Abstract:
In one embodiment, an intermodal cargo container includes a lid section having a rectangular box with an open bottom portion. A floor unit has a channel portion arranged around a periphery, and the channel portion received a bottom edge of the lid section. Locking mechanisms are arranged along an edge of the lid section to couple the lid section to plural rungs that extend across the channel portion. The sliding lock mechanism includes engagement tabs that engage associated rungs extending between two walls of the channel portion. Corner boxes are arranged at each corner of the floor unit. A sealing portion is provided within the channel so as to provide a fluid-tight seal when the lid section is coupled to the floor unit. An actuator mechanically assists in moving the lock mechanism. A gooseneck portion is arranged at each end of the container, and a spring assembly at a corner of the floor unit provides a spring tension to the sliding lock mechanism.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit under 35 USC 119(e) to Provisional application 60/793,418 filed on Apr. 19, 2006, the entire contents of which are incorporated herein by reference. 
     
     BACKGROUND 
       [0002]    This application relates to the intermodal shipping industry, and more particularly to containerization using intermodal shipping containers. Even more particularly, this application provides an improvement to homeland security by making inspection of containerized cargo faster, easier, and more reliable than conventional techniques. 
         [0003]    Containerization is a system of intermodal freight transport cargo transport using standard ISO containers (known as “Shipping Containers” or “Isotainers”) that can be loaded and sealed intact onto container ships, railroad cars, planes, and trucks. 
         [0004]    Intermodal shipping containers generally are hollow rectangular cubes which may vary in size from 20×8.5×8 feet, to 40, 45, and 50 foot lengths, which may rise in height to 9.5 feet. These containers generally have standardized dimensions and corner posts in accordance with industry standards applicable to intermodal shipping containers. 
         [0005]    There are five common standard lengths, 20-ft (6.1 m), 40-ft (12.2 m), 45-ft (13.7 m), 48-ft (14.6 m), and 53-ft (16.2 m). United States domestic standard containers are generally 48-ft and 53-ft (rail and truck). Container capacity is measured in twenty-foot equivalent units (TEU). A twenty-foot equivalent unit is a measure of containerized cargo capacity equal to one standard 20 ft (length)×8 ft (width)×8 ft 6 in (height) container. In metric units this is 6.10 m (length)×2.44 m (width)×2.59 m (height), or approximately 38.5 m 3 . These sell at about US$2,500 in China, the biggest manufacturer. Most containers today are of the 40-ft (12.2 m) variety and are known as 40-foot containers. 
         [0006]    The use of US measurements to describe container size, despite the fact the rest of the world uses the metric system, reflects the fact that US shipping companies played a major part in the development of containers. The overwhelming need to have a standard size for containers, in order that they fit all ships, cranes, and trucks, and the length of time that the current container sizes have been in use, makes changing to an even metric size impractical. 
         [0007]    Access to the interior of an intermodal shipping container has conventionally been limited to a door or doors on one end of the container. This conventional arrangement has made it difficult to load cargo of certain shapes, and has also made security inspections and physical access to the cargo at ports of entry problematic because access to the first-loaded cargo at the end of the container away from the door is generally difficult. In addition, the conventional door arrangement has resulted in a certain amount of undesirable pilferage. 
         [0008]    Further, the presence of doors on one end of the container results in a structural weakening of the container, thus limiting the number of containers that can safely be vertically stacked, as well as limiting access for offloading of cargo from the container. 
         [0009]    What is needed is a container configured to facilitate security inspection of cargo contained within the container. What is further needed is a cargo container that allows relatively easy physical access to cargo contained therein to reduce the time and effort of loading and unloading the container. What is still further needed is an intermodal cargo container without conventional doors that constrains or prohibits unauthorized access to the contents of the container, and which provides increased structural integrity and physical security. 
       SUMMARY 
       [0010]    The cargo container of this disclosure, marketed as “CakeBoxx”™, may have the same external dimensions as common ISO standard intermodal shipping containers. They are designed to fit into the system without any adjustments and perform the expected functions without changes in process or policy. They are designed to fit into the existing intermodal shipping system without any adjustments and perform the expected functions without changes in process or policy. Thus, the container of this disclosure has all the structural strength of ordinary containers, with increased compression load resistance, especially where the door hinges would normally be competing with the load bearing column for the limited available space. 
