Abstract:
Shipping containers that are wider than standard 8-foot (2.44 m) wide shipping containers and methods of shipping such extended width shipping containers are disclosed. The extended width shipping containers include: a roof; a base; a front end; a back end; two side panels; at least one door rotatable about a door rotation axis substantially perpendicular to the roof and the base; two pairs of end rails substantially perpendicular to the roof and the base; and two pairs of corner posts substantially perpendicular to the two side panels and the door rotation axis; wherein the corner posts are configured to support a greater compressive load than the end rails. Methods of shipping an extended width shipping container include: loading the shipping container with cargo; rotating the shipping container to a shipping orientation; placing the shipping container in an 8-foot (2.44 m) wide container cell of a ship; shipping the shipping container; removing the shipping container from the container cell; rotating the shipping container to a storage orientation; unloading the shipping container; transporting the shipping container over land; and utilizing the shipping container for storage of goods.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to shipping containers, and more particularly to shipping containers having an extended width and methods of shipping the same. 
         [0002]    Shipping containers are used to transport goods across oceans on large ships, and across land on truck beds. In order to transport shipping containers across seas, the shipping containers must conform to the Convention of Safe Containers, which determines the dimensions and load capacities of different shipping containers. Shipping containers of standard dimensions are generally loaded into container cells of a ship and stacked one upon another for transport. For example, it is known to provide shipping containers measuring 8 feet (2.44 m) in width and either 20 feet (6.10 m) or 40 feet (12.19 m) in length for loading into container cells of a ship, the container cells having approximately these same standard dimensions. 
         [0003]    Shipping containers are also used to store items at construction sites, homes, and other locations where storage is desired, and can be used accordingly upon completion of shipping. Different sizes of shipping containers may be desired according to the various applications for which the shipping container may be used. For example, shipping containers measuring 9½ (2.90 m) or 10 feet (3.05 m) in width may be desired for various storage applications. 
         [0004]    It is known to construct a shipping container having a width of 10 feet (3.05 m) and a height of 8½ feet (2.59 m). However, a shipping container with these dimensions cannot be transported in a standard 8-foot (2.44 m) wide container cell of a ship. 
         [0005]    It is also known to construct shipping containers having non-standard sizes to be used for various storage applications, and it is known to ship such non-standard sized containers by nesting smaller containers inside larger containers. Again, however, shipping containers having such non-standard dimensions cannot be shipped in standard 8-foot (2.44 m) wide ship container cells. 
       SUMMARY OF THE INVENTION 
       [0006]    Aspects of embodiments of the present invention are directed toward shipping containers having widths greater than a standard 8-foot (2.44 m) wide shipping container, and methods of shipping such extended width containers. Other aspects of embodiments of the present invention include shipping containers having widths of between 8½ feet (2.59 m) and 10 feet (3.05 m), such widths having special applications as storage containers after they have been used to ship goods or other containers. Other aspects of embodiments of the present invention include providing extended width shipping containers having a height of 8 feet (2.44 m) so that the containers can be turned 90 degrees on their sides to be shipped in a standard 8-foot (2.44 m) wide container cell. Still another aspect of embodiments of the present invention includes adding corner posts to top and bottom edges of ends of extended width shipping containers so that extended width shipping containers can be stacked on top of each other within standard 8-foot (2.44 m) wide container cells. 
         [0007]    A shipping container according to an embodiment of the present invention includes: a roof; a base opposite the roof; a front end connecting the roof to the base; a back end opposite the front end, the back end connecting the roof to the base; two spaced apart side panels substantially perpendicular to and connecting the roof to the base and substantially perpendicular to and connecting the front end to the back end; and at least one door rotatable about at least one door rotation axis substantially perpendicular to the roof and the base, the at least one door coupled to the back end. The shipping container also includes two pairs of end rails, each of the end rails connected to one of the ends and one of the two side panels and having a length in a direction substantially perpendicular to the roof and the base, and two pairs of corner posts, each of the corner posts connected to one of the ends and one of the group consisting of the roof and the base, and each of the corner posts having a length in a direction substantially perpendicular to the two side panels and the at least one door rotation axis. Each of the end rails is configured to support an end rail compressive load applied to the end rail in a direction substantially parallel to the direction of the length of the end rail, the end rail compressive load equal to any load less than an end rail failure load. Each of the corner posts is configured to support a corner post compressive load applied to the corner post in a direction substantially parallel to the direction of the length of the corner post, the corner post compressive load equal to any load less than a corner post failure load. The corner post failure load is greater than the end rail failure load. 
