Assembly System For Customizable Containers

Abstract

What is disclosed is an assembly system to create customizable, mobile, lightweight containers and container-like products ranging in size from consumer and commercial storage products to shipping containers and small mobile buildings. The system uses slidable interconnection of various profile shapes of elongated panel modules with same length standardized linear and corner panel connectors, to create container sleeves retained by customizable end framing to become container shells. The container shells are customized to size needed by the number of interconnected panel modules used and the length to which they are cut. Assembly of their few basic parts is simple with a limited range of tools and skills needed. The system further provides for simple, seamless, solid and reversible structural attachment of third party components, without welding or riveting, to achieve specific customization goals as needed. Finally, the system provides for easy and scar free disassembly for shipping, storage reconfiguration, or recycling.

Description

TECHNICAL FIELD

The proposed assembly system generally relates to the manufacture of mobile containers and the industry of modifying, enhancing and accessorizing new and existing containers. More specifically, it relates to the use of lightweight modular components to assemble and customize mobile containers and container-like products for special uses.

In the present context, containers and container-like products range in size from industrial shipping containers and mobile buildings through to transportable commercial, retail, exhibit, in-vehicle and recreational assemblies and all the way down to transportable shop furniture, storage cases and tool containers for commercial and consumer uses.

Most manufacturers and distributors of all size mobile containers and container-like assemblies offer minor and major modification options to their products for their customers. Many such major modifications are more time consuming, costlier and heavier than they need to be, mainly because the products being modified were not originally built with subsequent or future modification in mind, nor with optional lightweight features.

The proposed system allows easy, economical, customizable and reversible assembly of almost any size container-like product with relatively few modular parts. It helps a manufacturer, distributor or end user to create special use products or to market test new product designs or uses with working prototypes. It offers a first stage container shell assembly system with proprietary parts, with alternative gauges, sizes and profiles.

The system is based on three key features to achieve the ultimate customization and/or modification with virgin or recycled components, but without welding or riveting:

• • (i) Easy customizing by assembly of selected proprietary parts of the basic container shell for its intended use, with only standard tools and non-skilled labor.
  • (ii) Easy and seamless incorporation of third party customization components as needed, in the interior as well as on the exterior of the basic container shell design.
  • (iii) Easy reconfiguration, disassembly, storage or recycling of basic container parts and third party components of an already customized container product.

BACKGROUND—PRIOR ART

Prior art for systems enabling assembly of customizable containers appears limited. Many containers are customizable with respect to specific uses, but it appears that none are universally customizable, with respect to size and otherwise, unless built from scratch. Furthermore, when an existing container is modified, it most often involves adding parts or components, which in turn involves welding, riveting, gluing and other attaching methods.

Problem #1 is that many existing container surfaces are not structurally able to support attachments, which then requires costly and often unsightly reinforcement with blocking, bracing and bolting. Problem #2 is that many attachment means, like welding, cause deformations. Problem #3 is that most such attachments are non-reversible and non-adjustable, certainly not without leaving unsightly scars.

As already stated, many containers are customizable with respect to specific uses Customization systems exist for storage and shipping containers which can be fitted with insertable partitions, sub containers and dunnage materials. Many containers have removable walls or collapsible sides. The exhibition and retail industries have easily reconfigurable framing systems for display and lighting of merchandise and images. The construction, manufacturing, warehousing and distribution industries have similar systems.

Wall systems exist that allow customizable attachment of tools, materials and small containers. They include pegboards, slatwalls and louvered panels. They are all good examples of viable third party components that can be incorporated in either the interior or on the exterior of customizable containers assembled with the present system.

Listed below are some prior art patents involving two-sided slatwall panels, as well as patents involving container assemblies from shipping and housing to storage, including modular, convertible, collapsible and the like. The following is a tabulation of some prior art that presently appears relevant:

	Date	Patentee or
U.S. Pat. No.	Published	Applicant
6,701,678B1	Mar. 9, 2004	Skov
7,922,417B2	Apr. 12, 2011	Jimenez
8,033,404	Oct. 11, 2011	Keller
8,074,820B2	Dec. 13, 2011	Chu
8,672,137B2	Mar. 18, 2014	Seagle
8,826,601B2	Sep. 9, 2014	Gyori
9,296,514B2	Mar. 29, 2016	Ficker
9,518,386B2	Dec. 13, 2016	Ehsasi
9,596,948B1	Mar. 21, 2017	McGinnis
9,676,515	Jun. 13, 2017	Huggett

Skov proposes a modular storage enclosure created with assembled hollow panels, blow molded with high-density polyethylene. It is included in this summary of prior art because many of the stated objectives of this invention in terms of modularity and customization as well as ease of manufacture and assembly are also some of the objectives of the present invention. However, the similarity ends there. In its efforts to be universally versatile and adaptable to every conceivable market need, this invention tops all other prior art listed below in terms of assembly details and number of unique parts needed, perhaps not a problem for a volume molder and assembler. The patent is assigned to Rubbermaid, Inc.

