Patent Description:
In the case of greater weights and/or amounts of goods these goods are characteristically loaded into shipping containers or superstructures and are transported to the required locations via public roads, air, water or railway. In the case of shipping of this nature, the joint weight of the shipping containers, superstructures and of the goods together determine the transportable amount.

In the case of special consignments, such as in the case of chilled or frozen goods, in addition to the weight an important factor is to have good thermal insulation, and in certain cases a serious load capability is required due to the cooling apparatus. In addition shipping containers, superstructures must be able to withstand the external-internal effects occurring in the transport vehicle (twisting, shaking, forces originating from the movement of the chassis). In the same way, a bulletproof structure in the case of the transportation of works of art, money or other valuable consignments is of great significance so that these goods may be transported with greater security.

In the case of transportation performed on public roads, the transportation of the goods loaded onto goods vehicles may take place in a so-called superstructure, when the goods are not placed in a separate shipping container that may be independently moved, but in the load space forming an integral part of the goods vehicle. Such superstructures, load space formations are created together with the chassis of the goods vehicle and such superstructures and the goods vehicle cannot be disassembled into separate parts without a destructive process being applied. Alternatively the transportation may take place in containers, which are just lifted onto the goods vehicle and are secured there in a releasable way either to the goods vehicle or to another container. Then at the destination the container may be easily lifted off the goods vehicle.

Patent document number <CIT> presents a sandwich panel from which an insulated shipping container or superstructure may be assembled. The sandwich panels consist of two composite layers and of an insulation layer between them. The insulation layer contains a foam core material and a drying layer. In order to assemble a complete shipping container or superstructure, the sidewalls may be inserted between the support secured to the lower composite layer of the sandwich panel functioning as the floor and the upper layers of the floor. In the case of shipping containers formed in this way, the connection of the individual wall elements is performed with the secured supports. Because of the joints the walls necessarily have a large thickness in order to provide sufficient support and the formation of the sandwich panels does not make it possible to reduce the weight of the structure either. In addition, the formation of the supports at the joints takes the place of the insulation thereby forming thermal bridges at the corners.

Patent document number <CIT> presents a connection similar to the previous example for the assembly of small-sized shipping containers.

Utility model number <CIT> describes sandwich panels that consist of a hard foam and a covering layer on the one side, such as fibre-reinforced plastic, and these panels may be secured to each other using a H-profile beam. The straight joints presented for the connection of the elements to each other are suitable for connecting the elements to each other in a straight line and so for increasing the size of the wall element forming the elements. This solution, however, is unsuitable for connecting the various wall elements together. In addition the beams may create thermal bridges, which damages the insulating function.

Patent document number <CIT> describes a shipping container that is suitable for the transportation of a single work of art.

Patent document number <CIT> describes an insulation panel for use in thermally insulated shipping containers, wherein the panel comprising a rigid core of an insulation material, and the core being wholly encompassed within a polyethylene foam envelope. The disadvantage of the panel is that it creates thermal bridges, so it can only be thermally insulated with the foam envelope.

Patent document number <CIT> describes a superstructure especially for goods vehicles with a thermally insulated load space, cromprising wall elements and armour.

As a consequence of the above there is a need for a superstructure or shipping container that does not require beams to hold together its structure, that is sufficiently strong for the longer transportation of greater weights and that is built up from panels of a material that may be adapted for various purposes. For example, in the case of the transportation of cooled goods it should be well insulated and be free of thermal bridges, or in the case of the transportation of valuable goods it should have reinforced external protection. Furthermore, it should have a low weight as compared to its size so that with respect to the gross weight it should be possible to transport the most useful load (goods) possible in it and, when empty, it should not burden the goods vehicle more than necessary, thereby reducing its fuel consumption.

The present invention is based on the recognition that by securing low-weight panels to each other made using a material selected to ensure sufficient rigidity and by using appropriate joints, superstructures may be assembled without the use of supporting beams that are resistant to forces and that have a low weight due to the lack of beams and the selection of materials and that are adapted for use for goods vehicles with a thermally insulated load space.

