Pressure differential discharge system for a shipping container and methods of use
A pressure differential discharge system is provided for use with a shipping container. The pressure differential discharge system includes a manifold having a mock hatch configured for attachment about a manhole of the shipping container; a mating plate attached to the mock hatch and defining a valve aperture therethrough, the mating plate shaped complementary to the spillbox, wherein the mating plate and spillbox mate, the valve of the spillbox extending through the valve aperture of the mating plate for discharge of the shipping container.
Shipping containers can be used to carry a variety of liquids ranging from toxic chemicals to consumables such as wine and other beverages. When a shipping container is used to carry a chemical, for instance, from a loading point to a destination point, the shipping container must be cleaned thoroughly of chemical residue in order to reload the shipping container with another chemical. Often, the destination point may not have a cleaning station, so the shipping container must be shipped empty to a distant cleaning station to clean the chemical residue. This is inefficient and costly due to an empty transport or required repositioning of the shipping container. Even if the cleaning station is at the destination point, conventional cleaning of the cargo container is relatively expensive and inconvenient. Conventional cleaning is environmentally unfriendly due to hundreds of gallons of wastewater produced by such cleaning. Moreover, whether the shipping container is cleaned at the destination point or shipped to the distant cleaning station, the shipping container is unusable until cleaned and may be out of service for an undesirable period of time.
One approach to avoid conventional cleaning of the shipping container is to use a removable plastic carrier that lines an interior surface of the shipping container to carry the liquid chemical or the consumable liquid to the destination point. At the destination point, the liquid is discharged from the plastic carrier, which is removed from the shipping container and replaced with another, clean plastic carrier. These removable plastic carriers suffer from various drawbacks. For instance, the removable plastic carrier uses a plastic discharge sleeve attached near a bottom portion of the plastic carrier. At the installation point, a valve assembly on a lower exterior part of the shipping container is at least partially disassembled or removed entirely to open an aperture in the shipping container in order to extract the discharge sleeve through the aperture. Once the discharge sleeve has been extracted, the valve assembly is reassembled or reattached, which usually requires replacing numerous seals that are broken or spent during the extraction process. This sleeve extraction process requires intensive labor and skill, takes an inordinate amount of time and can be costly due to seal replacements or other damage to the valve assembly, and the valve must be replaced or special valves and fittings adapted for use with the liner must be installed.
In other instances, customers hook up a discharge hose to the valve on the lower exterior part of the shipping container and pressurize the shipping container via a pressure valve, usually located on top of the shipping container, to discharge chemical, industrial, food and other liquid products in a pressure differential (PD) discharge approach. No pump is needed but a pressure source is required to provide pressure, i.e., the liquid is pushed out instead of pulled out.
Podd teaches a “Spillbox System for a Shipping Container”, U.S. Ser. No. 11/231,399, filed Sep. 21, 2005, in which a drop in, pull out spillbox system is used with the conventional shipping container. Podd requires no preparation or modification of the shipping container. This spillbox system includes an elastomeric liner having a thickness of about 20 MIL to about 40 MIL with a reinforcement section having a thickness of about 40 MIL to about 80 MIL.
Podd further teaches a “Pressure Differential Manlid and Method of Discharging a Shipping Container Using a Pressure Differential”, U.S. Ser. No. 11/357,521, filed Feb. 17, 2006, which uses a mock manlid to discharge liquid cargo via a pressure differential between the interior pressure of a carrier and exterior ambient pressure. However, the mock manlid is attached to an interior liner before securing the mock manlid to the carrier.
A system is needed in the shipping industry that is designed specifically for discharging a shipping container using a liner and spillbox in which the system is quickly and easily attached to the liner, spillbox and the shipping container.
BRIEF SUMMARY OF THE DISCLOSUREThe present invention is directed in general to a pressure differential discharge manifold system, which includes a mock hatch or manlid having a built-in mating plate for use with a spillbox system. The hatch permits rapid discharge of various liquids through a valve system of a spillbox without requiring additional hoses, piping or coupling joints. Since the liquid cargo does not flow through a pump, no bruising or destabilization of the liquid cargo occurs, which is a common problem with wine and latex. Additionally, the components of the hatch are simple to manufacture, install and use. Other advantages of various embodiments of the invention will be apparent from the following description and the attached drawings, or can be learned through practice of the invention.