Jimenez proposes an interlocking connector for exterior walls and interior partitions to be used for the construction of cabinets and enclosures. Each connector has multiple slots to hold simple flat rectangular panels, which in turn become the walls and partitions.

Keller proposes a modular double-sided display panel assembled with multiple slat members. Each slat member has an upper engagement portion and a lower engagement portion. A panel may be constructed from multiple slat members by serially interconnecting generally horizontally disposed slat members in a vertical chain.

Chu proposes a portable work and storage container including a container frame, an enclosure arrangement and a wall panel affixing arrangement. The container frame includes a ceiling frame, a floor frame and four vertical corner posts spacedly extended between the ceiling frame and the floor frame. The patent is assigned to Pacific Container Network, Inc, a major container rental chain in Australia.

Seagle proposes a knockdown, lightweight, thermally insulated, shipping container made at least in part from a polymer core covered by a thermoplastic sheet layer. In one of the embodiments of the invention, the shipping container is modular, being adjusted to suit the item(s) to be shipped. The patent is assigned to Airdex International, a manufacturer of of airfreight pallets for perishable products and pharmaceuticals.

Gyori proposes a modular assembly capable of converting from a shipping container configuration into a building unit, and from a building unit into a shipping container configuration. From the shipping container configuration, a plurality of frame panels and unit panels moveably connected to a frame of the modular assembly are selectively positioned to form the floors, walls, and ceilings of the building unit configuration, thereby forming a living and/or commercial structure complete with electrical, water and sewage connections.

Ficker proposes a collapsible container having foldable side and end panels. The patent is assigned to Buckhorn, Inc., a major manufacturer of plastic containers.

Ehsasi proposes a metallic frame structure of a container-like, modular and mobile housing, an assembly kit for such a housing, as well as a hollow profile for such housing.

McGinnis proposes a freestanding structure with double-sided slatwall panels attached with different shelf support brackets. The patent is assigned to Megawall, Inc. a major slatwall manufacturer.

Huggett proposes a collapsible container for use in packaging and transportation. The collapsible container includes a number of panels each having a panel body, with elongate tubular members secured to edges of the bodies. Each of the tubular members has at least one recessed section that forms interlocking engagement means. The patent is assigned to Compact Crates Limited.

SUMMARY

The present system creates four sided container sleeves with open ends. Sleeve sides are panel modules slidably interconnected by same length linear connectors. Sleeves are sides slidably connected at right angles by same length corner connectors. The number of panel modules connected determines the height and width of each sleeve. The length of its panel and panel modules and connector determines the sleeve length. Panel modules can be cut to the desired length, or may be combined longitudinally. Framing attached to both ends of the open container sleeve retains the container shell. End framing can be open, closed, with custom apertures or doors, hinged, sliding, etc.

Each panel module in a sleeve can have alternative profiles for alternative uses. Ranging from straight to various profile shapes that retain customization components. Container interiors and exteriors can thus hold third party inserted parts and components. The system has alternative panel profiles that use the same linear and corner connectors. Panel profiles are interchangeable to create alternative use containers of the same size. Containers can easily be partly disassembled and reassembled for storage or transport. Used panel profiles can be repurposed or traded, for savings and elimination of scrap.

Many containers are used vertically where the ends form bottoms and tops. Containers assembled with the present system can be used vertically. However, many are used horizontally, which is typical for many container-like products such as drawer and shelving units, transport modules and mobile buildings.

The profiled shape of system panel modules enables the retention of matching dimensional lumber inserts as blocking for third party parts and components, flush with panel surfaces. One or more lumber blocking inserts can run from the length of a stub up to the full length of the container. As such it provides less costly and far greater structural stability for attachments, than provided by spot-welded or riveted attachment.

Examples of customizing with exterior third party attachments include basics like handles, forklift pockets and wheels, as well as means to connect the container to other surfaces and to other containers.

Examples of customizing with interior third party attachments include shelving and drawers, as well as heating, cooling, mechanical, electric and electronic components.

