TECHNICAL FIELD

[0001] The present invention relates generally to the handling of bulk materials, such as ore, coal, grain, fluids etc., for shipping/transport purposes. More particularly, the present invention relates to an improved cargo container for bulk materials, and in particular bulk ore.

BACKGROUND TO THE INVENTION

[0002] For many years, bulk materials have been loaded into the holds of ships by the use of conveyors. However, conveyors have disadvantages in that they cannot be used to load efficiently, or have restricted loading mechanisms which cannot deliver material to a desired location. In general, conveyor systems are expensive, require set-up time and are complex to handle. For this reason, it is preferred to use cargo containers of the type that are hoisted and located by the use of gantry cantilevered cranes. Container systems provide many advantages, including the ability to load and off-load such containers from various transport means, including flat-bed trucks and rail cars. Another benefit is that the bulk material within the containers is protected from the environment (by being protected from environmental exposure) and, in turn, the environment is protected from the bulk material (i.e. contamination by loss of the container contents).

[0003] The container according to the present invention is suitable for use with standard container-handling apparatus, and is also particularly suitable for use with the ROTAINER® container-handling apparatus of the Applicant's International (PCT) Application No. PCT/AU2010/001337 (entitled "Apparatus for handling containers"), the disclosure of which is incorporated herein by reference.

[0004] The upper edges of the walls of the container are preferably shaped to reduce the risk of accumulation of dust, water, spillage, waste material etc.

[0005] The container may have a removable lid forming a closure means for the container. Preferably, the lid is also shaped to reduce the risk of accumulation of dust, water, spillage, waste material etc., and to minimise the risk of water/moisture ingress into the container. SUMMARY OF THE INVENTION

[0006] The invention relates to a cargo container having side walls and a base and including:

(a) an outer framework; and

(b) an inner liner to hold bulk material therein.

[0007] Preferably, the outer framework is an openwork framework.

[0008] According to a first aspect of the invention, the outer framework of the cargo container includes a plurality of support ribs to strengthen the structure of the container for substantial weight-bearing support.

[0009] In a preferred embodiment, some or all of the support ribs have at least one cutout portion which form one or more apertures in the support rib. This allows the support ribs to retain strength, while minimising weight and cost attributable to the overall amount of material (steel or other metal) used.

[00010] Preferably, there are three apertures in each support rib.

[00011] However, although the above is a preferred option, it is possible to utilise support ribs which do not have any cut-out portions.

[00012] In a preferred embodiment, each support rib is substantially perpendicular to the base of the container.

[00013] Preferably, each support rib is wider at its base than toward the top thereof, to thereby provide increased load-bearing capacity of the container where required, toward the base of the container (the "base" and "top" of the support rib being defined with respect to the container being positioned with its base residing on a horizontal support surface, with the "base" of the support rib corresponding to the "base" of the container).

[00014] According to a second aspect of the invention, the upper edges of the side walls of the cargo container include a bevelled section with a gradient sloping downward toward the wall's outer surface such that the height (from the container base) of the inner perimeter of said bevelled section is greater than the height (from the container base) of the outer perimeter of said bevelled section, the terms "upper" and "downward" being defined with respect to the container being positioned with its base residing on a horizontal support surface. [00015] In a further aspect of the invention, the container may have a removable lid forming a closure means for the container, the lid having, on its lower surface, a bevelled section which is correspondingly shaped and located to engage with the bevelled section of the upper edges of the container's side walls, wherein the terms "lower" and "upper" are defined with respect to the container being positioned with its base residing on a horizontal support surface and the lid being positioned atop the container to thereby close the container.

[00016] The container is preferably of a substantially rectangular shape, with two (longer) longitudinal side walls, two (shorter) end walls and a base.

[00017] In the case where the container is round or oval, there are only side walls and no end walls.

