BACKGROUND

[0001] The present invention relates to a method and apparatus for covering internal surfaces of cargo container s with a protective layer for maintenance of internal cleanliness to meet standards for carriage of goods in such containers. The invention further relates to an applicator which dispenses a film of material for application to the floor walls and ceiling of a cargo container and particularly though not exclusively for shipping containers. The invention further relates to a method and assembly for application of a cover layer to internal surfaces of a container to enable the safe and compliant carriage of cargo including grains, foods and other products.

PRIOR ART

[0002] Since the advent of containerisation of cargo in the shipping industry a large variety of products such as household goods, vehicles, plant and equipment and many other commodities are transported in shipping containers. Products such as grain, iron ore, coal, and oil have in the past and before containerisation been transported loose in ship holds. Refrigerated shipping containers are used for products such as fruit and other perishable items that require a temperature controlled climate. Non-refrigerated shipping containers are used for other products which are not temperature sensitive and consequently do not have to be regulated or maintained within a specific temperature range. Other products, such as wines, are far less sensitive to temperature than would require them to be refrigerated, but nonetheless should be protected from extremes of temperature (both hot and cold). To reduce the range o temperature fluctuations inside a shipping container it has been proposed that the container should be fitted with a liner which restricts heat transfer between the air space containing the cargo and the ambient air. A prior art system of this type is disclosed in US patent specification No. 7416091 published on 26 August 2008.

[0003] Depending upon the goods carried in a cargo container the internal environment for the container must be adequate for the purpose. In the case of grain carriage for example, the internal surface of the container must meet a high standard of food grade cleanliness. When containers undergo wear and tear and in many cases corrosion the internal surface of the container degrades to a point where the container does not meet the cleanliness and internal finish requirements for enable carriage of some cargos. Local and international standards determine requirements for internal quality of containers particularly for those transporting foodstuffs. Since grain when trans ported loose in a container is in direct contact with t he walls of the container the walls must be clean and free of such defects as corrosion and other potential contaminants. When containers degrade through use over time, the surface of internal walls of the container may fall below standards of quality. Various methods have been adopted to line the inside of containers to protect cargos.

[0004] One example of a method for lining containers is disclosed in patent specification WO2010046790 which teaches a shipping container which includes a roof panel, an end panel and side wall panels. Cords are attached to the Hner in the vicinity of the end wall panel and extend tlirough loops along the top edges of the wall panels. Hooks, carried by the parts of the cords between the loops, are provided for attaching the cords to sets of lashing points of the shipping container. The cords can be anchored and then tensioned, in a temporary manner, to pull the top edges of the side wall panels towards the lashing points to facilitate cargo loading. When the cords are permitted to become slack, the roof panel drops down to envelope the loaded cargo.

[0005] The fitting of a liner to the interior of a container must be performed carefully, in order to avoid areas of high stress which could lead to tearing of the liner when the container is being used for the transport of goods. It is thus time consuming to suspend a liner appropriately within a container and subsequently to release a liner after use from a container, and in order to minimise the time required, various suspension techniques have been developed. Many of these techniques need the use of various hand or even power tools and require considerable care in order to ensure the liner is not punctured or torn during installation and will remain intact during loading of the product and the transportation thereof. During emptylng, the liner should remain in its installed position and not tear or leak. The method enables a flexible plastics material liner to be secured relatively easily and quickly within a cargo container. [0006] Tt is known common practice to transport liquids in flexible tanks which are large bladders that fit inside standard shipping containers. Some products, such as molasses, solidify during transit and cannot be pumped from the flexible tank in which they are transported until softened. A conventional way of softening the tank's contents is to provide a means of heating the tank from the outside. Typically the contents of the tank are heated until they are soft enough to allow them to be piimped from the bladder. To reduce the time taken to soften the contents of the flexible tank prior to pumping, and to minimize the energy required for this purpose, a liner is provided for a shipping container, which comprises means for temporarily attaching the roof panel of the liner to the roof of the shipping container. The method can include the step of temporarily attaching the roof panel of the liner to the roof of the container prior to loading the cargo, and releasing the temporarily attachments to permit the roof panel to drop down onto the cargo.