Examples of customizing with general, interior or exterior, third party attachments include colored, illustrated, textured, insulating or illuminated surfaces as well as utility walls, such as peg boards, slat walls and louvered panels.

Examples of customizing end frames include open or closed end walls with or without protruding features, as well as hinged or sliding doors, that may be opaque or transparent, decorated, embossed, engraved, perforated, or have openings that are otherwise customized.

The profiled wall panels have many other customization uses than for blocking. Many are demonstrated in the Detailed Description. Among those are slidable insertion of integrated components such as dunnage, electrical conduits and mechanical ducting, as well as shaft supports for mechanical and moving assemblies, self-loading devices, and in-vehicle container retention panels, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the proposed assembly system for customizable containers, and examples of alternative ramifications and embodiments thereof, provided below is a list of reference numerals, and a detailed description of the accompanying drawings wherein:

FIGS. 1A through 1E are perspective views of the assembly parts in a container shell.

FIGS. 2A through 2J are orthogonal views using panel size #1 to show the dimensions of nine alternative cross sectional sleeve profiles.

FIGS. 3A through 3F are orthogonal views of six panel sizes of the same panel profile.

FIG. 3G details the largest panel size #6 shown here, with a dimensional lumber insert.

FIGS. 4A through 4F are perspective views of FIGS. 3A through 3F, respectively.

FIGS. 5A though 5J are orthogonal views of five different panel module profile shapes.

FIGS. 6A through 6J are perspective views of FIGS. 5A through 5J, respectively.

FIGS. 7A through 7H are orthogonal views of two container sleeve assemblies.

FIGS. 8A through 8E are orthogonal views of screws in container sleeve to attach end frames, and perspective views of their alternate attachment with rods through frame fronts.

FIGS. 9A through 9F are orthogonal and perspective views of a container shell assembled with raised corner connectors allowing an outer skin to be seamlessly attached to the shell.

FIGS. 10A through 10L are perspective and orthogonal views of short container sleeves with lumber inserts in their linear connectors for bracing and container sleeve extension.

FIGS. 11A through 11H are perspective and orthogonal views of dimensional lumber single length and combos slidingly inserted into a single side, single deep panel module profile.

FIGS. 12A through 12L are perspective and orthogonal views of dimensional lumber single length and combos sliding inserted into a double side, single deep panel module profile.

FIGS. 13A through 13L are perspective and orthogonal views of non-lumber inserts.

FIGS. 14A through 14L are orthogonal views of container sleeve interior customization.

FIGS. 15A through 15F are perspective views of container sleeve interior customization.

FIGS. 16A through 16G are orthogonal views of container sleeves with exterior rails.

FIGS. 17A through 17H are orthogonal and corresponding perspective views of exterior customizations of container sleeves with inserts serving various purposes.

FIGS. 18A through 18G are perspective and orthogonal views and details of sliding and hinged doors and lids to further customize containers or container-like products.

FIGS. 19A through 19F are perspective views and details of container rolling means and views of lumber inserts that support a range of different interior mechanical components.

FIG. 20A is an orthogonal view of a retention panel on plywood for an SUV cargo area.

FIGS. 20B through 20H are perspective views of containers retained by the panel.

FIGS. 21A through 21H are orthogonal and perspective views of a tool container inserted in a cargo van. The unit holds sliding shelves, drawers, sliding slat wall and pegboard inserts.

FIGS. 22A through 22C are perspective views of commercial container-like products with lengthwise modified bottom rails inserted into a cargo van retention floor.

FIGS. 23A through 23C are perspective views of recreational container-like products with lengthwise modified bottom rails inserted into a cargo van retention floor.

LIST OF REFERENCE NUMERALS FOR PARTS SHOWN IN DRAWINGS

For expediency, the first digit in a reference numeral, up to 9, and the first two digits after that, identify the drawing sheet # where a referred part is first introduced:

• 110 Front End Frame
• 112 Rear End Frame
• 114 Panel Module
• 116 Linear Panel Connector
• 118 Corner Panel Connector
• 310 Dimensional Lumber Insert 4 by 6
• 910 Raised Corner Connector
• 912 Recess in Raised Corner Connector
• 1010 Linear Connector Insert
• 1410 Interior Panel Module
• 1412 Interior Linear Panel Connector
• 1414 Interior Hub Panel Connector
• 1810 Sliding Door Rail Guide
• 1812 Stationary Hinge Half
• 1910 Bottom Member of Container Rail
• 1912 Top Member of Container Rail
• 1914 Sidewall Shaft Support Insert
• 1916 Bottom Shaft Support Member
• 1918 Top Shaft Support Member
• 1920 Alternative Bottom Shaft Support Member
• 1922 Alternative Top Shaft Support Member
• 2010 In-Vehicle Panel Retainer Channel
• 2012 In-Vehicle Panel Insert Combo for Linear Connector
• 2012 In-Vehicle Panel Insert Combo for Panel Module

