Intermodal container loading and unloading system

Abstract

An intermodal container handling system (10) for collapsing a collapsible intermodal container (11a) comprising a pair of opposing side walls (13aa, 13ab) each hingedly connected to a top (15a) and a floor (17a), respectively, where the walls (13aa, 13ab) remain substantially parallel to each other when the collapsible container (11a) collapses from an expanded configuration to a collapsed configuration, where the walls (13aa, 13ab) remain substantially parallel to each other when the collapsible container (11a) collapses from the expanded configuration to the collapsed configuration. The handling system (10) comprises: a docking assembly (12) adapted for docking of the collapsible intermodal container (11a) in the deployed configuration; a collapsing assembly (14) operatively coupled to the docking assembly (12) via a transport assembly (20) adapted to releasably engage the docked collapsible container (11a) to facilitate movement of the collapsible container (11a) between the docking assembly (12) and the collapsing assembly (14); a folding sub-assembly (16) associated with the collapsing assembly (14), said folding sub-assembly (16) being adapted to releasably engage with a first side wall of the pair of opposing side walls (13a, 13ab), wherein movement of the folding subassembly (16) and the associated first side wall (13a) relative to a second one of the opposing side walls (13ab) moves the container (11a) between the deployed configuration and the collapsed configuration; a stacking assembly (18) operatively coupled to the collapsible assembly (14) via the transport assembly (20) adapted to facilitate movement of the container (11a) between the collapsible assembly (14) and the stacking assembly (18) for stacking in a vertical orientation with another collapsible intermodal container (11b, 11c, 11d) in a collapsed configuration and a vertical orientation.

Description

[0001] Related Applications

[0002] This application claims conventional priority from Australian Provisional Patent Application No. 2022901341, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present invention broadly relates to an intermodal container handling system for collapsing a collapsible intermodal container. The present invention also generally relates to a method of handling a collapsible intermodal container. The present invention also broadly relates to an intermodal container handling system and a method of handling a collapsible intermodal container and at least one additional collapsible intermodal container for unloading the containers from their packed configuration. Background Art

[0004] Constructing a foldable intermodal or freight container is known in the prior art. The foldable container preferably has a modular construction, such as disclosed in the applicant's international patent publication WO2018 / 145140 (WO'140) and PCT application PCT / AU2023 / 050354, which are incorporated herein by reference in their entirety. In a preferred embodiment of WO'140, the top of the box is hinged to the upper side of one wall, and the bottom plate is hinged to the lower side of the opposite wall. The container of this embodiment includes coupling members, which are pivotally connected to the top of the box or the bottom plate at one end and pivotally connected to the associated wall in the opposite wall at the opposite end. The hinged connection between the top of the box and the wall and the bottom plate and the other wall is in the form of a piano hinge, which cooperates with the coupling member to facilitate the collapse and expansion of the foldable container.

[0005] It is also known in the prior art to collapse a foldable freight container using a detachable platform and associated supports together with a mobile machine to facilitate the collapse of an unfolded container. The applicant discloses a collapsible intermodal container stacker in its international patent publication WO2018 / 195578 ​​(WO'578), which is used to collapse and stack multiple containers in a collapsed state, and the entire text of the international patent publication is incorporated herein by reference. In a preferred embodiment of WO'578, the container stacker includes a fixed platform and a pair of guide rails, which are fixed to a base plate for supporting the container during the collapse and subsequent stacking of the container. The container stacker also includes a fixed upright structure, which is fixed to the base plate and is arranged to anchor the side wall of the container to be collapsed. The container stacker also includes a pair of mobile slides, which are slidably mounted on the pair of guide rails and are arranged to releasably engage the opposite side walls of the side walls of the container. The moving skids each include a motorized winch and associated cables temporarily secured to the floor of the container, wherein actuation of the winch retracts the cables, thereby lifting the floor to provide collapse of the container with the opposing sidewalls traveling along the fixed platform toward the fixed upright structure and the anchored sidewalls.

[0006] Such prior art devices and associated practices used in collapsing and stacking foldable containers suffer from reliability and safety issues including their inability to consistently achieve safe and efficient collapse of foldable containers.

[0007] It should be understood that any identification of prior art in this patent specification is not to be taken as an admission that the prior art is common general knowledge in Australia or other countries. Summary of the invention

[0008] The present disclosure provides an intermodal container handling system for collapsing and / or unfolding a collapsible intermodal container, the collapsible intermodal container comprising a pair of opposing side walls, each side wall being hingedly connected to a roof and a floor, respectively, wherein the walls remain substantially parallel to each other when the collapsible container is moved between an unfolded configuration and a collapsed configuration, the handling system comprising:

[0009] A docking assembly adapted for docking of a collapsible intermodal container;

[0010] a collapse assembly operatively coupled to the docking assembly via a transport assembly, the transport assembly adapted to releasably engage a docked collapsible container to facilitate movement of the collapsible container between the docking assembly and the collapse assembly;

[0011] a folding subassembly associated with the collapse assembly, the folding subassembly adapted to releasably engage a first sidewall of the pair of opposing sidewalls, wherein movement of the folding subassembly and the associated first sidewall relative to a second sidewall of the opposing sidewalls moves the container between an expanded configuration and a collapsed configuration;

[0012] A stacking assembly is operatively coupled to the collapsing assembly via a transport assembly, the transport assembly being adapted to facilitate movement of a container in a collapsed configuration between the collapsing assembly and the stacking assembly for stacking or unstacking the container in a vertical orientation with another collapsible intermodal container in a collapsed configuration and in a vertical orientation.

[0013] Preferably, the transport assembly includes a pair of parallel conveyors along which the collapsible intermodal container moves from the docking assembly to the collapsing assembly and then to the stacking assembly.

[0014] Preferably, the pair of parallel conveyors are spaced apart a distance less than the length dimension of the collapsible container, wherein both said conveyors remain in contact with the floor of said container.

[0015] Preferably, each conveyor of the pair of conveyors comprises a plurality of rollers equally spaced apart at a distance less than a cross-sectional width of a floor frame of a floor of said container, thereby ensuring that at least two rollers of the plurality of rollers contact the floor frame during movement of said container between the docking assembly and the stacking assembly.

[0016] Preferably, it further comprises an anchoring subassembly associated with the folding subassembly and adapted to releasably engage with the second side wall, the anchoring subassembly being effective in anchoring the second side wall during movement of the first side wall toward the second side wall via the folding subassembly.

[0017] Preferably, it also includes a structural frame associated with the collapse assembly, the frame including an upper frame assembly and a lower frame assembly.

[0018] Preferably, the folding subassembly comprises a lower trolley and an upper trolley adapted to releasably engage the first side wall of the collapsible container at the collapse assembly, wherein joint movement of the lower trolley and the upper trolley effects collapse of said container.

[0019] Preferably, the lower box car is one of a plurality of lower box cars, each lower box car being slidably mounted on a corresponding lower rail of one or more parallel lower rails associated with the lower frame assembly, each lower box car including a retractable lower box car pin adapted to releasably engage a lower cross beam of a first side wall of a collapsible container during movement of the folding subassembly for collapsing the container.

[0020] Preferably, the upper box car is one of a plurality of upper box cars, each upper box car being slidably mounted on a corresponding upper rail of one or more parallel upper rails associated with the upper frame assembly, and each upper box car including a retractable upper box car pin adapted to releasably engage an upper cross beam of a second side wall of a collapsible container during joint movement of the lower box car and the upper box car for collapsing the container.

[0021] Preferably, the upper box cart of the folding subassembly is actuated via an upper box cart drive motor to slide along the upper guide rail, and the lower box cart of the folding subassembly is actuated via a lower box cart drive motor to slide along the lower guide rail.

[0022] Preferably, it also includes a top lock activator and a bottom lock activator, which are associated with the collapse assembly and are suitable for releasing the top lock and the bottom lock associated with the top and the first wall and with the bottom and the second wall, respectively, thereby allowing the collapsible container to be collapsed via the folding subassembly.

[0023] Preferably, the anchor subassembly includes an upper pin subassembly and a lower pin subassembly fixedly secured to the upper frame assembly and the lower frame assembly, respectively.

[0024] Preferably, the upper and lower carts of the folding subassembly are slidably mounted to the upper and lower frame assemblies, respectively, thereby allowing the first side wall to move toward the second side wall during movement of the folding subassembly and the engaged first side wall toward the anchored second side wall.

[0025] Preferably, the collapse assembly further comprises roof support means and floor support means adapted to releasably contact the roof and floor respectively to support the roof and floor during movement of the folding subassembly and subsequent collapse of the collapsible container from the expanded configuration to the collapsed configuration.

[0026] Preferably, the roof support means is mounted to the upper frame assembly and includes a magnetic coupling adapted to magnetically retain the roof to support the roof during collapse of the collapsible container.

[0027] Preferably, the floor support means is mounted to the lower frame assembly and comprises one or more wheels adapted to contact the floor to support the floor during collapse of the collapsible container.

[0028] Preferably, the collapse assembly further comprises a swing assembly adapted to releasably engage each end frame of a pair of opposing end frames of a collapsible container in an expanded configuration, the swing assembly being rotated toward the outside of the container for opening the pair of end frames to an open position, wherein the end frames are arranged substantially parallel to and along the outwardly facing surface of the first side wall.