In one aspect of the invention, a pressure differential discharge manifold for use with a spillbox includes a mock hatch configured for attachment about a manhole of a shipping container; a mating plate attached to the mock hatch and defining a valve aperture therethrough, the mating plate shaped complementary to the spillbox, wherein the mating plate and spillbox mate, a valve of the spillbox extending through the valve aperture of the mating plate for discharge of the shipping container. In this aspect, the mock hatch and the mating plate are made of metal such as stainless steel, aluminum, and the like. Since the pressure differential discharge manifold is robustly constructed to withstand pressures of about 4 BAR to about 6 BAR, it can weigh approximately 60 pounds; therefore, one or more carrying handles are attached to the pressure differential discharge manifold to facilitate its portability and positioning.
The pressure differential discharge manifold can also include a number of lugs for attaching the mock hatch to the shipping container. For instance, the lugs attach to respective latches found on the shipping container, which are used normally to attach and close a standard manlid on the shipping container.
Also in this aspect of the invention, the pressure differential discharge can have a support flange disposed proximate the valve aperture. The support flange is configured to position the valve for discharge.
Further in this aspect, a restraining plate can be spaced apart from the support flange, the restraining plate defining a restraining plate aperture therethrough, the valve being configured to extend through the valve aperture and the restraining plate aperture for connection of a hose.
In yet another aspect of the invention, a pressure differential discharge system for use with a spillbox defining a valve includes a pressure differential discharge manifold including a mock hatch and an mating plate connected to the mock hatch, the mock hatch being configured for attachment about a manhole of a shipping container, the mating plate defining a valve aperture therethrough; and a spillbox being configured for insertion between the pressure differential discharge manifold and the manhole, the spillbox including a valve, the mating plate shaped complementary to the spillbox, wherein the mating plate and spillbox mate, the valve of the spillbox extending through the valve aperture of the mating plate for discharge of the shipping container. One or both of the mock hatch and the mating plate are made of metal such as stainless steel for durability and pressure resistance.
The pressure differential discharge system in this aspect also includes a support flange disposed proximate the valve aperture, the support flange being configured to position the valve for discharge.
The pressure differential discharge system in this aspect also includes a restraining plate spaced apart from the support flange, the restraining plate defining a restraining plate aperture therethrough, the valve being configured to extend through the valve aperture and the restraining plate aperture for connection of a hose.
Also in this aspect of the invention, the spillbox and the mating plate are tightly spaced apart from each other such that upon pressurization a seal is formed therebetween.
In another aspect of the invention, a method of unloading a shipping container with a pressure differential discharge system includes placing a spillbox about a manhole in a shipping container such that the spillbox covers the manhole; placing a pressure differential discharge manifold over the spillbox, the pressure differential discharge manifold including a hatch and an mating plate defining a valve aperture therethrough, the mating plate being shaped complementary to a contour of the spillbox such that a valve of the spillbox extends through the valve aperture; connecting the hatch of the pressure differential discharge manifold to the shipping container; connecting a hose to the valve; and pressurizing the shipping container to cause a cargo in the shipping container to discharge through the valve.
Also according to the method in this aspect of the invention, the spillbox and the mating plate are tightly spaced apart such that upon pressurization, the spillbox and the mating plate move in a direction of each other to form a seal. In other words, the spillbox and the mating plate are molded complementary to each other to fit tightly together. Nevertheless, if desired, an o-ring or other additional seal can be provided.
Further, in this aspect the mating plate includes a support flange and a restraining plate defining a restraining plate aperture therethrough, the support flange and the restraining plate spaced apart from each other and disposed proximate the valve aperture, the valve extending through the restraining plate aperture, the support flange and the restraining plate controlling movement of the valve upon pressurization.
A valve or valve assembly suitable for use with various embodiments of the present invention are disclosed in U.S. patent application Ser. No. 11/231,399, filed Sep. 21, 2005 by Podd, which is incorporated herein by reference thereto for all intents and purposes. Likewise, suitable component materials and methods of pressurizing the shipping container can be found, for example but without limitation, in Podd, U.S. Ser. No. 11/357,521, filed Feb. 17, 2006, which is incorporated herein by reference thereto for all intents and purposes.
Other features and aspects of the present invention are discussed in greater detail below.
A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Detailed reference will now be made to the drawings in which examples embodying the present invention are shown. The detailed description uses numerical and letter designations to refer to features of the drawings. Like or similar designations of the drawings and description have been used to refer to like or similar parts of the invention.
The drawings and detailed description provide a full and written description of the invention, and of the manner and process of making and using it, so as to enable one skilled in the pertinent art to make and use it, as well as the best mode of carrying out the invention. However, the examples set forth in the drawings and detailed description are provided by way of explanation only and are not meant as limitations of the invention. The present invention thus includes any modifications and variations of the following examples as come within the scope of the appended claims and their equivalents.