Objects, Advantages and Users of Assembly System for Customizable Containers

It is the object of the present assembly system to provide easy ways to create mobile containers and container-like products that can be customized for increasingly specific uses and that can be further modified as new or changed uses are needed. It is a further object to provide lightweight container customization options without sacrificing structural integrity. It is yet a further object to provide easy ways of transporting or storing containers and container-like products, by simple sectional disassembly and reassembly.

Mobile container-like products customizable with this system include shelving and drawer units, tool and equipment containers, retail and exhibition fixtures, in-vehicle storage and delivery fixtures and furniture, food and catering delivery wagons as well as mobile commercial and recreational structures such as sales and construction offices, emergency and temporary housing, and the like.

Customized containers and container-like products are needed for ever increasing specialty uses and in very specific sizes and with the attachment of very specific third party components. Additionally, they may be used by manufacturers, distributors and commercial end users to market test working prototypes of their new product designs before investing in volume production tooling and machinery.

End users range from large to small industrial, commercial and government entities down to individual entrepreneurs and households. Finding specialized containers for their specific needs and budgets can be challenging, so it often requires modification of already available containers. The alternative is custom assembled containers.

A large proportion of containers and container-like products need to be transported to and from many temporary locations. A self-loading container is the subject of a current patent application by the present inventor. It can be incorporated into any container assembled with the present modular assembly system. It is useful when exterior lifting machinery is not available in either the loading or the unloading locations.

DETAILED DESCRIPTION—CONTAINER SLEEVES AND SHELLS—FIGS. 1A THROUGH 2J

FIGS. 1A through 1E are perspective views of the assembly parts in a container shell. FIG. 1A shows a fully assembled container shell. FIG. 1B shows a semi-exploded version of the shell, consisting of front end frame 110 and a rear end frame 112 that sandwich a container sleeve in between them. FIGS. 1C, 1D and 1E are detailed views. The sleeve is made up of four sides, or walls, connected at 90 degrees with corner panel connectors 118. Each sleeve side is made up of at least one panel module 114, or of several that are interconnected at 180 degrees with linear panel connectors 116.

The elongated panel modules, corner and linear connectors in a container sleeve are longitudinally and slidingly interconnected. They are all cut to the same length, which determines the length of the container sleeve. The number of panel modules and panel connectors in the sleeve walls determines the height and width of the sleeve profile or cross section.

The end frames have double edge flanges positioned to slide around, encase and retain the open container sleeve ends. Frames are attached by several alternative means depending on the vertical or horizontal use and strength needed of the container shell. Those means are described in subsequent FIGS. 8A through 8E.

The basic container sleeve requires only three unique parts slidingly interconnected: Panel modules, panel module linear connectors and panel module corner connectors. Panel modules have various vertical sizes, and for each they have various profile shapes. Linear and corner connectors fit all panel modules of a given size, irrespective of profile. Panel size #1 in FIGS. 1A through 1E is the current minimum size and gauge of the system. They have alternative profiles for alternative customizations, but all have the same width. The number of interconnected panel modules determines height and width of the sleeve. Its height and width is increased in dimensional steps commensurate with its panel widths. Panel modules, linear and corner connectors are cut to the desired length of the sleeve.

The basic container shell adds a front and a rear frame for two additional parts. End frames are generally fabricated of sheet metal to fit the height and width of the sleeve. A number of sleeve cross sections can be assembled with this panel #1 size and gauge. Some are more useful than others, thus limiting the number of end frame sizes needed.

Subsequent Figs. will show alternative panel sizes and profiles of the system.

FIGS. 2A through 2J are orthogonal views using panel size #1 to show the dimensions of nine alternative cross sectional sleeve profiles.

Each of FIGS. 2A through 2J show the alternative sleeve widths and heights in inches. They range from 32.875 wide by 20.063 high to 54.625 wide by 52.688 high. Many smaller and larger profiles can also be assembled, but are less likely to be needed. Sleeves can generally have lengths from 1 to 8 feet.