         [0008]    In another embodiment of the invention, a shipping container includes: two side panels opposite each other, each of the two side panels having a height of approximately 8 feet (2.44 m); a base between approximately 8½ feet (2.59 m) and 10 feet (3.05 m) wide and substantially perpendicular to and connecting the two side panels, the base comprising a plurality of cross members and a floor supported by the plurality of cross members, the base configured to support a cargo load greater than can be supported by the two side panels; two pairs of end rails, each of the end rails having a length in a direction substantially perpendicular to the base; and two pairs of corner posts, each of the corner posts having a length in a direction substantially perpendicular to the two side panels. Each of the end rails is configured to support an end rail compressive load applied to the end rail in a direction substantially parallel to the direction of the length of the end rail, the end rail compressive load equal to any load less than an end rail failure load. Each of the corner posts is configured to support a corner post compressive load applied to the corner post in a direction substantially parallel to the direction of the length of the corner post, the corner post compressive load equal to any load less than a corner post failure load. The corner post failure load is greater than the end rail failure load. 
         [0009]    In another embodiment of the invention, a method of shipping a shipping container having a height of approximately 8 feet (2.44 m), a width between approximately 8½ feet (2.59 m) and approximately 10 feet (3.05 m), a length in a direction of a length axis, at least one door, a storage orientation wherein the at least one door is rotatable about a vertical axis, and a shipping orientation wherein the at least one door is rotatable about a horizontal axis includes: removing the shipping container from a container cell of a ship, the container cell having a width of approximately 8 feet (2.44 m), and the shipping container having been in the container cell in the shipping orientation; and rotating the shipping container approximately ninety degrees about the length axis from the shipping orientation to the storage orientation. 
         [0010]    In one embodiment, a method of shipping a shipping container further includes: placing the shipping container in the container cell of the ship in the shipping orientation; and shipping the shipping container. 
         [0011]    In one embodiment, a method of shipping a shipping container further includes rotating the shipping container approximately ninety degrees about the length axis from the storage orientation to the shipping orientation before placing the shipping container in the container cell of the ship. 
         [0012]    In one embodiment, a method of shipping a shipping container further includes loading the shipping container with cargo before shipping the shipping container. 
         [0013]    In one embodiment, a method of shipping a shipping container further includes unloading at least some of the cargo from the shipping container after shipping the shipping container. 
         [0014]    In one embodiment, a method of shipping a shipping container further includes stacking the shipping container on another shipping container. 
         [0015]    In one embodiment, a method of shipping a shipping container further includes transporting the shipping container over land. 
         [0016]    In one embodiment, a method of shipping a shipping container further includes utilizing the shipping container for storage of goods after rotating the shipping container from the shipping orientation to the storage orientation. 
         [0017]    In one embodiment, a method of shipping a shipping container further includes renting the shipping container for shipping a load of cargo. 
         [0018]    In one embodiment, a method of shipping a shipping container further includes selling and delivering the shipping container after shipping the shipping container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where: 
           [0020]      FIG. 1  is a side perspective view of a shipping container according to an embodiment of the present invention; 
           [0021]      FIG. 2  is an end view of the back end of the shipping container of  FIG. 1 ; 
           [0022]      FIG. 3  is an end view of the front end of the shipping container of  FIG. 1 ; 
           [0023]      FIG. 4  is an end view of three stacked shipping containers according to an embodiment of the present invention; and 
           [0024]      FIG. 5  is a flow diagram of a method of shipping an extended width shipping container according to aspects of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    In the following detailed description, certain exemplary embodiments of the present invention are shown and described, by way of illustration. As those skilled in the art would recognize, the described exemplary embodiments may be modified in various ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, rather than restrictive. 
         [0026]    With reference to  FIGS. 1-3 , a shipping container  100  for the transport or storage of goods includes a roof  102  extending in a first direction along a length  116  of the shipping container  100  and extending in a second direction along a width  112  of the shipping container  100 . The shipping container also has a base  104  opposite and substantially parallel to the roof  102 . The base  104  also extends in a first direction along the length  116  of the shipping container  100  and in a second direction along the width  112  of the shipping container  100 . The base  104  is configured to support goods transported or stored in the shipping container  100 . The shipping container  100  also has a front end  106  connecting the roof  102  to the base  104 , the front end  106  extending along the width  112  of the shipping container  100  and along a height  114  of the shipping container  100 . A back end  108  of the shipping container  100  connects the roof  102  to the base  104  and is opposite the front end  106 . The back end  108  also extends along the width  112  of the shipping container  100  and along the height  114  of the shipping container  100 . The shipping container  100  also has two side panels  110  spaced apart from each other and substantially parallel. The two side panels  110  connect the roof  102  to the base  104  and are substantially perpendicular to each of the roof  102  and the base  104 . Each of the two side panels  110  also connect the front end  106  to the back end  108 . The side panels  110  extend along the length  116  of the shipping container  100  and along the height  114  of the shipping container  100 . 
