Patent ID: 12252880

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Intermodal containers, commonly referred to as shipping containers are generally rectangular. Referring now toFIG.1, a typical intermodal container (1000) has a floor (1002), sidewalls (1004), doors (1006), an end wall (1008) and a roof (1010). A standard container is typically 40 feet or 20 feet long, 8 feet 6 inches high and 8 feet wide. Intermodal containers are generally made of metal (steel) with at least the sidewalls (1004) and the end wall (1008) configured with a corrugated cross-section to increase the strength of the walls. The corrugations typically have a depth of 1.25 inches up to 2 inches. Corner posts (1012) provide added support for the container (1000) and sufficient support for lifting the container. Bottom frame members (1014) include openings (1016) for forklift tines or straps to lift the container (1000). The standardized containers (1000) are modular for closely fitting against adjacent containers (1000) and may also be stacked for storage and during transportation.

An insulating system (100) is formed of insulation units, inserts and interconnected panels, described hereinafter, that mount to the walls (1004) with glue or conventional fasteners. A finishing layer, such as paneling, drywall, siding or other finishing treatments mounts with fasteners, glue or other conventional mounting techniques to the insulation layers, insulation units, inserts and/or insulating panels. As explained hereinafter, the insulating system (100) includes insulation units having embedded studs that provide for mounting of other elements. For some applications, a coating such as paint, wallpaper or other final, exposed material that is visible may cover certain finishing layers, such as drywall. The system of the present invention provides for elimination of the conventional stud framing and roll-type insulation being installed in an intermodal container (1000) and provides improved R-value in a thinner layer, adding floor space and volume to the finished interior of an intermodal container. The insulating system (100) may also be added to the exterior of the intermodal container with or without additional insulation. The insulating system (100) may therefore be mounted to the inside, to the outside or to the inside and the outside of an intermodal container (1000). When mounted to an exterior of an intermodal container (1000), the insulating system (100) may create a rain screen cavity that promotes quick drying of any moisture within the walls. Moreover, the insulating system (100) isolates fasteners of exterior cladding and eliminates thermal bridging. The present invention is less expensive and easier to install than prior conventional building systems and techniques.

Referring now toFIGS.1-7, the insulation system may include insert type first insulation units (120) that provide for mounting against the corrugated faces of walls of an intermodal container. Each of the insulation units (120) has a profile that is complementary to the corrugated face of the intermodal container and configured to nest against a corrugated wall in a form-fitting manner. The first insulation units (120) also provide support so that fasteners may be attached to the insulation unit and other layers applied over the insulation units (120). Each insulation unit (120) includes a molded foam portion (122). Embedded within the foam portion (122) is a mounting stud (150). The stud (150) is generally a lightweight element extending longitudinally along the length of the insulation unit (120) and provides added support. The insulation unit (120) forms a center protruding face (124) with angled faces (126) on either side. The protruding face (124) and angled faces (126) are made to be complementary to the surface of the corrugated wall of an intermodal container (1000), such as shown inFIG.1. A first portion of the mounting stud (150) extends through to the protruding face (124) of the insulation unit (120). The opposite exposed face (128) is generally planar and has an opposite portion of the mounting stud (150) extend there through. On either side of the planar opposite face (128) are shoulder surfaces (130) and (132) that provide for receiving a corner of planar insulation panels, as explained hereinafter. A slot (134) is formed in the surface (132) and provides for applying adhesive or to form a channel to provide venting and/or drainage. The intersection of the angled faces (126) with the outer edge of the shoulder surface (130) forms a rounded edge (136). The rounded edge (136) also provides for forming a small channel when installed that may be used for adhesive and/or drainage or venting. The top of the insulation unit (120) includes a protruding tongue (138) and the bottom of the insulation unit (120) has a complementary groove (140) for receiving the tongue (138) so that the insulation units (120) may be stacked one upon another vertically and maintained in alignment. In one embodiment, the insulation units (120) are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder.

Referring now toFIGS.8-12, the stud element (150) is a lightweight molded element that provides internal support for the insulation units (120). The stud (150) is an elongate element that extends generally along the longitudinal axis of the insulation unit. The stud element (150) has a somewhat “H” shaped cross section with a first planar portion (152) and a second planar portion (158) joined by a center connecting portion (154). The center connecting portion (154) includes connecting ribs (156) that provide openings through which insulation extends to provide greater interaction for the stud. The first portion (152) includes channels (164) extending laterally transverse to the longitudinal axis. The second portion (158) includes ridges (160) extending transverse to the longitudinal axis of the mounting stud (150). The ridges (160) may extend through the second face of the insulation unit and provide for mounting or application of adhesive. It can be appreciated that the stud (150) eliminates a thermal connection through the insulation unit (120) and provides for receiving screws, nails or other fasteners, as well as for having adhesive mount to the exposed ridges (160) of the second portion (158) for secure mounting while eliminating a thermal path extending from front to rear through the thermally conductive path through the insulation unit. The first portion generally extends the length of the stud while the second portion and connecting portion (154) are divided into segments (162). The segments (162) allow for the stud element (150) and therefore the insulation unit (120) to have some degree of flexure should the application not be entirely planar and provides for adapting to expansion and/or contraction of the insulation units.

