Patent ID: 12256505

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the present invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the present invention, since the scope of the present invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides an ecosystem of electrified container(s), railcar(s), ship(s), connection pad(s), and/or semi-trailer(s).

The present invention provides a system (which, in certain embodiments, is an ecosystem) that allows containers to be linked by stacking and locked into place using electrified twist-lock connectors. Further, the system makes use of ambient sunlight to capture and store electricity within batteries contained in each container, for use in the transportation of the container(s), charging of other containers, and to provide electrical power where it may be needed. The ecosystem provides data logging and reporting on the linkage of the containers to each other, ships, railcars, trailers, and connection pads for the purpose of trading the energy contained in the containers and understanding how much energy the containers gather, store, and use. The ecosystem includes the electrification/motorization of railcars and semi-trailers that leverage the electricity stored in the containers for the use of moving the freight in the containers coupled (via the twist-lock connectors) to the ships, railcars, other containers and/or trailers. The present invention also includes wireless radio connections to and from the containers for the purpose of updating computer operating functions, transferring energy generation data and energy usage data to a distributed, cloud-computing data storage and reporting system that provides analytics, billing, and usage information.

Electrified containers in accordance with the present invention are a complete solution for harvesting, storing, and making use of electricity for the intended purpose of propelling the container during transport and providing electrical power to physical locations that may require remote power sources such as in emergency uses. The electrified corner couplings and electrified twist-lock connectors make possible the transfer of electricity to electrified/motorized trailers, ships, other containers and/or railcars. The present invention also makes use of data gathering and reporting to understand the impact of the electricity the containers are gathering and using while moving freight or delivering power to physical locations. Coupled with motivated/electrified ships, trailers, and/or railcars, the present invention uses readily available sunlight to generate electricity that can be used to motivate the freight during its transport journey or power facilities via NEMA connections, connection pads, or cranes that pick it up.

Because the present invention provides an integrated ecosystem, power is moved along with the freight in the most efficient manner possible. In certain embodiments, photovoltaic panels are mounted directly onto the containers being moved, and power is generated and stored in the container that needs to make use of it. Because the present invention specifies how containers couple simply and easily to trailers, railcars, ships and other containers, electricity is easily shared and used without complex or time-consuming and inefficient transferal processes.

Referring now toFIG.1, an electrified shipping container10is shown. Each electrified container10is assigned a unique identifying number. The unique identifying number may be displayed on the exterior of the container10and may be stored permanently in the computer and software code (e.g., embodied as a program executable on the computer) integrated with the electrified container10. The unique identifying number is used to signify all relevant data points related to the container10, e.g., point of origin, owner, manufacturer, etc.

Making reference toFIGS.1and4A-4B, prism panels14(e.g., embodied as a Fresnel lens) are provided that are formed from thin rows of horizontal prisms stacked vertically (seeFIG.4B) on a sheet of flexible transparent material. This is fused to a photovoltaic thin film sheet24to form a sunlight collection system, where sunlight26shining onto the walls of the container10at 45-degrees (or thereabout) is redirected through the rows of prisms14to shine directly onto photovoltaic thin film sheets24, as depicted inFIGS.4A and4B. Making reference toFIGS.1,4A,10,11, and14, the photovoltaic thin film sheets24are mounted to the prism panels14and then are mounted onto the containers' outer walls and roof to occupy the majority of these surfaces.

Making reference toFIGS.1-2B, electricity generated from sunlight26casting onto the sheets24is fed into a charge controller58, which regulates power to charge a battery array18. The battery array18is mounted into the subfloor16(e.g., joist bays) of the container10using battery mounting hardware (e.g., a mounting tray). The computer (which functions as a container controller) associated with the respective container and software code loaded on the computer monitors the battery array18and the charge controller58and logs it into its memory system. The computer may be mounted on the battery tray that retains the battery array18for ease of access and maintenance. For example, the following parameters are monitored and logged: electricity generated by the photovoltaic sheets24, electricity transferred into the battery array18, the unique identifying number(s) of any container10it is connected to, and transferring electricity to and or from, and the power used via a NEMA connection. A wireless network access device is used to make a computer data connection remotely to the container's computer to access logged data and to update the computer's software by using a cloud-based data repository. The cloud-based data repository makes all data available to authorized users of the repository based on permissions and roles assigned to each user.

