A construction system comprising a structural member adapted to fit on a steel frame which may be adapted to a standard container.

BACKGROUND

Containers are widely used all over the world for transportation and storage.

A significant feature of a shipping container is that shipping containers has standard sizes i.e. standard width, standard length and standard height. Standard sizes makes it possible to pack and/or load the containers very closely on e.g. off-shore transporting such as a ship or a vessel, and/or a-shore transporting such as road transports such as a truck or rail transports such as a train.

Commonly used shipping containers may comprise a rectangular steel frame provided with corrugated sheet metal panels making up the sides and top. While not all containers have corrugated sheet metal panels (for instance, refrigerated containers may have smooth exteriors), most have in order to get added strength. And while there can be some variability in the dimensions of the corrugations, most modern containers use the same corrugation dimensions.

GENERAL DESCRIPTION

In accordance with the present description, there is provided a flexible construction system comprising a light-weight wall which may be adapted to many different functionalities.

According to a first aspect the invention relates to a support part comprising one or two spacer units, such as one or more spacer units, extending in one or in two directions, e.g. one or more directions, the support part comprises a first surface and a second surface, the first surface is adapted to a frame or similar support, i.e. the first surface constitutes a contact surface being at least partly in contact with the frame during use, the second surface is provided with the one or two spacer units,

- a spacer unit comprises two surfaces, adapted in size and surface structure to attach/fix respectively and inner and an outer layer constituting a wall, normally the surface of the one or more spacer units extend either in full length or in full height of the wall but the surface of the one or more spacer units does not extend both in full length and in full height of the wall.

If the support part comprises two spacer units, the spacer units may extend in perpendicular directions or directions diverting by another angle.

In one or more exemplary support parts, the first surface of the support part may be adapted to fit to a surface of a beam of the frame or similar support which beam may have e.g. a triangular or rectangular or polygonal or round or oval outer cross-section/profile. In other words, the support part may be configured such that the first surface of the support part may abut an outer surface of a beam of the frame. The support part may thereby be securely attached to the frame, e.g. by having the first surface being at least partly in contact with an outer surface of the frame.

In one or more exemplary support parts, the first surface of the support part may be fastened to the frame by welding, by glue, with a clicking system, and/or by rivets.

In one or more exemplary support parts, the support part may be constituted of metal such as steel, iron, or aluminium, of a polymeric material, and/or of a composite material e.g. a reinforced polymer.

According to a second aspect of the invention, the invention relates to a construction comprising a wall comprising and a support part according to the first aspect. The wall comprises one or more inner layers and one or more outer layers. The one or more inner layers comprise a polymer material or a composite material or similar light weight material, and the one or more outer layers of the wall comprise either a composite material or a polymeric material or a glass material. The wall may for example be a wall or a s id e/top/ bottom of a shipping or cargo container. The construction may comprise one or more support parts according to the first aspect. For example, for each wall the construction may comprise a support part at the bottom of the wall and at the top of the wall. Further, a construction may comprise a wall comprising one or more support parts at the bottom of the wall and one or more support parts at the top of the wall. In other words, a support part may be constituted of one or more support parts, e.g. so that the dimensions of the wall, the support part, the spacer units, the one or more outer layers, and the one or more inner layers may be varied and/or adapted to the dimensions of a frame. The support part and the spacer units may thereby be divided in two or more parts for assembling a wall or a side of a construction. The construction may thereby be modular, e.g. comprising a wall consisting of one or more wall modules.

In one or more exemplary constructions, a wall may comprise two or more sub-walls or wall modules each comprising an inner layer and an outer layer. The wall may be constituted of two or more sub-walls arranged next to each other. When the wall comprises two or more sub-walls, each sub-wall may comprise a support part at the bottom of the sub-wall and at the top of the sub-wall, i.e. two support parts. In other words, the two or more sub-walls may together form a wall, such as a wall of a shipping or cargo container.

In one or more exemplary constructions, the construction comprises a frame made of metal such as steel or of wood.