         [0011]    The container of this disclosure may be scaled up or down and can come in any length, height or width that would be functional and desirable within the global intermodal shipping system. However, the net internal (“usable”) volume of a 40′ container of this disclosure exceeds the net internal volume of a conventional 40′ container because there is no need to reserve empty space above the load so that it can be lifted, for example, by a forklift. The container of this disclosure increases the net internal capacity by being able to be loaded from the side with wide, full span pallets loaded slightly more than 8 feet high, rather than from a more restrictive end through a door. Further, when closed, an embodiment of the container may be made impervious to pilferage, water, moisture, and light. 
         [0012]    As a consequence of the above, intermodal shipping containers of this disclosure are efficient, secure and convenient, and are desirable from the standpoint of increasing the ability to conduct efficient and timely security inspections at ports of entry, for example. 
         [0013]    In one embodiment, the container of this disclosure is a mechanically simple device with few moving parts and, when closed, does not readily reveal that there are any moving parts, doors, latches, or even any interior access. When opened, the container floor is completely accessible from all sides, and horizontal tubes inside a gutter portion are the “rungs” that comprise attachment points for the lower section. The corner posts may be configured to have permanent “twist locks” on them that both guide the descent of the top “canopy” and, when closed, rotate to form redundant security latches and direct line of tension connections. 
         [0014]    In one embodiment, an intermodal cargo container includes a lid section; a floor unit comprising a channel portion arranged around a periphery thereof, wherein the channel portion is arranged to receive a bottom edge portion of the lid section; and a sliding lock mechanism arranged to slidingly couple the lid section to plural rungs connected to and extending across the channel portion. 
         [0015]    In another embodiment, an intermodal cargo container includes a lid section comprising a rectangular box having an open bottom portion; a floor unit comprising a channel portion arranged around a periphery thereof, wherein the channel portion is arranged to receive a bottom edge portion of the lid section; plural sliding locking mechanisms arranged along an open edge of the lid section to slidingly couple the lid section to plural rungs connected to and extending across the channel portion, wherein the sliding lock mechanism comprises engagement tabs that engage associated rungs extending between two walls of the channel portion; corner boxes arranged at each corner of the floor unit and at corners of an upper portion of the lid section; a sealing portion arranged within the channel portion, wherein the sealing portion provides a fluid-tight seal when the lid section is coupled to the floor unit; an actuator arranged to mechanically assist in moving the sliding lock mechanism in responsive to an operator command; a gooseneck cavity portion arranged at each end of the container; and a spring assembly arranged at a corner of the floor unit so as to provide a spring tension to the sliding lock mechanism. 
         [0016]    In other aspects, the container may be lined with insulating material, or with food grade plastic film to allow raw foodstuffs, e.g., corn or grain, to be shipped. In additional aspects, at least the floor of the container may have slots or holes to allow the free flow of air into the container while maintaining cargo integrity, depending on the shipping need. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  illustrates a perspective view of a closed intermodal shipping container of this disclosure. Typically, both ends of the container are alike or similar; 
           [0018]      FIG. 2  depicts two sections two sections of the container vertically separated (approximately 4 feet), with a “gutter” running around the floor&#39;s perimeter being visible on the bottom section; 
           [0019]      FIG. 3  illustrates five main sub-assemblies of the container of this disclosure in a vertically exploded view; 
           [0020]      FIG. 4  provides a close-up view of fastening together of the two main assemblies when the top section is lowered into the perimeter gutter of the bottom section; 
           [0021]      FIG. 5  illustrates a sliding latch; 
           [0022]      FIG. 6  depicts a close-up view of a rung captured by a sliding latch, with the gutter wall removed for clarity; 
           [0023]      FIG. 7  is an end-view of a slightly opened container with the goose-neck tunnel; 
           [0024]      FIG. 8  provides a detail view of the interior of a corner post assembly including a corner post twist lock pin; 