BRIEF DESCRIPTION OF THE DRAWINGS

[00018] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:

Figure 1 is a side elevation of a container and lid (in open position) according to the present invention;

Figure 2 is a perspective view of the container of Figure 1, with the lid in closed position;

Figure 3 is a perspective view of the container of Figure 1, minus the lid;

Figure 4 is a section view of the container and lid of Figure 1 (with the lid in open position);

Figure 5 is a top plan view of the container of Figure 1 (minus the lid);

Figure 6 is a view of the container of Figure 1 (minus the lid), as loaded, with a section through the payload (midway along the length of the container) overlaid on the external perimeter of the container;

Figure 7 is a perspective view, similar to Figure 2, but illustrating a different

embodiment of a container according to the present invention, with the lid in open position; and

Figure 8 is a perspective view (from beneath) of the container and lid (in open position) of Figure 7. DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

[00019] The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain of the parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.

[00020] Turning now to the drawings, there is illustrated in Figures 1 to 8 a container 10 having a removable lid 11 (which is an optional but preferred feature to prevent environmental exposure or loss of contents).

[00021] The container 10 is preferably of a substantially rectangular shape, with two (longer) longitudinal side walls 12, two (shorter) end walls 13 and a base 14. The container has an inner liner 15 and an outer openwork framework 16. The outer openwork framework 16 includes, for example, a framework of rails (such as top rails 19, bottom rails 20, side rails 21 and/or base rails 22), together with support ribs 17.

[00022] According to a first aspect of the invention, the longitudinal side walls 12 and/or end walls 13 of the container include a plurality of support ribs 17. Preferably, the support ribs 17 are substantially perpendicular to the base of the container. It is preferred that some or all of the support ribs have at least one cut-out portion forming one or more apertures 18, which allow the ribs to retain strength, while minimising weight and cost attributable to the overall amount of material (steel or other metal) used.

[00023] There may, for example, be three apertures 18 in each support rib 17.

[00024] For the container depicted in Figures 1 to 3, there are twelve support ribs on each longitudinal side wall 12, and five ribs on each end wall 13. However, the number of support ribs can vary depending on user requirements or preferences. For example, the container depicted in Figures 7 and 8 has fourteen support ribs on each longitudinal side wall. [00025] Preferably, the container's inner liner 15 will have sloping longitudinal side walls 12a, which converge inwards toward the base 14a of the liner. Also, the inner liner preferably has no sharp edges or corners, with the joints where the longitudinal side walls of the liner meet its end walls, and where the longitudinal side walls and end walls of the liner meet its base, being rounded or radiused. This shaping of the inner liner assists in the free flow of bulk material (the payload) when being discharged from the container, and minimises the amount of product which might settle, stick to and remain in the container when discharging its payload. This stops a gross inefficiency of the current systems available to date.

[00026] Traditional container design was not suitable for use with a container rotation device such as the ROTAINER® container-handling apparatus of the Applicant's International (PCT) Application No. PCT/AU2010/001337, so a new concept was devised.

[00027] The outer framework 16 of the container preferably comprises a framework of rails and support ribs with: top rails 19; bottom rails 20; interconnecting side rails 21 connecting the top rails 19 with the bottom rails 20 (preferably, four interconnecting side rails 21 at each corner of a rectangular container 10); support ribs 17; and interconnecting base rails 22 passing beneath the base 14a of the inner liner and connecting the bottom rails 20 and/or support ribs 17 on either side of the container.

[00028] In one embodiment, as shown in Figure 4, a corresponding pair of support ribs 17 on either side of the container will be connected by an interconnecting base rail 22 passing beneath the base 14a of the liner, so that the combination of a pair of support ribs 17 (on either side of the container) with the interconnecting base rail 22 forms a substantially U-shaped element providing support to both the longitudinal side walls 12a and base 14a of the inner liner.

[00029] In another embodiment, as shown in Figures 7 and 8, the support ribs 17 extend between sloping sections 20a and 19a which interconnect the bottom rails 20 and top rails 19 (respectively) of the outer framework with the inner liner 15 of the container.

[00030] The support ribs 17 are shaped to conform with the shape of the inner liner. Where the liner has sloping longitudinal side walls 12a, the support ribs 17 will be correspondingly tapered from a wider base to a narrower peak, and will project inwards from the framework to rest against, and thereby support, the side walls 12a of the liner. This tapered shape of the support ribs 17 allows the support ribs to provide increased load-bearing capacity of the container where required, toward the base of the container.

