Abstract:
An ISO approved shipping container has a spatially rotated, molded thermoplastic polymer container shell and encapsulated by a load hearing structural exoskeletal steel container framework. The container is integrated with a commercially licensed or third party supplied internal covert electronic sensor package consisting of a possible combination of an internally mounted, geo-location detection system, data transmission communication devices, inner environmental and security sensors, energy storage and recharging system, and data storage system.

Description:
[0001]    This application claims the benefit of application Ser. No. 12/386,530 filed on Apr. 20, 2009. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Large, enclosed steel marine shipping and transporting containers are used for a number of purposes. One particular container, the so-called intermodal marine shipping container, has been the standard container of the marine transportation shipping industry since its introduction by Malcolm Mclean and Sea Land Shipping over sixty years ago. These containers are hollow, six-sided boxes, fabricated almost entirely of welded mild steel corrugated sheets, or aluminum and/or non-recyclable fiberglass reinforced plastic (FRP), in very few cases, such as in refrigeration containers. The containers are constructed in accordance with International Standards Organization (ISO) standard marine transportation size lengths of twenty feet, forty feet, forty five feet, forty eight feet, and fifty three feet, heights between eight feet and nine and a half feet, widths of eight feet. They are also provided with uniform distance lifting eyes and structural design specifications. 
         [0003]    Intermodal marine shipping containers are easily lifted, moved, and secured, so that they can be shipped by sea, air, or land. The containers, because they are typically manufactured from steel, are relatively heavy and have a high heat transfer ratio. They are labor intensive in their manufacture and assembly (almost 95% of all manufacturing being sent to low cost manufacturing countries), are prone to accelerated corrosion from sea (salt) elements, and are environmentally difficult to recycle. These steel containers are not capable of being scanned with present standard x-ray technology from the outside and, being steel, are incapable of accepting radio frequency (RF) transmissions without the use of exterior antenna. 
         [0004]    Representative examples of prior art intermodal marine shipping containers are disclosed with regard to the prior art discussed below. However, these containers are mainly made of mild steel, aluminum, or connected fiberglass reinforced panels, and, in a number of variations, they are configured to be collapsible or reduced in size to provide space savings during storage and transportation. All such containers would fail to obtain ISO certification through rigorous ABS testing for static loading bearing capability, vertical corner loading, and the watertight integrity required for marine intermodal shipping containers. The containers also were not developed to provide a solution to the problems of RF permeability for internal and external transmissions. 
         [0005]    U.S. Pat. No. 3,570,698 discloses a collapsible rectangular steel shipping container having opposed horizontally-hinged sidewalls which can be collapsed or folded inward and downward. 
         [0006]    U.S. Pat. No. 3,877,602 discloses a collapsible steel container with improved fastener assemblies, formed from a plurality of lightweight, insulating panel members, each detachably secured together along their respective edges by fastener assemblies. 
         [0007]    U.S. Pat. No. 4,214,669 discloses an elongated and box-like steel cargo container having end walls which can be pivoted longitudinally inwardly and downwardly to collapsed horizontal positions to the bottom walls. 
         [0008]    U.S. Pat. No. 5,190,179 discloses a collapsible framed, box type, waterproof shipping container including pivoting end walls and bi-folding side walls. 
         [0009]    U.S. Pat. No. 5,865,334 discloses a self-contained, segmented, six-sided reusable container, including both an assembled form and a collapsed form. The sides and ends are interconnected while the container is in its assembled form. 
         [0010]    U.S. Pat. No. 5,979,684 discloses a cargo container wherein at least two walls adjacent to each other are constituted using integrally formed FRP panels. The container has a sandwich panel including a core of plywood or polyurethane foam, and FRP skin as the main rigidity maintaining member. 
         [0011]    U.S. Pat. No. 7,002,472 discloses a container configured for transporting cargo on a transportation vehicle A method for transporting the container on the transportation vehicle is disclosed. Disposed within the container housing is at least one detector for detecting security deviations and a communications link capable of transmitting the possible threat information to a central cargo data collection location. 
         [0012]    U.S. Pat. Pub. No. 2004/0263329 discloses a container intrusion detection method and apparatus which emits a wireless signal within the container, detects the wireless signal near the container, and responds to detection of a change in a characteristic of the detected wireless signal by transmitting a wireless notification to a location remote from the container. 
         [0013]    U.S. Pat. Pub. No. 2005/0046567 discloses a container and contents monitoring system which utilizes a monitoring device, a reader, a server, a software backbone and a receptacle for housing a plurality of sensors. The device communicates with the plurality of sensors and the reader in order to determine the condition of the container and its contents. The reader transmits the information from the device to the server. The device determines if a container abnormality has occurred, based on at least one of the sensors located on or in the container. 
         [0014]    U.S. Pat. Pub. No. 2006/0016807 discloses a foldable, steel freight container, comprising a frame and other container components foldable for compactness. 
         [0015]    U.S. Pat. Pub. No. 2006/0144837 discloses a segmented cargo carrying container which can be disassembled and thus collapsed. 