In one or more exemplary constructions, solar cells (such as one or more solar panels, e.g. photovoltaic cells or panels) and/or or reinforcing material and/or insulation material is/are positioned in a space limited by one or more spacer units of the support part, the one or more inner layers, and the one or more outer layers. In one or more exemplary constructions, the one or more outer layers are constituted of an insulating material and cooling means, such as cooling coils, are positioned in the space limited by one or more spacer units, the one or more inner layers, and the one or more outer layers. The one or more inner layers may constitute a protective cover layer. In one or more exemplary constructions, the one or more outer layers of the wall are constituted of a light permeable material, such as glass, armoured glass, and/or a polymer such as acrylic or the like, e.g. to let light through to one or more solar cells.

In one or more exemplary constructions, the proportions of the second surface of the support part as well as the width of inner layers fastened to respectively the first and the second spacer unit are adapted in such a way that inner corners or surfaces of two inner layers attached to different spacer units of same support part is in contact with each other.

In one or more exemplary constructions, the second surface of the support part is fastened to a first spacer unit of the one or more spacer units and the one or more inner layer are fastened to a second spacer unit of the one or more spacer units, and wherein the proportions of the second surface of the support part as well as the width of the one or more inner layers are adapted in such a way that inner corners or surfaces of two inner layers attached to different spacer units of same support part are in contact with each other.

In one or more exemplary constructions, the construction comprises at least two walls or at least three walls or at least four walls or at least five walls of a shipping or cargo container.

When preparing a container comprising a metal frame with specially adapted walls, it is advantageous to retrofit the beams with a spacer unit as one design of a container frame may then be fitted to different kinds of cargo, e.g. cooling facilities, heating facilities, electricity production, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is an explanation of exemplary embodiments with reference to the drawings, in which

Figs. 1A-1D show four embodiments of a support part according to the invention.

Fig. 2A and 2B shows a cut-through view and a side view of a first embodiment of a section of a wall supported by support parts according to the invention.

Fig. 3A and 3B shows a cut-through view and a side view of a second embodiment of a section of a wall supported by support parts according to the invention.

Fig. 4 shows a cut-through view of two support parts according to the invention supporting three two-layered walls.

Fig. 5 shows a cut-through view of a support part according to the invention supporting two two-layered walls.

Fig. 6 shows a cut-through view of a support part according to the invention supporting one two-layered wall.

Fig. 7 shows a frame for a container which may be applied with walls supported by support parts according to the present invention. DETAILED DESCRIPTION

The use of the terms "first", "second", "third" and "fourth", "primary", "secondary", "tertiary" etc. does not imply a specific order but are included to identify individual elements. Moreover, the use of the terms "first", "second", "third" and "fourth", "primary", "secondary", "tertiary" etc. does not denote any order or importance, but rather the terms "first", "second", "third" and "fourth", "primary", "secondary", "tertiary" etc. are used to distinguish one element from another. Note that the words "first", "second", "third" and "fourth", "primary", "secondary", "tertiary" etc. are used here and elsewhere for labelling purposes only and are not intended to denote any specific spatial or temporal ordering.

When the words "in general" are used to describe an embodiment, it should be understood that the feature(s) described by these words may be used with any embodiment of the invention and not just with the embodiment of the paragraph where the features are described. "box-shaped" is used to describe a structure comprising 6 sides, four side pieces and two ends pieces joined by approximately rectangular corners. The structure of fig. 6 is box shaped according to the present document.

Furthermore, the labelling of a first element does not imply the presence of a second element and vice versa.

Fig. 1A, IB, 1C and ID illustrates four embodiments of a support part 1 according to the invention. A support part 1 according to the invention either comprises one spacer unit 2 extending in one direction from the surface of the support part 1 or two spacer units 2 extending in two different directions from the surface of the support part 1 which two different directions may be perpendicular.

Each spacer unit 2 indicates the direction for mounting of a two-layered wall extending from the support part 1. If the support part 1 comprises two spacer units 2, the two directions may be opposite i.e. parallel and differing by 180°, in which case the support part may function as a middle part or e.g. as an extra support. A support part 1 comprises a first surface 3 and a second surface 4, where the first surface 3 is adapted to fit to the surface of a frame 5 or another construction which frame 5 may define the in-use-position of the support part 1 as well as the in-use-position of the layers or walls attached to the support part 1. A body part of the support part 1 is the part of the support part 1 extending between the first surface 3 and the second surface 4, but the body part does not comprise the spacer units 2.

