Patent Publication Number: US-2011067312-A1

Title: Door Converter Assembly For Storage Containers

Description:
This application claims priority to US Provisional application filed Jun. 20, 2006 as Ser. No. 60/815,116, incorporated in its entity herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to storage containers. More particularly, the present invention relates to a door converter apparatus and method for converting storage containers to permit dual access into the storage container from opposing ends. 
     BACKGROUND OF THE INVENTION 
     International trade involves the transportation of products from one country to another, and typically involves transportation of manufactured products from China to distribution centers in Europe, the United States, and other countries. Shipment of many types of manufactured products is often accomplished with sea-going freighters. These freighters provide relatively inexpensive shipping costs for goods moving from manufacturers to consumers. 
     To facilitate handling of the products being shipped, manufacturers are provided with a standard-size shipping container. The shipping containers are generally rectangular in cross-section and of a standard size. The shipping containers are made of steel side walls and rectangular steel tubular framing members. Typically, one end of the shipping container is closed with a panel and the opposing end is closed with selectively openable doors for access into the shipping container. The shipping containers are sized for readily attaching to tractor trailer rigs or train cars for travel between the manufacturer and the port for ocean shipment. The freighters are specially configured for receiving, stacking, and securing these standard containers. The manufacturers fill the shipping containers with the particular products, and have the containers delivered to the port for shipment. Cranes load the storage containers in the hold of the freighter. 
     Upon arrival of the freighter at the destination port, the shipping containers are removed from the freighter and placed on tractor trailer rigs, trains or other ground transportation, for moving from the port to warehouses or other storage facilities for the owners of the container. After the contents of the storage container are unloaded, the shipping container is readily reused for return shipment of raw materials or other products. 
     However, many storage containers are not returned for reuse, but rather occupy storage areas. The storage containers are held for return, for reuse, and for moving products by tractor trailer truck or by rail. Recently, use has been made of the storage containers for temporary storage of products. 
     While these storage containers have provided temporary storage location for inventory, raw materials, and other products, there are drawbacks to their use. As noted above, typically, the storage containers have the single set of doors at one end of the storage container. For use as an interim storage location however, access into the container from opposing ends provides important benefits for persons and companies using these devices for short term, temporary or other types of storage. Heretofore, however, there has not been a suitable way to retrofit storage containers for new use as a dual access storage container. Accordingly, it is to such that the present invention is directed. 
     SUMMARY OF THE INVENTION 
     The present invention meets the need in the art by providing a retrofit after-market door converter assembly with a lifting device for holding and positioning the door converter assembly in an end of the storage container from which an end panel has been removed, according to a method for converting storage containers with the door converter apparatus to permit dual access into the storage container from opposing ends. 
     In one aspect, the present invention provides a door converter apparatus for installing in an end of a storage container from which an end panel has been removed, comprising a mounting frame having two opposing vertical members and two opposing horizontal members, each member having an end plate and a side plate, a pair of doors, each hingedly attached to a respective one of the vertical members; and a structure that selectively locks the doors in a plane defined by the mounting frame for shipment and installation of the door converter apparatus in an open end of a storage container, wherein the end plates of the mounting frame bear against a distal edge of the open end of the storage container and the side plates abut against an inside surface of the open end of the storage container, and being fixably secured, provide a selectively operable door for the storage container. 
     In another aspect, the present invention provides a method of converting a box storage container having a end closed by a panel and an opposing end having selectably openable doors for selective entry from opposing ends, comprising the steps of 
     (a) removing an end panel of a closed end of a box storage container to define an open end thereof having free distal edges; 
     (b) providing a door converter apparatus having a frame that defines end plates and side plates with at least one hingedly attached door; 
     (c) positioning the door converter apparatus within the open end of the box storage container with the end plates contacting against the free distal edges of the open end and the side plates adjacent respective walls of the box storage container; and 
     (d) fastening the end plates to the free edges and the side plates to the walls, wherein the door converter assembly, fasten to the end of the box storage container from which the panel was removed, provides a selectively openable and closeable door for the opposing end of the box storage container. 