         [0016]    None of the containers or container systems in the prior art addresses the many requirements and needs related to the law, economics, security, and practicality demanded in today&#39;s modern transportation shipping industry. 
       SUMMARY OF THE INVENTION 
       [0017]    It is thus the object of the present invention to provide a transportation shipping container which overcomes the disadvantages and limitations of prior shipping containers. 
         [0018]    It is the object of the present invention to provide a shipping container which is constructed from material other than mild steel, which is also RF transparent. 
         [0019]    It is another object of the present invention to provide a shipping container constructed of a one piece spatially molded container shell of uniform thickness made of thermoplastic polyethylene polymers. 
         [0020]    It is still another object of the present invention to provide a shipping container comprising an exoskeletal steel container framework encapsulating the molded shell, the container being constructed without the need for welding or mechanically assembled outer joints. 
         [0021]    It is a further object of the present invention to provide a shipping container which would withstand environmental conditions, e.g. thermal transfer, expansion, contraction, and still exhibit 100% watertight integrity. 
         [0022]    It is an additional object of the present invention to provide a shipping container which could be designed and built in accordance with ISO criteria and ABS extensive testing specifications, which would permit the container to be ISO approved and ABS certified. 
         [0023]    It is another object of the present invention to provide a shipping container capable of integrating devices which would determine geo-location, sense interior environmental conditions, and transmit such information in a cost and power efficient manner, without the use of an exterior antenna. 
         [0024]    It is a further object of the present invention to provide a shipping container which, as a result of its construction, provides for secure, covert communication capability with both internal and external RF transparency. 
         [0025]    It is another object of the present invention to provide a shipping container which could be effectively x-ray scanned for any potential bio, chemical, or nuclear hazards, prior, during, or after utilization of the container, in an efficient and cost-effective manner. 
         [0026]    It is an additional object of the present invention to provide a shipping container made of a material that is environmentally friendly and capable of being easily and efficiently recycled after useful utilization and product life cycle, in a cost effective manner. 
         [0027]    It is still another object of the present invention to provide a shipping container constructed of lighter weight material, which would increase energy efficiency. 
         [0028]    These and other objects are accomplished by the present invention, an ISO approved shipping container having a spatially rotated, molded, thermoplastic polymer container shell encapsulated by a load bearing structural exoskeletal steel container framework. The container is integrated with a commercially licensed or third party supplied internal covert electronic sensor package consisting of a possible combination of an internally mounted, geo-location detection system, data transmission communication devices, inner environmental and security sensors, energy storage and recharging system, and data storage system. 
         [0029]    The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention, itself, however, both as to its design, construction and use, together with additional features and advantages thereof, are best understood upon review of the following detailed description with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]      FIG. 1  is a perspective view of the ISO approved, ABS certified, assembled shipping container of the present invention. 
           [0031]      FIG. 2  is a side elevation view of the shipping container of the present invention. 
           [0032]      FIG. 3  is the top view of the shipping container of the present invention. 
           [0033]      FIG. 4  is an elevation view of the front end of the shipping container of the present invention. 
           [0034]      FIG. 5  is a perspective view of an assembled front end frame of the shipping container of the present invention. 
           [0035]      FIG. 6  is a perspective view of an assembled rear vertical frame and door of the shipping container of the present invention. 
           [0036]      FIG. 7  is a perspective view of an assembled bottom floor frame of the shipping container of the present invention. 
           [0037]      FIG. 8  is a perspective view of the assembled side connecting members of the shipping container of the present invention. 
           [0038]      FIG. 9  is a front perspective view of the transparent thermoplastic polymer shell of the shipping container of the present invention. 
           [0039]      FIG. 10  is a front perspective, exploded view of a partially assembled shipping container of the present invention, showing its components. 
           [0040]      FIG. 11  is a front perspective, exploded view of the fastening method utilizing mechanical fasteners and rivets of the partially assembled shipping container of the present invention. 
           [0041]      FIG. 12  is a rear perspective, exploded view of the shipping container of the present invention, showing one location for the installation of the electronic sensor package. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0042]    Referring to the drawings wherein identical reference numerals denote same elements throughout the various views,  FIG. 1  illustrates ISO approved, ABS certified molded shipping container  1 . The container comprises a one piece, six-sided, spatially molded, structural polyethylene container shell  2 , manufactured with a polyethylene resin, containing an ultraviolet inhibitor and color additive to retard aging and fading. With specific reference to  FIGS. 9 and 12 , structural shell  2  has top  3 , sides  4  and  6 , front end  8 , and open end  10 . Monocular floor  12 , molded of high density or linear tough waterproof, corrosion resistant low density, virgin or recycled polyethylene, forms the bottom of shell  2 . The shell has inset recesses  14  at its front end  8  and inset recesses  15  at its sides  4  and  6 . These inset recesses assist in maintaining the encapsulation of container shell  2  within container framework  22 , as described hereinafter. 
         [0043]    Shell  2  is integrally stiffened by molded vertical ribs  16  and horizontal ribs  18 . If desired, the molded ribs may be exteriorially coated with a material such as polytetrafluoroethylene (PTFE) to improve the release characteristics. One and one-eighth inch marine grade plywood, or equivalent material, deck  20  overlays floor  12 . 