The first surface 3 constitutes a contact surface being at least partly in contact with the frame 5 during use, whereas the second surface 4 is not in contact with the frame 5 during use and comprises the one or two spacer units 2 i.e. the space unit(s) 2 extend from the second surface 4. The spacer units 2 may be constituted of a material different from the second surface 4, but normally the spacer units 2 are made of the same material as the second surface 4 and the complete support part 1 including the spacer units 2 may be created in one operation e.g. by moulding, extrusion or another method for creating profiles.

The first surface 3 of the embodiment shown in fig. 1A comprises two straight or flat surfaces which are joined in a "convex" angular corner, this embodiment of a support part 1 fits with an open or L-shaped profile, e.g. the convex straight or flat surfaces according to this embodiment may be joined in any angle fitting the surface of the frame 5.

The first surface 3 of the embodiment shown in fig. IB comprise one straight or flat surface, this embodiment of a support part 1 e.g. fits with a triangular profile of a frame 5 or with a part of a frame 5 having a flat i.e. straight contact surface.

The first surface 3 of the embodiment shown in fig. 1C comprises two straight or flat surfaces which are joined in a "concave" angular corner, the shown embodiment of a support part 1 may fit with a rectangular beam or profile, e.g. the concave straight or flat surfaces according to such an embodiment may be joined in any angle which fits the surface of the frame.

The first surface 3 of the embodiment shown in fig. ID also comprises two straight or flat surfaces which are joined in a "concave" angular corner, the shown embodiment of a support part 1 fits with a rectangular beam or profile, e.g. the concave straight or flat surfaces according to such an embodiment may be joined in any angle which fits the surface of the frame. The embodiment comprises only one spacer unit 2 but the "concave" angular corner of the first surface 3 allows the support part 1 to be firmly positioned relative to the frame 5.

In general, an embodiment of a support part 1 according to the invention may comprise a first surface 3 adapted to fit to a round or oval profile of a frame 5.

In general, a spacer unit 2 extending from the second surface 4 normally comprises or provides a first contact surface 6 for an inner layer or wall part 8 and a second contact surface 7 for an outer layer or wall part 9. The first and the second contact surfaces 6, 7 are normally parallel and facing in opposite directions, further a spacer unit 2 has a third surface connecting the first and second contact surfaces which third surface faces an open space 10 between the inner and outer layer of a wall part during operation.

The two contact surfaces 6,7 of the spacer unit 2 are adapted in size and surface structure to attach/fix respectively the inner 8 and the outer 9 layers in such a way that the inner and outer layers together constitute a wall. Each contact surface 6, 7 of the spacer unit 2 may extend either in full length or in full height of the wall but normally the contact surfaces 6,7 of the spacer unit 2 do not extend both in full length and in full height of the wall. When the contact surfaces 6,7 - and consequentially the spacer unit 2 - do not extend both in full length and in full height of the wall, an open space 10 is provided between the inner 8 and the outer 9 layer of the wall, this open space 10 may be fully or partly occupied by another material e.g. insulating material such as rock wool, or functional components e.g. solar cells, measuring instruments or the like, during use. E.g. the support part 1 may be fastened to the frame 5 or a similar construction via the first surface 3 and normally the support part 1 is fastened by e.g. glue, with a clicking system, or by rivets or welding depending on the material constituting the spacer unit(2) and the layers of the wall.

The support part 1 as such may be constituted of a combination of materials e.g. the body part of the support part 1 may be constituted of a first material such as metal or a polymer or a composite material and the spacer units 2 may be constituted of a second material such as metal or a polymer or a composite material. According to one embodiment, the support part 1 is constituted of one material or same combination of material throughout, where all parts of the support part 1 includes the spacer units 2 and the body part, which material may be metal such as steel, iron, aluminium, or a polymer or a composite material e.g. a polymer reinforced with fibres or particles.

A support part 1 or a plurality of support parts 1 according to the invention may be used in the construction of polygonal constructions, e.g. rectangular or box-shaped units such as a container or a house or residence. A box-shaped unit normally comprises 6 walls, 4 side walls and a top and a bottom.

Walls supported by a support part 1 according to the invention may be either vertical or horizontal or inclined at any desired angle.