[00031] The top rails 19 are thicker and more robust than the normal upper edges of a conventional cargo container. These strengthened top rails 19 also allow for 360° rotation using twist lock pockets 31. By increasing the strength of the top rails 19 of the container, the container forms a "chassis" and becomes part of the integral design of the ROTAINER® container-handling apparatus. This allows for a lot less material (preferably, steel) to be used in the container's manufacture, and also eliminates the need for internal bracing or cross-frames to support the side walls when at 90° and the full load (of around 35 tonnes/35,000 kg) is applied, which in turn makes the unit lighter in construction and allows greater carrying capacity.

[00032] Preferably, there will be a gap between at least one of the walls of the container's liner 15 and the corresponding outer framework 16 of the container, to allow engaging member(s) of the container-handling apparatus to enter and engage with one or more walls (for example, both end walls 13a) of the inner liner, and to allow the container-handling apparatus to raise and lower the lid 11 (if present) of the container. This gap also assists in preventing material being unloaded from the container from coming into contact with the arms of the ROTAINER® container-handling apparatus.

[00033] For example, there may be a gap of 300 mm or 350 mm (approx.) between the end walls 13a of the inner liner and the corresponding outer framework.

[00034] In a preferred embodiment, as shown in Figures 7 and 8, there will be an infill section 20a sloping inwards and upwards (at, for example, a 45° angle) from the bottom rails 20 of the container, to meet up with and join to a corresponding lower part of the inner liner 15. The infill section will be provided on at least the end walls of the container, and preferably on all walls of the container. There may, for example (and as shown in Figure 8), be similar sections 19a provided on the underside of the top rails 19, which slope inwards and downwards (at, for example, a 45° angle) to meet up with and join to a corresponding upper part of the inner liner 15.

[00035] Load-rated tyne pockets 20b may be provided in, for example, the bottom rails 20 or corresponding infill sections 20a of the longitudinal side walls 12 of the container, to facilitate handling by forklifts or other container-handling equipment. [00036] According to a second aspect of the invention, the upper edges of the side walls (for example, top rails 19) of the container are shaped to reduce the risk of accumulation of dust, water, spillage, waste material etc. In particular, the upper edges may include a bevelled (angled) section 23 with a gradient sloping downward toward the wall's outer surface such that the height (from the container base 14) of the inner perimeter of bevelled section 23 is greater than the height (from the container base 14) of the outer perimeter of bevelled section 23, the terms "upper" and "downward" being defined with respect to the container being positioned with its base residing on a horizontal support surface. The bevelled (angled downward) top rails 19 direct any water to run off (rather than entering the inner liner of the container and contaminating its payload 32). This structure also assists in ensuring that any material that accumulates during loading of the container, including dust and spillage, falls off the container prior to transport, thus minimising environmental pollution (and also assists in preventing accumulation of dust, spillage or retained material during unloading of the container).

[00037] The container 10 preferably has a removable lid 11 forming a closure means for the container. The lid 11 reduces the risk of accumulation of dust, water, spillage, waste material etc. in the container 10. In particular, the shape of the lid helps to prevent water/moisture ingress into the container. The lid may, for example, have a bevelled section 24 on its lower surface 25, this bevelled section 24 being correspondingly shaped and located to engage with the bevelled section of the upper edges of the container's side walls, wherein the terms "lower" and "upper" are defined with respect to the container being positioned with its base residing on a horizontal support surface and the lid being positioned atop the container to thereby close the container.

[00038] The lid 11 enables the payload 32 to be completely covered until within the hold of the ship (where the lid is raised to allow discharge of the payload), thereby minimising dust problems. Lid 11 preferably includes a lid-latching mechanism 27, which is preferably located on the upper surface 26 of the lid, and which is operable either automatically (by the container-handling apparatus) or manually. In a preferred embodiment, there will be two or four central lifting points on the lid 11. The lid- latching mechanism can, for example, integrate with the ROTAINER® container- handling apparatus so that the unloading process can be accomplished without human labour or contact.

[00039] The lid-latching mechanism 27 engages with locks 28 located on the top rails 19 of the container, so that the lid thereby closes the container. For manual access to the lid- latching mechanism, the container may be provided with side ladders 29, and hand holds 30 on the top rails 19 of the container.