Referring again toFIGS.2,3and7, the mounting stud (150) extends through to both faces (124) and (128) of the insulation unit (120). It can be appreciated that at the protruding face (124), the ridges (160) extend through the foam portion (122) and provide for mounting of fasteners and/or application of adhesive. Moreover, the first portion (152) extends through the face (128) with transverse channels (164) exposed. The exposed mounting stud (150) provides for a visual indicator for centering the insulation unit (120) and for mounting fasteners and other elements to the insulation unit (120). As shown inFIG.7, the foam portion (120) extends through the open portions of the mounting stud (150) and provides an interlocking connection of the embedded mounting stud (150) with the foam (122).

Referring now toFIGS.13and14, an insulation insert (170) has an outer periphery somewhat similar to the insulation unit (120). The insert (170) has faces (172) that generally correspond to the angled faces (126) of the insulation unit (120) and a face (174) generally corresponding to the protruding face (124). The insulation inserts (170) may be used in conjunction with the insulation units (120) to provide a planar surface for mounting conventional planar insulation panels. As mounting of additional insulation and other layers may be to the insulation units (120), the insulation inserts (170) have no need for mounting and therefore do not incorporate an imbedded mounting stud. The insulation inserts (170) may be adhered or glued in place to keep them more secure. When the insulation units (120) and the insulation inserts (170) are used together against a corrugated wall, some of the recesses of the corrugated wall will received the insulation units (120) while other recesses of the corrugated wall receive the insulation inserts (170). In one embodiment, the insulation inserts (170) are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder.

It will also be appreciate that where greater support for mounting is required, some or all of the insulation inserts (170) may be eliminated. Where a high level of insulation is needed, it is generally preferred to have every recess in the corrugated wall filled. Therefore, in some configuration the system may use a more or fewer insulation units (120) or may only use the insulation inserts (120). However, for some applications, the walls may require little or no insulating. For such applications, some of the recess of a corrugated wall may be left empty to provide a vertical ventilation space.

Referring now toFIGS.15and16, there is shown a further embodiment of an insert, generally designated (180). The insert (180) also has a truncated pyramid shaped cross section with a pair of parallel opposite faces (182) and (184). The opposite faces (182) and (184) are connected at their sides by angled faces (186). The inserts (170) ofFIGS.13and14and (180) ofFIGS.15and16are similar except for the relative dimensions and are configured for insulating different walls having different corrugated shapes forming the intermodal containers. It can be appreciated however that further shapes are also possible that are configured to be complementary and fit closely against a wall of an intermodal container.

Referring now toFIG.17, there is shown the insulation of a wall system (100) mounted to a wall (1004) of an intermodal container. The insulation system (100) includes an inner finishing layer (102) and outer finishing layer (104). Mounted against the corrugated faces of the wall (1004) are insulation units (120) and insulating inserts (170). Moreover, conventional insulating panels (190) are mounted over the insulation inserts (170) and against the shoulder surfaces (130) and (132) of the insulation units (120). With this arrangement, a continuous insulation layer is obtained by the insulation units (120), inserts (170) and insulation panels (190). The shoulder surfaces (130) and (132) provide added support and strength for the insulation panels (190). When the insulation panels (190) and the finishing layer (104) are fastened to the insulation units, the system (100) expands and contracts as a unit. Moreover, it will be appreciated that although the insulation system is shown with insulation against both faces of the wall (1004) inFIG.17, such a system may also include insulation on only the inner face or on only the outer face of the wall (1004). Moreover, it can be appreciated that similar systems may be used against the roof and other surfaces of an intermodal container (1000) or other surfaces that have such a corrugated finish.

The insulating system (100) may also incorporate interconnected rectangular insulating panels (220) mounted in an edge-to-edge relationship. As shown inFIGS.19-23, the panels (220) are generally rectangular and include tongues (240) and complementary grooves (242), such as shown most clearly inFIGS.20and22, along the top and bottom surface and the ends of the panel (220). The tongues (240) and grooves (242) provide for alignment and connection along both the horizontal and vertical edges so that the panels (220) may be connected to extend horizontally and vertically in a continuous insulating layer. The panels (220) also include alignment tabs (244) and complementary notches (246) along the top and bottom edges that aid in aligning the panels (220) for final orientation and alignment. In one embodiment, the panels (220) are made of a closed cell expanded polystyrene material. Such a material is lightweight, provides excellent insulation performance and is impervious to water. Moreover, such material may include a fire retarder. Although a vapor barrier may also be added to the system, it can be appreciated that with the insulating layer (100) made of a water impervious material and with interlocking edges, the need for a separate vapor barrier used in many applications may be eliminated.

