Abstract:
An intermodal shipping container box assembly having front cube, rear cube and middle sections with the front cube and rear cube of variable lengths to provide a container box up to sixty and a half feet in length. The front and rear cubes have modified stacking post and casting block arrangements. The front cube and rear cube may include additional cross bracing. The front cube and middle section include a modified tunnel section for accommodating a vehicle chassis.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 62/014,447, filed Jun. 19, 2014. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a container box for use in the transportation of freight through multiple modes of transportation. 
       BACKGROUND OF THE INVENTION 
       [0003]    Current freight transportation by sea, rail, or road often occurs through the use of container boxes which are designed for use in multiple modes of transportation, i.e. intermodal transportation, and for use in various countries. The majority of shipping container boxes are twenty or forty foot container boxes built to standards defined by the International Standards Organization (ISO). In North America, fifty-three foot container boxes built according to ISO or Association of American Railroads (AAR) standards are also common. In use, container boxes may be lifted, stacked for storage or transportation by sea or rail, and mounted to a vehicle chassis or rail car for transportation by road or rail. 
       SUMMARY OF THE INVENTION 
       [0004]    Embodiments of the present disclosure provide a container box with an increased volume which may be used with existing vehicle chassis, lift equipment, rail cars and other container boxes. In one embodiment, a front cube section is provided with additional length, an improved stacking post and casting block arrangement, and an improved tunnel section for accommodating a vehicle chassis. In one embodiment, a rear cube section is provided with additional length and an improved stacking post and casting block arrangement. In a further embodiment, by combining the front and rear cube sections, with a middle section, a container box of varying and additional length is provided. A 60.5 foot container box may be provided by combining the front and rear cube sections, with a middle section approximately 39 to 40 feet in length. 
         [0005]    According to one embodiment, there is provided a container assembly, having a pair of top rails; a pair of bottom rails; a pair of front corner posts, each front corner post being coupled to a first end of one of the pair of top rails and a first end of one of the pair bottom rails; a pair of rear corner posts, each rear corner post being coupled to a second end of one of the pair of top rails and a second end of one of the pair bottom rails; a top front header coupled transversely to the pair of top rails and a front sill coupled transversely to the pair of bottom rails, adjacent the front corner posts; and a rear header coupled transversely to the pair of top rails and a rear sill coupled transversely to the pair of bottom rails, adjacent the rear corner posts. The front corner posts, top rails, bottom rails, top front header, front sill, rear header, rear sill, and rear corner posts define a generally rectangular container frame. The front corner posts, the top front header, the front sill and adjacent portions of the top rails and bottom rails define a front cube and the rear corner posts, the rear header, the rear sill and adjacent portions of the top rails and bottom rails define a rear cube. The remaining portions of the top rails and bottom rails define a middle section between the front cube and the rear cube. The assembly includes a pair of front stacking posts disposed between the front cube and the middle section and extending between respective top and bottom rails; and a pair of rear stacking posts disposed between the rear cube and the middle section and extending between respective top and bottom rails. The middle section may have a length in the range of 39 to 40 feet; the front cube may have a length in the range of 9 to 10.5 feet; and the rear cube may have a length in the range of 9 to 10.5 feet. The assembly includes a first pair of cross-brace members, each extending diagonally from one of the front corner posts adjacent the top rail to one of the front stacking posts adjacent the bottom rail; a second pair of cross-brace members each extending diagonally from one of the front corner posts adjacent the bottom rail to one of the front stacking posts adjacent the top rail; a third pair of cross-brace members, each extending diagonally from one of the rear corner posts adjacent the top rail to one of the rear stacking posts adjacent the bottom rail; and a fourth pair of cross-brace members, each extending diagonally from one of the rear corner posts adjacent the bottom rail to one of the rear stacking posts adjacent the top rail. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is an isometric top view of a container box according to an embodiment of the present disclosure; 