DETAILED DESCRIPTION—PANEL MODULE SIZES—FIGS. 3A THROUGH 4F

FIGS. 3A through 3F are orthogonal views of six panel sizes of the same panel profile. FIG. 3G details the largest panel size #6 shown here, with a dimensional lumber insert.

Six panel module sizes are shown, all with the same panel module profile shape. The material thickness or gauge increases in 3 steps from the smallest to the largest size. Other panel profile shapes are demonstrated in subsequent Figs. This panel module profile has channels shaped to laterally retain longitudinally inserted objects, but only on its one side facing the sleeve interior.

Each longitudinal channel has a crosswise profile with a bottom and two T shaped sides that end in opposing retainer wings at its top, with adjacent channels sharing sides. The channels of the different panel module sizes shown in FIGS. 3A through 3F have crosswise profiles matching various size profiles of commercially available softwood dimensional lumber. Each panel size is shown retaining in its top channel a different sized profile of dimensional lumber. Each lumber length is slidingly and longitudinally inserted into its channel. The greater part of one side of the lumber length is thus visible between the channel retainer wings. The lumber is therefore accessible for attachment of other parts and components, including additional lumber.

The lumber sizes shown here are typical, but do not include all dimensional lumber available. As such:

FIG. 3A shows panel size #1 for 1 by 3 lumber with the dimension of 0.750″×2.500″ FIG. 3B shows panel size #2 for 2 by 3 lumber with the dimension of 1.500″×2.500″ FIG. 3C shows panel size #3 for 2 by 4 lumber with the dimension of 1.500″×3.500″ FIG. 3D shows panel size #4 for 3 by 4 lumber with the dimension of 2.500″×3.500″ FIG. 3E shows panel size #5 for 3 by 6 lumber with the dimension of 2.500″×5.500″ FIG. 3F shows panel size #6 for 4 by 6 lumber with the dimension of 3.500″×5.500″

FIG. 3G details the fit of a regular 4 by 6 dimensional lumber length 310 longitudinally inserted. Using proper storage, kiln drying and premium wood grades minimizes warping and bowing of the lumber. Planing, routing or otherwise fitting of lumber may occasionally be needed. Panel modules may incorporate tolerances to minimize the extent of such fitting needed.

FIGS. 4A through 4F are perspective views of FIGS. 3A through 3F, respectively.

They demonstrate how the T shaped profile protrusions of this panel profile form channels to retain dimensional lumber. The lumber shown here runs the full length of the panel module. Depending on the customization needed, the channels can also retain shorter lumber lengths or stubs as well as combinations of dimensional lumber where only the inner member is retained in the channel. By leaving exposed part of one side of the inserted lumber, this panel profile can be used to retain blocking of various lengths for attachment of other objects. Such blocking is slidingly inserted in and retained by the panel module channels and by the container walls assembled with the panel modules.

Such blocking strengthens the panel module and the container sleeve in which it is inserted, as well as the attachment itself. It also provides a means of attachment that is reversible, as well as visually and structurally superior to riveting or welding. The channels of this panel module can also retain objects other than wood, inserted longitudinally, such as ducting, piping and conduits used in the building industries. For the retail and exhibition industries, these modules can retain temporarily inserted signing, illumination and display monitors. For the shipping with dunnage industry, softer materials and buffers can be longitudinally inserted in panel modules that form container walls.

It should be noted from the drawings that not only do the channel sizes increase from panel size #1 in FIG. 4A through to panel size #6 in FIG. 4F, but so does the panel gauge in order to retain increasing sizes and weights of lumber and other inserts.

DETAILED DESCRIPTION—PANEL MODULE PROFILE SHAPES—FIGS. 5A THROUGH 6J

FIGS. 5A though 5J are orthogonal views of five different panel module profile shapes.

FIGS. 5A through 5E show five different panel module profile shapes in their horizontal positions facing the sleeve interior, all mirrored at the bottom of the sheet. They are used in either the top or the bottom walls of a horizontal container sleeve assembly. They can be interconnected at 180 degrees with each other, using linear panel connector 116. Using corner panel connector 118, they can also be interconnected at 90 degrees with any one of the same five panel module shapes shown in their vertical positions in FIGS. 5F through 5J. Also facing the sleeve interior and mirrored on the right side of the sheet, they are used in the sidewalls of a horizontal container sleeve assembly.

The panel profile shapes of FIGS. 5A and 5F are straight, without any protrusions, that can be used whenever no attachments to a panel or to a container wall are needed.