         [0027]    In the present embodiment, the width  112  of the shipping container  100  is between approximately 8½ feet (2.59 m) and approximately 10 feet (3.05 m). The height  114  of the shipping container  100  is approximately 8 feet (2.44 m). Also, in preferred embodiments, the length  116  of the shipping container  100  is approximately 20 feet (6.10 m) or approximately 40 feet (12.19 m). In alternative embodiments, the width  112  and the length  116  of the shipping container  100  may be varied according to the storage requirements of the shipping container  100 . 
         [0028]    The roof  102 , front end  106 , and side panels  110  of the shipping container  100  are panels and may be formed from an anti-corrosive steel or other suitable material. The panels of the roof  102 , front end  106 , and side panels  110  may have a thickness of 2.0 mm, 1.6 mm, or any other suitable thickness. In the present embodiment, the panels of the roof  102 , front end  106 , and side panels  110  are corrugated in order to provide structural rigidity to the shipping container  100 . 
         [0029]    The shipping container  100  includes top side rails  117  and bottom side rails  119  extending horizontally along the length of the shipping container  100 . The roof  102  of the shipping container  100  extends between the top side rails  117 , and the base  104  of the shipping container  100  extends between the bottom side rails  119 . The top and bottom side rails  117 ,  119  are made of an anti-corrosive steel or other suitable material and may be formed from square or rectangular tubing or any other structural form providing suitable strength and support. The panels of the roof  102  and side panels  110  of the shipping container are welded to the top and bottom side rails  117 ,  119 . 
         [0030]    The base  104  of the shipping container  100  includes cross members placed laterally along a bottom surface of the shipping container  100  at predetermined intervals to provide structural support to the shipping container  100  and to provide an offset between a surface on which the shipping container  100  rests and an inside area of the shipping container  100 . Such an offset allows contents of the shipping container  100  to remain dry should moisture collect around the bottom surface of the shipping container  100 . The cross members are welded to each of the bottom side rails  119 . The base  104  also includes a floor extending between the bottom side rails  119 . The floor may be formed of hardwood plywood, for example. The cross members are secured to a bottom surface of the floor by fasteners or another suitable technique or device. The base  104 , according to an embodiment of the present invention, may be as described in U.S. Publication No. 2007/0138173. 
         [0031]    The shipping container  100  includes two pairs of corner posts  120  designed to bear the load of the shipping container  100 , particularly as shipping containers  100  are stacked one on top of another in a container cell of a ship or on a loading dock. The corner posts  120  have high strength and may be formed from rolled high tensile steel, for example. Each of the corner posts  120  has a length in a direction substantially perpendicular to the two side panels  110  of the shipping container  100 , the length being approximately equal to the width  112  of the shipping container  100 . Such a configuration, as shown in  FIGS. 1-4 , allows the corner posts  120  to provide maximum strength when the shipping container  100  is stacked on one of its side panels  110  (see  FIG. 4 ). In the embodiment shown in  FIGS. 1-4 , one of the first pair of corner posts  120  is connected to the front end  106  and the roof  102 ; one of the first pair of corner posts  120  is connected to the front end  106  and the base  104 ; one of the second pair of corner posts  120  is connected to the back end  108  and the roof  102 ; and one of the second pair of corner posts  120  is connected to the back end  108  and the base  104 . The corner posts  120  are connected to the various panels as described above by welding. 
         [0032]    The shipping container  100  also includes two pairs of end rails  124  extending vertically along the height of the shipping container  100 , such that each of the end rails  124  has a length in a direction substantially perpendicular to each of the roof  102  and the base  104  of the shipping container  100 . The end rails  124  are made of an anti-corrosive steel or other suitable material and may be formed from square or rectangular tubing or any other structural shape providing suitable strength and support. In the embodiment shown in  FIGS. 1-4 , one of the first pair of end rails  124  is connected to the front end  106  and one of the two side panels  110 ; one of the first pair of end rails  124  is connected to the front end  106  and the other of the two side panels  110 ; one of the second pair of end rails  124  is connected to the back end  108  and one of the two side panels  110 ; and one of the second pair of end rails  124  is connected to the back end  108  and the other of the two side rails  110 . The end rails  124  are connected to the various panels as described above by welding. 