[0029] Preferably, the folding subassembly includes one or more end frame lock actuators, which are suitable for respectively actuating end frame locks associated with each of the end frames, and the end frame locks are actuated when the end frames are in the open position to maintain the end frames in the open position when the collapsible container is in the expanded configuration.

[0030] Preferably, the swing assembly includes a swing arm pivotally mounted at one end to the lower frame assembly and mounted at an opposite end to a retractable swing pin assembly adapted to releasably engage with the end frame, wherein rotation of the swing arm enables opening of the end frame between a closed position and an open position when the swing pin assembly is engaged with the end frame.

[0031] Preferably, the swing arm is extendable so that the length of the arm can be adjusted.

[0032] Preferably, the stacking assembly comprises a series of collapsing tines, each collapsing tine being movable between an upright position and a collapsed position, a pair of adjacent tines in the series being adapted to support a collapsible container in a collapsed configuration in a vertical orientation, and another pair of adjacent tines in the series being adapted to support another collapsible container in a collapsed configuration in a vertical orientation and to be separated from the collapsible container.

[0033] Preferably, the collapsible container and another collapsible container are separated by a predetermined lateral spacing via the series of collapsing tines, and the predetermined lateral spacing allows the end frame of the other collapsible container to rotate from an open position to a closed position via a swing assembly for engagement with the second side wall of the collapsible container, thereby maintaining the container and the other collapsible container in a packaging configuration.

[0034] Preferably, the transport assembly includes a lower carriage subassembly mounted to the lower frame assembly and adapted to releasably engage the collapsible container for movement of the collapsible container between the docking assembly, the collapsing assembly, and the stacking assembly.

[0035] Preferably, the transport assembly further comprises an upper carriage subassembly mounted to the upper frame assembly and adapted to releasably engage the collapsible container for movement of the collapsible container with the lower carriage subassembly between the collapsing assembly and the stacking assembly.

[0036] Preferably, the upper slide subassembly and the lower slide subassembly each include a plurality of upper retractable pins and lower retractable pins arranged for releasable engagement with both the first side wall and the second side wall of the collapsible container for movement of the collapsible container while being maintained in an expanded configuration or a collapsed configuration via the retractable pins.

[0037] Preferably, the plurality of lower retractable pins and upper retractable pins of the respective lower slide subassemblies and upper slide subassemblies are adapted to engage with the lower cross beams and upper cross beams of the first side walls and the second side walls of both the collapsible container and the other collapsible container for moving the collapsible container and the other collapsible container from a collapsing assembly to a stacking assembly in a packaging configuration.

[0038] Preferably, the upper and lower carriage subassemblies together enable the collapsible container in a packed configuration to be moved from a collapsing assembly to a stacking assembly and thereafter only via the lower carriage subassembly to another docking assembly for subsequent removal and transport in the packed configuration.

[0039] Preferably, the plurality of upper retractable pins of the upper slide subassembly are adapted to release from the upper cross beams of the side walls of the collapsible container and another collapsible container in the enclosed configuration to allow the collapsible container and another collapsible container to move from the stacking assembly to another docking assembly solely under the influence of the lower slide subassembly.

[0040] Preferably, the docking assembly includes a diverter assembly adapted to longitudinally divert the collapsible container in an expanded configuration for alignment with the collapsing assembly and then place the aligned collapsible container on the pair of parallel conveyors for movement between the docking assembly and the collapsing assembly.

[0041] Preferably, the diverter assembly includes a pair of micro-shifter assemblies positioned at the docking assembly and adapted to contact the collapsible container at respective ones of the opposite ends of the collapsible container for longitudinal and lateral alignment of the container relative to the pair of parallel conveyors.

[0042] Preferably, the pair of nudge subassemblies each include an end nudge plate and a side nudge plate adapted to contact the end frame and the first side wall or the second side wall, respectively, to nudge the container for desired longitudinal and lateral alignment.

[0043] The present disclosure also provides a method of loading and unloading a collapsible intermodal container, the collapsible intermodal container comprising a pair of opposing side walls, each side wall being hingedly connected to a roof and a floor, respectively, wherein the walls remain substantially parallel to each other when the collapsible container is collapsed from an expanded configuration to a collapsed configuration, the method comprising:

[0044] docking the collapsible intermodal container in the deployed configuration at the docking assembly;

[0045] moving a docked collapsible container in a deployed configuration from a docking assembly to a collapsing assembly via a transport assembly configured to releasably engage the collapsible container;

[0046] collapsing a collapsible container at a collapse assembly by: (a) releasably engaging a folding subassembly with a first of the opposing side walls, (b) moving the folding subassembly and the associated first side wall toward a second of the opposing side walls, wherein the container collapses from its deployed configuration to a collapsed configuration;

[0047] The collapsible container in the collapsed configuration is moved from the collapsing assembly to the stacking assembly via the transport assembly for stacking in a vertical orientation with another collapsible intermodal container in the collapsed configuration and vertical orientation.

[0048] Preferably, collapsing the collapsible container involves releasably engaging an anchoring subassembly with the second sidewall, the anchoring subassembly being associated with the folding subassembly for anchoring the second sidewall during movement of the folding subassembly and associated first sidewall toward the anchored second sidewall.

[0049] Preferably, prior to collapsing the collapsing container at the collapsing assembly via the folding subassembly and the anchoring subassembly, the transport assembly is disengaged from at least the first wall of the collapsible container, thereby allowing the second side wall to move relative to the second side wall.

[0050] Preferably, before collapsing the collapsible container at the collapsing assembly via the folding subassembly, the top lock actuator and the bottom lock actuator are actuated to release the top lock and the bottom lock associated with the top and the first side wall and with the bottom and the second side wall, respectively, thereby allowing the first wall to move relative to the second wall.

[0051] Preferably, the folding subassembly and the anchoring subassembly are detached from the first side wall and the second side wall, respectively, before the collapsible container in the collapsed configuration is moved from the collapsing assembly to the stacking assembly via the transport assembly.

[0052] Preferably, the transport assembly engages with the first and second side walls of the collapsible container before the anchoring subassembly and the folding subassembly disengage from the first and second walls, thereby maintaining the collapsible container in a collapsed configuration, wherein the collapsible container remains in the collapsed configuration during movement of the transport assembly and the associated collapsible container to the stacking assembly.

[0053] Preferably, the folding subassembly comprises a lower cart and an upper cart, wherein collapse of the collapsible container at the collapse assembly involves releasable engagement and common movement of the lower cart and the upper cart with the first side wall.

[0054] Preferably, collapsing the collapsible container further involves supporting the roof and floor via respective roof and floor support means adapted to releasably contact the roof and floor at the collapsing assembly to support the roof and floor during movement of the folding subassembly and subsequent collapsing of the collapsible container from an expanded configuration to a collapsed configuration.

[0055] Preferably, the roof lifting means and the floor lifting means are released from the roof and the floor, respectively, before the collapsible container in the collapsed configuration is moved from the collapsing assembly to the stacking assembly via the transport assembly.

[0056] Preferably, collapsing the collapsible container involves a preliminary step of releasably engaging a swing assembly with each of a pair of opposing end frames of the container in an expanded configuration at a collapse assembly, the swing assembly being rotated toward the exterior of the container for opening the pair of end frames to an open position, wherein the end frames are arranged substantially parallel to and along the outwardly facing surface of the first side wall.

[0057] Preferably, collapsing the collapsible container involves an initial step of actuating end frame locks configured to hold corresponding ones of the end frames in a closed position when the collapsible container is in the expanded configuration, the end frame locks being actuated via end frame lock actuators.

[0058] Preferably, it also includes stacking the collapsible container in a collapsed configuration at the stacking assembly, and then stacking another collapsible container in a collapsed configuration in a vertical orientation at the stacking assembly and separating from the collapsible container.

[0059] Preferably, it also includes moving the stacked collapsible containers and another collapsible container in a collapsed configuration from the stacking assembly to the collapsing assembly at a fixed lateral spacing via a transport assembly, wherein the end frame of the other collapsible container is rotated inwardly from an open position to a closed position via a swing assembly for engaging with the second side wall of the collapsible container, thereby maintaining the container and the other collapsible container in a packaging configuration.

[0060] Preferably, the collapsible container in the packed configuration is returned to the stacking assembly via the transport assembly and then moved to another docking assembly via the transport assembly for subsequent removal and shipping in the packed configuration.

[0061] Preferably, the docking assembly includes a diverter assembly arranged to longitudinally and / or laterally divert the collapsible container in the expanded configuration at the docking assembly for alignment with the collapsing assembly, and then move the collapsible container between the docking assembly and the collapsing assembly via the transport assembly.

[0062] An unfolding subassembly is associated with an unfolding assembly and is configured to receive another collapsible container in a collapsed configuration from a stacking assembly via a transport assembly, the unfolding subassembly being arranged to unfold the other collapsible container at the unfolding assembly by: (i) releasably engaging the unfolding subassembly with a first side wall of the other container, (ii) moving the unfolding subassembly and the associated first side wall away from a second side wall of the opposite side walls of the other container, wherein the container unfolds from its collapsed configuration to an unfolded configuration, and (iii) moving an end frame of the other container from an open configuration to a closed configuration for engaging with the second side wall of the other container, thereby maintaining it in the unfolded configuration.