The figures, which are about to be described in detail below, generally show a pressure differential discharge system broadly designated by the numeral 10. The pressure differential discharge system 10 generally includes a pressure differential manifold 12 for use with a spillbox 14 and/or a liner 16. The pressure differential manifold 12 is contoured to fit the spillbox 14 with minimal clearance to create a seal under pressure as will be better understood from the following description and exemplary methods of operation.
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Further examples of the spillbox 14 and the liner 16 shown in
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The invention may be better understood with reference to an exemplary operation.
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While preferred embodiments of the invention have been shown and described, those skilled in the art will recognize that other changes and modifications may be made to the foregoing examples without departing from the scope and spirit of the invention. For instance, various durable, recyclable materials can be used for the liner as described herein. Also, the geometries of the valves, the types of valves as described herein, and male-female connections can be modified, reversed and the like to meet particular customer requirements. It is intended to claim all such changes and modifications as fall within the scope of the appended claims and their equivalents.
Claims
1. A pressure differential discharge system for use with a spillbox defining a valve, the pressure differential discharge system comprising:
- a mock hatch being configured for attachment about a manhole of a shipping container; and
- a mating plate disposed in the mock hatch and defining a valve aperture therethrough, the mating plate shaped complementary to the spillbox, wherein the mating plate and spillbox mate, the valve of the spillbox extending through the valve aperture of the mating plate for discharge of the shipping container.
2. The pressure differential discharge system as in claim 1, wherein the mock hatch and the mating plate are made of metal.
3. The pressure differential discharge system as in claim 1, further comprising a plurality of lugs for attaching the mock hatch to the shipping container.
4. The pressure differential discharge system as in claim 3, wherein the lugs attach to respective latches of the shipping container.
5. The pressure differential discharge system as in claim 1, further comprising a carrying handle.
6. The pressure differential discharge system as in claim 1, further comprising a support flange disposed proximate the valve aperture, the support flange being configured to position the valve for discharge.
7. The pressure differential discharge system as in claim 1, further comprising a restraining plate spaced apart from the support flange, the restraining plate defining a restraining plate aperture therethrough, the valve being configured to extend through the valve aperture and the restraining plate aperture for connection of a hose.
8. A method of unloading a shipping container with a pressure differential discharge system, the method comprising:
- placing a spillbox about a manhole in a shipping container such that the spillbox covers the manhole;
- placing a pressure differential discharge manifold over the spillbox, the pressure differential discharge manifold including a hatch and a mating plate defining a valve aperture therethrough, the mating plate being shaped complementary to a contour of the spillbox such that a valve of the spillbox extends through the valve aperture;
- connecting the hatch of the pressure differential discharge manifold to the shipping container;
- connecting a hose to the valve; and
- pressurizing the shipping container to cause a cargo in the shipping container to discharge through the valve.
9. The method of as in claim 7, further comprising forming a seal between the spillbox and the mating plate upon pressurization.
10. The method of as in claim 7, wherein the mating plate includes a support flange and a restraining plate defining a restraining plate aperture therethrough, the support flange and the restraining plate spaced apart from each other and disposed proximate the valve aperture, the valve extending through the restraining plate aperture, the support flange and the restraining plate controlling movement of the valve upon pressurization.
11. A pressure differential discharge system for use with a spillbox defining a valve, the pressure differential discharge system comprising:
- a pressure differential discharge manifold including a mock hatch and a mating plate disposed in the mock hatch, the mock hatch being configured for attachment about a manhole of a shipping container, the mating plate defining a valve aperture therethrough; and
- a spillbox being configured for insertion between the pressure differential discharge manifold and the manhole, the spillbox including a valve, the mating plate shaped complementary to the spillbox, wherein the mating plate and the spillbox mate, the valve of the spillbox extending through the valve aperture of the mating plate for discharge of the shipping container.
12. The pressure differential discharge system as in claim 11, further comprising a support flange disposed proximate the valve aperture, the support flange being configured to position the valve for discharge.
13. The pressure differential discharge system as in claim 11, further comprising a restraining plate spaced apart from the support flange, the restraining plate defining a restraining plate aperture therethrough, the valve being configured to extend through the valve aperture and the restraining plate aperture for connection of a hose.
14. The pressure differential discharge system as in claim 11, wherein the mating plate is a metal.
15. The pressure differential discharge system as in claim 11, further comprising forming a seal between the spillbox and the mating plate upon pressurization.
Type: Application
Filed: Jun 30, 2006
Publication Date: Jan 3, 2008
Inventor: Stephen D. Podd (Rouses Point, NY)
Application Number: 11/479,708
International Classification: B65D 25/04 (20060101);