Insulated cargo container and methods for manufacturing same using vacuum insulated panels and foam insulated liners

The present application relates to insulated cargo containers and, more particularly, to insulated cargo containers and their methods of manufacture.

Currently, many shippers utilize insulated or refrigerated large cargo containers (such as boxcars) to transport items that require the maintenance of specified temperatures during transit. Because these containers are required to maintain certain temperatures, the thermal efficiency of these containers is an important feature. Thermal efficiency is characterized by the thermal conductivity of a particular component or its inverse, its resistance to heat transfer commonly referred to as an R value.

In the past, large cargo containers were typically constructed of a combination of wood and metal members. Because members of this type typically possessed a low R-value, insulation, such as foam insulation, was often installed in these cargo containers to increase their thermal efficiency. Even with the use of insulation, however, the thermal efficiency of cargo containers of this type has not been as high as desired by users of these cargo containers. Therefore, there is a need for methods of constructing cargo containers with improved thermal efficiency.

One such existing method has involved placing additional insulating materials on the interior of the container. One drawback of this method is that placing additional insulating materials on the interior of the container reduces the interior dimensions of the cargo container. In turn, reducing the interior dimensions of the cargo container reduces the amount of space available for cargo. In addition, insulating materials located on the interior of a cargo container can also be subject to damage from the placement of cargo in the containers. This also reduces the thermal efficiency of the cargo container.

Therefore, there exists a need for methods of constructing boxcars with improved thermal efficiency without substantially reducing the interior dimensions of the car.

In accordance with the present invention, an insulated cargo container broadly comprises an underframe having a top surface and a bottom surface; a floor connected to the top surface of the underframe; a first side wall and a second side wall each having an interior surface and an exterior surface and each of the side walls includes a door having an interior surface and an exterior surface; a first end wall and a second end wall each having an interior surface and an exterior surface; a roof having an interior surface and an exterior surface, wherein the underframe, the floor, the first and second side walls, the first and second end walls and the roof being connected to form an enclosure; and one or more insulating liners, each comprising an insulating core disposed between an exterior skin and each of the interior surfaces or each of the exterior surfaces or both the interior surfaces and the exterior surfaces of the enclosure, in an amount sufficient to achieve a UA rating of less than about 300.

In accordance with another aspect of the present invention, a method for insulating a boxcar to achieve a UA rating of less than 300, the boxcar broadly comprising an underframe having a top surface and a bottom surface; a floor connected to the top surface of the underframe; a first side wall and a second side wall each having an interior surface and an exterior surface, and each of the side walls includes a door having an interior surface and an exterior surface; a first end wall and a second end wall each having an interior surface and an exterior surface; a roof having an interior surface and an exterior surface; wherein the underframe, the floor, the first and second side walls, the first and second end walls and the roof being connected to form an enclosure, broadly comprising the steps of attaching one or more insulating liners to the interior surfaces or the exterior surfaces or both the interior surfaces and the exterior surfaces of the enclosure, of the side walls, wherein the one or more insulating liners substantially cover the surfaces of the side walls; attaching one or more insulating liners to the interior surfaces or the exterior surfaces or both the interior surfaces and the exterior surfaces of the enclosure, of the end walls, wherein the one or more insulating liners substantially cover the surfaces of the end walls; attaching one or more insulating liners to the interior surface or the exterior surface or both the interior surface and the exterior surface of the enclosure, of the roof, wherein the one or more insulating liners substantially cover the surfaces of the roof; attaching one or more insulating liners to the floor, wherein the one or more insulating liners substantially cover the floor; installing at least one closure on the boxcar to cover a portion of an exterior surface of the boxcar not covered by the one or more insulating liners; and applying an insulating material to the bottom surface of the underframe.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a boxcar;

FIG. 1B is a side view of the boxcar of FIG. 1A;

FIG. 2 is a schematic view of a portion of the floor of the boxcar of FIGS. 1A and 1B;

FIG. 3 is a side view of the boxcar of FIGS. 1A and 1B;

FIG. 4 is an enlarged view of a door track of the boxcar of FIGS. 1A and 1B;

FIG. 5 is an enlarged view of a door track and a door track closure of the boxcar of FIGS. 1A and 1B;

FIG. 6. is an enlarged view of a door track and door track stops of the boxcar of FIGS. 1A and 1B;

FIG. 7 is a representation of an exemplary fastener for attaching a vacuum insulated panel to a sidewall of the boxcar;

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