Patent ID: 12187530

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

FIGS.1-8show an exemplary container10for the transport and storage of bulk materials such as proppant. The container10includes a pair of side walls12,14and a pair of end walls16,18. The side walls12,14are positioned in spaced relationship by the end walls16,18to form an upper rectangular or box structure or simply a box section20of the container10. The side walls12,14and end walls16,18are fabricated using a corrugated sheet material forming vertically-oriented corrugated walls, which structurally reinforce the side walls12,14and end walls16,18. Using corrugated sheet material in this manner eliminates the need for additional structural elements around the box section20, which reduces the overall weight of the box section20such that the height of the box section20may be increased by approximately 10 inches as compared to conventional proppant containers. Additionally, the corrugations in the sheet material effectively increases the volume within the box section20. A top wall22covers the top of the box section20and has an inlet24(FIG.5) formed therein for providing access to an interior of the box section20. A hatch26is mounted to the top wall22so as to cover the inlet24in the top wall22.

In the example shown in the figures, the top wall22is of a generally planar surface, though it will be understood that the top wall22can include one or more surfaces positioned at various angles. The hatch26is connected by hinges28to the top wall22. Latch30is used to secure the hatch26over the inlet24in the top wall22and may include a linkage (not shown) for manipulating the latch30to secure and release the hatch26from the ground in an area adjacent the box section20. A liner material or seal may be affixed around the periphery of the hatch26. This liner material can be of a rubber, elastomeric or polymeric material such that the contents of the container10are sealed within the interior of the container when the hatch26is properly closed over the inlet24.

The inlet24can have a length which is substantially greater than one-half of the width (extending between the end walls16,18) of the top wall22. The width of the inlet24is substantially less than the depth (extending between the side walls12,14) of the top wall22. The elongated configuration of the inlet24assures that corrugated can be received properly and quickly into an interior volume of the container10. The elongated nature of the inlet24avoids problems associated with restricted openings, such as small portholes, that could be formed on the top wall22. The hatch26can be placed over the inlet24. The hatch26can have an area slightly greater than the area of the inlet24to assure that the contents of the container10are retained properly therein in a liquid tight manner. As such, potential damaging effects of liquid penetration through the hatch26is effectively avoided. Furthermore, the placement of the hatch26over the inlet24further avoids the release of dust and silica particles from the interior of the container10.

The container10also includes a pair of side plates32,34extending from a lower edge of the side wall12,14and a pair of end plates36,38extending from a lower edge of the end walls16,18. A radiused corner section44is formed between a side plate32,34and an adjacent end plate36,38. The corner section44tapers from an upper end46to a lower end48adjacent a bottom discharge opening or bottom outlet42. The side plates32,34, end plates36,38and radiused corner sections44form a lower cone-shaped or funnel structure or simply a funnel section40, which extends downwardly from the box section20and terminates at the bottom outlet42. In one embodiment, the funnel section40is fabricated by joining four sections together, wherein each section includes a portion of a side plate32,34, a radiused corner section44and a portion of an end plate36,38. For example as best seen inFIGS.7and8, funnel section40.1is formed by a portion34.1of side plate34, a radiused corner44.1and a portion36.1of end plate36. Another funnel section40.2is formed by a portion34.2of side plate34, a radiused corner44.2and a portion38.2of end plate38. The funnel sections40.1,40.2are welded together at a butt joint40.3formed along a medial line34.3of the side plate34. The remainder of the funnel sections are formed in a similar manner. The box section20and the funnel section40together define an enclosed container storage volume50configured to store bulk materials such as proppant in the container10. The container storage volume50is configured to receive bulk materials such as proppant through the upper inlet24and discharge the bulk material through the bottom outlet42.

In some applications, the bulk material being transported and stored in the container10may have a relatively higher moisture or turbidity, such as wet or dirty proppant that has not been dried in post-mining operations. To this end, the radiused corner sections44provide a smooth transition between the side plates32,34and the end plates36,38that facilitates the smooth and continuous discharge of bulk material from the container10. In addition, portions of the container10may be treated to facilitate handling of such bulk materials. For example, the side plates32,34and the end plates36,38may be fabricated using a stainless steel material or a plastic material for providing a slipperier surface than that of mild steel. Alternately and/or additionally, the interior surfaces of the side plates32,34and the end plates36,38(e.g. the surfaces forming the interior volume of the container) may be coated with a low friction coating such as a PTFE material for reducing the coefficient of friction of the interior surfaces.

