The Patent Specification
37 The Patent specification ("the Specification") commences with a general description of the field of the invention followed by a brief description of prior art and the object of the invention. The Specification states (at page 1, lines 1-2) that the invention relates to bulk transport containers and, in particular, containers used in rail and road transport.
38 The discussion of the prior art (at page 1, lines 10-16) refers to the age of the designs of the containers presently used by both Australian and international transport companies to carry bulk products, which are based on designs that are at least 20 years old. The Specification states (at page 1, lines 17-19) that it is an object of the invention to provide a container for bulk product transport that is more efficient and cost effective than existing containers.
39 The Specification includes the following consistory statement (at pages 1, line 20 - 2, line 2):
With the above object in mind the present invention provides a container for transporting bulk material including two side walls, two end walls and a base, wherein at least one said side wall includes at least one ridge running along said at least one side wall between said end walls, and wherein said ridge is integrally formed within said at least one side wall and the distance from which said ridge projects from said side wall is greater than the thickness of said side wall.
Another form of the present invention provides a container for transporting bulk material and for rotary or side tip unloading, the container including two side walls, two end walls and a base, wherein at least one said side wall includes at least one internal ridge running along said at least one side wall between said end walls, the at least one internal ridge including a first wall portion and the material flows across the at least one ridge when unloading the container, and wherein said at least one ridge is integrally formed within said at least one side wall and said internal ridge has a depth greater than the thickness of said side wall.
40 The Specification then describes various preferred features as follows (at page 2, lines 3-32):
Preferably, there will be at least one internal ridge between each of the reinforcing members.
Preferably, there will be at least one internal ridge between an end wall and a first reinforcing means.
In some instances extra reinforcing members might be required to satisfy the structural strength of any or all panels on the side wall and/or floor and/or end wall.
Ideally, the internal ridge includes a first wall portion angled from the wall towards the interior of the container, and a second wall portion rejoining the first wall portion to the wall. The angle of the first wall portion is in the direction of flow during unloading of the material to be transported.
Alternatively, the internal ridge includes a first wall portion deflected inwardly a progressively increased degree relative to the intersection of the side wall and the base, and a second wall portion extending from the first wall portion and being deflected outwardly a progressively decreased degree relative to the intersection of the side wall and the base.
The angle of the first wall portion may be determined by subtracting the natural angle of repose of the transported product, from the angle the container is rotated during unloading. Whilst the first and second wall portions may be symmetrical, they may also be of uneven length.
In further embodiments, the internal ridge may also include a third wall portion between the first wall portion and the second wall portion. This third wall portion may be flat or concave. Any such flat third wall portion may additionally be parallel to the side wall.
In some applications, a partial internal ridge may extend along the top edge or rim of the side walls. Such a partial internal ridge may consist of the first wall portion of the internal ridge. In this case an additional strengthening member along the edge or rim of the side wall would be included.
In a preferred embodiment, the base of the container also includes at least one internal ridge extending substantially along the length of the base.
41 The Specification then states (at page 2a, lines 1-17):
A further form of the present invention provides a container for transporting bulk material and for rotary or tipping unloading, the container including two side walls, two end walls, and a base; said side walls including a plurality of vertical reinforcing members spaced along the length of each said side wall, wherein a section of said side wall between at least one adjacent pair of said reinforcing members includes at least one internal ridge running therebetween, the said at least one internal ridge including a first wall portion angled towards an interior of the container, wherein the angle is in the direction of flow of the material during the rotary or tipping unloading, and wherein said at least one internal ridge is integrally formed within said side wall and said at least one internal ridge has a depth greater than the thickness of said side wall.
It will be convenient to further describe the invention by reference to the accompanying drawings which illustrate possible embodiments of the invention and improvements over the prior art. Other embodiments of the invention are possible and consequently the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the present invention.
42 The Specification includes a detailed description of possible embodiments of the invention by reference to various drawings. These drawings are reproduced in Schedule A to these reasons.
43 Figure 1 depicts a conventional container. According to the Specification, the conventional container includes two side walls (1), a base (2), and two end walls (3). The size of these containers have certain dimensional limitations in that neither the height nor the width can exceed pre-defined dimensions determined by both rail and road standards and practical limitations of loading and unloading facilities. Whilst it is desirable to increase payloads, the size of conventional containers cannot be increased without decreasing their strength. The walls of these containers do not extend to the maximum possible dimensions due to the structural requirements of the container because the bulk product places extreme stresses on the walls which must be reinforced by a number of supporting or reinforcing members to strengthen the walls. These can conveniently take the form of ribs (4), extending around the body of the container. The addition of ribs to strengthen the walls results in a much heavier container and a decrease in the aerodynamics of the container.
