Abstract:
An improved power generation container providing improved access and installation and removable of components by using modular components. A self bailing and self-aligning exhaust system is further provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application is a continuation-in-part application of U.S. patent application Ser. No. 14/277,044, filed on May 13, 2014, which claims priority and benefit of U.S. provisional patent application having application No. 61/822,911, filed on May 13, 2013, and entitled “Power Generation Container Improvements.” All of the patent applications referenced immediately above in this paragraph are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to mobile containers for housing power generation machinery or stations, and more particularly, to semi-tractor trailer containers incorporating improvements for housing and accommodating power generation machinery. 
         [0004]    2. Description of Related Art 
         [0005]    Mobile power generation systems capable of delivering megawatts of power are known to offer certain advantages compared to power delivered from an electrical utility power distribution grid. Mobile power generation systems can provide power as needed at times of peak demand or during brownout in a distribution grid, or during an emergency caused by a failure in the distribution grid. A mobile power generation system can be located at places distant from a distribution network where there is need for power, thus minimizing any delay or the need or expense for constructing power lines to distant or remote places. 
         [0006]    The conventional method of transporting a mobile power station is to mount an industrial electric generator to the floor within a trailer or a stackable shipping container which is placed on a semi tractor trailer. Power generators are conventionally secured to the floor of a shipping container or semi trailer by aligning mounting holes of the generator to corresponding mounting apertures on the floor of the shipping container or semi trailer. Given the size and weight of industrial generating equipment, it can be very difficult to align mounting holes of the generating equipment with the mounting apertures in the floor. Furthermore, the mounting holes of generating equipment do not always align perfectly with the mounting apertures on the trailer floor, thus further complicating the mounting process. Additionally, the substantial weight of industrial equipment requires the floors mounting such equipment to be structurally reinforced to support such weight. Industrial generating equipment also can have some spillage of oil, fuel, coolant, and other fluids. When these fluids escape from the generating equipment, the fluids simply spill onto the floor, creating dangerous conditions for operators and maintenance personnel. U.S. Pat. No. 9,051,011, which is hereby incorporated by reference, discloses improvements for mounting industrial equipment to the floors of shipping containers or semi-tractor trailers. 
         [0007]    In addition to the need for improved floor mounting systems in such power generation containers, there also are needed improvements in facilitating access to the power generating machinery inside the containers, container exhaust systems, and mounting fixtures on the containers. 
       ASPECTS AND SUMMARY OF THE PRESENT INVENTION 
       [0008]    One aspect of the present invention is to facilitate and provide greater access to power generation machinery inside power generation containers. 
         [0009]    Another aspect of the present invention is to provide improved mounting fixtures for power generation containers that can be more easily painted, cleaned, and modified. 
         [0010]    A further aspect of the present invention is to provide improved exhaust and ventilation systems for power generation containers. 
         [0011]    An additional aspect of the present invention is to provide easy access ladders for maintenance on the roof of power generation containers. 
         [0012]    In order to achieve the above aspects and more, the present invention provides an improved power generation container providing improved access and installation and removable of internal machinery by using modular components. A self bailing and self-aligning exhaust system is further provided. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of a self-bailing door frame configured in accordance with the present invention; 
           [0014]      FIG. 1 a    is a perspective view of an estop receptacle configured in accordance with the present invention and mounted on the self-baling door frame of  FIG. 1 ; 
           [0015]      FIG. 1 b    is a perspective view of an estop blank plate configured in accordance with the present invention and mounted on the self-bailing door frame of  FIG. 1 ; 
           [0016]      FIG. 1 c    is a perspective view of a removable center post configured in accordance with the present invention for the self-bailing door frame shown in  FIG. 1 . 