Making reference toFIGS.3A,3B,10and11, a connection pad20(also labeled as element44inFIG.11and element52inFIG.12) is also provided. The connection pads20function as power adapters to transmit power and data from the containers10to any consumer/provider of electrical power that is not another electrified freight container10. Connection pads20facilitate the connection of electrified freight containers10to electrical systems other than electrified freight containers (e.g., railcars, semi-trailers, ships, etc.). Connection of electrified freight containers to container ships, or other electrified equipment is facilitated through the use of connection protocol ISO/NP 3874. As shown inFIG.3B, the connection pads20include corner castings12that engage corner castings12of an electrified container10(the corner castings12are discussed in greater detail below). Further, the pads20also include one or more outlets22to provide power to an standard electrical device, such as an extension cord.

Now turning toFIGS.5and6, each electrified container10creates a link to another container10, railcar (seeFIG.11), ship (seeFIG.12), connection pad20,44,52(seeFIGS.10-12), or semi-trailer42(seeFIG.1) by using an electrified twist-lock connector28. As shown inFIG.6, the twist-lock connector28includes rubber insulating tubes30, a gold pad32, spring34, and core rod36(made from, for example, brass or copper). The rubber insulating tube30protects the conductor from interference from the coupler. The electrified twist-lock28is a semi-automatic invention in that it is used for both lashing connections and fully-automatic, above lashing linkages between containers10per the ISO 3874 standards for Handling and Securing. To functionally enable a container system to function in a manner consistent with the present disclosure, a standard ISO 3874 twist-lock connector is modified to facilitate the flow of a single current through a single conductor, which is isolated from the twist-lock and the corner casting. The use of a twist-lock connector28at each corner (seeFIGS.5and9) allows independent electrical connections, four on the top and four on the bottom of each freight container10. The flow of electricity and data can be made from within each freight container10to a connected container or solar connection pad20. See, for example,FIGS.3,6, and8. The modified ISO 3874 twist-lock28may be cast in the die-cast mold as depicted inFIG.8.

Once in place, the electrified twist-lock28makes contact with the container10above and the container10, ship, semi-trailer42, railcar, or connection pad20,44,52below it by extending a single-conductor that makes connection with an electrified ISO 1161 corner casting/coupling12. As shown inFIGS.13A and13B, the corner casting12has a main body and further includes a grommet56and button54. The grommet56is used for electrical isolation, while the button54is used as an electrical conductor, and may be embodied as a a flat corrosion-resistant material used to directly conduct electricity. Through the single conductor connection, data and electricity is permitted to flow. As shown inFIG.9, the container10, having four corners and four connections on the top and bottom (total of 8), is therefore able to make a data connection and a power connection with another container10, ship, semi-trailer42, railcar, or connection pad20,44,52below it.

As detailed above, and in use, the present invention employs a container10to house batteries18, a computer, a charge controller58, a wireless network access device, a unique identifying number, electrified corner castings12, mounting hardware, and thin film photovoltaic sheets24to create a container10that can harvest, store, and supply electricity for use before, during, or after the freight transportation. The system makes use of sunlight26shining onto it to generate electricity via the thin film photovoltaic sheets24mounted on the container's exterior walls and roof. The electricity is routed to the charge controller58, which regulates the flow of electricity into the battery array18which is mounted into the subfloor16of the container10via battery mounting hardware.