A polygonal construction or construction comprising walls supported by a support part 1 according to the invention, may comprise two or more walls. Walls supported by a support part 1 according to the invention may constitute all walls of a polygonal construction i.e. including normally horizontal walls such as roof/top and floor/bottom, and normally vertical walls such as side walls and end walls. However, the walls supported by a support part 1 according the invention may also constitute a subset of the walls constituting the polygonal construction, e.g. the side walls including a top and a bottom whereas the end walls may be of a different construction, alternatively, the floor/bottom may be of a different construction.

If one or more wall(s) is/are of a different construction, the one end of a wall contacting this wall of different construction may comprise a support part 1 comprising only one spacer unit whereas the surface of the support part 1 extending towards and contacting the wall of different construction may be adapted to fix this wall of a different construction.

Fig. 2A and 2B shows a first embodiment of a section of a wall supported by a support part 1 according to the invention. Fig. 2B shows a side view of the embodiment and fig. 2A shows a cut-through view of the embodiment where the cut-through view is made along the line A-A of fig. 2B.

The wall comprises two layers, an inner layer 8 and an outer layer 9, and an upper or first spacer unit 2 and a lower or second spacer unit 2. The inner layer 8 has an outer surface 11 facing the outer layer 9, and the outer layer 9 has an inner surface 12 facing the inner layer 8. The opposing support parts 1 each comprise one spacer unit 2 which is not fully shown in these figures, but the opposing support parts 1 are fixed or attached to a not shown frame 5 or similar construction. According to this embodiment, each spacer unit 2 extends in full length of the wall, where the "length" in fig. 2A and 2B is the distance from left to right. The not shown body part of the support part 1 may also extend in the full length of the wall. This positioning of the spacer unit(s) 2 leaves an open space 10 between the two shown spacer units 2, which open space 10 may either remain empty with the intention to reduce the weight of the wall, or the open space may be provided with functional units or material adding a new functionality to the wall.

Each spacer unit 2 comprises two contact surfaces 6, 7, where each contact surface faces a layer 8, 9 of the wall, a first contact surface 13 faces the inner layer 8 and a second contact surface 14 faces the outer layer 9. When the inner and outer layers 8, 9 are mounted or fixed to a support part 1, the first contact surface 13 of the spacer unit(s) 2 is/are fixed to the outer surface of the inner layer 11 and the second contact surface 14 of the spacer unit(s) is/are fixed to the inner surface of the outer layer 12, and then the layers 8, 9 together with the two support parts form a wall.

In general, the length of either the inner layer 8, the outer layer 9 or both layers 8,9 may be adapted so that end-surfaces of the layer(s) is/are in contact with the second surface 4 of the support part 1 in such a way that the outer or inner or both layers are in tension between either two opposing support parts 1 in the case where a support part 1 is positioned at each end of the wall, or between a support part 1 and a surface of e.g. the frame 5 in the case where a support part 1 is only positioned at one end of the wall.

Fig. 3A and 3B shows a second embodiment of a section of a wall supported by a support part 1 according to the invention. Fig. 3B shows a side view of the embodiment and fig. 3A shows a cut-through view of the embodiment where the cut-through view is made along the line A-A of fig. 3B.

According to the second embodiment, each spacer unit 2 extends in full height of the wall, where the "height" in fig. 3A and 3B is the distance from top to bottom, i.e. in a normally perceived vertical direction. Although, the spacer units 2 of this embodiment do not each extend in the full length of the wall, where "length" is understood to be the direction perpendicular to the "height", the body part of the support part 1 may extend in the full length of the wall.

Fig. 3B shows three spacer units 2 extending between an upper and a lower support part 1.

According to this embodiment the spacer unit(s) 2 does/do not extend in full length of the wall, this positioning of the spacer units 2 therefore leaves a plurality of open spaces 10 between neighbouring spacer units 2 which open spaces 10 may either remain empty and reduce the weight of the wall significantly, or which open spaces 10 may be provided with functional units or material adding a new functionality to the wall e.g. insulating material such as rock wool, or functional components e.g. solar cells, measuring instruments, reinforcing material or the like.