[0063] Preferably, the transport assembly comprises a pair of parallel conveyors along which the packaged container moves from the docking assembly to the unfolding assembly and then between the unfolding assembly and the stacking assembly. More preferably, the pair of conveyors is also arranged to move another collapsible container from the unfolding assembly to another docking assembly. Still more preferably, the pair of parallel conveyors are spaced apart by a distance less than the length dimension of the container, wherein both of the conveyors remain in contact with the pair of opposing side walls of either or both of the collapsible container and the other collapsible container. Even more preferably, each of the pair of conveyors comprises a plurality of rollers equidistantly spaced apart by a distance less than the cross-sectional width of the wall frame of each of the pair of side walls of either or both of the containers, thereby ensuring that at least two of the plurality of rollers contact each wall frame during movement of the packaged container between the docking assembly and the unfolding assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] In order to achieve a better understanding of the nature of the present invention, preferred embodiments of the intermodal container handling system together with other aspects of the present technology will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0065] Figure 1A and Figure 1Bis an isometric detail view of an intermodal container handling system of a preferred embodiment of the first aspect of the present invention shown together with a collapsible intermodal container in an expanded configuration;

[0066] Figure 2 is an isometric view of the preferred embodiment intermodal container handling system of FIG. 1 shown without the collapsible intermodal container and associated equipment;

[0067] Figure 3 yes Figure 2 A plan view of an intermodal container handling system according to a preferred embodiment of the present invention;

[0068] FIG. 4A to FIG. 4C is an isometric detail view of a transport assembly derived from the preferred embodiment container handling system of the preceding drawings;

[0069] Figure 5A and Figure 5B From Figure 1 to Figure 3 An isometric detailed view of a lower folding subassembly and an upper folding subassembly obtained by collapsing the assembly of the preferred embodiment of the container handling system;

[0070] FIG. 6A to FIG. 6D From Figure 1 to Figure 3 An isometric detailed view of the upper folding subassembly and the sliding frame subassembly of the container handling system of the preferred embodiment;

[0071] 7A to 7D Figure 1 to Figure 3 An isometric view of a carriage subassembly of a transport assembly and a folding subassembly of a collapse assembly of a preferred embodiment of a container handling system;

[0072] Fig. 8A and Figure 8B From Figure 1 to Figure 3 An isometric detailed view of a floor support device obtained from a container handling system of a preferred embodiment of the present invention;

[0073] 9A to 9C From Figure 1 to Figure 3 An isometric detailed view of a top support device of a container handling system according to a preferred embodiment of the present invention;

[0074] Fig. 10A and Fig. 10B From Figure 1 to Figure 3 An isometric detailed view of the swing assembly of the collapse assembly of the preferred embodiment of the container handling system;

[0075] Fig.11A and Fig. 11B From Figure 1 to Figure 3An isometric plan view of a stacking assembly and its associated collapsed tines obtained by the container handling system of the preferred embodiment of the present invention;

[0076] FIG. 12A to FIG. 12D From Figure 1 to Figure 3 An isometric detailed view of a diverter assembly and its associated subassemblies obtained in accordance with a preferred embodiment of a container handling system;

[0077] Figures 13 to 27 is an isometric elevation view of a method of handling a collapsible intermodal container according to a preferred embodiment of the second aspect of the present invention, showing sequential steps of collapsing an intermodal container in a packed configuration together with at least one further collapsible intermodal container;

[0078] Fig.28 is a schematic diagram of an intermodal container handling system and an associated method for unloading a collapsible intermodal container in a packed configuration and at least one further collapsible intermodal container according to a preferred embodiment of the third and fourth aspects of the present invention. DETAILED DESCRIPTION

[0079] As shown in Figure 1 to Figure 3 As can be seen in the figure, there is an intermodal container handling system 10 of a preferred embodiment of the first aspect of the present invention, which is configured for collapsing an intermodal container 11a. The collapsible intermodal container 11a of this embodiment includes a pair of opposing side walls 13aa and 13ab, each of which is hingedly connected to the floor 17a and the box roof 15a, respectively, wherein when the collapsible container 11a moves between the expanded configuration and the collapsed configuration, the walls 13aa / ab remain substantially parallel to each other. It should be understood that the collapsible container 11a is constructed in other ways according to the applicant's co-pending Australian provisional patent application No. 2022901112. The disclosure of the specification of the Australian provisional patent application should be understood to be included herein in its entirety by this reference.

[0080] The intermodal container handling system 10 of the preferred embodiment of the first aspect broadly comprises:

[0081] a docking assembly 12 adapted for docking with the collapsible intermodal container 11a in the deployed configuration;

[0082] a collapsing assembly 14 comprising a folding subassembly 16 adapted to collapse the container 11a from its deployed configuration to a collapsed configuration;

[0083] A stacking assembly 18 is arranged for stacking the collapsed collapsible container 11a in a vertical orientation with another collapsible intermodal container (not shown) also in a collapsed configuration and in a vertical orientation.

[0084] In this embodiment, the intermodal container handling system 10 also includes a transport assembly 20 that is operatively coupled to the docking assembly 12, the collapsing assembly 14, and the stacking assembly 18 to facilitate movement of collapsible containers such as 11a between the assemblies 12 / 14 / 18. The transport assembly 20 includes a pair of parallel conveyors 22a and 22b along which the collapsible container 11a moves from the docking assembly 12 to the collapsible assembly 14 and then to the stacking assembly 18. The parallel conveyors 22a / b are spaced apart a distance less than the length dimension of the collapsible container 11a, wherein both of the conveyors 22a / b remain in contact with the container 11a. Figure 1B As best seen in FIG. 1 , the pair of conveyors 22a / b each include a plurality of rollers, such as 24aa and 24ab, spaced equidistantly from one another by a distance less than the cross-sectional width of a floor frame (not shown) of the floor 17a. The spacing ensures that at least two of the plurality of rollers, such as 22aa / ab, contact the floor frame during movement of the container 11a between, for example, the docking assembly 12 and the collapse assembly 14.

[0085] In this embodiment, the intermodal container handling system also includes a structural frame, generally shown at 26, which includes an upper frame assembly 28 and a lower frame assembly 30. Figure 2 As can be seen in the figure, the upper frame assembly and the lower frame assembly 28 / 30 are each made of a plurality of relatively large cross-section structural members, each of which has a maximum length that can be accommodated and transported in a 40-foot container. This detachable construction requires prefabricated joint brackets such as 27a for rigidly connecting adjacent structural members such as 25a and 25b. The pair of parallel conveyors 22a / b of the transport assembly 20 are mounted to the lower frame assembly 30. The transport assembly 20 also includes a lower slide subassembly shown at 32a and 32b mounted to the lower frame assembly 30, and an upper slide subassembly shown at 34a and 34b mounted to the upper frame assembly 28.

[0086] As can be seen in FIGS. 4-7 , the lower carriage subassembly 32a / b includes a pair of lower carriages 36a / b that are slidably mounted to a pair of lower conveyor rails 40a / b, respectively. Similarly, the upper carriage subassembly 34a / b includes a pair of upper carriages 38a / b that are slidably mounted to a pair of upper conveyor rails 42a / b, respectively. The lower conveyor rails 40a / b are mounted to the lower frame assembly 30 along with the pair of parallel conveyors 22a / b, and the upper conveyor rails 42a / b are mounted to the upper frame structure 28, wherein one of the pair of upper carriages 38a is vertically aligned with a corresponding lower carriage of the pair of lower carriages 36a and the other of the pair of upper carriages 38b is vertically aligned with the other of the pair of lower carriages 36b.

[0087] In this embodiment, each of the lower carriages 36a / b and the upper carriages 38a / b includes a plurality of lower and upper retractable pins such as 44aa to 44ah and 46aa to 46ah arranged for releasable engagement with the collapsible container 11a for movement of the collapsible container along the pair of parallel conveyors 22a / b. Figure 1B As can be seen in FIG. 1 , the outermost retractable pins such as 44aa and 44ah are arranged to releasably engage the first side wall 13aa and the second side wall 13ab of the collapsible container 11a in the expanded configuration for movement from the docking assembly 12 to the collapsed assembly 14. In this embodiment, the retractable pins such as 44aa and 46aa are combined with self-lubricating linear bearings 31aa and 33aa, see FIG. Fig. 7A and Figure 7B .like Figure 6C and Fig.6D As can be seen in the figure, in the collapsed configuration of the collapsible container 11a, adjacent upper retractable pins such as 46bg and 46bh of the upper slides such as 38b are arranged to releasably engage with the first and second side walls 13aa / ab of the container 11a. Similarly, adjacent lower retractable pins such as 44bg and 44bh of the lower slides such as 36b are arranged to releasably engage with the first and second side walls 13aa / ab of the container 11a. Therefore, the container 11a in the collapsed configuration can be moved between the collapsing assembly 14 and the stacking assembly 18 via the lower slide subassembly 32a / b and the upper slide subassembly 34a / b.

