base 4. Thus, top 14 is also preferably, although not necessarily, of a rectangular shape. Top 14 comprises top structural members 44 and 45 around the circumference of top 14. Top structural members 44 and 45 are similar is shape, size, material, and configuration as base structural members 41 and 42. Top 14 also comprises covering 26 which serves to encompass and shipping container 2. Covering 26 can be made of sheets or panels any material depending on the desired strength and weight. Preferably, covering 26 comprises sheets of corrugated steel. Optionally, although not depicted, structural members similar to base structural members 43, but for top 14 instead of base 4, could be added to top 14 for additional support or strength. The upper corners of top 14 are provided with top corner components 28. These top corner components are substantially similar in size, shape, and purpose as base corner components 16. Extending downwardly from top corner components 28 are upper corner posts 30. Extending downwardly from top 14 and from top structural members 44 (and optionally top structural members 45) is at least one upper post 32.

As shown in Figure 4, side walls 6 and 8 extend the length of shipping container 2. These side walls are connected by pivoting means 34 to sides 22 of base 4 which, as described below, allow the side walls to pivot into a substantially horizontal position relative to sides 22. Side walls 6 and 8 can be made of any material depending on the desired strength and weight, and of any desired thickness. Preferably, side walls 6 and 8 are made of a combination of plate and/or corrugated steel. Located along at least one portion of the side walls are at least one middle post 36. The number and location of at least one middle post 36 can be optimized depending on the weight, strength, and structural requirements for shipping container 2. Preferably, although not necessarily, pivoting means 34 are located at the intersection of corresponding middle posts and lower posts. The side walls of shipping container 2 can optionally include structural supports as known in the art. See, for example, U.S. Patent No. 5,190,179, the disclosure of which is incorporated herein by reference.

As depicted in Figure 5, end walls 10 and 12 extend the width of shipping container 2. The end walls are made of any material providing sufficient structural strength, such as corrugated steel, and of any desired thickness. At the side edge, both end walls have middle corner posts 38. As described below, middle corner posts 38 connect upper corner posts 30 with the lower corner posts 20. On an interior portion of the middle corner posts adjacent the side walls are aligning means 40, which align the end walls and the side walls. The aligning means can be any suitable means known in the art. Preferably, the aligning means is a small sheet of plate steel on middle corner posts which abuts the inside of the respective side wall. Alternatively, one or both of the end walls can be modified to comprise shipping doors as illustrated in Figure 7, or as otherwise known in the art. See, for example, U.S. Patent Nos. 4,506,798 and 5,190,179, the disclosures of which are incorporated herein by reference. Here, the end wall(s) has been separated into a set of doors 50 which can be opened when the container is in its un-collapsed state. The set of doors are connected to middle corner posts 38 by any suitable connection means which allows them to fold outward, such as by at least one hinge.

To lock the doors in place, at least one locking vertical end wall lock bar 52 is provided in each door. The locking bars are coupled to the end wall and sides 24 via end wall couplers 54. The base structural members 42 of base 4 and top structural members 45 of top 14 are then provided with a corresponding locking mechanism (not shown) to keep the doors from opening.

An optional feature of the shipping container of the present invention is illustrated in Figure 8. This optional feature allows at least one of sides 24 to be configured to contain side doors 56 which can open into interior 58 of the shipping container in its collapsed state. As depicted, sides 24 can be divided into two doors which open outward, pivoting on pivoting means 60, thus providing access to interior 58 of the collapsed shipping container.

Side doors 56 can have locking mechanism(s) similar to the locking mechanism for the doors on the end walls for holding them when not opened. These door locking mechanisms can be any suitable means known in the art, as noted above, but are preferably configured as shown in the Figures. The preferred locking mechanism to hold the door shut comprises vertical lock bars 62 or rods which extend over top 14 and base 4. Coupler(s) 64 can be used to secure the vertical lock bars the doors and corresponding locks in top 14 and base 4 can be employed to secure the doors in a closed configuration. Additionally, the locking mechanism can comprise at least one horizontal bar 66 to secure the doors shut. Coupler(s) 68 can be used to secure the at least one horizontal lock bar to the door.