The single side single deep panel module profile shape in FIGS. 5B and 5G have T shaped protrusions forming retaining channels on its one side only. This panel profile shape can be used whenever longitudinally inserted blocking for or with attachments is needed on only the inside of the sleeve and container shell wall. In addition to support for blocking, this panel module can support slidingly inserted objects such as drawers, sliding shelves and vertical storage surfaces such as pegboards, slat walls and louvered panels.

The double side single deep panel module profile shape in FIGS. 5C and 5H forms retaining channels on both of its sides. It can be used whenever blocking or other longitudinal inserts are needed on both sides of the panel module and container shell wall. Inserted blocking most economically includes dimensional lumber, but can also be other elongated parts with similar crosswise profiles. The visible side of the blocking can here be accessible for attachments from either the interior or exterior of a sleeve in which it is inserted. Attachments can include elongated L or U channels also supporting slidingly attached objects inside or outside the container shell.

The single side double deep panel module profile shape in FIGS. 5D and 5I forms double deep retaining channels on its inside only. It can be used whenever multiple, or double deep combinations of blocking or other inserts are needed on the inside of the sleeve and container wall. Typical uses would be for retaining hollow conduits in building walls, with other material or insulation layered in front or behind the conduits. The advantage of this panel shape is the ability to access the conduit and its content from the panel ends without removing or disturbing the wall finishing materials.

The double side double deep panel module profile shape in FIGS. 5E and 5J forms double deep retaining channels on both its sides. It can be used whenever multiple, or double deep combinations of blocking or other inserts are needed on both sides of the sleeve and a specialty container wall. This shape is likely to be needed for interior rather than for exterior building walls.

FIGS. 6A through 6J are perspective views of FIGS. 5A through 5J, respectively.

DETAILED DESCRIPTION—CONTAINER SHELL ASSEMBLY—FIGS. 7A THROUGH 10G

FIGS. 7A through 7H are orthogonal views of two container sleeve assemblies.

FIG. 7A is a container sleeve with a top, a bottom and two side walls, with panel #1 sizes having alternative shaped profiles all slidably interconnected. The walls have each been customized for their intended use with various profile shapes of panels connected by linear panel connectors. Corner panel connectors have in turn connected the four walls. The corner connectors have here been positioned vertically. FIG. 7B is the same sleeve partially exploded to demonstrate the vertical position of the corner connectors

FIGS. 7C and 7D show a sleeve having walls customized with other panel shapes. This sleeve has horizontally positioned corner connectors. This slightly reduces its height and increases its width compared to the previous sleeve with vertically positioned corner connectors. So with identical corner connector parts, sleeve dimensions can be tweaked vertically or horizontally to fit sleeve into tight spaces depending how it is assembled.

FIGS. 7E and 7F detail the self-bracing corners of the respective assemblies. FIGS. 7G and 7H show the same corners, but as exploded detail views. Subsequent orthogonal FIG. 14I shows self-bracing of interior panel modules 1410 with interior center panel connector 1414.

Bracing of a Container Assembly Explained

The present assembly system relies on sliding interconnections of extruded panel modules with same length linear connectors and corner connectors.

Extrusions, including aluminum, are never perfectly straight. As the material in its malleable state emerges from its respective profiled dies it undergoes solidification in a downstream process. Even with rigid downstream controls, the extrusions are subject to minor twisting and warping. These effects are minimized by highly skilled extruders, but increase with the extruded lengths specified.

Consequently, to make sliding interconnections possible, the current assembly design needs to incorporate tolerances. The longer the sliding interconnections specified, the larger the tolerances needed. Tolerances can result in slightly loose sliding inter-connections. This is particularly true, the shorter and the more numerous the parts that are used in a sliding assembly. So, to brace, tighten, stiffen or otherwise stabilize a container sleeve, the following means are used in the present container assembly system:

(i) A self-bracing profile design, common to all its sleeve assemblies, as shown in previous FIGS. 7E and 7F, where walls are connected at right angles by same length corner panel connectors. The container sleeve corners depend not only on the corner panel connectors for stability. In addition, these connectors brace panel modules against each other at two other points offset from the corner point connection to achieve additional strength through leverage. Four such stable corner connections are key to the stability of the total container sleeve. Many container sleeves using the current assembly system also have interior divider walls assembled with interior panel modules similarly braced against each other by interior center panel connectors, further increasing the sleeve stability.

(ii) Optional bracing if needed, of linear connectors against the adjacent panel modules they connect is most economically accomplished by routed or otherwise modified dimensional lumber inserts, the lengths of which may be shorter or longer than, or the exact container length, as shown in FIGS. 10C though 10H.