[0088] It will be appreciated that the lower carriages 36a / b and upper carriages 38a / b of the lower carriage subassembly 32a / b and upper carriage subassembly 34a / b of the transport assembly 20 are thus effective in both moving the collapsible container 11a and maintaining it in either the expanded or collapsed configuration. In this example, lower and upper retractable pins such as 44aa to 44ah and 46aa to 46ah are adapted to engage lower and upper cross beams (not shown) of the first and second side walls 13aa, 13ab of the collapsible container 11a, respectively. As best seen in FIG. 6 , the lower carriages 36a / b and upper carriages 38a / b are driven for sliding movement along the lower conveyor rails 40a / b and upper conveyor rails 42a / b, respectively, via the lower and upper endless conveyor drive belts 37a / b, 39a / b. An upper conveyor drive belt such as 39b is driven at one end of an upper conveyor rail 42b via a conveyor drive motor 41b connected to an associated conveyor drive pulley 43b. The opposite end of the upper rail 42b includes a conveyor drive pulley 45b engaged by the drive belt 39b. It should be understood that the lower carriage subassembly 32a / b has a similar construction, including a lower conveyor drive belt such as 47a, which extends the entire length of the lower frame assembly 30 and includes a conveyor drive motor 49aa / ab and associated pulleys 51aa / ab located at both ends of the lower conveyor rails 40a and 40b.

[0089] In this embodiment, the folding subassembly 16 of the collapse assembly 14 includes four (4) lower box cars and four (4) upper box cars of substantially identical construction. For simplicity, the folding subassembly 16 is described and labeled as a pair of lower box cars 48a and 48b and a pair of upper box cars 50a and 50b adapted to releasably engage the first side wall 13aa of the collapsible container 11a. The loading and unloading system 10 also includes an anchoring subassembly that includes four (4) lower pin subassemblies and four (4) upper pin subassemblies, but for simplicity, is described and labeled as lower pin subassemblies 52a and 52b and upper pin subassemblies 54a and 54b that are fixedly secured to the lower frame assembly 30 and the upper frame assembly 28, respectively. The lower carts 48a / b of the folding subassembly 16 each include a retractable lower cart pin 56a / b adapted to releasably engage the lower cross beam of the first side wall 13aa, and the upper carts 50a / b each include a retractable upper cart pin 58a / b adapted to releasably engage the upper cross beam of the first side wall 13aa of the container 11a. The lower carts 48a / b and the upper carts 50a / b are slidably mounted to lower and upper sliding rail pairs 60a / b and 62a / b, respectively, which are mounted to the lower frame assembly 30 and the upper frame assembly 28. In this embodiment, the lower pin assembly 52a / b and the upper pin assembly 54a / b are fixedly fixed to the lower sliding rail 60a / b and the upper sliding rail 62a / b, respectively, and are adapted to releasably engage the lower cross beam and the upper cross beam of the second side wall 13ab of the container 11a. The lower box car 48a / b and the upper box car 50a / b are operatively connected to the lower box car drive motor 53a / b and the upper box car drive motor 55a / b, which are respectively mounted to the fixed lower pin assembly 60a / b and the upper pin assembly 62a / b. Each drive motor such as 53a / b is actuated to slide the lower box car 48a / b forward and backward along the corresponding sliding rail 60a / b.

[0090] It will be appreciated that the collapse of the collapsible container 11a is achieved at the collapse assembly 14 via the operation of the folding subassembly 16. In this embodiment, the lower box car 48a / b and the upper box car 50a / b releasably engage the lower and upper cross beams of the first side wall 13aa, and the lower pin assembly 52a / b and the upper pin assembly 54a / b releasably engage the second side wall 13ab. It will then be appreciated that the movement of the lower box car 48a / b and the upper box car 50a / b and the associated first side wall 13aa toward the second side wall 13ab causes the container 11a to collapse from its deployed configuration to a collapsed configuration. During this collapse operation, the second side wall 13ab is anchored at the collapse assembly 14 via the lower pin assembly 52a / b and the upper pin assembly 54a / b. In this embodiment, the upper retractable cart pin 58a / b for each of the upper carts 50a / b together with the lower pin subassembly 52a / b of the anchor subassembly serves the secondary function of releasing the top and floor locks (see Figure 5B ). The bottom plate lock and the top box lock are constructed according to the disclosure of the applicant's co-pending Australian provisional patent application No. 2022901112.

[0091] As can be seen in Figures 8 and 9, the collapse assembly 14 also includes a floor support device 57 and a box top support device 59, which are adapted to releasably contact the floor 17a and the box top 15a respectively to support the floor and the box top during the collapse of the collapsible container 11a. The box top support device 59 is mounted to the upper frame assembly 28 and includes a magnetic coupling 61, which is used to magnetically retain the box top 15a to support the box top. The floor support device 57 is mounted to the lower frame assembly 30 and includes one or more wheels such as 66, which are adapted to contact the floor 17a to support the floor during the collapse of the collapsible container 11a. The box top support device 59 includes a telescopic support 68, and the magnetic coupling 61 swings around the telescopic support to accommodate the tilt of the box top 15a during the collapse of the collapsible container 11a. The retractable struts 68 are mounted to an upper carriage support 70 that is configured to traverse the upper frame structure 28 during collapse of the collapsible container 11a. The floor support 62 includes a pivot arm 72 having a wheel 66 mounted to a distal end thereof. The pivot arm 72 pivots about a lower support beam 74 mounted to the lower frame structure 30. The floor support 57 also includes a hydraulic actuator 76 that is pivotally anchored to the lower support beam 74, wherein an associated reciprocating rod 78 of the lower support beam is secured to the pivot arm 72 approximately midway along the length of the lower support beam. Thus, the pivot arm 72 pivots about the floor beam 74 under the action of the hydraulic actuator 76, which rocks within the beam 74 while driving the pivot arm 72 upward or downward as desired.

[0092] As can be seen in FIG. 10 , the collapse assembly 14 also includes a swing assembly 80 mounted to the lower frame assembly 30. The swing assembly 80 is effectively replicated at each end of the collapse assembly 14 and is adapted to releasably engage each of a pair of opposing end frames 19aa and 19ab of the collapsible container 11a in the expanded configuration. The swing assembly 80 is designed to rotate outwardly of the collapsible container such as 11a for opening the pair of end frames 19aa / ab to an open position in which the end frames are substantially parallel to and disposed along the outwardly facing surface of the first side wall 13aa. In this embodiment, the swing assembly 80 includes a swing arm 82 that includes a turntable 84 pivotally mounted at one end to a base plate 86 associated with the lower frame assembly 30. The swing arm 82 is mounted at the opposite end to a retractable swing pin subassembly 88, which is adapted to releasably engage with a corresponding end frame such as 19ab, wherein rotation of the swing arm 82 effects opening of the end frame 19aa between a closed position and an open position. The swing assembly 80 also includes a swing motor 90, which is mounted to the base plate 86 and operatively coupled to the turntable 84 to effect rotation thereof. In this embodiment, the swing arm 82 is extendable, having a telescopic construction, so that the length of the arm 82 can be adjusted to change the length of the arm during opening or closing of the end frame 19aa / ab if necessary.

[0093] As can be seen in FIG. 11 , the stacking assembly 18 of this embodiment includes a series of collapse tines 92aa to 92ea and their relative pairs 92ab to 92eb, each collapse tine being independently movable between an upright position and a collapsed position. It should be understood that adjacent tines such as 92aa / ba and 92ab / bb are spaced apart and adapted to support a collapsible container such as 11a in a collapsed configuration in a vertical orientation. Similarly, the relative pairs 92da / ea and 92db / eb of adjacent tines are spaced apart and adapted to support another collapsible container such as 11d in a collapsed configuration in a vertical orientation. In this embodiment, the collapsible container 11a and another collapsible container 11d are separated by a predetermined lateral spacing via the series of collapse tines 92aa to 92ea and 92ab to 92eb, which allows the end frames 19da and 19db of another collapsible container 11d to rotate from an open position to a closed position. It will be appreciated that the end frames 19da / db in the closed position are aligned with the second side wall 13ab of the collapsible container 11a for engagement therewith, thereby retaining said container 11a and the further collapsible container 11 in a packed configuration.

[0094] As can be seen in Fig. 12, the docking assembly 12 of this embodiment includes a diverter assembly 96 mounted to the lower frame structure 30 and adapted to longitudinally divert collapsible containers such as 11a in the expanded configuration at the docking assembly 12. This longitudinal diversion of the collapsible container 11a is intended to align the collapsible container 11a with the collapse assembly 14 and then ultimately place the aligned collapsible container 11a on the pair of parallel conveyors 22a / b for movement between the docking assembly 12 and the collapse assembly 14. In this example, the diverter assembly 96 includes a pair of micro-shift sub-assemblies 98a and 98b, which are substantially mirror images of each other, including a pair of opposing walls 99aa / ab and 99ba / bb, one of the walls such as 99ba being fixed and the other wall 99bb being hinged around the lower frame assembly 30. The micro-shift subassembly 98a / b also includes an end wall 99ac / bc positioned between corresponding ends of the opposing walls 99aa / ab and 99ba / bb and hinged about the lower frame structure 30. Thus, each micro-shift subassembly 98a / b surrounds a corresponding one of the opposing ends of a collapsible container such as 11a to micro-shift the collapsible container for placement at the docking assembly 12. Each of the opposing walls and end walls such as 99ba / bb / bc has an upper inclined surface 101ba / bb / bc for sliding contact with the collapsible container 11a during placement at the docking assembly 12. Each inclined surface such as 101bc includes a plurality of wear plates such as 102bc, which in this example are made of high density polyethylene (HDPE). Opposing walls and end walls such as 99ba / bb / bc also each include rollers 103ba / bb / bc mounted within upright and inwardly facing surfaces 105ba / bb / bc of the micro-shifter assembly 98b for rolling contact with corresponding faces of the collapsible container 11a. Articulated adjacent walls such as 99ab and 99ac are each articulated for lowering or raising via actuator rods such as 104ab and 104ac.