Each of the layers 8, 9 together constituting the wall according to the invention, may be made of a relatively hard and rigid material, which material can maintain a straight surface when mounted. Normally, the two layers 8, 9 are not constituted of identical materials, nor is the thickness of the two layers 8,9 normally identical as each layer 8, 9 is adapted to the purpose of the construction in which the wall is to be positioned.

The inner layer 8 may be a composite material, i.e. a plate-shaped material comprising two or more layers e.g. of a fibre-reinforced polymer (FRP) such as carbon -fib re- re info reed polymer (CFRP) or glass-reinforced plastic (GRP).

Normally, the material of the inner layer 8 is adapted to provide an inner surface allowing for easy cleaning i.e. the inner surface of the inner layer 1 is hard and smooth, e.g. the inner layer 8 is adapted to provide insulation in order to keep the room at the inside of the wall either cold or warm, and normally the material of the inner layer 8 should be able to withstand hits during loading.

The outer layer 9 may also comprise or be constituted of a fibre-reinforced polymer e.g. adapted to resist moisture and/or UV-light, however the outer layer 9 may also be made of a transparent material or a material permeable to sunlight, e.g. the outer layer may comprise or be constituted of acryl or armoured glass or polycarbonate or similar protecting material allowing sunlight to penetrate into the open space(s) 10 and e.g. drive solar cells, e.g. photovoltaic cells or panels positioned inside the open space(s) 10. The outer surface of the outer layer and the outer surface of e.g. a solar cell or panel arranged in an open space 10 may not be flush with the outer surface of the support part and/or the frame. In other words, the outer surfaces of the outer layer and the outer surface of e.g. a solar cell or panel are not co-planar or axial with the outer surface of the support part. In other words, the outer surface of the support part does not outward the same distance as the outer surface of the outer layer and/or the outer surface of e.g. a solar cell or panel. An advantage of having the outer surface of the outer layer and the outer surface of e.g. a solar cell or panel arranged in an open space 10 that are not flush with the outer surface of the support part and/or the frame is that the outer layer may and/or the solar cell or panel may be protected from shocks and damages. The frame 5 may comprise rectangular or rounded beams joined to form a box or a box-like structure, the beams of the frame 5 need not be solid, the beams may be a hollow structural section (HSS) i.e. a metal profile having a hollow cross section.

The beams of a frame 5 may be made of steel or another metal or alternatively of a material of similar strength and similar modulus of elasticity. E.g. the frame 5 is made of a composite material e.g. a reinforced polymer.

Optionally, open spaces 10 limited by spacer units 2 and the inner and outer layer 8 and 9 may be used e.g. for solar cells and/or or reinforcing material such as metal net or the like and/or insulation material.

If the open space 10 and therefore the wall is provided with solar cells, the entity comprising the wall can produce electricity during use when placed outside, such as exposed to sunlight.

Figure 4 illustrates an embodiment comprising two oppositely positioned support parts 1. The L-profiled frame 5 which would fit to this embodiment of the support part 1 is not shown in the figure. Each wall extending from a support part 1 comprises an inner layer 8 and an outer layer 9.

In general, the thickness of the inner layers or the second surface 4 of the support part(s) 1 may be adapted in such a way that two neighbouring and perpendicular or otherwise relatively angled inner layers 8 hide or cover the support part 1, i.e. the two neighbouring inner layers 8 may touch or overlap each other.

Figure 5 illustrates an embodiment where a frame in form of a beam 5 may be fitted with a support part comprising two spacer units 2 i.e. the beam is normally constructed independently of the support part 1. This support part 1 may be fixed to the beam 5 before or during construction of the wall. The support part 1 comprises a first spacer unit 2 extending in one direction and a second spacer unit 2 extending in a second direction and a connecting body part, i.e. the body part, comprising the first and second surfaces 3, 4 of the support part where the first surface 3 is adapted to fit a corresponding surface of the beam 5.

The first surface 3 of the support part 1 may define exactly which angular position the support part 1 must have relative to a beam 5 i.e. the first surface 3 of the separate support part 1 corresponds to the surface for fastening of the beam 5. E.g. if the beam 5 is rectangular, the first surface 3 of the separate connector part 1 corresponds to the corner of the rectangular beam 5 and the correspondence of the two surfaces will define the precise angle in which to position the support part 1 during mounting. This increases speed when fitting and mounting support parts 1 to beams 5.