(iii) Adding end framing to the container sleeve completes the container shell and its bracing. End framing with double flanges encase and retain both the inside and the outside surfaces of the open sleeve ends as previously shown in FIG. 1D. As further shown in FIGS. 8A through 8E next, there are at least two means of attaching end framing to container shells.

FIGS. 8A through 8E are orthogonal views of screws in container sleeve to attach end frames, and perspective views of their alternate attachment with rods through frame fronts.

The end frames have double edge flanges positioned to slide around, encase and retain the open container sleeve ends. Frames can be attached by screws through the outer edge flanges that also go through panel connectors and panel modules, finally received by perpendicular neoprene or silicone anchors in corner sleeve voids. In most assemblies, only eight screws are necessary, one in each of their eight corners. Optional screws can be added as needed where shown.

For even stronger frame attachments, four rods with threaded ends go though the sleeve voids longitudinally from the outside front to the outside rear frames, where they are tightened with nuts against the sleeve ends. Both methods allow slight torqued displacement when container rests on uneven surfaces.

FIG. 8A is an orthogonal view of the upper left front corner of a container sleeve to which end framing is attached by screws perpendicular to sleeve walls. Screws and their optional locations are shown. The screws are set back from the shell by the thickness of the end framing which is not shown here to avoid hiding essential assembly details. Detailed FIG. 8B shows corner connector screw locations. Detailed FIG. 8C shows linear connector screw locations.

FIG. 8D is a perspective partly exploded view of end framing attached with four rods running through longitudinal voids in the container corners. The connector rods are slightly longer than the container shell, so nuts on their threaded ends can be tightened up against the end frames as shown in detailed FIG. 8E.

The major stress on end frame attachment is lateral and primarily taken up by the interconnections of the panel modules, the connectors and the end framing flanges. The screws simply serve to prevent longitudinal movement of the parts in relation to each other. That is a minor stress as long as the container shell is positioned horizontally and its contents is not heavy bulk or otherwise unsecured.

When container is used vertically, many of the optional screw locations in the bottom end frame may be needed. For heavy vertical use, rod attachment is preferable. For extended container sleeves, as shown in subsequent FIGS. 10E through 10H, rod attachment of end frames is mandatory.

FIGS. 9A through 9F are orthogonal and perspective views of a container shell assembled with raised corner connectors allowing an outer skin to be seamlessly attached to the shell.

FIG. 9A shows a container shell, the outside surface of which is determined by the shapes of the individual panel profiles interconnected. FIG. 9F shows a container shell, the outside surface of which is customized by the addition of an outer skin of rigid sheets. The interim FIGS. 9B, 9C, 9D and 9E show the parts and steps involved in this assembly. FIG. 9B is an orthogonal view of a container shell assembled with raised corner connectors where the outer skin sheets are ready to be attached to each of the four sleeve sides. FIG. 9C details the shape of the raised corner connector 910 and its recesses 912 that allow rigid outer skin sheets to be inserted under and retained by the container shell end frames. FIG. 9D is a perspective view of FIG. 9B. FIG. 9E is a detailed perspective view of FIG. 9C, again showing raised corner connector 910 and its recesses 912.

An outer skin in the container shell assembly can have at least three purposes:

(i) It can help protect the outer surface of panel modules, preserving them for reuse.
(ii) It can help protect the container shell from moisture, aided by silicone caulking.
(iii) It can allow printed, illustrated and various color skin sheets to cover container.

FIGS. 10A through 10L are perspective and orthogonal views of short container sleeves with lumber inserts in their linear connectors for bracing and container sleeve extension.

FIG. 10A is a view of a short container sleeve being assembled and FIG. 10B details its assembly with a vertically inserted corner panel connector. FIG. 10C is an orthogonal view of a same size sleeve in which modified dimensional lumber has been inserted in its linear panel connectors, in this case to serve as sleeve wall bracers. FIG. 10D details the crosswise profile of linear connector insert 1010 longitudinally inserted to brace the linear connector against the adjacent panel modules it connects.

FIG. 10E is an orthogonal view of several inserts 1010 used to combine two short container sleeves longitudinally to arrive at a longer extended sleeve. FIG. 10F is a perspective view of it. FIG. 10G is an orthogonal view of the completed sleeve extension and FIG. 10H is a perspective view of it. It should be noted that insets 1010 have a slightly skinnier routed version when used for sliding inserts, such as sleeve extensions and later, as in FIGS. 14C and 15C, for insertion of integrated shelving units. For illustrative purposes only, all inserts 1010 in the extended sleeve are here shown as longer than the extension itself, where they would normally be cut to the actual length of the extended sleeve.