[0095] like Fig.12DAs best seen in the drawings, the diverter assembly 96 of this embodiment also includes four (4) support roller assemblies 106a to 106d oriented parallel to the longitudinal dimension of the collapsible container 11a and mounted to the lower frame assembly 30 in opposing pairs. One pair of roller lift assemblies such as 106a and 106b contacts the lower cross beam of the first side wall 13aa of the container 11a, while another pair of roller lift assemblies 106c and 106d contacts the lower cross beam of the second wall 13ab of the container 11a. Each roller lift assembly such as 106a includes a series of adjacent rollers 108a to 108h positioned side by side and parallel to each other within the upper lift housing 110a. The upper lift housing 110a is coupled to the lower lift housing 112a via lift shafts 114aa and 114ab. The lifting device such as 106a also includes a hydraulic lifter 116a, which is positioned between the lifting shafts 114aa / ab and is designed to raise and lower the upper shell 110a and its associated rollers 108a to 108h relative to the lower shell 112a. The lower shells 112a to 112h are mounted to the lower frame structure 30, wherein independent operation of the lifting devices 106a to 106d facilitates alignment of containers such as 11a under the influence of the diverter assembly 96.

[0096] like Figures 13 to 27 As can be seen in the preferred embodiment of the method of handling a collapsible intermodal container of the second aspect of the present invention, there is a method of handling a collapsible intermodal container of the preferred embodiment of the second aspect of the present invention. In this embodiment, the collapsible container 11a is substantially the same as the intermodal container of the exemplary deployment of the intermodal container handling system 10 of the first aspect of the present invention. Similarly, the intermodal container handling system 10 of the preferred embodiment of the first aspect of the present invention is used to implement the preferred method of the second aspect of the present invention. Therefore, the reference numerals of the components of the preferred embodiment of the first aspect are the same as the reference numerals of the components of the method of the preferred embodiment of the second aspect of the present invention.

[0097] The method of loading and unloading a collapsible intermodal container 11a of the preferred embodiment of the second aspect broadly comprises:

[0098] The collapsible intermodal container 11a in the expanded configuration is docked at the docking assembly 12 (see Fig.13 );

[0099] moving the docked collapsible container 11a in the deployed configuration from the docking assembly 12 to the collapsing assembly 14 via a transport assembly 20 configured to releasably engage the collapsible container 11a (see FIG. 14 );

[0100] Collapsing the collapsible container 11a at the collapse assembly 14 by: (a) releasably engaging the folding subassemblies 34a and 34b with a first of the opposing side walls 13aa / ab of the container 11a, (b) moving the folding subassembly 34a / b and the associated first side wall 13aa toward a second of the opposing side walls 13aa / ab, wherein the container 11a collapses from its deployed configuration to a collapsed configuration (see FIGS. 15-19 );

[0101] The collapsible container 11a in a collapsed configuration is moved from the collapsing assembly 14 to the stacking assembly 18 via the transport assembly 20 for stacking in a vertical orientation with another collapsible intermodal container 11d in a collapsed configuration and vertical orientation (see FIG. 20 ).

[0102] With respect to step 1, the collapsible container 11a is lowered into the docking assembly 12, with rollers such as 103ba providing rolling movement on the side walls 13aa of the container 11a, and horizontal pads of upper inclined surfaces such as 101bb protecting the side walls such as 13ab during positioning (see Fig. 12B and Fig. 12C ). Typically, lifting and lowering of the container 11a into the docking assembly 12 is accomplished via a forklift (not shown). The collapsible container 11a is placed on the pair of opposing roller lifts, such as 106a and 106b, which in operation adjust (i) the relative height of the container 11a in preparation for lowering it onto the pair of roller conveyors 22a / b, and (ii) the effective length of the container 11a on the roller conveyors 22a / b. It will be appreciated that the micro-shift subassembly 98a / b is actuated to move the unfolded container 11a on the roller lifts 106a / b so as to properly position the container 11a at the docking assembly 12 before the container 11a is moved to the collapsing assembly 14.

[0103] Regarding step 2, the hinged walls such as 99ab and 99ac of the micro-shift subassembly 98a are lowered approximately 90 degrees to allow the deployed container 11a to be moved out of the docking assembly 12 (see Fig. 12A ). The lower carriage subassembly 32a / b of the transport assembly 20 is retracted via retractable pins such as corresponding retractable pins in 44aa and 44ah (see Figure 1B and Figure 4A) releasably engage the opposing side walls 13aa and 13ab of the deployed container 11a. In this embodiment, all retractable pins such as 44aa to 44ah associated with the associated carriage 36a of the carriage subassembly 32a move together and are driven up and down by independent drive motors. It will be understood that only the outermost retractable pins such as 44aa / ah engage the deployed container 11a, while the central retractable pins 44ab to 44ag are positioned in the channel of the floor 17 between adjacent floor members (not shown). The lower carriage subassembly 32a / b, including the conveyor drive motor 49aa / ab and the associated pulley 51aa / ab, achieves movement of the lower carriage 36a / b via the lower conveyor drive belt 47a / b. The container 11a is thus moved out of the docking assembly 12 along the pair of roller conveyors 22a / b toward the collapse assembly 14 under the action of the lower carriage subassembly 32a / b.

[0104] With respect to step 3, before the collapsible container 11a is collapsed at the collapse assembly 14, the method involves aligning the swing assembly 18 with the collapsible container 11a at the opposite end of the collapse assembly 14 in the expanded configuration (see Fig. 10A ) is a preparatory step for releasably engaging the corresponding end frames of the pair of opposite end frames 19aa and 19ab of the collapsible container 11a of the container 11a. The swing assemblies such as 80 are each rotated toward the outside of the container 11a to open the pair of end frames 19aa / ab to an open position. In this embodiment, the retractable swing pin subassembly 88 releasably engages the end frames such as 19ab, wherein the rotation of the swing arm 82 achieves the opening of the end frame 19ab. The end frames 19aa / ab are thus rotated 270 degrees from the closed position to the open position, in which these end frames are retained by actuation of the end frame locking pins. It should be understood that before opening the end frames 19aa / ab, the end frame locks associated with the upper cross beams of each end frame 19aa / ab must be actuated via end frame lock actuators such as 51aa and 51ba fixed to the upper frame assembly 28 (see Figure 5B and Fig. 16B ).

[0105] With regard to step 3, before the collapsible container 11a collapses at the collapsible assembly 14, both the floor support means such as 57 and the roof support means such as 59 contact the floor 17 and the roof 15 to support the floor and the roof (see Fig. 16B and Fig. 16C). It will be appreciated that the wheels such as 66 of the floor support 57 contact the floor members of the floor 17 and the magnetic coupler 61 of the top support 59 is electronically actuated to magnetically attach to the top 15. The top and floor locks associated with the top 15 and floor 17 are released via top and floor lock actuators which, in this embodiment, take the form of upper retractable cart pins such as 58a / b and lower pin subassemblies 52a / b (see Figure 5B ). It will be appreciated that in alternative embodiments, the floor actuator and the top actuator may be operated and mounted independently of the folding subassembly 16.

[0106] With regard to step 3, the folding subassembly 16, which has been engaged with the associated first side wall 13aa, moves toward the second side wall 13ab, wherein the container 11a gradually collapses from its deployed configuration to the collapsed configuration (see FIGS. 17 and 18). To allow this collapsing action, the lower carriage subassembly 32a / b is first disengaged from the first and second walls 13aa / ab of the collapsible container 11a (see Fig. 8A and Fig. 9A ). In this embodiment, the second side wall 13ab is anchored in a fixed manner via an anchoring subassembly or in this example via a lower pin assembly 52 / b and an upper pin assembly 54a / b. It will be understood that the bottom plate support device 57 and the box top support device 59 support the box top 15a and the bottom plate 17a respectively during the collapse of the container 11a. The lower box car 48a / b and the upper box car 50a / b of the folding subassembly 16 move together. The bottom plate support device 57 and the box top support device 59 cooperate in their movement to ensure that the support of the bottom plate 17a and the box top 15a is maintained during the collapse of the container 11a. It should be understood that when the collapsible container 11a approaches its collapsed configuration, the bottom plate support device 57 and the box top support device 59 will be released from the bottom plate 17a and the box top 15a. The floor supports 57 and roof supports 59 are moved out of the collapsible container 11a to ensure that they do not hinder the collapse of the container 11a in its final stage (see Figure 19).