           [0025]      FIG. 9  provides a second detailed view of the interior of a corner post assembly showing the corner post twist lock pin in a rotated position used when the upper and lower sections are mated; 
           [0026]      FIG. 10  provides a view of the center-span “ISO casting” where mechanical release action is accomplished; 
           [0027]      FIG. 11  provides a perspective view of the sliding latch bar springs and corner “twist-locks” in the normal “closed” position; 
           [0028]      FIG. 12  is illustrative of a bottom frame in an embodiment of this disclosure; 
           [0029]      FIG. 13  illustrates an end view of the frame of  FIG. 12 ; 
           [0030]      FIG. 14  illustrates a bottom view of the frame of  FIG. 12  showing both goose-neck tunnels; 
           [0031]      FIG. 15  illustrates a bare platform of the container ready for loading; 
           [0032]      FIG. 16  provides a perspective view of a closed intermodal shipping container of the disclosure; 
           [0033]      FIG. 17  depicts an exemplary slider strap; 
           [0034]      FIG. 18  provides an exploded view of an exemplary corner casting; 
           [0035]      FIG. 19  illustrates an exemplary embodiment of an actuator useful to latch and unlatch the top portion to/from the floor section; 
           [0036]      FIGS. 20-21  provide additional view of the actuator arrangement of  FIG. 19 ; and 
           [0037]      FIG. 22  provides an end view of the container illustrating a void or reserved space useful for enclosing container security mechanisms and/or electronic alarm assembly. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]    In one embodiment, the container is a relatively simple device requiring few moving parts and, when closed, the container is outwardly configured so that it is not readily apparent that there are any moving parts, doors, latches, or even any interior access. 
         [0039]    In  FIG. 1 , Intermodal Shipping Container  100  (“container”) is illustrated in an exterior perspective view, and is seen to comprise floor support frame  110 ; upper section or canopy  120 ; gooseneck area or “tunnel”  130 ; ISO corner box assemblies  140 ; separation point or plane  150  used as a reference plane to illustrate the separation of canopy  120  from floor support frame  110 ; center span assembly  160 ; corner columns  170 ; and latch housing  180 , generally joined to canopy  120  by welding, for example. 
         [0040]    In the expanded perspective view of  FIG. 2 , the above elements are illustrated along with further details of floor support frame  110  and latch housing  180 , as well as the interior of container  100 . Floor support frame  110  includes perimeter channel or “gutter”  210  around the periphery of frame  110  and floor  240 . Channel  210  may included a rubberized or other type of sealing material therein (not shown) which can provide a liquid and/or airtight seal between the interior of container  100  and the external environment. 
         [0041]    The frame perimeter comprises channel  210  that may be of a convenient width and height, e.g., 5.5 inches±1.5″ on either axis. Perimeter channel rungs or horizontal tubes  230  span channel  210  along both long sides of container  100 . End rungs  250  span channel  210  along both ends of container  100  above gooseneck area  130 . Floor or deck  240  is attached to frame  110  to provide a surface on which cargo may be arranged. Floor  240  may be a solid material such as wood, metal, or synthetic material, e.g., ECOBoard®. Alternatively, floor  240  may comprise a grating having slots or other openings such as slotted boards to allow fresh air to flow into and out of container  100 , and which may be desirable for the secure shipment of fresh fruits and vegetables, for example. 
         [0042]      FIG. 2  illustrates that floor  240  is completely accessible from all sides for loading or unloading when container  100  is opened. In  FIG. 2 , the upper and lower sections are vertically separated by approximately 4 feet, and gutter  210  running around the perimeter of floor  240  is visible. 
         [0043]    Horizontal tubes  230  inside gutter  210  are the “rungs” that comprise the attachment points for the lower section of container  100 . Further, corner posts  140  have permanent “twist locks” on them that both guide the descent of the top canopy  120  and, when closed, rotate to form redundant security latches and direct tensioned connections that secure canopy  120  to support frame  110 . 
         [0044]    The five main sub-assemblies of container  100  are illustrated in the vertically exploded view of  FIG. 3 . These include frame  110 , made of steel or other suitable material, for example, that may be supportably connected to floor  240 . Latch housing  180  captures side latch sections  310  and end latch sections  360  so as to allow only one axis of back-and-forth sliding motion when interconnected with spring assembly  320  and spring  340 . Latch housing  180  may be connected to canopy  120  by welded joints, for example. Cross-bracing  330  is connected across the width of frame  110  to provide additional support for floor  240  and to stiffen container against torque and other stresses, and may be made of steel or other suitable materials, for example. 