         [0044]    Shipping container  1  also comprises outer, load bearing exoskeletal container framework  22 , substantially encapsulating container shell  2 . Container framework  22  comprises a number of components including side connection member  24  having top frame  26  and side frames  28 ,  30 ,  32 ,  34 ,  36  and  38 , and side connection member  40  having top frame  42  and side frames  44 ,  46 ,  48 ,  50 ,  52 , and  54 , best seen in  FIG. 8 . Cross frames  56  and  58  interconnect members  24  and  40 . Further connections are provided by inner cross-braces  60  and outer cross-braces  62 . 
         [0045]    Top frames  26  and  42  are open at their ends  26   a  and  26   b  and  42   a  and  42   b . The bottom ends at  30   a ,  46   a , and  52   a  of side frames  30 ,  46 ,  52  and of  36  (bottom end not shown) are open as well. 
         [0046]    Container framework  22  also comprises bottom floor frame  64 , as best seen in  FIG. 7 . Floor frame  64  comprises side floor frame  66  having open ends  66   a  and  66   b  and side floor frame  68  having open ends  68   a  and  68   b . Floor frame  64  also comprises transverse beams  70 , longitudinal floor connecting beams  72 , and forklift pockets  74 . Vertical inserts  69  extend up from side floor frames  66  and  68 . 
         [0047]    Container framework  22  further comprises front end frame  76 , best seen in  FIG. 5 , and door frame  92 , best seen in  FIG. 6 . Front end frame  76  comprises side frames  78  and  80 , bottom frame  82 , top frame  83 , cross frames  84  and  86 , and top inserts  88  and bottom inserts  90 , each extending from corner casings. Forklift pockets  85  are located in bottom frame  82 . 
         [0048]      FIG. 6  shows the assembled rear section of container  1 , which comprises door frame  92  having side connecting frames  94  and  96 , bottom connecting frame  98  with forklift pockets  104 , top connecting beam  99 , and top inserts  100  and bottom inserts  102 , each extending from corner casings. Hinge doors  106 , having polymer door inserts  110  and associated door hardware  108 , provide access to the interior of container  1 . 
         [0049]      FIG. 10  illustrates the method of assembly of container  1 . Shell  2  is first lowered onto floor frame  64 . Side connection members  24  and  40  are positioned so that they fit squarely within inset recesses  15  in the sides of shell  2  and are aligned such that inserts  60  of side floor frame  68  are inserted into open bottom ends  46   a  and  52   a  of side frames  46  and  52  of connection member  40 . Not shown, but in like manner, it can be appreciated that inserts  69  of side floor frame  66  are inserted into the open bottom ends of side frame  30  and  36  of connecting member  24 . 
         [0050]    Front frame  76  is aligned with front end  8  of shell  2  such that cross frames  84  and  86  are positioned within inset recesses  14 . Door frame  92  is aligned with open end  10  of shell  2 . Top inserts  88  of front end frame  76  are inserted into open end  26   a  of top frame  26  and open end  42   a  of top frame  42 , and bottom inserts  90  of the front frame are inserted into open end  66   a  of side floor frame  66  and open end  68   a  of side floor frame  68 . Top inserts  100  of door frame  92  are inserted into open end  26   b  of top frame  26  and open end  42   b  of top frame  42 , and bottom inserts  102  of the door frame are inserted into open end  66   b  of side floor frame  66  and open end  68   b  of side floor frame  68 . Front end frame  76  and door frame  92  are then hydraulically compressed onto top frames  26  and  42  of side connection members  24  and  40 , and side floor frames  66  and  68  of floor frame  64 , thus forming container framework  22 . Container shell  2  is thereby maintained encapsulated within container framework  22  by means of its compressed position within the framework, assisted by the positioning of connecting members  24  and  40  within inset recesses  15  and cross frames  84  and  86  of front frame  76  within inset recesses  14 . 
         [0051]      FIG. 11  shows a perspective view illustrating the assembly method of exoskeletal container framework  22 , connected through a series of retaining strips  112  and mechanical rivets  114 . 
         [0052]      FIG. 12  illustrates the covert installation of a commercially licensed or third party supplied enclosed electronic sensor package. The package optionally consists of a combination of an internally mounted ego-location detection system, date transmission communication devices, inner environmental sensors, and a data storage system, all enclosed within a watertight plastic enclosure casing  120  located in monocular floor system  12 , below the plywood deck  20 . Internal antennae  122  is installed in the upper roof section and connected with associated electrical wiring. 
         [0053]    Container  1  is designed for use as an intermodal shipping container specifically adapted to be transported by ship, rail, or truck. It has ISO standard lengths, as previously noted, of between twenty to forty-eight, heights of between eight feet and nine and a half feet, and an eight foot width. 
         [0054]    Certain novel features and components of this invention are disclosed in detail in order to make the invention clear in at least one form thereof. However, it is to be clearly understood that the invention as disclosed is not necessarily limited to the exact form and details as disclosed, since it is apparent that various modifications and changes may be made without departing from the spirit of the invention.