Reversible Shipping Container Expansion Insert

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Solution Overview

Problem

Hard wall expandable ISO containers are expensive, require skilled labor for custom metal weldments, and are not cost-effective for markets beyond militaries and well-funded government agencies, such as emergency housing.

Innovation Solution

A compact, reversibly convertible expansion insert for ISO shipping containers, featuring a frame assembly with torsionally hinged roof and floor assemblies, pivot wall assemblies, and gas piston springs, which can be easily installed without heavy machinery, expanding the container's living space while maintaining weather resistance and CSC certification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If hard wall expandable ISO containers are used, then the container can be expanded into housing units, but the cost and complexity of installation increase due to custom metal weldments and skilled labor requirements

Engineering Contradiction:

Improveexpandability into housing unitsVSAvoidinstallation complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The expansion system is divided into separate modular components: expansion frames that fit within container corners, panel assemblies with integrated hinges, and corner posts with pivot mechanisms. This segmentation eliminates the need for custom metal weldments and allows installation without skilled welding labor, while still enabling the container to expand into housing units.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If custom-built expandable containers are manufactured, then expansion functionality is achieved, but shipping costs increase due to large size and specialized construction

Engineering Contradiction:

Improveexpansion functionalityVSAvoidshipping cost

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The expansion frames are designed to nest within the corner spaces of standard ISO containers when not in use. The modular panels and corner posts can be stored compactly within the container structure, allowing the expansion system to be shipped as a kit rather than as a large pre-assembled unit, thereby reducing shipping costs while maintaining full expansion functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Device complexity

If extensive custom metal weldments are performed, then expansion assemblies are created, but the requirement for skilled labor and time increases

Engineering Contradiction:

Improveexpansion assembly capabilityVSAvoidskilled labor requirement

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

Traditional metal weldments are replaced with mechanical connection systems including bolted joints, pinned connections, and interlocking frame structures. The corner posts use pivot mechanisms and the panels use hinge connections that allow assembly through simple mechanical fastening rather than welding, eliminating the need for skilled welding labor while maintaining expansion assembly capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The expansion insert increases the ISO container's floor area from 139 to 373 square feet, allows for rapid deployment and compact storage, and can be installed by one person in under 30 minutes, reducing costs and enabling entry into non-military markets by simplifying logistics and distribution.

Implementation Method 1

the insert further includes a spring diagonally connected to the frame left pivot wall edge and the roof assembly, and a spring diagonally connected to the frame right pivot wall edge and the roof assembly. In embodiments, the spring is a gas piston spring.

Methodology Applied

Scientific EffectGas piston spring: Spring

Implementation Method 2

the insert includes a frame assembly torsionally hinged to each of a roof assembly and a floor assembly

Methodology Applied

Scientific EffectTorsional hinge: Hinge

Implementation Method 3

the insert includes a sidewall assembly hinged to the floor assembly... a left hand pivot wall assembly rotatable in relation to the frame left hand pivot wall; and there is a right hand pivot wall is rotatable in relation to the frame right hand pivot wall

Methodology Applied

Scientific EffectHinge: Hinge

Data Source

PatentUS11391036B2Shipping container expansion insert

Publication Date: 2022.07.19 REBOX CONTAINERS INC

AI summary

An expansion insert for converting an ISO shipping container into a housing unit is provided, the insert having a compacted form reversibly convertible to a expanded form. The insert has a frame assembly torsionally hinged to a roof assembly and a floor assembly. Two pivot walls and a sidewall are also built into the insert. The insert may be compacted for shipping, expanded after insertion into an ISO container, and compacted again on the ISO container.