         [0045]    Spring assemblies  320  contain associated springs  340  that intersect sliding latch sections  310 . These are the mountings and springs that apply outward pressure to the sliding latch sections  310  and, when container  100  is closed, springs  340  remain engaged with rungs  230  and  250  of channel  210 . 
         [0046]    In one embodiment, upper section  120  could be the top seven or more feet of an ordinary shipping container, except for corner columns  170 , which may be reinforced for additional strength. 
         [0047]    The fastening together of the two main assemblies, i.e., canopy  120 —latch housing  180  together with floor  240 —floor support frame  110 , is accomplished by lowering top section  120  into perimeter gutter  210  of bottom section  110 , which causes sliding latch sections  310  and  360  to initially move out of the way, then latch onto rungs  230  and  250 . 
         [0048]    In operation, and when canopy  120  is lowered onto the lower section, sliding latches  310  and  360  strike the sloped sides  350  of gutters  210  which are sloped sides of the corner casting boxes  140 . This causes latch sections  310  to slide sideways far enough that curved engagement tabs or “claws”  510  in  FIGS. 5 , and  6  allow rungs  230  or  250  from the lower section to settle into the cutout section of latch housing  180 , and to rest on cutout or notched section  370 . 
         [0049]    As the upper section is lowered to its resting position, twist-locks  260  will come into alignment with hole  810  (see  FIG. 8 ) in corner post  140 , as the previously mentioned spring tension will force sliding latches  310  and  360  outwards into the hole on face  350  in  FIG. 18 , thus capturing the corner casting and all the rungs in the lower frame gutters as depicted in  FIG. 6 . In one embodiment, there may be 64 such claws  510  and rungs  230 / 250  within channel  210  of frame  110 , around the perimeter of container  100 . 
         [0050]    The ends of container  100  may each have four short sections of the “sliding latches”  410  as shown in  FIG. 5 , and the sides of container  100  may each have two much longer sections. (See page 11.) All 12 pieces release with inward motion and capture with outward motion. 
         [0051]      FIG. 6  illustrates a close-up of a captured rung  250 , with the gutter wall removed to aid in exposition. Other perimeter rungs  230  are visible below, in their normal positions. 
         [0052]      FIG. 7  provides an end view of a slightly opened container  100  with a goose neck tunnel  130  clearly visible. Unlike conventional containers, both ends of container  100  may have such tunnels  130 , thus eliminating the need for conventional “north-south” pre-alignment of containers when changing modes of transportation. 
         [0053]    Corner post twist locks  260  act as guides, but they can then be turned to lock container  100  shut. All conventionally appropriate seals and locks may be attached either at one or more of twist locks  260 , or near spring assemblies  320 . A detail of the interior of corner post assembly is shown in  FIG. 8 . When the upper and lower sections are mated, twist lock pin  260  may be rotated as seen in  FIG. 9 . 
         [0054]    Corner twist locks  260  are somewhat redundant fasteners in some respects, and may not be completely necessary to the functional latching together of the upper and lower sections of container  100 . But, when used, their inaccessibility and strength will make it very difficult to illicitly intrude into a container interior, and nearly impossible to do so without leaving dramatic, indelible evidence of such intrusion. 
         [0055]    Also visible in  FIG. 9  is the slight vertical lip  910  around the perimeter of the deck or floor  240 . Lip  910  provides an edge to “grab” the bottom of a pallet as it is being lowered to the deck and to hold it, precisely located, as a forklift truck driver pulls the forks from the pallet that is being loaded. Such precise location of the pallet edge helps maximize the utility of the entire deck area and minimize the likelihood of cargo protruding beyond the floor edge. This makes it easier to load pallets that extend the full  8  foot span of the cargo deck. Lip  910  is shorter than the thickness of typical pallet bottom boards and does not interfere with normal operations. 
         [0056]    Optional center-span assembly  160  or “ISO casting” looks somewhat like the castings that were placed in the middle of conventional 40′ containers so that they could be stacked on top of two common 20 ft. containers. Center-span assemblies  160  are fully functional as ISO locking points, but they also provide access to the inward ends of the sliding latch bars or side latch sections  310  and any associated locks, seals and springs. In another aspect, castings  160  are absent and the latching function is accomplished either by actuator  1910  or by manual means with conventional hand tools through a mid-span slit. 