[0007] WO9701496 (Al) also discloses a liner for the bulk transport of flowable products in a cargo container. The liner has a pair of corner fillet boards extending diagonally across two lower corner regions at one end of the container. The liner is in the form of a bag fabricated from flexible plastics sheet material, so as to fit closely within the container . The two portions of the liner which, when the liner is installed in a container, are disposed generally in corner regions and are pre-shaped to closely to follow the three-dimensional topology of the container and the fillet boards extending across the corner regions. The fillet boards may be received in pockets pre-formed in said portions of the liner. Both of the above methods and associated apparatuses involve significant expense and a high cost labour component.

[0008] Abstract of GB2329374 (A) discloses another method of securing a flexible plastics liner within a cargo container using a plurality of elastic retaining cords. Each cord is either attached to the liner at a suitable position , or is passed through a loop or other receptor secured to the liner. Each cord has a self-jamming cleat secured at or adjacent one end, to permit the cord to be coupled to a member provided within the container and then tensioned so as to suspend the liner therewithin. The cord may be passed through a hole in the member or a loop may be formed around the member. [0009] US2001002017 (A1) discloses a method of securing a flexible plastics liner within a cargo container and which uses a plurality of plastic retaining cords. Each cord is either attached to the liner at a suitable position, or is passed through a loop or other receptor secured to the liner. Each cord has a self-jamming cleat secured at or adjacent one end, to permit the cord to be coupled to a member provided within the container and then tensioned so as to suspend the liner therewithin. The cord may be passed through a hole in the member or a loop may be formed around the member.

[0010] In summary the known prior art inventions individually or collectively as described all experience significant problems even though they attempt to provide a more efficient alternative to the traditional methods. There is a long felt want in the, industry to provide an economic and useful alternative to the known methods which is relatively economic to manufacture, reduces labour and is simple to apply. It can be seen form the aforesaid that although in the past, many attempts have been made to improve the internal cleanliness quality of containers the known methods have been expensive, inconvenient and inefficient.

[001 1] There is a need to improve the prior art methods and apparatuses to overcome the disadvantages which exist in those methods and to provide an efficient alternative which reduces tum around time for cargo containers and to bring used containers to a required standard for transportation of goods.

INVENTION

[0012] The present invention seeks to ameliorate the shortcomings of the prior art. With this in mind, the present invention provides a method and apparatus for covering internal surfaces of cargo containers with a protective layer for maintenance of internal cleanliness to meet standards for carriage of goods in such containers. The invention further provides an applicator which dispenses a film of material for application to the floor walls and ceiling of a cargo container and particularly though not exclusively for shipping containers. The invention further relates to a method and assembly for application of a cover layer to internal surfaces of a container to enable the safe and compliant carriage of cargo including grains, foods and other products. [0013] In its broadest form the present invention comprises:

an apparatus for application of a protective cover over the inside surface of a cargo container, the apparatus comprising; a frame including;

a first member which receives and retains thereon a roll of cover material;

a guide roller and an operating handle extending from the frame,

wherein when the frame is laid against a surface of the inside of the container, the handle urges the frame in one direction, whereupon the cover material unfurls to dispense the cover material in an opposite direction thereby applying the cover to the inside surface of the container as the applicator is passed along the surface of the container.

[0014 ] In another broad form the present invention comprises:

an apparatus for application of a protective cover over the inside surface of a cargo container, the apparatus comprising;

a first support plate and a second support plate;

first, and second struts joining the plates and spanning therebetween;

a first member spanning between the plates which receives and retains thereon a roll of cover material;

at least one guide roller which guides passage of the protective cover as the cover unrolls;

handles extending form the struts,

wherein when the apparatus is disposed against a surface of the inside of the container, operator uses the handles to urge the apparatus along a wall surface in a first direction, whereupon the cover material unfurls to dispense the cover material in an opposite direction thereby applying the cover to the inside surface of the container as the applicator is passed along the surface of the container.

[0015] According to a preferred embodiment the surface of the container is a wall surface and the apparatus is disposed vertically such that the axis of rotation of the cover material is normal to the direction of travel of the apparatus.

[0016] In a broad form of a method aspect the present invention comprises:

a method for application of a protective cover to an inside surface of a cargo container, using an apparatus comprising a frame including a first member which receives and retains thereon a roll of cover material; a guide roller and an operating handle extending from the frame,

the method comprising the steps of;

a) mounting the roll of cover material on the first member of the apparatus;

b) feeding the cover material about the outside of the at least one guide roller such that an adhesive back of the cover material opposes a surface to which the cover material is to be applied;

c) urging the handle in a first direction so that the roll of cover material is dispensed via the guide rollers in an opposite direction;

d) continuing movement of the frame in said first direction until a predetermined area of inner surface of the container is covered with the cover material.