     In another aspect, the present invention provides a lifting frame for picking up and holding a door converter apparatus in an end of a box storage container from which an end panel has been removed during box storage conversion to provide selectively openable doors from opposing ends of the box storage container, comprising: a support frame having two opposing side members, a bottom member and an opposing top member rigidly joined together; a pair of intermediate members attached transverse to the two opposing side members; a pair of U-shaped forklift pockets attached to a first one of the transverse members; a second pair of forklift pockets attached to and extending from the top member; two pairs of connectors, each pair of connectors attached to a respective one of the transverse members for selectively moving from a first position for engaging a portion of the door converter assembly and a second position for securing the door converter assembly to the lifting device; and two opposing legs pivotally attached to the side members and moveable from a folded position and an erect position extending outwardly from the side member, wherein the lifting assembly, being connected to the door converter assembly by the moveable hooks, holds the door converter assembly in an open end of a box storage container for installation or with the pivotable legs moved to the extended position supporting the door converter assembly in a standing position for installation in an open end of a box storage container. 
     Objects, features, and advantages of the present invention will become readily apparent upon reading of the following detailed description in conjunction with the drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1D  illustrate a door converter assembly for storage containers according to the present invention, showing in plan view a frame ( FIG. 1A ), a door set assembly ( FIG. 1B ), and a pair of doors ( FIG. 1C ), with a sectional view ( FIG. 1D ). 
         FIG. 2  is a perspective view of a lifting device for installing the door converter assembly illustrated in  FIGS. 1A-1D  into an open end of a storage container according to the present invention. 
         FIG. 3  illustrates the lifting device carried by a forklift truck for picking up one of the door converter assemblies illustrated in  FIGS. 1A-1D  from a stack of such assemblies in order to position the assembly in an open end of the storage container. 
         FIG. 4  illustrates the door converter assembly attached to the lifting device carried by the forklift truck. 
         FIG. 5  illustrates the door converter assembly attached with cables to the forklift truck for lifting to an erected position. 
         FIG. 6  illustrates the door converter assembly being raised by the forklift truck prior to installation in the storage container. 
         FIG. 7  illustrates the door converter assembly standing in an erected position prior to repositioning the forks of the forklift truck for picking up the door converter assembly in order to install the door converter assembly in an open end of the storage container. 
         FIG. 8  illustrates the door converter assembly supported on the forks of the forklift truck and positioned near an open end of a storage container for installation. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the drawings in which like reference numerals indicate like parts,  FIGS. 1A-1D  illustrate a converter assembly  10  having a frame  12  ( FIG. 1A ), a door converter assembly  10  ( FIG. 1B ), and a pair of doors  14  ( FIG. 1C ), with a sectional view  FIG. 1D .  FIGS. 1A-1D  illustrate the door converter assembly  10  in accordance with the present invention for converting a storage container having a first end closed by a panel and an opposing end with selectively openable doors to a dual-access container thorough selectively openable doors on the opposing ends. The door converter assembly  10  includes the frame generally  12  and at least one door generally  14  mounted in the frame  12 . The illustrated embodiment has two opposing doors attached by hinges  15  to the frame  12  as discussed below. 
     With reference to  FIG. 1A , the frame  12  includes two spaced-apart side members  16 , a sill member  18 , and a header member  20 . The members  16 ,  18  and  20  are angle members or similar structures that each define at least an end plate  22  and a side plate  24 . The members  16 ,  18  and  20  are rigidly joined at respective distal ends to form the frame  12 . 
     With reference to  FIG. 1C , the doors  14  in the illustrated embodiment are conventional steel panel doors of a type commonly used in sea-going box storage containers. The doors  14  include a frame  26  and a panel  28  held by the frame. 