         [0057]    A slight, e.g., less than 2 inch, inward motion of sliding latch bars  310  pulls engagement claws  510  aside and allows latch housings  180  to be lowered into floor support frame  110 . This inward motion may be accomplished with conventional hand tools or, in one embodiment, with pneumatic, hydraulic or electric power tools (not shown) that use the ISO holes to locate themselves prior to applying force on the springs. 
         [0058]    Mechanical release action may be accomplished at the middle of the container  100  by powered mechanical action. For example, and as illustrated in  FIGS. 19-21 , a mechanical or electromechanical latch actuator  1910  may be included to aid in latching and unlatching the various slide latch mechanisms  310 . Latch actuator  1910  may be pneumatically actuated, or hydraulically actuated, or may be motor driven, as in the conventional art, all under operator control (not shown). 
         [0059]    Spring  340  and sliding latch sections  310  comprise a relatively simple assembly. The components are easy to fabricate and assemble and the resultant function is very strong, durable and easy to maintain. No lubrication is necessary and no part that might be considered “delicate” is exposed to possible damage. The motion needed to lock and unlock the two sections is a short back and forth, straight line motion. 
         [0060]    In terms of producing the novel container of this disclosure, all but the lower 9 inches is similar to a conventional ISO standard container design which may be reused to a great extent, including the floor and center bracing. Rungs  230  along the sides, and four of the eight rungs  250  on each end may be 1 inch in diameter, and the four rungs over the goose neck tunnel sections  130  may be approximately half that size, e.g., ½ inches in diameter, and made of a suitable material, e.g., steel. 
         [0061]    Side latch sections  310  and end latch sections  360  may be, for example, 5/16 inch metal stock which is approximately 5 inches wide, and side latch sections  310  may be 18 ft., 9½″ long on the sides. Rather than heating, cutting and forming the “C-shaped” or “J-shaped” engagement tabs  510 , it may be desirable to simply weld short pieces of channel with an approximate 1 inch throat to the unmodified strap. 
         [0062]    The corner box assemblies  140  or castings may be the same as conventional Isocontainers, except that the two inner sides have sloped surfaces  350  that push the side latch sections  310  and end latch sections  360  back as top  120  is inserted into floor support frame  110 , and the top of corner block  140  has a twist lock or corner post twist lock  260  which may be rotated to “lock” corner box  140  to upper section  120 . 
         [0063]    In another embodiment, useful for certain cargo, e.g., grain or other raw foodstuffs, container  100  may be inverted so that floor support frame  110  is located at an upper position, and so that the top of canopy  120  becomes the “bottom” of container  100 , this enabling the containment of grain-type or other loose cargo. The inside portion of canopy  120  may be lined with a food grade plastic liner (not shown), typically a 6 mil polyethylene sheet. 
         [0064]    Further, security of container  100  may be enhanced beyond that provided by the locking features, discussed above, by use of conventional alarm devices suitably arranged in void or reserved space  2210 , as illustrated in  FIG. 22 . Still further, a conventional Global Positioning System (GPS) transceiver (not shown) may also be enclosed in reserved space  2210  to aid in tracking of container  100  while in transit. 
         [0065]    Optional port  2220  may be used to obtain a gas sample of the contents of container  100 , in the case of the potential presence of flammable or noxious vapors in side container  100  or, in an alternative embodiment, port  2220  may be configured as a viewing port arranged to allow for viewing of the contents of container  100  from outside the container. 
         [0066]    A method of offloading or inspecting a container of this disclosure includes the steps of decoupling the top section from the floor unit; removing the top section from the bottom section; inspecting the contents/cargo of the container by visual or instrument means (e.g., x-ray); and removing contents of the container from the side or ends of the container floor. 
         [0067]    Conversely, cargo may be loaded into the container from the side and ends; the top section may be lowered onto the lower section or floor unit; and the top section may then be coupled onto the floor unit. 
         [0068]    In an embodiment suitable for grain transport, the container top (lined with a food grade plastic sheet) may be inverted; the cargo poured into the inverted top section; and what was known as the “bottom” or “floor” unit may be coupled to the inverted top section. Because of the presence of the ISO corner boxes, the container of this disclosure may be shipped either in a “normal” or an “inverted” orientation. 
       LIST OF REFERENCE NUMBERS 
       [0069]      
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
               