Shipping container 2 of the present invention can be used to store and transport any suitable goods and products as known in the industry. Moreover, shipping container 2 can be used as an intermodal container, e.g., it can be employed to store and transport goods over land, air, and sea.

After storing and transporting goods, shipping container 2 can be collapsed and transported without goods. As depicted in Figure 9, top 14 of the shipping container is removed from the container by lifting vertically. Upper corner posts 30 of top 14 and upper posts 32 disengage respectively from middle corner posts 38 and middle posts 36. All of these posts, including the corner posts, are designed to mate and fit within each other in any suitable manner, such as by the bottom of the upper posts having male fittings and the top of the middle posts having female fittings (or vice versa). Top 14 is then set aside and used later as described below.

Next, as illustrated in Figure 10, the end walls are removed from shipping container 2 by lifting them vertically, thus removing middle corner posts from the lower corner posts. Like the upper and lower corner posts, the middle and lower corner posts are designed to mate and fit within each other in any suitable manner, such as by the bottom of the middle corner posts having male fittings and the top of the lower corner posts having female fittings (or vice versa). As shown in Figure 11 (which does not depict the side walls for clarity), the end walls are then placed on the floor 70 of base 4.

Next, the side walls are collapsed by any suitable means known in the art. Preferably, as illustrated in Figure 12, the side walls are collapsed using pivoting means 34 by rotating them into a substantially horizontal position and laying them over the end walls on base floor 70. The middle posts have been also folded away from the lower posts, as illustrated in Figure 12, thus leaving the top of the lower post(s) exposed. The position of the side walls after being folded is shown in Figure 13. The sides 22 and 24 have remained substantially vertical while the side walls 6 and 8 have moved into a substantially horizontal position onto end walls 10 and 12.

Next, top 14 is then placed back onto the shipping container as depicted in Figure 14. By removing the side walls (along with middle corner posts 38), the lower corner posts have been exposed. The upper corner posts which are then lowered into the lower corner posts. Likewise, the bottom of the upper posts fit within the top of the corresponding lower posts. Thus, top 14 is lowered onto the sides 22 and 24 of base 4, with all upper and lower posts (including corner posts) mating or integral with each other. The resulting structure of the collapsed shipping container is illustrated in Figure 15.

As shown in Figure 15, the height of shipping container 2 has been drastically reduced. For the illustrated shipping container, the height has been reduced from about 8 feet (96 inches) to about 24 inches. Thus, the height of the shipping container has reduced by at least about when collapsed.

By reducing the height of the shipping containers into the collapsed configuration, more collapsed shipping containers can be transported when compared to non-collapsed shipping containers. For the shipping container illustrated in the Figures, four successive collapsed shipping containers could be stacked on top of each other by using their respective corner components. Thus, four collapsed shipping containers could be transported in the same space it takes to transport one non-collapsed shipping container.

As illustrated in Figures 16a and 16b, the corner posts of the present invention can be configured in any suitable manner such that the upper corner posts 30 mate with the middle corner posts 38, which in turn mate with the lower corner posts 20. When the middle corner posts are removed, the upper corner posts 30 mate with the lower corner posts 20. As shown in Figure 16c and 16d, the posts of the present invention can be configured in any suitable manner such that the upper posts 32 mate with the middle posts 36 and lower posts 18. The middle posts do not mate, but are integral, with the lower posts. When the middle posts are pivoted, the upper posts must mate with the lower posts.

Where portions of the posts or corner posts do not mate with each other and are merely integral, structural elements may be added to increase their strength. For example, the bottom of the lower posts, the bottom and middle of the middle posts, and/or top of the upper posts may be completely filled (e.g., making it solid) or partially filled (e.g., with a sleeve or runner).

At the intersections of flat surfaces in the present invention, two optional features may be included. First, weather stripping or any other known sealant as known in the art can be employed. Second, the edges of the flat surfaces may be made with an L-shape to improve the structural strength thereof.

Having described the preferred embodiments of the present invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are possible without departing from the spirit or scope thereof.

Claims

CLAIMS I claim:

1. A collapsible shipping container, comprising: a base having a plurality of structural members; a top having a plurality of structural members; a pair of end walls, each end wall having edge structural members mating with at least one of the top structural members and at least one of the base structural members, the end walls detachable from the top and the base; and a pair of side walls, each side wall having at least one structural member with the bottom thereof integral with at least one of the base structural members and the top thereof mating with at least one of the top structural members, the side walls detachable from the top and pivotally mounted to the base.