           [0007]      FIG. 2  is an isometric bottom view of a container box according to an embodiment of the present disclosure; 
           [0008]      FIG. 3  is an isometric cut away view of a container box according to an embodiment of the present disclosure with the roof and side walls removed; 
           [0009]      FIG. 4  is a curbside side view of a container box according to an embodiment of the present disclosure; 
           [0010]      FIG. 5  is a roadside side view of a container box according to an embodiment of the present disclosure; 
           [0011]      FIG. 6  is a top view of a container box according to an embodiment of the present disclosure; 
           [0012]      FIG. 7  is a bottom view of a container box according to an embodiment of the present disclosure; 
           [0013]      FIG. 8  is a front view of a container box according to an embodiment of the present disclosure; 
           [0014]      FIG. 9  is a rear view of a container box according to an embodiment of the present disclosure; 
           [0015]      FIG. 10A  is a close-up isometric view of circled portion A from  FIG. 3  and  FIG. 10B  is a close-up bottom view of portion A; 
           [0016]      FIG. 11A  is a close-up isometric side view of circled portion B from  FIG. 3  and  FIG. 11B  is a close-up isometric top view of portion B; 
           [0017]      FIG. 12  is close-up side view of the container box and circled portion C from  FIG. 3 ; and 
           [0018]      FIG. 13  is an isometric cut away view of a container box according to a further embodiment of the present disclosure. 
       
    
    
       [0019]    Like reference numerals are used in the drawings to denote like elements and features. 
         [0020]    While the invention will be described in conjunction with the illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. 
       DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0021]    Embodiments of the present disclosure provide a container box having an increased length and volume for carrying freight for intermodal transportation. The container box is comprised of modified front and rear cube sections which may be assembled with a middle section to create a container box up to 50.5 feet in length. 
         [0022]      FIGS. 1 to 9  illustrate embodiments of container box assembly  10  including a front cube  15 , a rear cube  20  and a middle section  25 . In some embodiments the container box assembly  10  is approximately 60.5 feet long with a middle section  25  approximately 39 to 40 feet in length, and typically 39 feet, 4 inches; a front cube  15  up to approximately 9 to 10.5 feet in length; and a rear cube  20  up to approximately 9 to 10.5 feet in length. In this embodiment, the 60.5 foot container box assembly  10  provides an increase in volume of approximately 15% over current 53 foot container box assemblies. It will be appreciated that different lengths of container boxes, from 58 feet up to 60.5 feet, may be achieved by varying the length of the front cube  15  and rear cube  20  disclosed herein while maintaining the length of the middle section  25 . 
         [0023]    When assembled, the container box assembly  10  typically comprises a base  30 , a curbside sidewall  32   a,  a roadside sidewall  32   b,  a roof  34 , a front wall  36  and rear doors  38 . The walls  32   a,    32   b,  base  30  and roof  34  extend from the front of the container box and the front cube  15  to the rear of the container box at the end of the rear cube  20 . Except as noted herein, the container walls  32   a,    32   b,  base  30  and roof  34  generally may be constructed according to known implementations such as for a steel container box assembly comprised primarily of corrugated sheet steel or an aluminum container box assembly comprised primarily of sheet aluminum. It will be appreciated that other materials may be used for construction of the container box assembly. 
         [0024]    Other implementations for the container box assembly  10 , including but not limited to an insulated or refrigerated container box, also may be provided. In these embodiments, the length of the front cube  15  may be shortened to provide space for a heating unit or a refrigeration unit and frame in order to provide a container box assembly  10  having an overall length of up to 60.5 feet. In other embodiments, such units may be placed within the front cube  15  of the container box assembly  10 . 