The computer and software code is linked to the battery array18for the purpose of monitoring each battery cell's health and status, such as charge level, number of charge cycles, available volts. The computer determines if the batteries18in the battery array18in the container10are full. If they are, electricity generated by the photovoltaic sheets24is allowed to pass to the container10electrically connected above or below it to charge its battery array18. The computer is also linked to the charge controller58to log voltage generated by the photovoltaic sheets24, electricity transferred to the batteries18, and errors generated by the charge controller58. The computer is also linked to the electrified corner castings/couplers12to monitor connections to the container10. Based on the unique identifying number of the container10being coupled to it, the software of the computer is programmed to execute instructions that will grant access to transfer electricity to/from the container10. The computer is also linked to the wireless network access device and regulates a data connection to the computer of the container10by other computers attempting to connect to the system.

As exemplified inFIGS.10-12, when a container10is connected to an electrified railcar (FIG.11), electrified semi-trailer42(FIG.10), electrified ship (FIG.12), or connection pad20,44,52, the computer will verify that an electrical connection can be made. Using a verification method, such as a 5-volt verification method, to ensure a reliable connection at all four points of contact can be maintained, a high voltage connection and a data connection are initiated. When the container10is separated from another container10, electrified railcar, electrified semi-trailer42, connection pad20,44,52, or ship, the electrical connection is terminated, and the event is logged into the computer's memory system for later synchronization with the cloud-based control system. Electricity generated, used, and transferred to and from each container10is logged by the computer(s) in each container10and periodically uploaded to the cloud-based data repository and control system for analysis and reporting. Referring specifically toFIG.10, the computer can be used to start, stop and initiate regenerative braking operations of motors46on the semi-trailer. This can be enabled by sensors that are placed within the couplers that feed data into the computer(s) of the container10.

The computer will use logic gates to grant authority based on the unique identifying number of connected containers10, determine if cells within the photovoltaic sheets24are non-functional, determine charging levels for any specific battery in the battery array18, grant authority via the wireless network access device, and grant authority to connected trailers42, ships, and railcars requesting use of the electricity stored in the battery array18.

As is readily apparent from the forgoing, the components of the present invention can be used in semi-trailers, in railcars, utility trailers, or any structure with walls and a roof that receive direct sunlight whether they are designed to move freight or not. For example, the same electricity capture and storage components described can be used to power refrigerated storage containers, heated containers, and any other device used to move any said freight-hauling containers.

In an exemplary embodiment, the electrified ecosystem may be used as follows. The various stakeholders in the global shipping industry (also referred to as “users”) would use the present invention to harvest, store, and use energy to power the storage and transportation of global freight. Users would use the present invention to turn sunlight into a beneficial source of power to move freight without the need to use the various fossil fuels used across the shipping industry. Users could deploy the present invention to power storage facilities, semi-trailers, utility trailers, buses, or ships without the need to refuel and transfer power between transportation platforms. Users could leverage this ecosystem to motivate tractor trailers, railcars, and the ships themselves, as well as linking the ISO shipping containers with each other to increase the capture, storage, and distribution of solar power.

The present invention can be applied to utility trailers, freight trailers, and any freight-hauling container including semi-trailers, railcars, or utility trailers that receive direct sunlight before, during, or after its transport. The present invention can be applied directly to the exterior surfaces of freight ships, busses, vans, delivery vehicles, and railcars.

In accordance with the present invention, a process for cleaning the miniature prismatic bar sheets on the vertical sides of the ISO 668 freight containers is also provided. The process makes use of a gantry-type system similar to the retrofitting assembly (FIG.14) described in this document. The process for cleaning the prismatic sheets resembles the brush assemblies use in commercial car washing systems.

An additional process is also included in the present invention for the repair and replacement of photovoltaic cells and the prismatic sheets. Repair and replacement processes facilitate the removal of the prismatic sheets and the damaged cells by trained workers following documented processes. The use of modular components facilitates rapid, error-free replacement of damaged cells without replacing entire photovoltaic arrays or panel assemblies.