In accordance with the above the present invention relates to a superstructure especially for goods vehicles with a thermally insulated load space, which has wall elements and armour, and characteristic of which is that the wall elements are constructed from negative profiles and/or positive profiles and a filling part, the negative profiles and/or the positive profiles form a frame that encompasses the filling part, the wall elements have a front panel and a back panel, and the tongues located on the positive profiles of the individual wall elements connect into the grooves located on the negative profiles of the neighbouring wall elements.

According to a preferred embodiment of the superstructure according to the invention the order of the layers of the negative profiles and the positive profiles forming the wall elements from the inside progressing towards the outer sides is as follows: core material and laminate; which laminate contains resin and a substrate material; and the filling part of the wall elements contain core material.

According to another preferred embodiment of the superstructure according to the invention, the core material is selected from among the following: polystyrene foam, PVC foam, polyethylene foam, balsawood, or a combination of these; the substrate material is selected from among the following: glass fibre matting, woven glass fibre, biaxial fibreglass, balsawood, or carbon fibre, aramid, or a combination of these; and the resin is selected from among the following: epoxy resin, polyester resin, low styrene polyester resin, vinyl ester resin, or a combination of these.

According to another preferred embodiment of the superstructure according to the invention the armour is polyester panelling, or metal panelling, preferably glass fibre reinforced polyester panelling.

According to another preferred embodiment of the superstructure according to the invention the core material is polystyrene foam, the substrate material is biaxial fibreglass, and the resin is epoxy resin.

According to another preferred embodiment of the superstructure according to the invention among the wall elements one of them is a floor element, and at least one front panel and/or back panel of the floor element contains at least one further layer of laminate, and preferably at least one further layer of balsawood as substrate material between two layers of laminate.

According to another preferred embodiment of the superstructure according to the invention the front panel and the back panel of the wall elements are provided with armour in such a way that after the wall elements have been secured to each other substantially the entire surface of the front panel and the back panel are covered with armour.

Another preferred embodiment of the superstructure according to the invention also contains an apparatus selected form the following: cooling apparatus, freezing apparatus, heating apparatus, ventilation apparatus, watering apparatus and a combination of these.

In addition the present invention also relates to the manufacture of the superstructures according to the above, which contains the following steps:.

The superstructure according to the invention may be preferably used for the transportation of heat-sensitive goods.

The superstructure according to the invention may be preferably used for the transportation of works of art, money, or gold.

The essence of the superstructure according to the invention consists of that the connection of panels with suitable rigidity to each other using suitable joints provides sufficient strength and low weight in the case of an appropriate selection of materials for the manufacture of superstructures suitable for the transportation of goods. Due to the lack of thermal bridges such superstructures may be used to good effect in goods vehicles with a thermally insulated load space.

In the context of the present invention shipping container is understood to mean transportation apparatuses in which goods may be loaded for the purpose of transportation. These shipping containers are characteristically closed on all sides and are preferably supplied with a loading opening, or door. However, those possibilities are not excluded when these shipping containers are open on at least one side, for example, for the purpose of facilitating unloading. Shipping containers are understood to mean transportation devices secured to goods vehicles with releasable fixing, or transportation devices placed on goods vehicles without securing, which are characteristically rectangular cuboid in shape, but they may also have various shapes depending on the shape of the transported goods and the type of unloading.

In the context of the present invention superstructure is understood to mean transportation apparatuses that are created together with the chassis of the goods vehicle.

In the context of the present invention work of art is understood to mean valuable objects the value of which is at least equal to the value of silver of the same weight.

Both superstructures and shipping containers are secured to the goods vehicle during transportation. The difference between the two transportation apparatuses is that while the shipping container may be lifted off the goods vehicle and the shipping container, along with the goods inside it, may be transferred onto another vehicle or set down onto the ground, a superstructure may not be removed along with the goods from the goods vehicle, instead the goods themselves must be loaded into and out of the superstructure of the goods vehicle. However, from the point of view of the present invention, it is not necessary to differentiate between these two types of transportation apparatus, because the idea behind the invention may be applied to both types of transportation apparatus. Due to this, in the following, in the context of the present invention it will be called a superstructure, but the concept of superstructure will also include shipping containers.

<FIG> shows a superstructure marked in its entirety with reference sign <NUM>. The connection fittings of the superstructure <NUM> each consist of the connection of one negative profile <NUM> and one positive profile <NUM>, and these form the frame of the front wall <NUM>, the back wall <NUM>, the sidewalls <NUM>, the floor element <NUM> and the roof element <NUM>. The middle parts of each of the individual wall elements are filled with filling parts <NUM>. Lines separating the individual profiles have been indicated on the front wall <NUM> for the purpose of better understanding.