     As shown in  FIG. 1B , hinges  15  attach the doors  14  to the respective side member  16  for positioning in a closed position in a plane defined by the frame  12  or in an open position pivoted on the hinges outwardly of the frame. The doors for storage containers include an exterior door handle and locking device generally  32 . The handle and lock device  32  includes an elongate cylindrical member  34  held by spaced-apart loops  36  attached to the panel  28 . The opposing distal ends of the cylindrical tube  34  define extended fingers. A pair of stubs  38  mount to the sill member  18  and the header member  20  in alignment with the cylindrical tube  34  for selective engagement by the fingers upon rotation of the tube. A handle  40  pivotally attaches to the tube  34 . The handle  40  moves from a first position engaged in a latch  42  to a second position for rotation of the tube  34 . Rotating the tube  34  causes the finger to engage or disengage from the stubs  38 . With the fingers engaged to the stub, the doors  14  are locked; the tube  34  is rotated to release the fingers from the stubs  38  in order to swing the doors  14  open on the hinges  15 . An anti-racking bracket generally  44  (see  FIG. 1D ) locks opposing doors  14  together for shipping and handling until installed. A door gasket  45  seals between the edge of the door  14  and the frame  12 . 
       FIG. 2  illustrates in perspective view a lifting device  50  configured for holding the door converter assembly  10  for installation in an open end of a storage container, as discussed below. The lifting device  50  includes opposing side members  52 , a lower transverse member  54  and an opposing upper transverse member  56 . A pair of intermediate transverse members  58  connect between the side members  52 . A pair of leg hooks  60  attach at a first end to the lower transverse member  54 . A distal free end of the leg hook  60  defines a hook for engaging one of a pair of stand legs generally  64 . One of the stand legs  64  is illustrated in the collapsed position and the other stand leg  64  is illustrated in the extended positions. The stand leg  64  includes a leg member  66  and a diagonal arm  68 . The stand legs  64  pivotally attach to a respective side member  52 . The stand legs  64  pivot from a first collapsed position aligned with the lower transverse member  54  and a second extended position. 
     Two forklift pockets  70  attach to the lower transverse member  54 . The forklift pockets are U-shaped members that rigidly connect to and extend laterally from the lower intermediate transverse member  58 . The forklift pockets  70  each define an opening through which the forks of a forklift truck may extend generally parallel to a plane defined by the side members  52 . 
     A pair of upper lift pockets  76  attach to the upper transverse member  56 . The upper lift pockets  76  are elongated tubes that extend laterally from a side of the upper transverse member  56 . One end  77  of the tubes includes lateral flanges  79  with openings that align with openings in the upper transverse member  56 . The aligned openings receive bolts (not illustrated) for connecting the tubes to the upper transverse member  56 . The upper lift pockets  76  are open-ended and sized for receiving forks of a forklift truck, as discussed below. 
     A pair of lift rings  78  attach to the upper transverse member  56 . A flexible elongated lifting member  79 , such as a wire cord or chain, attaches to the lift ring  78 . In the illustrated embodiment, the lifting member  79  includes an intermediate fork guide  80 . The intermediate fork guide  80  is triangular, with one side that bears on an upper surface of a fork while the other sides extend along side the sides of the fork as discussed below. 
     The lifting device  50  includes a clamp or engaging device to attach the lifting device to the door converter assembly  10 . In the illustrated embodiment, the intermediate transverse members  58  each include a pair of clamps generally  82 . The clamp  82  includes a threaded shaft  84  that extends through a threaded connector  86 . The shaft  82  extends through the intermediate transverse member  58  and terminates at a distal end in a J-bend or hook  87 . The diameter or curved and defined by the hook  87  is suitable for receiving the cylindrical tube  34  of the door converter assembly  10 . A wheel  88  attaches to the threaded shaft  84 . Rotation of the wheel  88  causes the threaded shaft  84  to rotate and move the hook  87  relative to the intermediate transverse member  58 . Rotating the turn wheel  88  in a first direction moves the hook  87  away from the intermediate transverse member  58 ; turning the wheel in the opposite direction draws the hook closer. 
     With reference to  FIG. 8 , the door converter assembly  10  of the present invention closes an end  96  of a storage container  98  that has been opened by removing an end panel  99 . The door converter assembly  10  installs during a conversion of the storage container  98  from a single-access end to dual-access ends with doors in opposing ends. The door converter assemblies  10  are shipped in a stack of assemblies to a storage location for conversion of storage containers. The lifting device  50  is used for picking up the door converter assembly  10  from the stack, pivoting the door converter assembly to an upright position, and lifting the door converter assembly for holding in the end  96  of the storage container  98  being converted to dual access. 