           [0017]      FIG. 1 d    is an enlarged view of the self-bailing door frame shown in  FIG. 1 ; 
           [0018]      FIG. 1 e    is another perspective view of the self-bailing door frame shown in  FIG. 1 ; 
           [0019]      FIG. 1 f    is an enlarged view of the removable center post shown in  FIG. 1   c;    
           [0020]      FIG. 1 g    is an enlarged view of the estop receptacle shown in  FIG. 1   a;    
           [0021]      FIG. 1 h    is an enlarged view of the estop receptacle shown in  FIGS. 1 a  and 1 g   , wherein a cover plate is included over the estop receptacle; 
           [0022]      FIG. 1 i    is an exploded view of the estop receptacle and cover plate shown in  FIG. 1   h;    
           [0023]      FIG. 1 j    is an enlarged view of the estop blank plate shown in  FIG. 1   b;    
           [0024]      FIG. 1 k    is an enlarged view of the estop blank plate shown in  FIGS. 1 b    and  1   j;    
           [0025]      FIG. 1L  is an enlarged rear view of the removable center post shown in  FIGS. 1 c    and  1   f;    
           [0026]      FIG. 1 m    is an enlarged view of the bottom of an end of the removable center post shown in  FIG. 1L ; 
           [0027]      FIG. 2  is a perspective view of a dual door assembly configured in accordance with the present invention; 
           [0028]      FIG. 2 a    is a perspective view of a door latch configured in accordance with the present invention; 
           [0029]      FIG. 2 b    is an enlarged view of the dual doors shown in  FIG. 2 ; 
           [0030]      FIG. 2 c    is an enlarged view of one of the duel doors shown in  FIGS. 2 and 2   b;    
           [0031]      FIG. 2 d    is an enlarged view of the door latch shown in  FIG. 2   c;    
           [0032]      FIG. 2 e    is an exploded rear view of the door latch shown in  FIG. 2   d;    
           [0033]      FIG. 3  is a perspective view of a self-bailing roof exhaust system configured in accordance with the present invention; 
           [0034]      FIG. 3 a    is an exploded view of the self-bailing roof exhaust system shown in  FIG. 3 ; 
           [0035]      FIG. 3 b    is a perspective view of the heat sink shown in  FIG. 3 ; 
           [0036]      FIG. 3 c    is a perspective view of the non-heat conductive ring shown in  FIG. 3 ; 
           [0037]      FIG. 3 d    is a perspective view of the exhaust adapter assembly shown in  FIG. 3 ; 
           [0038]      FIG. 3 e    is a perspective view of the flange clamp shown in  FIG. 3 ; 
           [0039]      FIG. 3 f    is an exploded view of the exhaust adapter assembly shown in  FIG. 3  including exhaust bellows; 
           [0040]      FIG. 3 g    are additional views of the self-bailing roof exhaust system shown in  FIG. 3  including the lower exhaust bellow; 
           [0041]      FIG. 4  is a perspective view of a storable ladder configured in accordance with the present invention; 
           [0042]      FIG. 4 a    is a perspective view of the ladder shown in  FIG. 4 ; 
           [0043]      FIG. 4 b    is a perspective view of the ladder receptacle shown in  FIG. 4 ; 
           [0044]      FIG. 4 c    is an enlarged perspective view of the folding bar shown in  FIG. 4 ; 
           [0045]      FIG. 5  is a perspective view of a removable front wall of a power generation container configured in accordance with the present invention; 
           [0046]      FIG. 5 a    is a perspective view of the end frame shown in  FIG. 5 ; 
           [0047]      FIG. 5 b    is an enlarged view of the removable air intake louver shown in  FIG. 5 ; 
           [0048]      FIG. 5 c    is an enlarged view of the front wall shown in  FIG. 5 ; 
           [0049]      FIG. 5 d    is an exploded view of a ventilation system configured in accordance with the present invention; 
           [0050]      FIG. 5 e    is an enlarged view of the radiator section of the power generation container shown in  FIG. 5 d   , wherein the radiator panels and roof ventilation have been removed; 
           [0051]      FIG. 5 f    is an enlarged view of the removable frame of the roof of the radiator section of the power generation container shown in  FIG. 5   d;    
           [0052]      FIG. 5 g    is an enlarged view of the air discharge screen supported by the removable from on the roof of the radiator section of the power generations container; and 
           [0053]      FIG. 5 h    shows exploded views of the ventilation system shown in  FIG. 5   d.    