<FIG> shows the negative profile <NUM>. The negative profile <NUM> consists of an internal part 1a, an external part 1b and a groove <NUM> located between the two parts, which is for ensuring the structural connection of the superstructure <NUM>.

<FIG> shows a positive profile <NUM>, the tongue <NUM> part of which connects into the groove <NUM> part of the negative profile <NUM>.

<FIG> shows the layer order of the negative profile <NUM>. This consists of an internal core material <NUM>, a resin <NUM> encompassing this and a substrate material <NUM> placed on it. The substrate material <NUM> is covered with resin <NUM>. The substrate material <NUM> along with the two layers of resin <NUM> form a continuous layer, which in the following is called a laminate <NUM>. In other words the core material <NUM> of the negative profile <NUM> is covered on all sides by a laminate <NUM>. Armour <NUM> is glued onto the negative profile <NUM> produced in this way onto the front panel a and back panel b parts after formation as a wall element.

The structure of the filling part <NUM> contains core material <NUM>.

The walls of the superstructure <NUM> may be assembled from the negative profiles <NUM>, the positive profiles <NUM>, and the filling parts <NUM>, as is shown in <FIG>. These walls may create a front wall <NUM>, a back wall <NUM>, two sidewalls <NUM>, a floor element <NUM> and a roof element <NUM> in the case of a cuboid or rectangular cuboid superstructure <NUM>.

The structure of the floor element <NUM> may be seen in <FIG>. The floor element <NUM> consists of four negative profiles <NUM> and a filling part <NUM>. A frame is created from the four negative profiles <NUM>, which is made possible by that the ends of the negative profiles <NUM> are cut off at an angle of approximately <NUM>° (<FIG>). The filling part <NUM> is placed into the middle, empty part of the frame created in this way, in such a way that by itself or with the use of resin <NUM> it fills in the space between the negative profiles <NUM>.

Following this the assembled floor element <NUM> is preferably provided with an additional layer of laminate <NUM> in the way shown in <FIG> at least on the front panel a and back panel b surfaces so that the floor element <NUM> forms a continuous element. The structure may also be reinforced with a layer of balsawood, as additional substrate material <NUM>, between two layers of laminate <NUM> preferably at least on one of its surfaces so that a floor with a greater load-bearing capability is obtained. Furthermore, for the purpose of reinforcing the structure, it may be worthwhile leaving the laminate <NUM> placed on the back panel b surface longer at the back panel b surface and folding it up at least along the two facing sides so that it covers at least a part of the front panel a surface so as to reinforce the structure of the floor element <NUM> in this way.

In the course of the manufacture of the floor element <NUM> to facilitate the curing of the resin <NUM> and, optionally, the adhesive, it is worthwhile placing it on a vacuum table, subjecting it to a pressure of at least <NUM> mbar and waiting for the final development of the layers, for the curing of the resin to be completed. After the resin has cured, armour <NUM> is secured to the front panel and back panel of the floor element <NUM> on the vacuum table with high-strength structural adhesive.

In the case of assembling the front wall <NUM> and the back wall <NUM>, two vertically positioned negative profiles <NUM> and two horizontally positioned positive profiles <NUM> are used to create the frame. The filling part <NUM> is placed into the middle, empty part of the front wall <NUM> and back wall <NUM> so that by itself or using adhesive or resin <NUM> it fills the space between the negative profiles <NUM> and the positive profiles <NUM>. Following this with laminate <NUM> reinforcing, armour <NUM> is glued to at least the front panel a and back panel b preferably also in a vacuum.

In the case of the assembly of the roof element <NUM> four negative profiles <NUM> are used to form the frame, and a filling part <NUM> is used in the middle part in such a way that it fills in the empty part of the roof element <NUM> by itself or with the use of adhesive or resin <NUM>. In order to maintain the rigidity of the roof element <NUM>, armour <NUM> is secured to its front panel a and to its back panel b using high-strength structural adhesive.

The sidewalls <NUM> are produced in the same way as the roof element <NUM>, only with the difference that positive profiles <NUM> are used instead of negative profiles <NUM>.