[0017] According to a preferred embodiment the frame comprises side struts and spanning therebetween the first member, one guide roller and an intermediate member which retains the handle. According to a preferred embodiment the cargo container is a shipping container.

[0018] The present invention provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying illustrations, like reference characters designate the same or similar parts throughout the several views. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. It will be convenient to hereinafter describe the invention in relation to a plastics cover material in the present exemplary application. However, it is to be appreciated that the invention may be constructed from other materials.

BRIEF DESCRIPTION OF DRAWINGS

[0019] The present invention will now be described in more detail according to a preferred but non limiting embodiment and with reference to the accompanying illustrations, wherein:

Figure 1. shows a perspective view of a typical 40 foot cargo container according to prior art.

Figure 2. shows a perspective vjew of a typical 20 foot container according to prior art.

Figure 3. shows an elevation external view of the doors of a typical cargo container. Figure 4. shows an elevation view of internal end wall corrugations of a typical container.

Figure 5 shows an elevation view of an internal wall of a container

Figure 6 shows a long section through a part of the wall of the container of figure 4 showing the geometry of the wall profile.

Figure 7 shows a perspective view of a lining applicator assembly located inside a cargo container.

Figure 8 shows an applicator according to an alternative embodiment adapted for application of the cover material to the floor of a container.

Figure 9 shows a lining applicator of the type shown in figure 7 applying a cover film to vertical walls of a container.

Figure 10 shows an applicator supported by a gantry according to an alternative embodiment adapted for application of the cover material to a floor, roof or wall of a container.

Figure 1.1 shows the applicator of figure 10 with corresponding numbering adjusted for wall and floor lining.

Figure 12 shows the applicator of figure 10 this time adjusted for lining a ceiling. DETAILED DESCRIPTION

[0020] The present invention to be described below in more details provides an alternative to the known prior art and the shortcomings identified. The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying representations, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying illustrations, like reference characters designate the same or similar parts throughout the several views.

[0021] It is to be appreciated that the invention is not limited to the particular assembly described . The examples referred to herein are illustrative and are not to be regarded as limiting the scope of the invention. While various embodiments of the invention have been described herein, it will be appreciated that these are capable of modification, and therefore the disclosures herein are not to be construed as limiting of the precise details set forth, but to avail such changes and alterations as fall within the purview of the description.

[0022] Throughout the specification a reference to cover material can be taken to mean any material which is applied to or against the inner surface of a container an includes adhesive plastics material or any other material capable of being dispensed by the applicator devices described herein.

[0023] Figure J. shows a perspective view of a typical 40 foot container 1 according to the prior art. Container of this type are manufactured from high strength steel. The roof 2, walls 3 and 4 are usually corrugated with rib formations which impart significant strength to the container.

[0024 ] Figure 2. shows a perspective view of a typical 20 foot container 10 according to prior art. Figure 3. shows an elevation external view of the doors 30 and 31 of a typical cargo container 33 . The doors close an internal space which receives and retains the cargo. Looking inside the container, Figure 4 shows an elevation view of internal end wall corrugations 34 of a typical container. Figure 5 shows an elevation view of an internal corrugated wall 40 of a container 41. Figure 6 shows a long section through a part of the wall 40 of the container 41 of figure 4 showing the corrugated geometry of the wall profile.

[0025] Figure 7 shows a perspective view of a lining applicator assembly 50 located inside a cargo container 51. Applicator 50 shown is adapted for applying a cover liner to vertical walls 52, 53 and 54. Applicator 50 comprises a support plate 55 mounted on ground engaging castor wheels 56 and 57. This allows an operator to move applicator 50 along the walls during application of a cover material. Applicator 50 further comprises overhead plate 58,which is connected to support plate 55 via struts 59 and 60. Mounted between plates 55 and 58 is a primary roller 61 which receives and retains a roll of cover material 62. Located along edge 63 of plate 55 are three auxiliary guide rollers 64, 65 and 66 which guide cover material 62 during application to walls 52, 53 and 54. An operator manually urges the applicator 50 along walls 52, 53 and 54 using either one or more of bandies 67, 68 or 69.

