Insulated cargo containers

• US 20050252164A1
• Filed: 06/13/2005
• Published: 11/17/2005
• Est. Priority Date: 03/05/2004
• Status: Active Grant

• Current Assignee: Martin Marietta Materials Incorporated (Martin Marietta Composites Incorporated)
• Original Assignee: Martin Marietta Materials Incorporated (Martin Marietta Composites Incorporated)
• Inventors: Seiter, Joseph A., Zupancich, Ronald J.
• Granted Patent: US 7,587,984 B2
• Time in Patent Office: Days
• US Class Current: 52/745.20
• CPC Class Codes: B61D 17/18 Internal lining, e.g. insulating
• CPC Class Codes: B61D 27/0081 of wagons for transporting refrigerated goods vehicles for transporting refrigerated goods B60P3/20
• CPC Class Codes: B65D 90/06 Coverings, e.g. for insulating purposes
• CPC Class Codes: Y02T 30/00 Transportation of goods or passengers via railways, e.g. energy recovery or reducing air resistance

Abstract

The prevention discloses a method of insulating an existing boxcar. The method allows for the application of improved insulation materials to improve the R-Value of an existing boxcar without building a new boxcar. In one implementation, the method includes preparing multiple insulating panels comprising an insulating layer and an outer skin located on at least one face of the insulating layer and attaching the insulating panels on an exterior surface of the side walls, end walls, and roof of the boxcar. The method also includes installing closures on uncovered areas of the boxcar and applying foam insulation to the bottom surface of the boxcar.

Claims

1. A method of insulating a cargo container, wherein the cargo container comprises an underframe having a top and bottom surface;

a floor connected to the top surface of the underframe;

first and second side walls having exterior surfaces;

first and second end walls having exterior surfaces, and a roof having an exterior surface, the underframe, floor, first and second side walls;

first and second end walls, and roof being connected to form an enclosure, the method comprising;

preparing at least one insulating panel comprising an insulating layer and at least one outer skin located on at least one face of the insulating layer;

attaching at least one insulating panel on an exterior surface of the first side wall, wherein the at least one insulating panel substantially covers the exterior surface of the first side wall;

attaching at least one insulating panel on an exterior surface of the second side wall, wherein the at least one insulating panel substantially covers the exterior surface of the second side wall;

attaching at least one insulating panel on an exterior surface of the first end wall, wherein the at least one insulating panel substantially covers the exterior surface of the first end wall;

attaching at least one insulating panel on an exterior surface of the second end wall, wherein the at least one insulating panel substantially covers the exterior surface of the second end wall;

attaching at least one insulating panel on an exterior surface of the roof, wherein the at least one insulating panel substantially covers the exterior surface of the roof;

installing at least one closure on the boxcar to cover a portion of an exterior surface of the cargo container not covered by a insulating panel; and

applying foam insulation to the bottom surface of the underframe.

2. The method of claim 1, wherein the at least one outer skin of the at least one insulating panel comprises fiber-reinforced plastics and wherein the insulating layer comprises urethane foam.

3. The method of claim 1, wherein the at least one outer skin of the at least one insulating panel comprises metal and wherein the insulating layer comprises urethane foam.

4. The method of claim 1, wherein the at least one outer skin of the at least one insulating panel comprises fiber-reinforced plastics and wherein the insulating layer comprises a vacuum insulated panel.

5. The method of claim 1, wherein the at least one outer skin of the at least one insulating panel comprises metal and wherein the insulating layer comprises a vacuum insulated panel.

6. The method of claim 1, further comprising:

removing the floor;

attaching at least one insulating member to the top surface of the underframe; and

attaching at least one floor panel to the at least one insulating member to form a floor of the cargo container.

7. The method of claim 6, wherein the at least one insulating member is constructed by pultrusion from fiber-reinforced plastics.

8. The method of claim 6, wherein attaching at least one floor panel comprises attaching the at least one floor panel to the at least one insulating member such that the floor panel does not contact the underframe.

9. The method of claim 1, wherein attaching at least one insulating panel on an exterior surface of the first side wall, second side wall, first end wall, second end wall, and roof, comprises:

applying an adhesive to a surface of the at least one insulating panel to attach the insulating panels to the exterior surface of the first side wall, second side wall, first end wall, second end wall, and roof; and

mechanically fastening the at least one insulating panel to the exterior surface of the of the first side wall, second side wall, first end wall, second end wall, and roof.

10. The method of claim 9, wherein applying an adhesive further comprises applying glass beads in the adhesive to achieve a uniform bondline thickness.

11. The method of claim 1, wherein attaching at least one insulating panel on an exterior surface of the roof results in spaces between the exterior surface of the roof and the insulating panel, and further comprising application of foam insulation in the space between the exterior surface of the roof and the insulating panel.