In order to create the structure of the superstructure <NUM>, the wall elements produced in the way described above are fitted together in such a way that the tongue parts <NUM> of the individual wall elements are fitted into the groove parts <NUM> of the neighbouring wall elements.

Naturally, the invention is not restricted to the wall elements named above, the order of the layers of the wall elements may be extended on the condition that at least one layer of laminate <NUM> or armour <NUM> is required on the front panel a and the back panel b in order to keep the wall element together.

The positive profiles <NUM> of the sidewalls <NUM> may be fitted into the negative profiles <NUM> of the floor element <NUM> with the use of the grooves <NUM> and the tongues <NUM>. Following this the front wall <NUM> and the back wall <NUM> may be fitted into the negative profiles <NUM> of the floor element <NUM> and, as the next step, the tongues <NUM> located on the sidewalls <NUM> may be fitted into the grooves <NUM> of the front wall <NUM> and the back wall <NUM>. <FIG> depicts the back right corner of a superstructure <NUM> assembled in this way with the assembly of the floor element <NUM>, the back wall <NUM> and the sidewall <NUM>. The roof element <NUM> may be placed on the structure constructed in this way, the negative profiles <NUM> of which slip over the tongues <NUM> of the sidewalls <NUM>, the front wall <NUM> and the back wall <NUM>.

This side joint assembly, in other words how a horizontal groove <NUM> with a vertical tongue <NUM>, or a horizontal tongue <NUM> with a vertical groove <NUM> creates the connection between the wall elements, makes it possible to create a superstructure <NUM> of the appropriate load-bearing capacity without the use of separate beams or rigidity elements.

Naturally, the individual wall elements may be provided with a door or opening, which opening may be only for permitting the entry of light, closable, or completely open as well, or for permitting the flow of air, for example. In addition, in the case of superstructures <NUM> used for various purposes, the superstructure <NUM> may be provided with various accessory apparatuses, such as a cooler, freezer or heating apparatus in the case of heat-sensitive loads, watering apparatus in the case of the transportation of plants, and ventilation apparatus in the case of the transportation of animals, etc. In addition, it is necessary to secure the superstructure <NUM> onto the goods vehicle, or to create it so it is integral with the chassis of the vehicle, which belongs to the compulsory knowledge of the person skilled in the art.

The superstructure <NUM> assembled in this way is self-supporting, in other words it maintains its structural state without any external force. For the performance of various logistics tasks, the connection of the individual wall elements to each other may be reinforced with the use of adhesive, own-material adhesive reinforced with a substrate material <NUM>, with resin <NUM> used in the production of the profiles, or with the use of other non-releasable fixing methods so that the structure of the superstructure <NUM> is capable of withstanding greater external forces. External forces are understood to mean forces acting upon the superstructure <NUM> from outside, such as objects, vehicles colliding with it, and forces exerted from inside such as forces originating from the movement of the objects or load placed inside the superstructure <NUM>.

The roles of the layers used in the case of the individual elements of the superstructure <NUM> are different. The role of the core material <NUM> is to fill the space so that the substrate material <NUM> has something to secure to. In addition, it has an insulating role, especially if the function of the superstructure <NUM> is the storage of heat-sensitive goods, such as, for example, cooled, frozen goods, or if the objective is to keep the goods warm. The core material <NUM> may be polystyrene foam, PVC foam, polyethylene foam, balsawood, etc. The core material <NUM> may have a honeycomb structure, for example.

The role of the resins <NUM> is to secure the various structural layers to each other and to create a smooth surface for the adhesion of the armour <NUM>. For example, the following may be used as resin <NUM>: epoxy resin, polyester resin, low styrene polyester resin, vinyl ester resin. The selection of the appropriate resin <NUM> belongs to the compulsory knowledge of the person skilled in the art in the knowledge of the core material <NUM> and the substrate material <NUM>.

The role of the substrate material <NUM> is to reinforce the load-bearing capacity and durability of the individual wall elements. The substrate material <NUM> makes it possible for the individual wall elements to withstand the weight of larger consignments and to be resistant to external forces. Such substrate material <NUM> may be glass fibre matting, woven glass fibre, biaxial fibreglass, balsawood, or carbon fibre, aramid.