[0026] Figure 8 shows an applicator 70 according to an alternative embodiment adapted for application of the cover material to the floor of a container. Applicator 70 according to this embodiment is adapted for application of protective cover material 71 to inside surface floor 72 of cargo container 73. Applicator 70 comprises a frame 74 including side bars 75 and 76 and transverse members 77, 78 and 79. Mounted on member 77 is a roll of adhesive cover material 80 which is free to rotate about member 77. Member 77 forms a rotational axis for cover material. Frame member 79 retains a guide roller 81 which is free to rotate about member 79. Extending from the frame member 78 is operating handle 82. Cover material 71 unfurls about frame 74 and passes around guide roller 81 in the direction of arrow 84 .

[0027] When the frame 74 is laid against surface 72 of the inside of container 73, the handle 82 urges the frame in one direction shown by arrow 83. Trailing end 84 of cover material 80 is dispensed in the direction of arrow 84, sticks to surface 72 as applicator 70 advances in the direction of arrow 83. It will be appreciated that applicator 70 can be arranged so that the roll of cover material 71 can be applied by pulling on handle 82 rather than pushing in the direction of arrow 83. In some cases it may be more convenient to push rather than pull in which case the cover material 71 can be mounted and fed on the inside instead of on the outside of guide roller 81 as shown. The cover material 71 is applied to the inside surface 72 of the container 73 as the applicator is 70 passed along the surface of the container. Applicator 70 can be used to apply a surface cover to all inside surfaces ( roof, walls, floor), of a container but is it preferred that applicator 70 be used for lining the floor of containers in a sweeping motion so the operator does not have to take the weight of the applicator. Applicator 70 can be adapted for application of lining or cover material to the corners where the to

[0028] Figure 9 shows the lining applicator 90 of the type described in figure 7 applying a cover film liner 91 to vertical walls 92 and 93 of a container 94. Applicator 90 shown applies liner 90 to vertical walls 92 and 93. Applicator 90 comprises a support plate 95 mounted on ground engaging castor wheels 96 and 97. This allows an operator to move applicator 90 along the walls during application of cover liner 91. Applicator 90 further comprises overhead plate 98 which is connected to support plate 95 via struts 99 and 100. Mounted between plates 95 and 98 is an axle 101 which receives and retains roll 102 of cover liner 92. Located along edge 103 of plate 95 are three auxiliary guide rollers 104, 105 and 106 which guide cover liner 91 during application to walls 92 and 93. An operator manually urges the applicator 90 along walls 92, 93 in the direction of arrow 107 using either one or more of handles 108 or 109. To facilitate application of cover liner 91, one or more of rollers 104, 105 and 106 are urged against walls 92 and 93 as applicator 90 is urged by an operator in the direction of arrow 107. Although figure 9 shows one pass of cover material liner 91 for the purpose of illustration, in order to fully seal/line walls 92 and 93, additional passes may be required to cover exposed parts of walls 92 and 93. Typically it would be likely to require two or three passes along each wall of the applicator to fully cover each wall with liner 91 but this would depend upon the height of the wail and height of the applicator.

[0029] Figure JO shows an applicator 120 supported by a gantry 121 according to an alternative embodiment. In this embodiment the applicator 120 is capable of applying a cover liner 122 to a floor roof or wall of a container. In figure 10 cover material liner 122 is applied to a vertical wall 123. Applicator 120 comprises a mounting member 124 which retains roll 125 of liner 122. As roll 125 unfurls during application of liner 122, guide roller 126 urges liner 122 against wall 123. Since liner 122 has an adhesive backing it easily sticks to corrugations of wall 123. Applicator 120 is mounted on gantry 121.

[0030} Gantry 121 is mounted on a hoist 127 which allows gantry 121 to be adjusted over the height of the hoist. This allows gantry 121 to apply liner 122 on a vertical and horizontal surfaces. Typically when laying liner 122 from ceiling to floor, gantry 121 will be elevated to a required height then lowered in the direction of arrow 128 until the wall is lined. This process is repeated as required until the inner wall of the container is fully covered. Liners can be applied vertically or horizontally. An operator can select an applicator apparatus appropriate for the lining task required. Associated with the gantry 121 is a drive assembly 130 which facilitates travel of the gantry 121 during unrolling of the cover liner as the apparatus travels along the face of the container surface. Hoist 127 allows adjustment of the elevation of the gantry. Drive assembly 130 includes a drive chain 131 engaging a drive wheel 132 which actuates unrolling of liner 122 and allows advancement of said gantry during application of the liner 122. Hoist 127 also includes a height adjusting mechanism which allows an operator to selectively adjust the height of the gantry at the commencement of the application. Once the gantry is set at a particular level it may then be hand operated by winch to enable gradual unrolling of roll 125 in the direction of arrow 128 so eventually the whole surface to be lined is fully covered. Hoist 127 and gantry 121 can be adjusted to enable lining of a wall, floor or ceiling of a container. Gantry 121 includes a main frame 135 and auxiliary support frame 136 which supports a roller support member 137. Gantry 121 can be raised or lowered in the directions indicated by arrow 138.