In an exemplary embodiment, the system/ecosystem may be made/built out, as described above, and as follows. Building the present invention requires access to the components listed and a container10to mount them into and/or onto. The photovoltaic thin film panels24are mounted to the exterior walls and roof of the container10using, for example, a marine-grade adhesive that can be melted to allow the removal of panels that become damaged. The design intention behind the use of individual photovoltaic cells24is to minimize functional disruption in that damage to one individual cell will not disrupt the generating abilities of an entire grouping or array of cells. In contrast with conventional photovoltaic panels, damage to one cell24of the present invention will not interrupt the production for all the cells24. Other coupling/adhering techniques, besides the marine grade adhesive, may be used, as appropriate. The twist-lock mechanism28may be formed, in part, using a die cast mold40, as shown inFIG.8.

As shown inFIG.7, an extruder38for producing the prism panels14is shown. This prismatic extruder38follows well-known processes for extrusion, but uses bulk transparent plastic material for the creation of optically suitable prisms.

The battery arrays18are composed of multiple battery cells that are placed into groups and using battery mounting hardware, secured into the subfloor16of the container10, under the flooring, and between the bracing that creates the floor of the container. The computer, charge controller58, and wireless network access device are also mounted in the subfloor16of the container10with the wireless network access device's antenna mounted on an external surface of one end of the container10. The software code for the computer may be loaded into the computer2via a bootstrap process. The cloud-computing data warehouse and control system may be created by using a global public cloud service provider to host and replicate the data and control software.

As shown inFIG.14, a process for retro-fitting existing ISO 668 freight containers to become electrified with photovoltaic cells, batteries, and associated hardware and electronics for the purpose of collecting solar energy, the storage of electrical energy, the electrical connection of, and transfer of electrical energy is shown.FIG.14depicts the gantry-type structure to retrofit existing ISO 668 freight containers with the corner castings12, prism panels14, photovoltaic cells24, and battery array18. Furthermore,FIG.14is conceived of a mobile or semi-permanent station. Using documented processes and trained professionals, the prism panels14, cells24, and battery array18can be attached, while the corner castings12require the removal of existing corner castings in favor of the novel ones discussed herein.

The present invention is dependent upon electrified ships, trailers, and railcars to make the system truly functional and beneficial. However, electrical power can be harvested and used by the containers at the beginning and end of their journeys as well to supply power to shipyards, factories, stores, warehouses, and countless other facilities. Linking the containers by stacking them allows entire cargo ships to arrive at port with fully charged containers ready to power trailers, railcars, and facilities.

The aspects of the present invention described above that incorporate a computer-based data processing system and method described above is for purposes of example only, and may be implemented in any type of computer system or programming or processing environment, or in a computer program, alone or in conjunction with hardware. The present invention may also be implemented in software stored on a computer-readable medium and executed as a computer program on a general purpose or special purpose computer. For clarity, only those aspects of the system germane to the invention are described, and product details well known in the art are omitted. For the same reason, the computer hardware is not described in further detail. It should thus be understood that the invention is not limited to any specific computer language, program, or computer. It is further contemplated that the present invention may be run on a stand-alone computer system or run from a server computer system that can be accessed by a plurality of client computer systems interconnected over an intranet network, or that is accessible to clients over the Internet. In addition, many embodiments of the present invention have application to a wide range of industries. To the extent the present application discloses a system, the method implemented by that system, as well as software stored on a computer-readable medium and executed as a computer program to perform the method on a general purpose or special purpose computer, are within the scope of the present invention. Further, to the extent the present application discloses a method, a system of apparatuses configured to implement the method are within the scope of the present invention.

The present invention has been described in terms of exemplary embodiments solely for the purpose of illustration. Persons skilled in the art will recognize from this description that the invention is not limited to the embodiments described but may be practiced with modifications and alterations limited only by the spirit and scope of the appended claims.