A frame52includes vertical posts54disposed at the corners between adjacent side walls12,14and end walls16,18and extend downwardly past the bottom outlet42. Cross beams56extend between vertical posts54along the upper and lower edges of the box section20. A locating cap66, similar to locating cap58, is disposed at the upper end of vertical posts54and has a locating feature such as a pin formed thereon. As best seen inFIGS.8and9, the vertical posts54have an L-shaped cross section with a first leg of the cross section welded to one of the side walls12,14and a second leg of the cross section welded to one of the end walls16,18. In this way, the vertical posts54are integrated into the box section20to provide added storage capacity of the container10. A plug plate60is located in each of the vertical posts54and provides a transition between the box section20and the funnel section40of the container10. In particular, a top region of the plug plate60fits within the L-shaped cross section and a bottom region of the plug plate60matches with the upper end46of the radiused corner section44. The plug plate60angles downwardly to direct bulk material stored in the vertical post54into the funnel section40.

The frame52further includes a base section62which may be placed on the ground, on a vehicle bed or on a hopper stand, a conveyor assembly or similar support structures. The base section62includes cross beams64extending between the lower ends of the vertical posts54. A locating cap58is disposed at the lower end of each vertical posts54and has a locating feature such as a receptacle formed therein for receiving a pin formed on the cap58so that storage containers10may be arranged in stacked relationship.

The base section62support the funnel section40and surrounds the bottom outlet42. To this end, the base section62also includes an angular gusset68located beneath each side plate32,34and a pair of angular gussets70,72located beneath each end plate36,38. Each of the gussets68,70,72may have holes formed therethrough for reducing the weight of the base section62while, at the same time, preserving the structural integrity of the gussets68,70,72. A rectangular shaped reinforcing plate74is affixed around the bottom outlet42so as to provide structural integrity thereto. A sliding gate mechanism (not shown) may be coupled to the reinforcing plate74adjacent to the bottom outlet42for enabling the controlled release of bulk material from the enclosed interior volume50of the container10.

The gussets68,70,72extend inwardly from the cross beams64and terminate at tubular beams76for supporting the weight of the bulk material bearing on the funnel section40and provide a solid and stable configuration for the container10. This arrangement of gussets has been found to optimize the structural integrity of the side plates and end plates for the support of the heavy weight of the bulk material within the interior of the container. The configuration of the angular gussets68,70,72establishes the angle of the side plates32,34and end plates36,38, which are configured to maximize the amount of bulk material that can be contained within the interior volume of the container10, while, at the same time, to discharge the entire contents within the enclosed interior volume50through the bottom outlet42. In particular, the side plates32,34extend at an angle of approximately 37° with respect to horizontal. Similarly, the end plates36,38extend at an angle of approximately 31° with respect to horizontal.

Tubular beams76extend between the cross beams64beneath the side walls12,14. As best seen inFIG.7, the tubular beams76are laterally spaced at a distance larger than the bottom outlet42so as not to impede the flow of bulk material from the container10. The tubular beams76are configured to receive the forks of a forklift truck or similar lifting apparatus, which facilitates lifting and transporting of the container10.

In an exemplary embodiment, the container10may have a width (i.e., between side walls12,14) of approximately 96 inches, a length (i.e. distance between end walls16,18) of approximately 118 inches, and a height (i.e., distance from grade to top of stacking cone) of approximately 127 inches. In this way, the container10is suitable for transportation on a railcar or on a trailer though one skilled in the art, after reading this specification, will understand that other modes of transportation are permissible as well. In order to transport the containers on highways, certain weight restrictions must be addressed. In order to comply with weight restrictions on roads, the total weight of a container10fully loaded with bulk material should be no greater than 52,000 pounds. Containers fabricated in accordance with the detailed description provided herein provides an enclosed interior volume of approximately 600 cubic feet and can safely store about 50,000-51,000 pounds of bulk material, while complying with the above-stated requirements. As previously noted, these containers are also configured for stacking such that a first container is located on the ground, a vehicle bed or on support structure and a second container is located on top of the first container. In this regard, the container10should be fabricated with materials having adequate strength and structural elements having sufficient stiffness to support the load of one or more container in a stacked relationship.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.