[0107] With respect to step 4, both the lower carriage subassembly 32a / b and the upper carriage subassembly 34a / b are positioned in the collapse assembly 14 for releasable engagement with the container 11a in the collapsed configuration (see Figure 6C and Fig.6D). It will be understood that the upper slide 38a / b moves on the upper frame assembly 28 via a drive motor, pulley and endless drive belt system, which has a similar construction and operates in the same manner as the corresponding components of the lower slide subassembly 32a / b. The lower retractable pins and upper retractable pins such as 44ag / ah and 46ag / ah are extended for engagement with the first and second side walls 13aa / ab of the container 11a in the collapsed configuration. The collapsed container 11a is moved from the collapsing assembly 14 to the stacking assembly 18 via the lower slide subassembly 32a / b and the upper slide subassembly 34a / b by folding down all but one of the opposing collapsing tine pairs of the stacking assembly 18, such as 92aa and 92ab (see Fig.19B ). It will be appreciated that the lower retractable pins 44ag / ah and upper retractable pins 46ag / ah of the lower and upper carriage subassemblies 32a / b, 34a / b serve the secondary function of retaining the container 11a in its collapsed configuration as it moves toward and into the stacking assembly 18. The adjacent collapse tines 92ba and 92bb are raised to retain the collapsed container 11a in its vertical orientation (see FIG. 1 ) upon release of the lower and upper carriage subassemblies 32a / b, 34a / b. Fig. 20B ).

[0108] The method of this embodiment involves repeating the process described in the previous paragraphs for the second collapsible container 11b, the third collapsible container 11c and the fourth collapsible container 11d, respectively. In this example, the fourth container is interpreted as "another container" as broadly defined in this specification. The method may alternatively involve the collapse of one or two other containers, where "another container" is understood to be the second container 11b or the third container 11c. Figures 21 to 22 show the process of collapsing the second container 11b, the third container 11c and the fourth container 11d, respectively. In this example, the fourth container is interpreted as "another container" as broadly defined in this specification. The method may alternatively involve the collapse of one or two other containers, where "another container" is understood to be the second container 11b or the third container 11c. Fig. 27 The additional steps involved in the method of this preferred embodiment of the second aspect of the invention are shown.

[0109] The method of loading and unloading a collapsible intermodal container of a preferred embodiment of the second aspect further comprises:

[0110] Moving the collapsed containers 11a to 11d from the stacking assembly 18 to the collapsing assembly 14 via the transport assembly 20 (see FIGS. 21 and 22 );

[0111] The end frames 19da and 19db of the fourth or further collapsible container 11d are closed for engagement with the second side wall 13ab of the first collapsible container 11a, thereby maintaining the first collapsible container and the further container 11d in the enclosed configuration (see FIGS. 23 and 24). Fig.24 );

[0112] Moving the containers 11a to 11d in the packed configuration from the collapsing assembly 14 to the stacking assembly 18 (see FIG. 25 );

[0113] The containers 11a to 11d are moved from the stacking assembly to another docking assembly via the transport assembly for subsequent removal and shipment in a packed configuration (see FIGS. 26 and 27). Fig. 27 ).

[0114] Regarding additional step 1, the lower carriage subassembly 32a / b and the upper carriage subassembly 34a / b engage the collapsed containers 11a to 11d positioned at the stacking assembly 18 (see Fig.21B and Fig. 21C ). The lower retractable pins 44aa to 44ah and the upper retractable pins 46aa to 46ah of the lower slides 36a / b and the upper slides 38a / b are extended to engage the opposing first side walls 13aa to 13da and second side walls 13ab to 13db of each of the four (4) containers 11a to 11d. The collapse tines 92aa to 92ea and their opposing tines pairs 92ab to 92eb are then lowered 90 degrees to allow the collapsed containers 11a to 11d to be moved from the stacking assembly 18 to the collapsing assembly 14 (see Fig. 22B ).

[0115] Regarding additional step 2, each swing assembly such as 80 engages a corresponding one of the end frames of another container 11d such as 19da to rotate it closed from the current open position (see Fig. 23B and Fig.23C Prior to this closing action, the end frame lock between the end frame 19da and the first wall 13da of the other container 11d is activated via an end frame lock actuator such as 63A (see Figure 5B and Fig.23A ) is disengaged. The swing assembly 80 is operated to close the end frame such as 19da in the same manner as it opens the end frame such as 19aa, but in the opposite direction. The end frames 19da and 19db thus hold the containers 11a to 11d in the packed configuration with the aid of the end frame locks, see for example the relevant disclosure of the applicant's co-pending Australian provisional patent application No. 2022901112.

[0116] Regarding additional step 3, the lower carriage subassembly 32a / b and the upper carriage subassembly 34a / b engage the containers 11a to 11d in the packed configuration and move the containers from the collapsing assembly 14 to the stacking assembly 18 (see FIG. Fig.25A). The first of the pairs of collapsed tines 92aa and 92ab of the opposing pairs of collapsed tines is raised, while the remaining tines are lowered, wherein the packaging containers 11a to 11d are positioned within the stacking assembly 18 adjacent the raised tine pairs 92aa / ab. The last pair of collapsed tines 92ea and 92eb is then raised, wherein the packaging containers 11a to 11d are supported in their vertical orientation between the raised tine pairs 92aa / ab and 92ea / eb. The upper carriage subassembly 34a / b is then released from the containers 11a to 11d (see Fig.25B and Fig.25C ).

[0117] Regarding the additional step 4, the lower carriage subassembly 32a / b is used alone to move the packaging container 11a to 11d from the stacking assembly 18 to another docking assembly 23 (see Fig.26A and Fig.26B ). Prior to this movement, the outermost pairs of tines 92aa / ab and 92ea / eb are lowered to allow packaging containers 11a to 11d to travel on the pair of roller conveyors 22a / b. Similarly, the adjacent pair of hinged walls of each corresponding micro-movement subassembly for the other docking assembly 23 is lowered to allow packaging containers 11a to 11d to enter the other docking assembly 23. The adjacent walls of the pair of micro-movement subassemblies are then returned to their vertical settings to support packaging containers 11a to 11d, which are expected to be subsequently removed from the other docking assembly 23 (see Fig. 27 ). The flow diverter assembly and the associated micro-movement sub-assembly of the other docking assembly 23 have substantially the same construction and operation as the flow diverter assembly 96 and the micro-movement sub-assembly 98a / b of the previous docking assembly 12.

[0118] like Fig.28 As can be seen schematically in the Figure 1, there is an intermodal container handling system and an associated method for unloading a collapsible intermodal container and at least one further collapsible intermodal container (not shown) in a packed configuration according to the third and fourth aspects of the invention. In preferred embodiments of these aspects of the invention, the collapsible container and further collapsible container and the container handling system are substantially identical to the containers 11a and 11d and the handling system 10 of the preferred embodiments of the first and second aspects of the invention. Accordingly, the same reference numerals are used for corresponding components.

[0119] The intermodal container handling system 10 of the preferred embodiment of the third aspect broadly comprises:

[0120] a docking assembly 23 adapted to dock the collapsible container in the enclosed configuration with another collapsible container whose end frames have been moved to a closed position for engagement with a second of the opposing side walls of the collapsible container in the collapsed configuration, thereby maintaining the containers in the enclosed configuration;

[0121] a transport assembly 20 adapted to releasably engage at least one of the collapsible container or another collapsible container to facilitate movement of the docked containers in a packaged configuration together from a docking assembly 23 to a deployment assembly 14 operatively coupled to the docking assembly 23;

[0122] a disengagement subassembly 80 associated with the deployment assembly, the disengagement subassembly being arranged to disengage a container in a packed configuration by: (a) releasing engagement of an end frame of another container with a second side wall of the container, (b) moving the end frame from a closed position to an open position disposed substantially parallel to and along an outwardly facing surface of a first of the opposing side walls of the other container;

[0123] a stacking assembly 18 operatively coupled to the deployment assembly 14 and arranged to receive the detached container from the deployment assembly 14 via the transport assembly 20;

[0124] An unfolding subassembly 26, which is associated with the unfolding assembly 14 and is configured to receive another collapsible container in a collapsed configuration from the stacking assembly 18 via the transport assembly 20, the unfolding subassembly 26 being arranged to unfold the other collapsible container at the unfolding assembly 14 by: (i) releasably engaging the unfolding subassembly 26 with a first side wall of the other container, (ii) moving the unfolding subassembly 26 and the associated first side wall away from a second side wall of the opposite side wall of the other container, wherein the container unfolds from its collapsed configuration to an unfolded configuration, and (iii) moving the end frame of the other container from an open configuration to a closed configuration for engaging with the second side wall of the other container, thereby maintaining it in the unfolded configuration.