       
    
    
       [0054]    The foregoing has outlined, rather broadly, the preferred features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed invention and specific embodiments as a basis for designing or modifying other structures for carrying out the same purposes of the present invention, and that such other structures do not depart from the spirit and scope of the invention in its broadest form. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0055]    Referring now to the drawings,  FIG. 1  illustrates a door frame  10  for a self-bailing door assembly to be located on the side of a power generation container, such as a semi-tractor trailer. Self bailing refers to the ability to directly receive or accumulate rain water without it entering the power generation container. The self-bailing achieved by specific gravity, all components fit from under another component with the bottom being sealed and self-draining the exterior. The frame  10  includes an outer rim or outer panel  12  that preferably are weld together at the corners  13  to form a rectangular configuration. The frame  10  houses and mounts the dual door assembler  14  shown in  FIG. 2 . A removable center post  16  shown in  FIG. 1 c    is secured within the frame  10  by fitting one end of the post  16  within a slot  18  in the top of the frame  10 , and the other end of the post  16  in a notch  20  in the base or bottom of the frame  10 . The frame  10  preferably is constructed of a metal, such as steel. 
         [0056]      FIG. 1 a    illustrates an estop receptacle  22  mounted to the outer rim  12  of the frame  10 . The estop receptacle  22  houses components for an emergency stop button for a power generation system to be contained within the power generation container. 
         [0057]      FIG. 1 b    illustrates a flat blank plate  24  for covering an unused port or aperture for mounting an estop receptacle  22 . The blank plate  24  preferably is constructed of metal and can be easily removed or replaced for adding or removing an estop receptacle  22 . 
         [0058]    In accordance with the present invention, the estop receptacle  22  can be easily added or removed from estop ports or apertures  37 . Moreover, the estop receptacle  22  can be pre-wired and installed on any outer surface of a container by simply making an aperture in the container for the wiring to pass through, and the bolting or welding the estop receptacle to the outer surface of the container. This feature of the present invention enables estop receptacles to be easily added to desired upper locations when a container is on the ground, or located in a lower location when a container is located at a higher location, such as when on a semi-trailer, or at multiple estops at multiple locations. A blank plate  24  can easily cover an unused estop port  21 . By enabling estop receptacles  22  to be easily removed and repositioned to a preferred located, this reduces the cost of having to provide multiple estop receptacles  22  for various potential locations. 
         [0059]    Additionally, enabling the estop receptacle to be added or removed allows the estop receptacle to be easily painted and cleaned, thus preventing rust and dirt built up. The numeral intricate structures and fixtures located within the estop receptacle make it very difficult to paint and clean when mounted, this leading to rust and corrosion. By enabling the estop receptacle  22  to be painted completely before being mounted by submerging in it in paint, enables the estop receptacle to be completely covered by paint and thoroughly protected from rust and corrosion. Moreover, the estop receptacle  22  can be removed for easy cleaning or repainted if needed. It the estop receptacle was welded to the container wall, as is conventionally, done such thorough cleaning or painting would not be possible. 
         [0060]      FIG. 2  illustrates a dual door assembly  14  configured in accordance with the present invention for mounting within a door opening of a power generation container. 
         [0061]      FIG. 2 a    is an enlarged view of the door latch configured in accordance with the invention shown in  FIG. 2 . 
         [0062]      FIG. 1 d    is an enlarged view of the frame  10  shown in  FIG. 1 . In addition to the rim or outer frame  12 , illustrated are the upper slot  18 , preferably formed by a curved U-bar mounted to any inner frame or rim  27 , and the notice  20  formed between two bars or rods  17 . Screw holes  23  are located within the end of the bars  17  for securing the bottom end  19  of the removable post  16  within the notch  20 . A spacer wall  11  is located between and perpendicular to the inner rim  27  and the outer rim  12 . Mounting holes  25  are located within the outer rim  12  for securing the frame  10  within an opening in the side of a power generation container.  FIG. 1 e    provides another perspective view of the frame  10 . 