12. The method of claim 1, wherein installing at least one closure further comprises attaching the closure to at least one of the insulating panels.

13. The method of claim 1, wherein installing at least one closure further comprises installing the closures to cover any exterior surfaces of the first side wall, second side wall, first end wall, second end wall, or roof not covered by a insulating panel.

14. The method of claim 1, wherein the foam insulation applied to the bottom surface of the underframe is urethane foam.

18. The method of claim 1, wherein installing at least one closure further comprises installing the closures to cover any exterior surfaces of the first side wall, second side wall, first end wall, second end wall, or roof not covered by a insulating panel.

15. A method of insulating a cargo container, wherein the cargo container comprises an underframe having a top and bottom surface;

a floor connected to the top surface of the underframe;

first and second side walls having exterior surfaces;

first and second end walls having exterior surfaces, and a roof having an exterior surface, the underframe, floor, first and second side walls;

first and second end walls, and roof being connected to form an enclosure, and a door providing access to the enclosure comprising;

preparing at least one insulating panel comprising an insulating layer and at least one outer skin located on at least one face of the insulating layer;

attaching at least one insulating panel on an exterior surface of the first side wall, wherein the at least one insulating panel substantially covers the exterior surface of the first side wall;

attaching at least one insulating panel on an exterior surface of the second side wall, wherein the at least one insulating panel substantially covers the exterior surface of the second side wall;

attaching at least one insulating panel on an exterior surface of the first end wall, wherein the at least one insulating panel substantially covers the exterior surface of the first end wall;

attaching at least one insulating panel on an exterior surface of the second end wall, wherein the at least one insulating panel substantially covers the exterior surface of the second end wall;

attaching at least one insulating panel on an exterior surface of the roof, wherein the at least one insulating panel substantially covers the exterior surface of the roof;

attaching at least one insulating panel on an interior surface of the door, wherein the at least one insulating panel substantially covers the interior surface of the door;

installing at least one closure on the boxcar to cover a portion of an exterior surface of the cargo container not covered by a insulating panel; and

applying foam insulation to the bottom surface of the underframe.

16. The method of claim 15, wherein the at least one outer skin of the at least one insulating panel comprises fiber-reinforced plastics and wherein the insulating layer comprises urethane foam.

17. The method of claim 16, wherein the at least one outer skin of the at least one insulating panel comprises metal and wherein the insulating layer comprises urethane foam.

19. A method of insulating a cargo container, wherein the cargo container comprises an underframe having a top and bottom surface;

a floor connected to the top surface of the underframe;

first and second side walls having exterior surfaces;

first and second end walls having exterior surfaces, and a roof having an exterior surface, the underframe, floor, first and second side walls;

first and second end walls, and roof being connected to form an enclosure, and a door providing access to the enclosure comprising;

preparing at least one insulating panel comprising an insulating layer and at least one outer skin located on at least one face of the insulating layer;

attaching at least one insulating panel on an exterior surface of the first side wall, wherein the at least one insulating panel substantially covers the exterior surface of the first side wall;

attaching at least one insulating panel on an exterior surface of the second side wall, wherein the at least one insulating panel substantially covers the exterior surface of the second side wall;

attaching at least one insulating panel on an exterior surface of the first end wall, wherein the at least one insulating panel substantially covers the exterior surface of the first end wall;

attaching at least one insulating panel on an exterior surface of the second end wall, wherein the at least one insulating panel substantially covers the exterior surface of the second end wall;

attaching at least one insulating panel on an exterior surface of the roof, wherein the at least one insulating panel substantially covers the exterior surface of the roof;

attaching at least one insulating panel on an interior surface of the door, wherein the at least one insulating panel substantially covers the interior surface of the door;

installing the at least one closure on the boxcar to cover a portion of an exterior surface of the cargo container not covered by a insulating panel;

removing the floor;

attaching at least one insulating member to the top surface of the underfrarne; and

attaching at least one floor panel on the insulating members to form a floor of the cargo container; and

applying foam insulation to the bottom surface of the underframe.

20. A cargo container comprising:

an underframe having a top and bottom surface;

a floor connected to the top surface of the underframe;

first and second side walls having exterior surfaces;

first and second end walls having exterior surfaces,

a roof having an exterior surface, the underframe, floor, first and second side walls;

first and second end walls, and roof being connected to form an enclosure; and

at least one insulating panel comprising an insulating layer and at least one outer skin located on at least one face of the insulating layer, the at least one insulating panel located on the exterior surface of at least one of the first side wall, second side wall, first end wall, second end wall, or roof; and

wherein the R-Value of the cargo container is at least 28.