The role of the armour <NUM> used as the protective covering is to keep the wall elements together and to provide external protection. Possible armour <NUM> materials include plastic, preferably glass fibre reinforced polyester panelling, polyester panelling, or metal panelling, such as aluminium or steel.

The armour <NUM> used for keeping the completed wall elements together and as an external covering is secured to the given wall element using adhesive. Such adhesive may be MS polymer, polyurethane, hybrid or two-component structural adhesive, or the resin <NUM> used for the wall elements with the substrate material <NUM> or without it.

The assembly of the superstructures may take place in four steps, when in the first step the negative profiles <NUM> and the positive profiles <NUM> are manufactured, which perform a bracing role, and it is through these that the various wall elements are connected to each other. The length of the profiles is formed so that they correspond to the length of the planned wall element, preferably a certain length shorter than the wall element itself in order to make it possible to glue the elements. Furthermore, due to the <NUM>° connection between the walls that is generally used, it is necessary to form the ends of the profiles at an angle of <NUM>°. Naturally, if certain of the walls of the superstructure <NUM> connecting to one another are not at right angles to each other, the ends of the profiles must be formed at a different angle, as is known to the person skilled in the art.

In the second step the individual wall elements are created in such a way that the frame of the given wall element is assembled using the negative profiles <NUM> and/or the positive profiles <NUM>, and the empty area enclosed by the profiles is filled with core material, thereby creating the filling part <NUM> element. Depending on use, additional laminate <NUM>, substrate <NUM> may be secured to a part of or to the entire assembled wall element. For example, in the case of a floor element <NUM> at least one of the entire surfaces of the floor element <NUM>, preferably surface a may be preferably covered with balsawood and/or biaxial fibreglass as substrate material <NUM>, so that it can withstand the load of the cargo.

<FIG> shows the order of the layers of an embodiment of the floor element <NUM>, which progressing from the inside to the outside contains core material <NUM>. The core material <NUM> is covered on both sides by a laminate <NUM>. Due to the load-bearing capacity of the floor element <NUM>, a balsawood layer is also used as substrate material <NUM> on the future upper surface, which is again covered with laminate <NUM> so that the armour <NUM> may be secured onto it as external covering. Furthermore, in order to reinforce the structure, the laminate <NUM> on the surface opposite to the surface reinforced with substrate material <NUM> is left longer and folded up onto the surface covered with substrate material <NUM>, which in this way covers it from above at the edges. Due to this the armour <NUM>, as shown in <FIG>, is thinner on surfaces above the laminate <NUM>, and where there is no laminate <NUM>, there it is thicker for the purpose of ensuring an even surface. Naturally those solutions are not excluded when the laminate <NUM> is thicker at the inner parts, or due to the pressure exerted the layers at the external parts are more compacted, thereby creating tight contact on the entire surface.

In the third step the armour <NUM>, preferably fibreglass reinforced polyester panelling, is secured to the surface of the front panel a and of the back panel b of the wall element.

In the last step the assembled wall elements are fitted to one another, thereby creating the superstructure <NUM>.

In the case of manufacture performed in two steps there is no need for the separate manufacture of profiles and filling parts, instead by using a tool corresponding to the size of the wall element, the wall elements are produced in one step using the aforementioned groove <NUM> and tongue <NUM> formations. At least one layer of laminate <NUM>, optionally with further substrate material <NUM> reinforcing, is placed onto the front panel a and onto the back panel b of the wall element containing core material <NUM>. Additionally, in the second step armour <NUM> is applied onto the wall element, onto its front panel a and back panel b.

In the case of single-step manufacture, the wall elements are produced in one step and at least two layers of the laminate <NUM> are applied. Preferably they are treated with a gel or other surface-protection agent, as in the case of single-step manufacture the laminate <NUM> takes on the role of the armour <NUM> and the gel or other surface-protection agent is important from the point of view of UV protection.

In the cases of wall elements with large dimensions, it may be necessary to assemble these from several elements. In such cases, in the way according to <FIG>, both the groove <NUM> and the tongue <NUM> parts are formed on the same wall element, which connect to a sidewall element <NUM> formed in the same way. Such a joint also serves as additional bracing in the longitudinal or lateral direction, when this is required due to greater loading.