In general, a support part 1 may e.g. be made of metal e.g. steel or iron and may be fixed to the beam 5 by either welding, riveting, gluing or other methods used to attach metal parts to each other. Alternatively, a support part 1 may be made of a polymer material such as a composite material e.g. a polymer reinforced with fibres or particles, and may be fixed to the beam 5 by riveting, gluing or other methods used to attach polymer or composite parts to metal parts or to other polymer or composite parts.

Figure 6 illustrates an embodiment where a frame in form of a beam 5 is fitted with a support part 1 comprising one spacer units 2. According to this embodiment, the spacer unit 2 is constituted of a support part 1 which is to be fixed to the beam 5 before or during construction of the wall. The support part 1 comprises a one spacer unit 2 extending in a downward direction according to the figure, and the body part of the support part 1, comprises the first and second surfaces 3, 4 of the support part 1 where the first surface 3 is adapted to fit a corresponding surface of the beam 5.

The first surface 3 of the support part 1 of this embodiment is angled and is in contact with a surface of the beam 5 facing in two different directions, this feature makes it easier to position the support part during mounting and increases the strength of the fastening between support part and beam after mounting.

A traditional one-layer wall 15 may be positioned adjacent to the wall according to the invention. Such a common one-layer wall 15 may e.g. be constituted of a steel plate e.g. a corrugated steel plate. Normally, the support part 1 of this embodiment will mirror the mounting of a similar support part in an opposite not shown corner.

Figure 7 shows a frame 5 of a standard container which frame 5 may be fitted with walls according to the invention. The walls according to the invention may constitute all sides of a container unit in order to reduce the weight of the container compared to a traditional container build of steel walls and provided with a wooden floor. Normally the walls according to the invention may constitute at least two long side walls and the top wall i.e. the roof. The end walls and the floor of the container may be constituted of other materials as the end walls and the floor may need other functionalities.

For a standard container it will be possible to reduce the weight of the container significantly by using the construction according to the invention. I.e. a traditional container of 40 f made of steel weighs around 3740 kg and can carry a cargo of around 27.000 kg. A container comprising the walls of the construction according to the invention may weigh around 40% of a traditional container i.e. between 2000-2500 kg depending on the choice of material for the walls. As the frame and floor may be identical to a normal container made exclusively of steel, a container constructed according to the invention will be able to carry a cargo of around 30.000 kg.

As the walls of the invention is not necessarily of same thickness as the beams used for the frame, the inside volume of a container constructed according to the invention may be increased compared to a traditional container.

Also, if the open space 10 between the inner and outer walls are provided with solar cells, it is possible to create an electrical circuit through several containers stacked on top of one another. The containers may be connected through electric wiring positioned in the frame, possibly constituted by the frame, and the surfaces of the metal corner units of the container may be constructed as connectors which connectors create electrical contact between two containers.

In one or more exemplary constructions, when the open space 10 between the inner and outer walls are provided with solar cells, it may for example be possible to connect a container comprising a construction according to the disclosure, which is located e.g. on a ship or a vessel, stored on a harbour or dock, a truck, or a train, to a transformer for providing electricity for different uses on the dock or harbour, the ship or vessel, the truck, the train. A container may thereby be used as an energy source when a vessel is docked in a harbour, when the container is being stored, and/or when the container is transported on a vessel, a truck, or train. A container may thereby be used for the energy/electricity consumption on a vessel, a harbour, a truck, or a train.

In one or more exemplary constructions, when the open space 10 between the inner and outer walls are provided with solar cells, a container or the like comprising a construction according the disclosure, may comprise a battery which may be charged by the solar cells of the construction. The energy harvested during the day by the solar cell of a container may thereby be stored on the battery for use later on, e.g. when the sun is down, such as at night. A battery located in a container may further be used as a ballast in the container when containers are lifted and moved around.

The outer measures of a container should fit to common standards for containers; however, the inner measures of a container may vary. I.e. the outer layer 9 of a wall according to the invention may normally not extend beyond the outer limit of the frame 5, but the inner layer 8 may extend into the inner space of the container if this is considered necessary, and the present invention makes it possible to take this into consideration and adapt the inner and outer layers for a series of different purposes without extending the outer layer beyond the outer limit of the frame 5.