         [0063]      FIG. 2 b    illustrates the dual door assembly  14 , and  FIG. 1 f    illustrates the removable center post  16  which is located between the doors  31  and  33 . The dual door assembly  14  including the removable post  16  are to be located within an opening in the side of a power generation container in order provide easy access to the power generation machinery contained inside. The doors  31 , 33  each include a door latch  30  and mounting hinges  32 , On the opening side of the door are included door latches  34 . 
         [0064]      FIG. 1 g    illustrates an enlarged view of the estop receptacle  22  bolted to the rim  12  of the frame  10  shown in  FIG. 1 . 
         [0065]      FIG. 1 h    is a detailed view of the estop receptacle  22  including a cover plate  36  bolted to the rim  12  of the frame  10  shown in  FIG. 1 . The  152  E-Stop outside body (top) receives  154  E-Stop mounting plate and  155  front cover mounting plate and are aligned by means of slot and tang construction with  152  E-Stop outside body (bottom) clamping them by means of  158  E-Stop mounting bolts,  160  E-Stop Mounting washers and  162  E-Stop mounting nuts.  152  E-Stop outside body is connected to  150  Mounting frame Stud and  160  E-Stop Mounting washers and  162  E-Stop mounting nuts.  156  front cover is mounted to  155  by means of  157  front cover mounting bolts. The pre wired E-Stop Switch is mounted to  154 E-Stop mounting plate by means of  157  front cover bolts in  172  riv-nuts.  164  Rear electrical cover with be mounted to  152  by means of  166  Rear electrical cover bolts and  168  Rear electrical cover washers through  170  Rear electrical cover mounting holes into  152  E-Stop outside body by means of  172  riv-nuts. 
         [0066]      FIG. 1 i    is an exploded view of the estop receptacle  22  and cover plate  36  mounted to the rim  12  of the frame  10 . An aperture  37  in the rim  12  of the frame  10  is shown for receiving wiring from electrical components to be mounted within the estop receptacle  22 . The estop receptacle is modularly constructed of symmetrical parts, so that they can easily be replaced and minimize cost by using minimal similar parts. 
         [0067]      FIG. 1 j    is an enlarge view of the blank plate  24  covering an unused estop mounting aperture  37  on the outer rim  12  of the frame  10 . Bolts  21  mount blank plate  24  to the outing rim  12  of the frame  10 . 
         [0068]      FIG. 1 k    is an enlarged view of the black plate  24  shown in  FIGS. 1 b    and  1   j.  Bolts  21 , nuts  37 , and washers  39  are shown securing the blank plate  24  to the outer rim  12 . 
         [0069]      FIG. 1L  is an enlarged view of the removable center post  16  shown in  FIG. 1 c   . Edges  40  are formed in the front  41  of removable center post  16  for receiving the corner edges of the doors  31 , 33  when is the closed position. Apertures  42  are located in the sides of both the top end  44  and the bottom end  19  of the post  16  for securing the post  16  into a secured position within the frame  10 . 
         [0070]      FIG. 1 m    is an enlarged view of the rear  45  and bottom end  19  of the removable center post  16 . The top end  44  and the bottom end  19  of the post are identical, so it does not matter which end is first inserted into the slot  18  of the frame  10  when securing the post  16  in place. Also illustrated are the other side of the edges  40 . Nuts or bolts  43  are shown for securing the bottom end  19  of the post  16  within the notch  20  of the frame  10  when mounting the post  16  in place. 
         [0071]      FIG. 2 c    is an enlarged view of door  33  shown in  FIG. 2 b   . Illustrated are the hinges  32 , door latch handle  30 , and release latches  34 .  FIG. 2 d    is an enlarged view of the door latch  30  shown in  FIG. 2   c.    