         [0025]      FIGS. 1 and 2  and the cutaway view of  FIG. 3  illustrate the construction of the front cube  15  according to an embodiment of the present disclosure. The front cube  15  includes two front corner posts  40  and two stacking posts  42  as well as top rails  44  and bottom rails  46 . Each front corner post  40  is coupled to one end of the top rail  44  and one end of the bottom rail  46 . Upper and lower members or beams couple the top rails  44  and bottom rails  46 . Specifically, near the front corner posts  40 , a top front header  41  extends transversely between the pair of top rails  44  and a front sill  43  extends transversely between the pair of bottom rails  46  to define a square frame. The length of the front cube  15  is extended by up to 9 to 10.5 feet by increasing the length of the top rails  44  and bottom rails  46  and by increasing the number of side posts  48  and roof bows  50 . In one embodiment, the density of side posts  48  and roof bows  50  is increased in the front cube  15  as can be seen from  FIGS. 1-3 . In one embodiment, the front cube  15  includes top rails  44  and bottom rails  46  having a height increased by about two inches, to a height of approximately 6 inches. In one embodiment, the thickness of the top rails  44  may be increased from 0.135″ to approximately 0.25″. Different configurations of the top rails  44  and bottom rails  46  are provided to increase the strength of the lengthened front cube  15 . The top rails  44  and bottom rails  46  may be comprised of steel, such as high strength low alloy steel of 50,000 psi to 60,000 psi minimum yield strength. 
         [0026]    In one embodiment, as illustrated in  FIGS. 10A and 10B , the front corner posts  40  may be tapered and flat, or rounded to provide a swing clearance of 2.0 metres or less when the container box assembly  10  is mounted to a vehicle chassis (not shown). 
         [0027]    In one embodiment, as shown in  FIGS. 2 and 7 , the front section of the container box assembly  10 , including the front cube  15  and an adjacent portion of the middle section  25 , includes a modified tunnel section  52  to accommodate an extendible pull out section on a gooseneck chassis. Specifically, the tunnel section may be constructed as a 170 inch section with a depth of either 3¼″ (shallow tunnel) or 4¾″ (deep tunnel) to allow for optimal inside height of the container box., 
         [0028]      FIGS. 1 and 2  and the cutaway view of  FIG. 3  also illustrate the construction of the rear cube  20 . The r cube  20  includes two rear corner posts  60  and two stacking posts  62  as well s top rails  64  and bottom rails  66 . Each rear corner post  60  is coupled to one end of the top rail  64  and one end of the bottom rail  66 . Upper and lower members or beams couple the top rails  44  and bottom rails  46 . Specifically, near the rear corner posts  60 , a rear header  61  extends transversely between the pair of top rails  64  and a rear sill  63  extends transversely between the pair of bottom rails  66  to define a square frame. The length of the rear cube  20  is extended by up to 9 to 10.5 feet by increasing the length of the top rails  64  and bottom rails  66  and by increasing the number of side posts  48  and roof bows  50 . In one embodiment, the density of side posts  48  and roof bows  50  is increased in the rear cube  20  as can be seen from  FIGS. 1-3 . In one embodiment, the rear cube  20  includes top rails  64  and bottom rails  66  having a height increased by about two inches. In one embodiment, the thickness of the top rails  64  may be increased from 0.135″ to approximately 0.25″. Different configurations of the top rails  64  and bottom rails  66  of the rear cube  20  are provided to increase the strength of the lengthened rear cube  20 . The top rails  64  and bottom rails  66  may be comprised of steel, such as high strength low alloy steel of 50,000 psi to 60,000 psi minimum yield strength. 
         [0029]    Except as noted herein, the middle section  25  generally may be constructed according to known implementations such as for a steel container box assembly comprised primarily of corrugated sheet steel or an aluminum container box assembly comprised primarily of sheet aluminum. The middle section  25  comprises a pair of top rails  67  which support a plurality of roof bows  50  and the roof  34  and a pair of bottom rails  68  which support the base  30 . One top rail  67  and one bottom rail  68  are illustrated in  FIG. 3 . A plurality of side posts  48  extend vertically between the top rails  67  and bottom rails  68  for supporting the side walls  32   a,    32   b.  In one embodiment, the top rail  44  of the front cube, the top rail  67  of the middle section  25 , and the top rail  64  of the rear cube comprise separate rails coupled together at the stacking posts  42 ,  62 ; and the bottom rail  46  of the front cube, the bottom rail  68  of the middle section  25 , and the bottom rail  66  of the rear cube  20  comprise separate rails coupled together at the stacking posts  42 ,  62 . In one embodiment, the top and bottom rails  44 ,  64 ,  46 ,  66  in the respective front cube  15  and rear cube  20  comprise steel and the top and bottom rails  67 ,  68  in the middle section  25  comprise aluminum. 