Each of the panels (220) includes a generally planar outer face (222) having a series of parallel passages (228) that may serve as wiring chases or for running tubing, fiber optics or other elements through the insulating layer without requiring cutting into the panels (220). Indicator lines (224) are aligned with the passages (228) and a centerline (225) acts as a cutting line for cutting the panels (220) into even halves. The passages (228) also allow water to drain. When the panels (220) are attached, horizontally extending channels (226) are formed. The horizontal channels (226) bypass the vertical passages (2280so that utilities may be run in both directions without intersecting. The vertical passages (228) provide for easy insertion and routing of wiring, tubing and other elements into the foam material that are typically placed inside walls. In some embodiments, the small section of panel foam between the horizontal channel (226) and the vertical passage (228) may be removed so the channels (226) and the passages (228) connect. Further raceways may also be formed in the panels (220) as is needed. A cutting guide may provide for trimming the panels (220) to a common size and provides a guide for forming a straight edge. It can be appreciated that in one embodiment, the panels are approximately 44 inches wide and 24 inches high (122×61 cm). A typical depth for a panel (220) is two inches (5 cm) at the narrower section and about 3.25 inches at the deepest depth of a corrugation. Such a size provides for standard alignment and easily transporting the panels (220) down narrow staircases such as often lead to a basement. Moreover, smaller panels are easier to fit around openings that large sheets that cover multiple openings.

The panels220also include mounting elements (150) that serve as studs embedded into the panels. In one embodiment, each panel (220) includes two embedded mounting studs (150). The mounting studs (150) extend vertically when the panels (220) are installed. The mounting studs (150) may be placed at conventional spacing such as at 16 inch (41 cm) centers or varying on center spacing such as approximately 22 inch centers as is typical with wood stud construction. The mounting studs (150) extend to a first face of the panels (220) and provide a surface for gluing as well as receiving conventional fasteners such as bolts, screws and/or nails. The mounting studs (150) are lightweight, but provide rigidity and strength to the panels (220).

To mount to corrugated walls, such as sidewalls (1004) of an intermodal container, an inner mounting face (230) of each panel (220has a corrugated surface that is complementary to the corrugated surface of the sidewalls (1004). The corrugated mounting surface (230) includes protruding portions (232) alternating with recesses (234). The protruding portions (232) include a planar face (236) and tapering connection surfaces (238) that lead from the protruding planar face (236) to the planar face of the inner recess (234) and are oblique to the faces (234) and (236). The inner recessed surface (234) and the planar faces (236) of the protruding portions (232) are generally parallel to one another and to the exposed surface on the opposite side of each panel (220). The protruding portions (232), the recesses (234) and the connection surfaces extend generally vertically to align with the complementary portions of the corrugated walls of the intermodal container (1000). The configuration of the panels (220) provides a close fit against the corrugated walls (1004) without gaps.

It can be appreciated that intermodal containers (1000) may be insulated with an insulation layer (100) having combination of the insulation panels (220) and/or the insulation units (120) and/or the insulation inserts (170). Other insulation, such as the planar insulation panels (190), may be added to the insulation layer (100). It may be that for some surfaces or for areas in which there are openings such as windows and doors, the insulation panels (220) may be more appropriate or less appropriate and the insulation units (120), insulation inserts (170) and planar panels (190) may be more or less appropriate for other applications. Moreover, some portions of surfaces may utilize the panels (220) while the other portions along a same wall may utilize a combination with the insulation units (120), insulation inserts (170) and planar insulation panels (190). It can further be appreciated that one face of a wall may be used with one combination of insulating elements while the other wall may have a different combination. It can further be appreciated that additional insulating layers may be added over the top of the insulation units (120), insulation inserts (170) and planar panels (190) and the insulating panels (220). The types of finishing layers may also vary depending on the application and use and the R-value needed to be obtained for the insulation system (100). For some conditions and applications, only a rain screen is needed and it may be advantages to use only insulation units (120) for a thinner profile and to provide open spaces for ventilation.

Although the panels (220) are useful for many applications, intermodal containers (1000) may be constructed irregularly due to welding beads, warping and other manufacturing defects so that an even on-center spacing may not be maintained. With such irregularities, some panels may need to be cut so the panels can spread apart or so the panels can slide together tightly. The use of individual insulation components (120), (170), (190) that fit into a corresponding single recess overcome issues with maintaining alignment of protrusions and corresponding recesses.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.