In the first step the negative profiles <NUM> and the positive profiles <NUM> used for the purpose of bracing and as connection elements are manufactured, preferably using a tool-pair (tools for producing grooves and tongues). The width of the profiles is <NUM> and the height of the profiles is <NUM>. The height of the profiles determines the thickness of the wall element assembled from them. The groove <NUM> has dimensions of <NUM>*<NUM>, and the dimensions of the tongue are <NUM>*<NUM>. The core material <NUM> used in the case of the profiles is polystyrene foam, and SR <NUM> epoxy resin and laminate <NUM> containing biaxial fibreglass are secured onto its entire surface.

In the second step the individual wall elements are created. In the case of the floor element <NUM>, the frame is formed with four negative profiles <NUM> and the filling part <NUM> is filled with core material <NUM> consisting of XPS polystyrene foam. Following this the laminate <NUM> is placed on the entire front panel a and back panel b of the floor element <NUM>.

The wall element is placed on a vacuum table under a pressure of <NUM> mbar to facilitate the curing of the resin <NUM> used in the laminate <NUM>.

Four negative profiles <NUM> are also used in the case of the roof element <NUM> and the filling part <NUM> is filled with XPS polystyrene foam. The roof element <NUM> does not contain additional substrate material <NUM> or laminate <NUM>.

The front wall <NUM> and the back wall <NUM> contain two vertical negative profiles <NUM> and two horizontal positive profiles <NUM> in addition to the core material <NUM> of XPS polystyrene foam serving as the filling part <NUM>.

The sidewalls <NUM> contain four positive profiles <NUM>, apart from this their production corresponds to that described in the case of the roof element <NUM>.

In the third step armour <NUM> consisting of polyester panelling is secured to both surfaces of the wall elements on a vacuum table using two-component structural adhesive.

Finally, in the fourth step, the individual wall elements are assembled and the gaps are filled with SR <NUM> epoxy resin, thereby creating the superstructure <NUM>.

The structure of the superstructure <NUM> according to example <NUM> may be reinforced with the use of larger-sized elements. The height of the negative profile <NUM> according to the example is <NUM> and its width is <NUM>. The size of the groove <NUM> is <NUM>*<NUM>. The height of the positive profile <NUM> is <NUM> and its width is <NUM>. The size of the tongue <NUM> is <NUM>*<NUM>.

Furthermore, the floor element <NUM> is covered with a layer of balsawood, as additional substrate material <NUM>, on its front panel a, onto which a further layer of laminate <NUM> is placed and the laminate <NUM> placed on the back panel b is folded up onto this last layer of upper laminate <NUM>. At the same time the other wall elements are also reinforced with laminate <NUM> covering their entire front panels a. A pressure of <NUM> mbar is applied on the vacuum table.

In the case of the use of the superstructure <NUM> for the transportation of heat-sensitive goods, XPS polystyrene is used as core material <NUM> due to its insulation ability and low weight, because, due to this, it may be used at a greater thickness.

The superstructure <NUM> may be used for the transportation of valuable goods, especially money, gold or works of art. In this case meta aramid substrate material <NUM> and epoxy resin subjected to a ballistics test are used in the laminate <NUM>.

The advantage of the solution according to the invention is that there is no need for separate beams or braces for the connection of the individual wall elements, which makes manufacture simpler and cheaper. In addition, due to the materials used, the side joints and the lack of separate beams, the weight of the superstructure <NUM> may be reduced as compared to the state of the art. A significant advantage of the superstructure <NUM> according to the invention is that due to the lack of beams thermal bridges reducing the effectiveness of the insulation are not formed.

Claim 1:
Superstructure (<NUM>) especially for goods vehicles with a thermally insulated load space, which has wall elements (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) and armour (<NUM>), characterised in that the wall elements (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) are constructed from negative profiles (<NUM>) and/or positive profiles (<NUM>) and a filling part (<NUM>), the negative profiles (<NUM>) and/or the positive profiles (<NUM>) form a frame that encompasses a filling part (<NUM>), the wall elements (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) have a front panel (a) and a back panel (b), and tongues (<NUM>) located on the positive profiles (<NUM>) of the individual wall elements connect into grooves (<NUM>) located on the negative profiles (<NUM>) of the neighbouring wall elements.