2. The shipping container of claim 1 , wherein the base structural members include members located at corners of the base.

3. The shipping container of claim 2, wherein the base includes a floor and sides extending upwardly from the base and perpendicular to the floor.

4. The shipping container of claim 3, wherein the base structural members extend upwardly from the base.

5. The shipping container of claim 4, wherein the base structural members and the sides extend upwardly to substantially the same height.

6. The shipping container of claim 4, wherein the top structural members include members located at the corners of the top.

7. The shipping container of claim 6, wherein the top structural members extend downwardly from the top.

8. The shipping container of claim 1 , including means for aligning the end walls and the side walls.

9. The shipping container of claim 1 , including pivotally mounting the side walls to the base by using pivoting means.

10. The shipping container of claim 1 , wherein the base, top, end wall, and side wall structural members are tubular .

11. The shipping container of claim 10, wherein the bottom of the top structural members, the bottom of the end wall structural members, and the bottom of the side wall structural members have a substantially similar diameter.

12. The shipping container of claim 11 , wherein the top of the base structural members, the top of the end wall structural members, and the top of the side wall structural members have a substantially similar diameter.

13. The shipping container of claim 3, further comprising dividing at least one of the end walls into doors with means for holding the doors shut and dividing at least one side of the base into doors with means for holding the doors shut.

14. The shipping container of claim 7, wherein each end wall edge structural member mates with a top corner structural member and a base corner structural member.

15. The shipping container of claim 14, wherein each side wall structural member is integral with a base structural member and mates with a top structural members.

16. A collapsed shipping container, comprising: a base having a plurality of structural members; a top having a plurality of structural members; a pair of end walls detached from the top and the base; a pair of side walls, the side walls detached from the top and pivotally mounted to the base; and an interior enclosed by the base and top; wherein the top rests on the base with at least one base structural member mating with at least one top structural member and the end walls and side walls located in the interior.

17. The shipping container of claim 16, wherein the base structural members include members located at corners of the base.

18. The shipping container of claim 17, wherein the base includes a floor and sides extending upwardly from the base and perpendicular to the floor.

19. The shipping container of claim 18, wherein the base structural members extend upwardly from the base.

20. The shipping container of claim 19, wherein the base structural members and the sides extend upwardly to substantially the same height.

21. The shipping container of claim 19, wherein the top structural members include members located at the corners of the top.

22. The shipping container of claim 21 , wherein the top structural members extend downwardly from the top.

23. The shipping container of claim 16, wherein the base, top, end wall, and side wall structural members are tubular.

24. The shipping container of claim 22, wherein each top corner structural member mates with a base corner structural member.

25. The shipping container of claim 24, wherein each top structural member mates with a base structural member.

26. A method for collapsing a chipping container having a base with a plurality of structural members, a top with a plurality of structural members, end walls detachable from the base and the top of the shipping container, and side walls detachable from the top and pivotally mounted to the base; the method comprising: removing the top; removing the end walls and placing them on the base; pivoting the side walls to a substantially horizontal position overlying

the end walls; and placing the top so it rests on the base with at least one base structural member mating with at least one top structural member.

27. The method of claim 26, including placing the top so it rests on the base with each base structural member mating with each top structural member

28. A collapsible shipping container, comprising: a base having a plurality of upwardly-extending structural members, including corner structural members; a top having a plurality of downwardly-extending structural members, including corner structural members; a pair of end walls, each end wall having edge structural members mating with a top structural member and a base structural member, the end walls detachable from the top and the base; and a pair of side walls, each side wall having structural members integral with the base structural members and mating with the top structural members, the side walls detachable from the top and pivotally mounted to the base.

29. A collapsed shipping container, comprising: a base having a plurality of upwardly-extending structural members, including corner structural members; a top having a plurality of downwardly-extending structural members, including corner structural members;

a pair of end walls detached from the top and the base; a pair of side walls, the side walls detached from the top and pivotally mounted to the base; and an interior enclosed by the base and top; wherein the top rests on the base with the base structural members mating with the top structural members and the end walls and side walls located in the interior.