         [0033]    Each of the end rails  124  is configured to support a compressive load applied to the end rail  124  in a direction substantially parallel to the direction of the length of the end rail  124 . Also, each of the corner posts  120  is configured to support a compressive load applied to the corner post  120  in a direction substantially parallel to the direction of the length of the corner post  120 , such as a load that is applied to each of the corner posts  120  when another shipping container is stacked on one of the side panels  110  of the shipping container  100 . In present embodiments of the invention, the geometries and materials of construction of the corner posts  120  and the end rails  124  are such that the end rails  124  will fail under a compressive load less than the least compressive load under which the corner posts  120  will fail. 
         [0034]    The corner posts  120  also provide structural support for lifters or a crane, which grasp the shipping container  100  at corner fittings  130  and the corner posts  120  to stack and/or transport individual shipping containers  100  at a loading dock or on a ship, as is known in the art. Corner fittings  130  are located at ends of the corner posts  120 . The corner fittings  130  include openings  132  for engagement by the lifters or crane. The corner fittings  130  are formed of casted weldable steel, for example. The corner posts  120  and the top and bottom side rails  117 ,  119  are welded to the corner fittings  130 . 
         [0035]    The shipping container  100  also has at least one door  140  providing access to an inside area of the shipping container  100 . In the present embodiment, the shipping container  100  includes two hinged doors  140  located at the back end  108  of the shipping container  100 . Alternative embodiments may include at least one door  140  located at the front end  106  of the shipping container  100 , replacing the panel of the front end  106  described above, as opposed to, or in addition to, the at least one door  140  located at the back end  108 . For example, one embodiment of a shipping container  100  may include two hinged doors  140  located at the back end  108  and two hinged doors  140  located at the front end  106  of the shipping container  100 . The doors  140  are rotatable about axes substantially perpendicular to the roof  102  and the base  104  of the shipping container  100  and also substantially perpendicular to the direction of the lengths of the corner posts  120 . 
         [0036]    The shipping container  100  may also include door support posts  142 , each door support post  142  supporting one of the hinged doors  140  and having a length in a direction substantially perpendicular to the roof  102  and the base  104  of the shipping container  100 . The length of each door support post  142  is approximately equal to the height  114  of the shipping container  100 . Each of the door support posts  142  may be connected to one of the side panels  110 , either the back end  108  or front end  106 , and/or one of the end rails  124  of the shipping container  100 . Alternatively, the door support posts  142  may be combined with the end rails  124  into unitary structural members. In addition to supporting the doors  140 , the door support posts  142  provide strength and structural rigidity to the shipping container  100 . The door support posts  142  may be formed from a rectangular bar, for example, or other suitable structural shape. In the present embodiment, each of the two hinged doors  140  is connected to one of the door support posts  142  by at least one hinge  144 . The doors  140 , the door support posts  142 , and the hinges  144  may be formed from an anti-corrosive steel or other suitable material, and may be connected as described above by welding. 
         [0037]    The shipping container  100  may also include forklift pockets  160 . The shipping container  100  may be lifted using the forklift pockets  160  located along a lower edge of the shipping container  100 , near a surface on which the shipping container  100  rests. The forklift pockets  160  extend laterally along the base  104  of the shipping container  100 , and are spaced along the length of the shipping container  100  to allow for engagement with a forklift, which lifts the shipping container  100  as known in the art. In the area of the forklift pockets  160 , openings are cut in the bottom side rails  119  through which prongs of a forklift may pass into the forklift pockets  160 . 
         [0038]      FIG. 4  shows three shipping containers  100  according to an embodiment of the present invention stacked one upon another, as the shipping containers  100  would be positioned in a container cell of a ship during transport, or as they may be stored at a loading dock or other storage area. The shipping containers  100  are stacked on one of their side panels  110 . Because the orientation of the corner posts  120 , as described above, is such that the direction of the lengths of the corner posts  120  is perpendicular to the side panels  110  of the shipping containers  100 , the compressive load of the stacked shipping containers  100  is applied in a direction substantially parallel to the lengths of the corner posts, and is thereby supported by the corner posts  120 . 