44 The Specification states (page 4, lines 9-10) that the invention reduces the number of ribs that are required compared to a conventional container of equal size which will reduce the container's weight and improve the container's aerodynamics resulting in a more cost effective container. The Specification also states that the container of the invention may be used for bulk transportation by either road or rail.
45 Figures 2a and 2b illustrate a preferred embodiment. Figure 2b includes a sectional drawing (Section AA) to better show the internal ridge. The longer element shown in Section AA turning to the right-hand side of the drawing (toward the interior of the container) and then back towards the left (toward the exterior of the container) incorporates the internal ridge.
46 The Specification states that the preferred embodiment has two side walls (5), two end walls (7) and a base (6) and at least one internal ridge (8). The main element of the internal ridge is a first portion (8a) which extends from the wall of the container at an angle towards the interior of the container. A second portion (8b) can be adapted to complete the internal ridge by rejoining the wall to the end of the first portion. The internal ridge may also include a third portion (8c) which joins the first and second portions.
47 The Specification states that the internal ridge is designed to run along the length of the side wall between the supporting frame members. The number and placement of the internal ridges may be dependent upon the size of the container and may reduce the number of strengthening ribs required on a conventional container.
48 The angle at which the first portion of the internal ridge extends from the wall of the container (Ø1) is described in the Specification in some detail. The Specification states (at pages 4, line 26 - 5, line 12):
It is noted that as we move along the first portion 8a from the side wall 5, the angle between the side wall 5 and the position on the first portion 8a relative to the intersection of the side wall 5 and base 6 progressively increases. Similarly, as we return along the second portion 8b, the angle relative to the intersection between the side wall 5 and base 6 progressively decreases.
The angle Ø1 at which the portion 8a, extends from the wall 5 towards the interior of the container is chosen to ensure that the product to be carried by the container is unloaded completely. That is, the angle is preferably dependent on the type of product carried and on the method the operator uses to unload the product. The dimensions of the internal ridge 8, are further determined as a function of the structural strength required and of the natural angle of repose of the material that is to be transported.
The angle at which the first portion 8a extends towards the interior of the container may preferably be determined by the following mathematical formula:
Ø1< Ø2-Ø3 - 90
where
Ø1-is the angle between the vertical wall 5, and the first portion 8a.
Ø2-is the angle the container is rotated in the unloading facility.
Ø3-is the natural angle of repose for the product to be transported.
49 The Specification states that the natural angle of repose (Ø3) is dependent on the product to be carried and includes an explanation of how this angle can be determined. The shape of the second and third portions (8b, 8c) are chosen to complete the internal ridge (8) and fulfil the structural requirements of the container. The Specification states at page 6, lines 19 - 34:
The length and shape of the internal ridge 8, will depend on the structural requirements of the side walls 5 and the base 6. It will also depend on the spacing between supporting frame members 9, and the natural angle of repose of the material. As the distance or spacing between the supporting frame members 9 increases, it will be necessary to increase the depth 16 of the internal ridge 8, to ensure the necessary structural strength. Accordingly, it is possible to design a container specifically for a certain type of material to be transported, by considering the mass of the material and the pressure the material will place on the walls of the container.
A container constructed with an internal ridge of the present invention provides a container that is able to transport bulk product. Furthermore, the internal ridge acts as an in-built longitudinal structural stiffener. This internal ridge, then ensures that the structural requirements, such as strength, fatigue resistance, and buckling capacity, are met, while ensuring that more product can be loaded into a container that has the same exterior dimensions as a conventionally designed container.
50 The Specification also states at pages 8, line 29 - page 9, lines 1-6:
By the addition of at least one internal ridge in the wall of the container, the present invention results in a container that is lighter than conventional containers as the side wall containing the internal ridge does not require as many structural reinforcements as conventional containers, since the internal ridge itself adds to the structural strength of the wall. Again this can be seen by comparison of Figures 1 and 2, whereby the number of ribs or strengthening elements is less than [over to page 9] in the original design. The decrease in the number of ribs 9 also leads to a cheaper container. The decrease in the number of vertical elements, and protruding parts generally improves the aerodynamic shape of the container, thereby making a more efficient and economical container. Further, because fewer welds are required the design ensures that there are fewer areas of stress concentration, thereby making the improved container more fatigue resistant.