         [0072]      FIG. 2 e    is an exploded rear view of the door latch  30  shown in  FIG. 2 d   . The outside handle  101  is mounted to the lockable outside handle base  102  and to the door  33  by mounting bolts  36  and outside mounting nuts  37 . The symmetrical door rod assembly  103  is mounted to the door  33  by the symmetrical control with safety escape handle mounting screws  39 . The handle  101  rotates the square shaft  35  through the lockable outside handle base  102 , the boomerang clocking mechanism  38 , the symmetrical door rod control with safety escape handle  104 , the safety handle  105 , the normal control rod actuator  108 , while rotating the inside door handle  107 . The rotation of said square shaft is clocked by boomerang clocking mechanism  38  about the single mounting bolt  36 , and this clocking can be reversed by flipping the boomerang clocking mechanism  38  because it has reversed geometry. The square shaft  35  rotates the normal door rod control  108  to engage perpendicular actuator pins  110  that move the door rod actuators  106  to unlatch the door release latches  34 . The safety escape handle  105  can rotate independently of said square shaft  35  to engage perpendicular actuator pins  110  in the symmetrical door rod control with safety escape handle  104  that moves the door rod actuators  106  to unlatch the door latches  34  in the event that the door  33  becomes locked from the outside. The safety escape handle  105  can still open the door  33  from the inside. Additionally, the reverse geometry design of the components shown in  FIG. 2 e    of the latch  30  enable this design to work on either a left or right opening door, simply by reversing the components of the latch  30   
         [0073]      FIG. 3  is a perspective view of an exhaust adapter assembly  50  configured in accordance with the present invention. The exhaust adapter assembly  50  is designed to be located on the roof or top of a power generation container housing power generation machinery. Illustrated is a metal pan  52  including an integral drain  54 . The sides  53  of the pan  52  prevent water on the roof of the power generation container from flowing into the base area  54  of the exhaust adapter assembly  50 . The drain  55  enables rain water failing into the base area  54  to flow off the base area  54 . Thus, this design prevents rain water surrounding the exhaust from flowing into the exhaust  51 . 
         [0074]      FIG. 3 a    is an exploded view of the exhaust adapter assembly  50  illustrated in  FIG. 3 . Illustrated are fastening bolts  57 , rotatable split flange clamp  58 , exhaust adapter assembly  56 , heat seat member  59 , mounting member  61 , and mounting bolts  62 . In accordance with the present invention, the exhaust adapter assembly  56  mounts to the heat sink member  59 , which is then mounted to the mounting member  61 . The rotatable split flange clamp  58  mounts to exhaust bellows  120  ( FIG. 3 f   ), and the rim  60  of the exhaust adapter assembly  56  fits inside the inner rim and ledge  65  of the rotatable split flange clamp  58 , thus enabling the exhaust bellows  120  to rotate freely and adjust by rotating the rotatable split flange clamp  58  relative to the exhaust adapter assembly  56  and its upper rim  60 . 
         [0075]      FIG. 3 b    illustrates the exhaust adapter assembly of  FIG. 3  with only the pan  52  and mounting member  61  illustrated. 
         [0076]      FIG. 3 c    is an enlarged view of the heat sink member  61 . The heat sink member  61  preferably is a glass fiber gasket made by good quality high temperature resistant and high strength glass fiber cloth, coating with Nonmetal rubber or fluorine. Through a special process pressing and cutting, the heat sink member is high temperature resistant, thermal insulated, fireproofed, corrosion resistance, ageing resistance, and has a high strength and smooth appearance. 
         [0077]      FIG. 3 d    is an enlarged view of the exhaust adapter assembly  56 . Included in the exhaust adapter assembly are mounting holes  121  and an upper rim  60  configured to rotate freely inside the rotatable split flange clamp  58  mounted to the exhaust bellows  120 . The lower rim  122  is bolted to the heat sink member  61  and then the mounting member  61 . The mounting member  61  is a metal gasket welded to the base  54  of the pan  52  of the exhaust adapter assembly  50 . 
         [0078]      FIG. 3 e    is an enlarged bottom view of the rotatable flange clamp  58  shown in  FIG. 3 . Also shown are mounting holes  123  for bolting the rotatable flange to the exhaust bellows  120 . 