[00040] The container preferably includes a plurality of engaging members 31 for cooperation with one or more movable or rotatable mechanism of the container-handling apparatus such that, when the container is being handled by the container-handling apparatus, the container is rotatable through 360°, in either direction. More preferably, there are four twist lock pockets 31, one at each top corner of the container, and these are preferably strengthened to the extent required to allow for the forces when the container is being rotated 360° by only these top four twist locks. This structure allows the container to be rotated 360°, in either direction, while only being held/supported by the four top standard twist lock pockets 31.

[00041] The container of the present invention is formed from suitably robust materials, and preferably is fabricated from welded steel, preferably of around 3 mm in thickness.

[00042] The container can readily be designed and manufactured to comply with all relevant Australian and other relevant Standards for transport and shipping (including ADG7, the 7th Edition of the Australian Dangerous Goods Code, which is specific to the material being transported), for payloads up to 35 tonnes. It has a simple structure to suit assembly line mass production, and can be used with existing conventional technology, such as standard container-handling apparatus.

[00043] The payload geometry is however optimised to suit handling by the ROTAINER® container-handling apparatus of the Applicant's International (PCT) Application No. PCT/AU2010/001337, including use of the lid lift and lid-latching mechanism of that container-handling apparatus.

[00044] The container of the present invention can be constructed to have the dimensions required for a standard 20ft ISO shipping container.

[00045] Conventional containers for bulk ore are so-called "half-height" containers, with side walls of around 1 metre in height. If the side walls were any higher, they would bend under the weight of their payload.

[00046] The structure of the container of the present invention, and in particular the support ribs 17, prevents bending of the side walls and allows the container to be constructed with higher side walls to fit in a standard container space for transport. For example, the side walls of the present container can have a height of around 2.2 metres.

[00047] Also, with a conventional "half-height" container, the lid extends to the outer edges of the end walls, and the container-and-lid combination is not therefore suitable for use with ROTAINER® container-handling apparatus. By way of contrast, the container- and-lid combinations of the present invention, as described with respect to Figures 1 to 8, are compatible with ROTAINER® container-handling apparatus.

[00048] The structure and dimensions of the outer framework 16 of the container can therefore readily be selected to comply with ISO container standards, to ensure compatibility with existing container-handling infrastructure. A typical container, according to the present invention, is sufficiently strong to hold up to 35 tonnes of payload, with a 74.5% fill ratio, when packed evenly at around 2.0 tonnes per cubic metre (for example, with the symmetrical distribution of payload 32 illustrated in Figure 6). Current ISO containers usually have a gross weight of 33,000kg (load including container), whereas a container according to the present invention can be designed for a gross weight of 38,000kg (load including container).

[00049] The following is a brief description of how the container of the present invention can be utilised.

[00050] The empty container arrives at the loading station. The lid is removed and stored out of the way so that the container can be loaded with product (e.g. bulk ore). As a preliminary step in the loading process, the container is inspected internally for "carryback" residual material, left over from previous loads. Any "carry-back" material must be removed before the container is re-loaded. The container is then loaded with product. The lid is placed on the container. The lid is locked, preferably automatically using a lid- latching device, to seal the container. The container is transported to a holding stand until the container ship arrives. The container is then moved out to a crane or other loading device for loading into the vessel. The container is picked up by the crane (or other loading device), which preferably utilises the ROTAINER® container-handling apparatus of the Applicant's International (PCT) Application No. PCT/AU2010/001337. The container is then moved out to a position over the ship, and lowered into an appropriate position where its load can be discharged into the ship's hold. The lid- latching device of the container-handling apparatus is lowered to connect with the container lid. The latching/locking mechanism of the lid is then unlocked by the lid- latching device. The lid is raised, and the container is rotated to discharge its load (e.g. bulk ore) into the ship's hold. The container-handling apparatus further rotates the container until the container is stopped automatically in a horizontal position, with the open top of the container being uppermost. The lid is then placed back onto the container and automatically re-locked (using the lid-latching device). The container is then lifted from the ship, and returned to the dock for sending back to the loading station.

[00051] Throughout this specification, except where the context requires otherwise due to express language or necessary implication, the word "comprising" is used in the sense of "including", i.e. the features specified may be associated with further features (whether or not specifically mentioned) in various embodiments of the invention.

[00052] While specific embodiments of the invention have been described, it should be appreciated that various modifications and variations can be made without departing from the principles and scope of the invention.