[0125] It should be understood that the method of loading and unloading the collapsible intermodal container and another collapsible intermodal container of the preferred embodiment of the fourth aspect broadly includes:

[0126] docking the collapsible container in the enclosed configuration with another collapsible container at the docking assembly 23, the end frame of the other collapsible container in the collapsed configuration having been moved to a closed position for engagement with a second of the opposing side walls of the collapsible container in the collapsed configuration, thereby maintaining the containers in the enclosed configuration;

[0127] moving the docked containers in the packaged configuration together from the docking assembly 23 to the deployment assembly 14 via a transport assembly 20 configured to releasably engage at least one of the collapsible container or another collapsible container;

[0128] disengaging the container in the packed configuration at the deployment assembly 14 by: (a) releasing engagement of an end frame of another container with a second side wall of the container, (b) moving the end frame from a closed position to an open position disposed substantially parallel to and along an outwardly facing surface of a first side wall of the opposing side walls of the other container;

[0129] Moving the detached container from the unfolding assembly 14 to the stacking assembly 18 via the transport assembly 20;

[0130] Moving another collapsible container in a collapsed configuration from the stacking assembly 18 to the unfolding assembly 14 via the transport assembly 20;

[0131] Another collapsible container is deployed at the deployment assembly 14 by: (i) releasably engaging the unfolding subassembly 26 with a first side wall of the other container, (ii) moving the unfolding subassembly 26 and the associated first side wall away from a second side wall of the opposing side walls of the other container, wherein the container is deployed from its collapsed configuration to an deployed configuration, and (iii) moving the end frame of the other container from an open configuration to a closed configuration for engaging with the second side wall of the container, thereby maintaining it in the deployed configuration.

[0132] It should be understood that the other steps involved in the preferred embodiment of the fourth aspect generally correspond to the steps of the method of the second aspect. In this embodiment, the steps themselves and the order of the steps are generally reversed from the second aspect to the fourth aspect.

[0133] In view of having described the preferred embodiments of various aspects of the present invention, it will be apparent to those skilled in the art that the intermodal container handling system has at least one or more of the following advantages:

[0134] The loading and unloading system efficiently and automatically encloses two or more collapsible intermodal containers;

[0135] The loading and unloading system and method are capable of relatively stably and consistently enclosing two or more collapsible containers;

[0136] The loading and unloading systems and methods are relatively safe in construction and operation, thereby reducing associated OH&S issues;

[0137] The intermodal container handling system has a modular construction suitable for off-site prefabrication for delivery and on-site assembly / commissioning.

[0138] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. The components of the preferred embodiment of the container handling system may vary as long as the core features and functions are retained. For example, the transport assembly may deviate from the preferred embodiment, in which case the pair of roller conveyors are driven to achieve movement of the container. The folding subassembly may deviate from the preferred embodiment, in which case the collapse action is effectively reversed as long as the first sidewall is anchored and the second sidewall moves toward the first sidewall. It is also possible that the top support device and / or the bottom support device are used as a folding subassembly, in which case one of the opposite sidewalls of the container remains fixed, while the other sidewall of the wall is pushed toward the fixed wall under the action of the lowering of the top or the raising of the bottom plate, and in the preferred configuration of the collapsible container, the top or bottom plate is "bound" to the corresponding sidewall of the pair of opposite sidewalls.

[0139] All such changes and modifications are considered to be within the scope of the invention, the nature of which is determined from the foregoing description.

Claims

1. An intermodal container handling system for collapsing and / or unfolding a collapsible intermodal container, the collapsible intermodal container comprising a pair of opposing side walls, each side wall being hingedly connected to a roof and a floor, respectively, wherein the walls remain substantially parallel to one another when the collapsible container is moved between an unfolded configuration and a collapsed configuration, the handling system comprising: a docking assembly, the docking assembly being adapted for docking with the collapsible intermodal container; a collapse assembly operatively coupled to the docking assembly via a transport assembly, the transport assembly adapted to releasably engage a docked collapsible container to facilitate movement of the collapsible container between the docking assembly and the collapse assembly; a folding subassembly associated with the collapse assembly, the folding subassembly adapted to releasably engage a first sidewall of the pair of opposing sidewalls, wherein movement of the folding subassembly and the associated first sidewall relative to a second sidewall of the opposing sidewalls moves the container between the deployed configuration and the collapsed configuration; A stacking assembly is operatively connected to the collapsing assembly via the transport assembly, the transport assembly being adapted to facilitate movement of the container in the collapsed configuration between the collapsing assembly and the stacking assembly for stacking or destacking the container in a vertical orientation with another collapsible intermodal container in a collapsed configuration and in a vertical orientation.

2. The intermodal container handling system of claim 1, wherein the transport assembly includes a pair of parallel conveyors along which the collapsible intermodal container moves from the docking assembly to the collapsing assembly and then to the stacking assembly.

3. The intermodal container handling system of claim 2, wherein said pair of parallel conveyors are spaced apart a distance less than a length dimension of said collapsible container, wherein both of said conveyors remain in contact with said floor of said container.

4. The intermodal container handling system of any one of claims 2 or 3, wherein each conveyor of the pair of conveyors comprises a plurality of rollers spaced equidistantly apart at a distance less than a cross-sectional width of a floor frame of the floor of the container, thereby ensuring that at least two of the plurality of rollers contact the floor frame during movement of the container between the docking assembly and the stacking assembly.

5. The intermodal container handling system of any of the preceding claims, further comprising an anchoring subassembly associated with the folding subassembly and adapted to releasably engage the second side wall, the anchoring subassembly effectively anchoring the second side wall during movement of the first side wall toward the second side wall via the folding subassembly.

6. The intermodal container handling system of claim 5, further comprising a structural frame associated with the collapse assembly, the frame comprising an upper frame assembly and a lower frame assembly.

7. The intermodal container loading and unloading system according to claim 6, wherein the folding subassembly includes a lower box car and an upper box car, and the lower box car and the upper box car are suitable for releasably engaging with the first side wall of the collapsible container at the collapse assembly, and the joint movement of the lower box car and the upper box car achieves the collapse of the container.

8. An intermodal container loading and unloading system according to claim 7, wherein the lower box car is one of a plurality of lower box cars, each lower box car being slidably mounted on a corresponding lower rail of one or more parallel lower rails associated with the lower frame assembly, and each of the lower box cars including a retractable lower box car pin, the retractable lower box car pin being suitable for releasably engaging the lower cross beam of the first side wall of the collapsible container during movement of the folding subassembly for collapsing the container.

9. The intermodal container loading and unloading system according to claim 8, wherein the upper box car is one of a plurality of upper box cars, each upper box car being slidably mounted on a corresponding upper rail of one or more parallel upper rails associated with the upper frame assembly, and each of the upper box cars including a retractable upper box car pin, the retractable upper box car pin being suitable for releasably engaging an upper cross beam of the second side wall of the collapsible container during the joint movement of the lower box car and the upper box car for collapsing the container.

10. The intermodal container handling system according to claim 9, wherein the upper box car of the folding subassembly is actuated via an upper box car drive motor to slide and move along the upper guide rail, and the lower box car of the folding subassembly is actuated via a lower box car drive motor to slide and move along the lower guide rail.

11. The intermodal container handling system according to claim 10, further comprising a top lock activator and a bottom lock activator, wherein the top lock activator and the bottom lock activator are associated with the collapse assembly and are adapted to release the top lock and the bottom lock associated with the top and the first wall and with the bottom and the second wall, respectively, thereby allowing the collapsible container to be collapsed via the folding subassembly.

12. The intermodal container handling system according to any one of claims 9 to 11, wherein the anchor subassembly comprises an upper pin subassembly and a lower pin subassembly fixedly secured to the upper frame assembly and the lower frame assembly, respectively.

13. The intermodal container handling system of claim 12, wherein the upper box car and the lower box car of the folding subassembly are slidably mounted to the upper frame assembly and the lower frame assembly, respectively, thereby allowing the first side wall to move toward the second side wall during movement of the folding subassembly and the engaged first side wall toward the anchored second side wall.

14. An intermodal container handling system according to any one of claims 12 or 13, wherein the collapse assembly further comprises a box top support device and a floor support device, wherein the box top support device and the floor support device are adapted to releasably contact the box top and the floor, respectively, to support the box top and the floor during movement of the folding subassembly and subsequent collapse of the collapsible container from the expanded configuration to the collapsed configuration.

15. The intermodal container handling system of claim 14, wherein the roof support device is mounted to the upper frame assembly and includes a magnetic coupler adapted to magnetically retain the roof to support the roof during collapse of the collapsible container.

16. An intermodal container handling system according to any one of claims 14 or 15, wherein the floor support device is mounted to the lower frame assembly and includes one or more wheels, the one or more wheels being adapted to contact the floor to support the floor during collapse of the collapsible container.

17. An intermodal container loading and unloading system according to any one of claims 14 to 16, wherein the collapse assembly further comprises a swing assembly adapted to releasably engage each end frame of a pair of opposing end frames of the collapsible container in the expanded configuration, the swing assembly being rotated toward the exterior of the container for opening the pair of end frames to an open position, wherein the end frames are arranged substantially parallel to and along an outwardly facing surface of the first side wall.

18. The intermodal container handling system of claim 17, wherein the folding subassembly comprises one or more end frame lock actuators adapted to respectively actuate end frame locks associated with each of the end frames, the end frame locks being actuated when the end frames are in the open position for maintaining the end frames in the open position when the collapsible container is in the expanded configuration.