         [0030]    Casting blocks  70  are provided at the bottom of each stacking post  42 ,  52  for securing the respective front cube  15  and rear cube  20  and the container box assembly  10  to a container chassis, container ship, rail car or other container box (not shown). Casting blocks  70  also may be provided at the top of each stacking post  42 ,  62  for securing the container box assembly  10  to other container boxes placed on top of the container box  10 , or to a railcar or container ship. It will be appreciated that additional casting blocks  70  may be positioned in the container box assembly  10 , such as by providing casting blocks  70  at the front corner posts  40  and rear corner posts  60  as described above. Alternatively or additionally, four casting blocks  70  may be provided on the top and/or bottom of the container box assembly  10  according to ISO or ARR dimensions and positions for securing the container box assembly  10  to other containers. Thus, existing container box assemblies, or container box assemblies according to the present disclosure, may be placed on top of and secured to the container box assembly. Casting blocks  70  also may be used with existing equipment for lifting the container box. 
         [0031]    Additional casting blocks  70  may be provided, for example, at the bottom of each front corner post  40  and at the bottom of each rear corner post  60  for securing the container box assembly  10  to a vehicle chassis. As shown in  FIGS. 10A and 10B , the casting blocks  70  at the front corner post  40  may be inset from the side of the container box assembly  10  in order to achieve the swing clearance noted above. 
         [0032]    In one embodiment, when assembled, the container box  10  includes at least four casting blocks  70  in the roof  34  at the top of each stacking post  42 ,  52  and the base  30  includes at least four casting blocks  70  at the bottom of each stacking post  42 ,  62 . With a container box assembly  10  having a middle section  25  approximately 39-40 feet in length, the casting block positions are configured to match current ISO 40-foot stacking posts positions. In this embodiment, the approximately 60.5 foot container box assembly  10  may be used with and stacked on top of existing container boxes, such as a 40 foot container box, or a 53 foot container box provided with stacking posts at the standard 40 foot positions. In use, for example when the container box assembly  10  is stacked on top of a 40 foot single pack railcar, or on top of a multipack  53  foot railcar, the 60.5 foot container box assembly  10  closes the gap or spacing which exists between railcars, thereby decreasing the drag on the train and improving fuel efficiency. 
         [0033]    With casting blocks  70  provided in the front corner posts  40  and rear corner posts  60  of the container box assembly  10 , the assembly may be secured on a container chassis, such as through the use of a combination of twist locks or pin locks. Other embodiments may allow for the securement on the chassis through the casting blocks  70  located at the stacking posts  42 ,  62  or at other intermediate locations as noted above. 
         [0034]    In one embodiment, the front cube  15  and the stacking posts  42  include modified and additional parts to enable the front cube  15  to be extended while allowing the container box assembly  10  to be mounted to other container boxes, chassis etc., at various positions. Similarly, the rear cube  20  and stacking posts  62  may include modified and additional parts to enable the rear cube  20  to be extended while allowing the container box assembly  10  to be mounted to other container boxes, chassis etc. at various positions. 
         [0035]    As illustrated in  FIGS. 11A and 11B  with respect to the front cube section  15 , a roof impact plate  80  may be provided which is increased in length and extends across the width of a front roof header assembly  82 . In one embodiment, the roof impact plate  80  is trapezoidal in shape and welded to the top rail  44 , to the roof header assembly  82  and to the casting block  70 . In some embodiments, the casting block  70  is welded to the top of the stacking post  42 . The roof header assembly  82  is first welded around the casting block  70  and then the roof impact plate  80  is welded to the roof header assembly  82  and to the casting block  70 . The roof impact plate  80  defines a notched portion to accommodate the casting block  70 . Similar roof impact plates  80  may be provided at each stacking post  42 ,  62  in the front and rear cube sections as seen in  FIGS. 1 ,  3  and  6 , with a rear roof header assembly being disposed between the rear cube  20  and the middle section  25 . 