         [0079]      FIG. 4  illustrates a storable foldable ladder assembly  70  configured in accordance with the present invention. Illustrated are the straight ladder  72  located within a receptacle  74 . The receptacle  74  is to be mounted to the outer side of a power generation container. The ladder  72  is mounted to the receptacle  74  by rotatable bars  75  that each are pivotally mounted to the ladder  72  and the receptacle  74 . The ladder  72  is rigid and includes rungs  71  between the sides  73  of the ladder  72 . Clasps  76  hold the ladder  72  in place within the receptacle  74  is the closed position. 
         [0080]      FIG. 4 a    illustrates the ladder  72 . Apertures  77  located near the top and bottom on the sides  73  of the ladder  72  are used for bolts  78  to pivotally mount the ladder  72  via the bars  75  to the receptacle  74 .  FIG. 4 b    illustrates the receptacle  74  containing pivotally mounting bracket  80  having apertures  81  for pivotally mounting the bars  75  using bolts  78 .  FIG. 4 c    illustrates the pivoting bar  75  shown in  FIG. 4  for rotatably mounting the ladder  72 . The bar  75  includes pivotally mounting holes  82 , 83  for pivotally mounting the ladder  72  to the receptacle  74  using bolts  78 . 
         [0081]    In accordance with the present invention, the ladder  72  is contained within the receptacle  74  is the closed and used position. When a person wants to access the roof of a power generation container including the ladder assembly  70 , the person simply releases the ladder  72  for the clasps  76  and rotates the ladder down and outward from the receptacle  74 . The lock bar  84  of the bar  75  prevents the bar  75  from rotating past a 90 degree angle from the side of a container, thus keeping the ladder away from the receptacle  74  in the open position. When the user is down with the ladder  72 , the user simply pushes the ladder back up and inside the receptacle  74  and locks the ladder  72  within the receptacle  74  using the clasp  76 . 
         [0082]      FIG. 5  illustrates a power generation container  90  configured in accordance with the present invention. In accordance with the present invention, the front end  91  of the container  90  is removable to provide greater and easier access to the contents therein, such as the fuel tank  92  and gen set. The front end  91  of the container  90  includes a gooseneck end frame  95 , a removable air intake louver  93 , and a front wall  94 . 
         [0083]      FIG. 5 a    illustrates the gooseneck end frame assembly  95 .  FIG. 5 b    illustrates an enlarged view of the front louver  93 .  FIG. 5 c    illustrates an enlarged view of the removable front wall  94  which preferably is bolted to the gooseneck end frame  95  for easy removal and attachment. 
         [0084]      FIG. 5 d    is a perspective view of the rear end of the container  90  shown in  FIG. 5 , wherein the radiators for the power generation machinery are typically located. Illustrated are the adjustable exhaust assembly  50  and the foldable ladder assembly  70 . 
         [0085]    Also illustrated are the dual doors  31  and  33 . In accordance with the present invention, louvers (not shown) on the sides  96  of the container  90  are removable to provide greater and easier access to the radiator section and machinery contained therein, such as the radiator machinery. 
         [0086]    In accordance with a further aspect of the present invention, the roof on the rear end  97  of the container  90  can be removed to allow the radiator machinery, or other machinery, to be lowered or raised via the opening  98  in the roof of the container  90  by removing modular components, such as the anti racking frame  99  and the air discharge screens  100 . The screen  100  is secured and removed from the frame  99  by using mounting hardware, such as bolts, and the frame  99  is similarly attached and removed from the top of the container  90 . 
         [0087]      FIG. 5 e    is an enlarged view of the rear  15  of the container  90  showing the modular components of the frame  99  and the screen  100  removed from the roof of the container  10  to provide greater access to the machinery inside, and raise or lower machinery via the roof of the container  90 . Rear doors  102  also provide access to the machinery within the rear  15  of the container  10 . 
         [0088]      FIG. 5 f    is an enlarged view of the anti-racking frame  99 , and  FIG. 5 g    is an enlarged view of the screen  100 . 
         [0089]    While specific embodiments have been shown and described to point out fundamental and novel features of the invention as applied to the preferred embodiments, it will be understood that various omissions and substitutions and changes of the form and details of the invention illustrated and in the operation may be done by those skilled in the art, without departing from the spirit of the invention.