19. An intermodal container handling system according to any one of claims 17 or 18, wherein the swing assembly includes a swing arm pivotally mounted at one end to the lower frame assembly and mounted at an opposite end to a retractable swing pin assembly adapted to releasably engage with the end frame, wherein rotation of the swing arm effects opening of the end frame between the closed position and the open position upon engagement of the swing pin assembly with the end frame.

20. The intermodal container handling system of claim 19, wherein the swing arm is extendable so that the length of the arm can be adjusted.

21. An intermodal container loading and unloading system according to any one of claims 17 to 20, wherein the stacking assembly includes a series of collapsing tines, each collapsing tine being movable between an upright position and a collapsed position, a pair of adjacent tines in the series of tines being adapted to support the collapsible container in a collapsed configuration in the vertical orientation, and another pair of adjacent tines in the series being adapted to support the other collapsible container in a collapsed configuration in the vertical orientation and to be separated from the collapsible container.

22. The intermodal container loading and unloading system according to claim 21, wherein the collapsible container and the other collapsible container are separated by a predetermined lateral spacing via the series of collapsing tines, and the predetermined lateral spacing allows the end frame of the other collapsible container to rotate from the open position to the closed position via the swing assembly for engagement with the second side wall of the collapsible container, thereby maintaining the container and the other collapsible container in a packaged configuration.

23. The intermodal container handling system of claim 22, wherein the transport assembly includes a lower slide subassembly mounted to the lower frame assembly and adapted to releasably engage the collapsible container for movement of the collapsible container between the docking assembly, the collapsing assembly, and the stacking assembly.

24. The intermodal container handling system of claim 23, wherein the transport assembly further comprises an upper slide subassembly mounted to the upper frame assembly and adapted to releasably engage with the collapsible container for movement of the collapsible container with the lower slide subassembly between the collapsing assembly and the stacking assembly.

25. The intermodal container handling system of claim 24, wherein the upper slide subassembly and the lower slide subassembly each include a plurality of upper retractable pins and lower retractable pins arranged to releasably engage both the first side wall and the second side wall of the collapsible container for movement of the collapsible container while being retained in the expanded configuration or the collapsed configuration via the retractable pins.

26. An intermodal container loading and unloading system according to claim 25, wherein the plurality of lower retractable pins and upper retractable pins of the corresponding lower slide sub-assembly and upper slide sub-assembly are suitable for engaging with the lower beams and the upper beams of the first side wall and the second side wall of both the collapsible container and the other collapsible container for moving the collapsible container and the other collapsible container from the collapsing assembly to the stacking assembly in the packaging configuration.

27. An intermodal container handling system according to any one of claims 24 to 26, wherein the upper slide subassembly and the lower slide subassembly together enable the collapsible container in the packaged configuration to be moved from the collapsing assembly to the stacking assembly, and thereafter moved only via the lower slide subassembly to another docking assembly for subsequent removal and transport in the packaged configuration.

28. An intermodal container handling system according to claim 27, wherein the plurality of upper retractable pins of the upper slide sub-assembly are adapted to be released from the upper cross beams of the side walls of the collapsible container and the other collapsible container in the packaging configuration to allow the collapsible container and the other collapsible container to move from the stacking assembly to the other docking assembly solely under the influence of the lower slide sub-assembly.

29. An intermodal container loading and unloading system according to any one of claims 2 to 28, wherein the docking assembly includes a diverter assembly, which is suitable for longitudinally diverting the collapsible container in the expanded configuration for alignment with the collapsing assembly, and then placing the aligned collapsible container on the pair of parallel conveyors for movement between the docking assembly and the collapsing assembly.

30. An intermodal container handling system according to claim 29, wherein the diverter assembly includes a pair of micro-shifter assemblies, which are positioned at the docking assembly and are suitable for contacting the collapsible container at corresponding ends of the opposite ends of the collapsible container for longitudinal and lateral alignment of the container relative to the pair of parallel conveyors.

31. An intermodal container handling system according to claim 30, wherein the pair of micro-shift sub-assemblies each include an end micro-shift plate and a side micro-shift plate, and the end micro-shift plate and the side micro-shift plate are suitable for contacting the end frame and the first side wall or the second side wall respectively, so as to micro-shift the container for desired longitudinal and lateral alignment.

32. A method of loading and unloading a collapsible intermodal container, the collapsible intermodal container comprising a pair of opposing side walls, each side wall being hingedly connected to a roof and a floor, respectively, wherein the walls remain substantially parallel to one another when the collapsible container is collapsed from an expanded configuration to a collapsed configuration, the method comprising: docking the collapsible intermodal container in the deployed configuration at a docking assembly; moving a docked collapsible container in the deployed configuration from the docking assembly to a collapsing assembly via a transport assembly configured to releasably engage the collapsible container; collapsing the collapsible container at the collapse assembly by: (a) releasably engaging a folding subassembly with a first of the opposing sidewalls, (b) moving the folding subassembly and the associated first sidewall toward a second of the opposing sidewalls, wherein the container collapses from its deployed configuration to the collapsed configuration; The collapsible container in the collapsed configuration is moved from the collapsing assembly to a stacking assembly via the transport assembly for stacking in a vertical orientation with another collapsible intermodal container in the collapsed configuration and vertical orientation.

33. A method according to claim 32, wherein collapsing the collapsible container involves releasably engaging an anchoring subassembly with the second side wall, the anchoring subassembly being associated with the folding subassembly for anchoring the second side wall during movement of the folding subassembly and the associated first side wall toward the anchored second side wall.

34. The method of claim 33, wherein prior to collapsing the collapsing container at the collapsing assembly via the folding subassembly and the anchoring subassembly, the transport assembly is disengaged from at least the first wall of the collapsible container, thereby allowing the second side wall to move relative to the second side wall.

35. A method according to any one of claims 32 or 33, wherein before the collapsible container is collapsed at the collapsing assembly via the folding subassembly, a top lock actuator and a bottom lock actuator are actuated to release the top lock and the bottom lock associated with the top and the first side wall and with the bottom and the second side wall, respectively, thereby allowing the first wall to move relative to the second wall.

36. The method of any one of claims 33 to 35, wherein the folding subassembly and the anchoring subassembly are detached from the first side wall and the second side wall, respectively, before the collapsible container in a collapsed configuration is moved from the collapsing assembly to the stacking assembly via the transport assembly.

37. The method of claim 36, wherein the transport assembly engages the first side wall and the second side wall of the collapsible container to retain the collapsible container in the collapsed configuration before the anchoring subassembly and the folding subassembly disengage from the first wall and the second wall, wherein: During movement of the transport assembly and associated collapsible container to the stacking assembly, the collapsible container remains in the collapsed configuration.

38. The method of claim 37, wherein the folding subassembly includes a lower cart and an upper cart, wherein collapse of the collapsible container at the collapse assembly involves releasable engagement and common movement of the lower cart and the upper cart with the first side wall.

39. A method according to any one of claims 32 to 38, wherein collapsing the collapsible container further involves supporting the roof and the floor via respective roof support devices and floor support devices, the roof support devices and the floor support devices being adapted to releasably contact the roof and the floor at the collapsing assembly to support the roof and the floor during movement of the folding subassembly and subsequent collapse of the collapsible container from the expanded configuration to the collapsed configuration.

40. The method of claim 39, wherein a roof lift and a floor lift are released from the roof and the floor, respectively, prior to moving the collapsible container in a collapsed configuration from the collapsing assembly to the stacking assembly via the transport assembly.

41. A method according to any one of claims 32 to 36, wherein collapsing the collapsible container involves a preliminary step of releasably engaging a swing assembly with each of a pair of opposing end frames of the container in the expanded configuration at the collapse assembly, the swing assembly being rotated toward the outside of the container for opening the pair of end frames to an open position, wherein the end frames are arranged substantially parallel to and along the outwardly facing surface of the first side wall.

42. A method according to claim 41, wherein collapsing the collapsible container involves an initial step of actuating end frame locks, wherein the end frame locks are configured to maintain corresponding end frames of the end frames in the closed position when the collapsible container is in the expanded configuration, and the end frame locks are actuated via end frame lock actuators.

43. The method according to any one of claims 41 or 42, further comprising stacking the collapsible container in the collapsed configuration at the stacking assembly, and then stacking the other collapsible container in the collapsed configuration in the vertical orientation at the stacking assembly and separating from the collapsible container.

44. The method according to claim 43 further includes moving the stacked collapsible containers and the other collapsible container in a collapsed configuration from the stacking assembly to the collapsing assembly at a fixed lateral spacing via the transport assembly, wherein the end frame of the other collapsible container is rotated inwardly from the open position to a closed position via the swing assembly for engagement with the second side wall of the collapsible container, thereby maintaining the container and the other collapsible container in a packaging configuration.

45. The method of claim 44, wherein the collapsible container in the packaged configuration is returned to the stacking assembly via the transport assembly and then moved to another docking assembly via the transport assembly for subsequent removal and shipping in the packaged configuration.

46. ​​A method according to any one of claims 32 to 45, wherein the docking assembly includes a diverter assembly, which is arranged to longitudinally and / or laterally divert the collapsible container in an expanded configuration at the docking assembly for alignment with the collapse assembly, and then move the collapsible container between the docking assembly and the collapse assembly via the transport assembly.

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