         [0036]    An additional plate or inner corner gusset  86  is added in one embodiment in a plane parallel to and below the roof impact plate  80  and the roof header assembly  82 . The inner corner gusset  86  may be a triangular or 5-sided shape as shown and extend from a first edge of the roof header assembly  82  along the top rail  44  into the front cube section to the first roof bow designated as roof bow  50   a  in  FIG. 11B . The inner corner gusset  86  may be welded to the first edge of the roof header assembly  82  and to the top rail  44 , it may extend out to provide a support to fasten the closest roof bow  50   a.  While shown in detail with respect to the front cube section of  FIG. 3 , a similar inner corner gusset  86  may be provided in the stacking posts  62  of the rear cube  20 . The inner coiner gusset  86  in the rear cube  20  extends from an edge of the roof header assembly  82  adjacent the rear cube  20 , along the top rail  64  into the rear cube section  20  to the first roof bow  50 . 
         [0037]    In some embodiments, a modified upper corner post gusset  88  is provided on each stacking post  42 ,  62  along a plane parallel to the side wall  32  of the container box assembly  10 . A close-up illustration of the modified upper corner post gusset  88  for the rear cube  20  is provided in  FIG. 12 . The upper corner post gusset  88  may comprise first and second steel plates which are welded to respective bottom edges of the top rail  44  and to the sides of the stacking post  62 . In one embodiment, the first steel plate extends into the rear cube  20  up to approximately 25 inches or more towards a second adjacent side post  48   a  in the rear cube  20 , as shown in  FIG. 12 . In one embodiment, the second steel plate extends up to approximately 15 inches into the middle section  25  of the container box to a first adjacent side post  48   b  in the middle section  25 . 
         [0038]    In one embodiment, the roof impact plate  80 , the inner corner gusset  86  and the upper corner post gusset  88  comprise steel plates welded to the other components of the front cube  15 , rear cube  20  and middle sections  25  as noted above. In other embodiments, the roof impact plate  80 , the inner corner gusset  86  and the upper corner post gusset  88  comprise plates which are riveted and/or monobolted through with the plate and stacking post and the plate and upper rail connections. 
         [0039]    In a further embodiment illustrated in  FIG. 13 , cross-bracing  90  may be provided along each of the side walls  32   a,    32   b  to increase the rigidity of each of the front cube  15  and rear cube  20 . The cross-bracing  90  may comprise ⅛″ to ¼″ thick flatbar with a width of 2″ to 4″ wide depending on the rigidity required. In some embodiments, the cross-bracing  90  may comprise high strength, low alloy steel. The cross-bracing  90  may be mounted between the lower front corner adjacent the front corner post  40  to the top corner of the adjacent stacking post  42  along the sidewall  32   a  and from the top or upper front corner adjacent the front corner post  40  to the bottom corner of the stacking post  42  along the sidewall  32   a  as shown. Similar cross-bracing  90  may be provided between the front corner post  40  and the adjacent stacking post  42  along the sidewall  32   b,  as shown in  FIG. 13 . Similar cross-bracings  90  also may be provided along the sidewalls  32   a,    32   b  between the rear corner posts  60  and the stacking posts  62  between the rear cube  20  and middle section  25 , as shown. In one embodiment (not shown), the cross-bracing  90  may comprises separate segments fastened or welded between adjacent side posts  48  at angles extending between the stacking posts  42 ,  62  and adjacent front corner posts  40  or rear corner posts  60 . 
         [0040]    Thus, it is apparent that there has been provided in accordance with the embodiments of the present disclosure a container box assembly and front and rear cube sections for a container box assembly which provide an increased volume for intermodal freight transportation and which fully satisfy the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives modifications and variations as fall within the spirit and broad scope of the invention.