     The storage container  98  is prepared for conversion by removing the panel  99  at the closed end. This is accomplished by cutting out the steel panel on the end of the storage container inwardly of the tubular frame members. The cutting is accomplished using suitable metal cutting equipment, including a cutting torch or a plasma cutter. Once the closed end is opened, the door converter assembly  10  is installed.  FIGS. 3-8  illustrate the process of picking up the door converter assembly  10 , pivoting the door assembly to an erect position and positioning the door converter assembly in the open end of a container. As shown in  FIG. 3 , the upper lifting pockets  76  attach to the upper transverse member  58 . A conventional forklift truck  90  having forks  92  is operated to insert the forks  92  into the loops  70  of the lifting device  50 . The lifting device  50  is positioned on the uppermost door converter assembly  10  in the stack. The lifting device  50  clamps to the door converter assembly  10 . This is accomplished by positioning the hooks  87  at the distal ends of the clamps  82  under the tubular members  34 . Each of the wheels  88  is rotated, to move the threaded bolt  84  in the connector  86  and thereby bring the hook  87  into engaging contact with the respective tubular member  34 . The forklift truck  90  operates to lift the door converter assembly  10  off of a stack and then place the selected door converter assembly  10  on the ground as shown in  FIG. 4 . The forklift  90  removes the forks from the loops  70 . 
     With reference to  FIG. 5 , the respective free ends of both of the lifting members  79  attach to the forklift  90 . The intermediate fork guides  80  slide onto the extending forks  92 . The forklift  90  is positioned with its front wheels bearing against an edge of the lifting device  50 . The stand legs  64  pivot from the collapsed or folded position to the extended lateral position (see  FIG. 6 ). The leg hooks  60  pivot from the lower transverse member  54  and connect to the respective stand leg  64  to lock the stand leg in the extended position. The forks of the forklift  90  are elevated. The lifting members  79  cause the opposing end of the clamped lifting device  50  and the door converter assembly  10  to rise, pivoting about the end against the front wheels of the forklift  90 . The intermediate fork guide  80  slides longitudinally on the forks  92  as the clamped device  50  and assembly  10  pivot upwardly, as illustrated in  FIG. 6 . The stand legs  64  pivoted to the extended position allow the clamped lifting device  50  and the door converter assembly  10  to stand as shown in  FIG. 7 . 
     With continuing reference to  FIG. 7 , the clamped device  50  and assembly  10  pivot to an erected position supported by the stand legs  64 . The forklift  90  lowers, and moves to insert the forks  92  into the upper lift pockets  76 . The forklift  90  then lifts the clamped device  50  and assembly  10 . With reference to  FIG. 8 , the forklift  90  moves forwardly to orient the lifted clamp device  50  and assembly  10  relative to the open end  96  of the storage container  98 . The forklift  90  then positions the supported clamped device  50  and assembly  10  in the open end of the storage container. The side plates  24  of the frame  12  slide longitudinally beside the respective side wall, bottom, and top of the open end of the storage container. The end plates  22  contact the respective edges of the open end of the storage container. With the forklift  90  stationary, the door converter assembly  10  is rigidly connected to the end of the storage container by welding the side walls, the bottom, and the top to the respective side and end plates of the frame members. The clamps  82  are released, by rotating the wheels  88  in the opposing direction to move the hooks  87  away from engaging contact with the tubes  34 . The forklift  90  is moved away from the rigidly connected door assembly on the storage container. The doors  14  are operated conventionally using the door handle and locking device  32  for access into the storage container from the formerly closed end. 
     The foregoing specification describes above the present invention of the door converter assembly for converting box storage containers having one end closed by the panel and the opposing end with selectively openable doors to dual-access with selectively openable doors in opposing ends and the lifting device to hold the door converter assembly during the conversion process, including the steps necessary for making and using various embodiments thereof, and for converting box storage containers for dual access. It is to be understood, however, that numerous changes and variations may be made in the construction of the converter within the spirit and scope of the present invention and that modifications and changes may be made therein without departing from the scope thereof as set forth in the appended claims.