[0031 ] Figure 11 shows the applicator of figure 10 with corresponding numbering adjusted for floor lining after application of liner 122 to wall 123. In this setting gantry 121 is lowered so that guide roller 140 urges liner 122 against floor surface 141.

[0032] Figure 12 shows the applicator 120 of figure 10 this time adjusted for lining a ceiling 150. Applicator 120 is capable of applying a cover liner 122 to ceiling 150. Applicator 120 comprises a mounting member 137 which retains roll 125 of liner 122. As roll 125 unfurls during application of liner 122, guide roller 126 urges liner 122 against ceiling 150. Since liner 122 has an adhesive backing it easily sticks to corrugations of cejjing 150. Applicator 120 is mounted on gantry 121. Gantry 121 is mounted on a hoist 127 which aJJows gantry 121 to be adjusted over the height of the hoist. This allows gantry 121 to apply liner 122 on ceiling 150. This process is repeated as required until ceiling 150 is fully covered. Associated with the gantry 121 is a drive assembly 130 which facilitates travel of the applicator. Once the gantry is set at a particular level it may then be hand operated by winch 151 to enable gradual unrolling of roll 125 so eventually the whole surface to be lined is fully covered.

[0033] In use typically an operator will fit a roll of cover material to a selected applicator. That selection will usually depending upon whether the cover or liner is to be applied to the walls, floor ceiling or corners of a container. Once the roll of adhesive material is mounted to the feed roller and end of the material is initially fed about guide rollers and set at a start location. As the apparatus is urged in a direction along the surface, the roll unfurls and the adhesive material engages the inner surface of the container. This process is repeated until the inner surface of the container is protected. This might involve two or three passes along one surface depending upon the width of the roll of cover material and the height or width of the surface to which the cover material is to be attached.

[0034] Roll 125 is loaded onto a core rod 153 which passes through the centre of the roll 125. The ends of the roll can be secured with end caps. The roll 125 is installed with the adhesive side facing out once unwound. A leading end of the roll is passed through a bole at the top of the applicator and the bottom of the roll sits in a bole at the bottom of the applicator. A handle attached to the bottom of the roll support to aid correct lifting.

[0035] To apply liner to floor / roof corner sections the liner film is affixed to the edge of the container wall. This should preferably cover an equal amount of wall and floor at the corner. A leading edge of the film is secured to one end following which the film is ' urged towards the other. The film is then smoothed to both edges. This process is repeated for both sides and the rear of the container. It is repeated where the wall meets the ceilings, ensuring that the film is firmly secured to the top-side rail. This section is a requirement for bulk grain. [0036] Application of the liner to wall sections.

The applicator machine is moved into the container either using a forklift, floating platform or if the siuface is level with the container floor, rolling across into the container. A layer of film is applied to the rear wall. Next a wall laminator applies a a layer of the film starting 300mm from the rear right hand corner of the container that covers the rear corners and rear wall finishing 300mm after the rear left hand corner. Film is applied from the front right hand side of the container pulling the film out so that it covers the entire wall at the entrance (excess film can be trimmed.) This is continued around the wall of the container doubling up over the rear wall and rear comers. The liner is trimmed once finished. A centre roller will move in and out to push the film, onto the wall. Medium pressure needs to be applied to the applicator to ensure that all rollers are in contact with the wall to achieve the best application.

[0037] Application of the liner to a Floor: A floor liner is transferred into the container. A small amount of ^' liner is unrolled and fixed to the door sill, he film is then applied to the floor of the container ensuring that the outside edge overlaps the film applied to the comers. Once completed the excess film is trimmed from the edges of the container doors. The aim is to ensure that all parts of the inside surface are sealed. The liner may be formed from an opaque or translucent material. A transparent liner is appropriate where authorities require the capacity to view inside container surfaces to check for unwanted contamination from such sources as bacteria dirt, chemicals and the like.

[0038] It will be recognised by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the over spirit and scope of the invention.