         [0039]    With reference to  FIG. 5 , a flow diagram of a method  500  for shipping extended width shipping containers is shown. In task  510 , a shipping container having a height of approximately 8 feet (2.44 m) and a width between approximately 8½ feet (2.59 m) and approximately 10 feet (3.05 m) is loaded with cargo in the inside area of the shipping container such that the cargo is supported by a floor of the shipping container. The shipping container has at least one door that is rotatable about a vertical axis while the floor of the shipping container is parallel to and nearest the ground. In such an orientation, the shipping container is in a storage orientation. The cargo may be any goods or items desired to be shipped, including other containers. The cargo may be loaded manually, by forklift, by crane, by conveyor belt, or by any other technique, or combination thereof, suitable for loading cargo into a shipping container. 
         [0040]    Task  520  includes rotating the shipping container on its side so that in the rotated orientation, the shipping container is approximately 8 feet (2.44 m) wide and stands between approximately 8½ feet (2.59 m) and approximately 10 feet (3.05 m) high. Additionally, in the rotated orientation, or shipping orientation, one of the shipping container&#39;s side panels is facing downward, and the floor of the shipping container is in a vertical orientation. Also, the at least one door of the shipping container is rotatable about a horizontal axis. The shipping container may be rotated by any suitable technique. Alternatively, task  520  may be performed prior to task  510 . 
         [0041]    In task  530 , the shipping container is placed in a container cell of a ship in a shipping orientation, the container cell having a width of approximately 8 feet (2.44 m). Task  530  may further include stacking the shipping container on another shipping container already in the container cell, and/or subsequently stacking at least one additional shipping container on top of the placed shipping container. The shipping container may be placed in the container cell of the ship by using a forklift, crane, lifters, or any other suitable device or combination thereof. 
         [0042]    In task  540 , the shipping container is shipped over a body of water with the cargo loaded therein. The shipping container remains in the shipping orientation while being shipped. 
         [0043]    In task  550 , the shipping container is removed from the container cell of the ship. The shipping container may be removed from the container cell of the ship by using a forklift, crane, lifters, or any other suitable device or combination thereof. 
         [0044]    In task  560 , the shipping container is rotated back to the storage orientation so that the floor is on the bottom, the shipping container is between approximately 8½ feet (2.59 m) and approximately 10 feet (3.05 m) wide and approximately 8 feet (2.44 m) high, and the at least one door is rotatable about a vertical axis. The shipping container may be rotated by any suitable technique. 
         [0045]    Task  570  includes unloading at least some of the cargo from the shipping container upon arrival at a shipping destination. The cargo may be unloaded manually, by forklift, by crane, by conveyor belt, or by any other technique, or combination thereof, suitable for unloading cargo from a shipping container. Alternatively, task  570  may be performed prior to task  560 . 
         [0046]    In task  580 , the shipping container may be transported over land, such as by truck and/or railway, to another destination after having reached a shipping destination by sea. Transporting a shipping container by truck and/or railway according to task  580  may also be performed before the shipping container is shipped by sea. Alternatively, task  580  may be performed prior to task  560  and/or task  570 . 
         [0047]    In task  590 , the shipping container may be utilized for storage of goods after the shipping container has been shipped to a shipping destination. The goods stored may be the same goods that were loaded into the container before shipping if task  570  is omitted. While used for storage of goods, the shipping container is in its storage orientation. 
         [0048]    The present invention may be used according to an advantageous financing model. The shipping container  100  may be constructed at a shipping origin. The shipping container  100  may be used to ship cargo across seas from the shipping origin to a shipping destination. The shipping container  100  may be rented to a shipping company, which then uses the shipping container  100  for shipping cargo from the shipping origin to the shipping destination. The shipping container  100  may be sold to a third party, preferably at the shipping destination, for use in shipping across sea or land, or sold as a container for the storage of goods, as would most likely be the case for extended width shipping containers  100 , as described above. In this manner, the manufacturer or seller of shipping containers  100  can transfer shipping containers  100  from the shipping origin to the shipping destination without having to pay shipping costs associated with transporting the shipping containers  100  as cargo. One-way rental of the shipping containers  100  also precludes the necessity of having to pay the costs associated with returning the shipping containers  100  to the shipping origin. 
         [0049]    Although the present invention has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. For example, the corner posts  120  or forklift pockets  160  may have other configurations or structures. Also, as another example, the tasks of the method  500  for shipping an extended width shipping container may be performed in a different order than the one described above and shown in  FIG. 5 . Furthermore, some of the tasks of the method  500  for shipping an extended width container may be omitted, or additional tasks not described above may be included, without departing from the invention. 
         [0050]    It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present embodiments of the invention should be considered in all respects as illustrative and not restrictive, the scope of the invention to be determined by the claims supported by this application and the claims&#39; equivalents.