Segmented Roof Flat-Pack Container for ISO Shipping
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Solution Overview
Problem
Existing shipping containers with oversized dimensions are bulky and expensive to ship when empty, as they do not fit into standard ISO containers in a flat-packed configuration, and modular roofs are not weather-tight, making them inefficient for storage and transport.
Innovation Solution
A modular container design with a shoebox-style roof and disassemblable components that fit into ISO containers in a compact, flat-packed state, featuring a shoebox flange, u-channel, and crossmembers for structural integrity and weather tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If shipping containers are made with oversized dimensions to meet storage needs, then storage capacity is improved, but shipping cost and efficiency deteriorate because they cannot fit into standard ISO containers in flat-packed configuration
Solution Approach 1:
The container is divided into multiple separable components including side walls, end walls, floor sections, and roof panels that can be detached and packed separately. This segmentation allows each component to be compacted to fit within standard ISO container dimensions while maintaining the ability to assemble a larger storage volume when deployed
Solution Approach 2:
The container components are designed to collapse or fold in multiple dimensions, transforming from a three-dimensional expanded structure to a flattened two-dimensional configuration for shipping. The side walls and end walls can fold inward, the floor can collapse vertically, and the roof panels can be segmented and stacked, enabling efficient space utilization within ISO container height and width constraints
2Productivity
If modular roofs are used to enable flat-packing, then shipping efficiency is improved, but weather tightness deteriorates due to junctions between roof panels
Solution Approach 1:
Multiple roof panels are designed to join together to form a continuous, integrated roofing surface. The joining mechanisms include overlapping edges with sealants, interlocking joints with weatherproof gaskets, or integrated framing members that create a unified structure. This merging approach maintains weather tightness across panel junctions while allowing the roof to be disassembled into manageable sections for flat-packing
Solution Approach 2:
Weatherproof sealing elements such as rubber gaskets, foam strips, or adhesive sealants are introduced as intermediary materials at the junctions between roof panels. These intermediaries fill gaps and prevent water penetration while allowing the panels to be separately manufactured and assembled, thus maintaining both weather tightness and modularity
3Loss of energy
If containers are made disassemblable for flat-packing, then shipping cost is reduced, but structural integrity deteriorates during assembly
Solution Approach 1:
Connection points, alignment features, and structural joints are pre-designed and pre-positioned on container components during manufacturing. This preliminary action ensures that when components are assembled, they automatically align correctly and engage structural joints that restore full strength. The pre-configured connection geometry eliminates assembly errors and ensures consistent structural integrity across all assembled units
Solution Approach 2:
Traditional mechanical fastening systems that may compromise structural continuity are replaced with advanced connection technologies such as welded joints, bonded connections, or interlocking mechanisms that create monolithic-like strength. These substitution systems maintain structural integrity comparable to traditional permanent construction while still allowing for disassembly and reassembly
4Reliability
If roof panels are made as single units for weather tightness, then reliability is improved, but they cannot fit into ISO containers when width exceeds 7.7 feet
Solution Approach 1:
The roof structure is divided into multiple smaller panels that can be independently manufactured to fit within ISO container dimensions. These segmented panels are designed with joining mechanisms that create a continuous weatherproof surface when assembled, allowing the overall roof span to exceed 7.7 feet while each individual panel remains compact enough for standard container shipping
Data Source
AI summary
A modular container is provided having a base. A plurality of panels is coupled to the base to form an enclosure having an internal volume. The plurality of panels substantially defines an outer perimeter, and substantially defines a top circumferential edge of the modular container. At least one door provides access to the internal volume. A roof having a shoebox flange is coupled to the plurality of panels. The shoebox flange circumscribes the roof and defines the outer perimeter of the roof. The shoebox flange fits over the top circumferential edge. The roof comprises a plurality of individual roof panels that are fastenable together. The modular container, when in a disassembled and flat-packed state, fits at least one of horizontally and vertically in an ISO container.