               
                 No. 
                 Name 
                 FIGS. 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 100 
                 Intermodal shipping container 
                 1, 2, 16 
               
               
                 110 
                 Floor support frame 
                 1, 2, 3, 4, 7, 8, 10, 12, 13, 14, 15, 16, 19, 
               
               
                   
                   
                 20, 21, 22 
               
               
                 120 
                 Upper section or canopy 
                 1, 2, 3, 4, 7, 16, 21, 22 
               
               
                 130 
                 Gooseneck area or “tunnel” 
                 1, 2, 3, 4, 7, 8, 12, 13, 14, 15, 16 
               
               
                 140 
                 ISO corner box assembly 
                 1, 2, 3, 4, 7, 8, 12, 13, 15, 16, 18 
               
               
                 150 
                 Separation point or plane 
                 1 
               
               
                 160 
                 Center span assembly 
                 1, 2, 3, 10, 12, 13, 14, 15, 16, 20 
               
               
                 170 
                 Corner column 
                 1, 2, 3, 4, 7, 16 
               
               
                 180 
                 Latch housing 
                 2, 3, 4, 6, 7, 8, 9, 10, 11, 20, 21, 22 
               
               
                 210 
                 Perimeter channel or “gutter” 
                 2, 3, 4, 8, 12, 13, 14, 15, 19 
               
               
                 230 
                 Perimeter channel rungs or horizontal 
                 2, 8, 12, 13, 14 
               
               
                   
                 tubes 
               
               
                 240 
                 Floor or deck 
                 2, 3, 4, 6, 8, 9, 10, 11, 15 
               
               
                 250 
                 End rungs 
                 2, 3, 6, 8, 912, 15 
               
               
                 260 
                 Corner post twist lock 
                 2, 3, 4, 7, 8, 9, 11, 12, 13, 14, 15, 18, 22 
               
               
                 310 
                 Side latch sections 
                 3, 4, 7, 8, 10, 11, 17, 19, 20 
               
               
                 320 
                 Spring assembly 
                 3, 11 
               
               
                 330 
                 Cross-bracing 
                 3, 10, 12, 13, 14 
               
               
                 340 
                 Spring 
                 3, 10, 11 
               
               
                 350 
                 Sloped side 
                 3, 4, 7, 12, 13, 15, 18 
               
               
                 360 
                 End latch sections 
                 3, 4, 5, 6, 8, 9, 10, 11 
               
               
                 370 
                 Cutout or notched section 
                 3, 4, 6, 7, 8 
               
               
                 510 
                 Curved engagement tab or “claw” 
                 4, 5, 6, 9, 17 
               
               
                 810 
                 Corner post hole 
                 8, 9 
               
               
                 910 
                 Vertical lip or edge 
                 9, 11, 15 
               
               
                 1010 
                 Access hole 
                 10, 13, 15, 16 
               
               
                 1110 
                 Center span rung 
                 11 
               
               
                 1810 
                 Block 
                 18 
               
               
                 1910 
                 Latch actuator 
                 19, 20, 21 
               
               
                 2210 
                 Enclosed electronics space 
                 22 
               
               
                 2220 
                 Sampling port 
                 22