FIGS. 10I through 10L are detail views of FIGS. 10F and 10H.

DETAILED DESCRIPTION—CONTAINER SLEEVE INSERTS—FIGS. 11A THROUGH 13L

FIGS. 11A through 11H are perspective and orthogonal views of dimensional lumber single length and combos slidingly inserted into a single side, single deep panel module profile.

FIG. 11A shows a single length dimensional lumber insert in the top channel of a single side, single deep panel module profile shape. It further shows an expanded dimensional lumber combo insert in the middle channel. Finally, a double expanded lumber combo insert is shown in the bottom channel of the module. In the insert combos, the inside lumber length is slidingly inserted in the module channels The outside lumber length of the expanded combo and the middle lumber length of the double expanded combo are one dimensional size narrower than the inside lumber length to which they are attached. That is to fit within and protrude through the retainer wing gaps, so thereby able to attach to themselves other parts or components mounted outside the panel surface.

Orthogonal FIG. 11B further illustrates these single length and combo dimensional lumber inserts as do detailed FIGS. 11C and 11D.

FIGS. 11E through 11H show the same, but compressed combos, where the middle length is a narrow plate of the same gauge and thickness as the panel module itself. This allows any subsequently attached components to be flush with the panel surface.

Depending on their end use, inserts of lumber or other materials and other inserted components may be shorter than the length of the module in which they are retained.

FIGS. 12A through 12L are perspective and orthogonal views of dimensional lumber single length and combos slidingly inserted into a double side, single deep panel module profile.

FIG. 12A shows single length inserts facing outwards from both sides of the panel. FIG. 12B is an orthogonal view of FIG. 12A. FIGS. 12C and 12D are details of those views.

FIG. 12E shows expanded combo inserts facing outwards from both module sides. In the bottom channel of this module, a compressed version of the combo is inserted. FIG. 12F is an orthogonal view of FIG. 12E. FIGS. 12G and 12H are details of those views.

FIG. 12I shows double expanded inserts facing outwards from both module sides. In the bottom channel of this module, a compressed version of the combo is inserted. FIG. 12J is an orthogonal view of FIG. 12I. FIGS. 12K and 12L are details of those views.

FIGS. 13A through 13L are perspective and orthogonal views of non-lumber inserts.

FIG. 13A shows hollow inserts in a single side, single deep panel module profile. Hollow inserts may be used as conduits for electrical, mechanical or other components. They may also be ducting for hot or cold air delivery and return in a container or building A double section hollow insert is shown in the top channel, a hollow expanded insert in the middle channel and a hollow double expanded insert in the bottom channel. The expansion or middle length shown here is dimensional lumber, but could also be hollow or compressed if needed. Hollow inserts are typically extruded using plastics or fiberglass materials, but could also be sheet metal ducting.

FIG. 13B is an orthogonal view of FIG. 13A. FIGS. 13C and 13D are details of it.

FIG. 13E also shows hollow inserts in a single side, single deep panel module. However, these hollow inserts form anchors that retain attached foam or buffer material. Such material can be for insulation, transport dunnage or for other buffering purposes.

FIG. 13F is an orthogonal view of FIG. 13E. FIGS. 13G and 13H are details of it.

FIG. 13I also shows hollow inserts in a single side, single deep panel module. However, these hollow inserts form anchors that retain attached air inflated soft cushions. This can also be for insulation, transport dunnage or for other buffering purposes.

FIG. 13J is an orthogonal view of FIG. 13I. FIGS. 13K and 13L are details of it.

Operation—Container Sleeve Interior Customization—FIGS. 14A Through 15F

FIGS. 14A through 14L are orthogonal views of container sleeve interior customization.

FIG. 14A shows the customization of the walls of a temperature controlled container, or a miniature version of a small mobile building. Hollow inserts have been slid into the channels of the various panel modules forming the walls, ceiling and floor to encase electrical, plumbing and mechanical components.

After all the inserts with their components are in place, the walls and ceiling may be covered by insulation and paneling or sheet rock, and the floor with sub and finished flooring. The advantage of hollow inserts carrying component is the ease of temporarily extracting the inserts lengthwise from the sleeve ends for repair, reconfiguration or addition of components. FIG. 14D details the multi chambered ceiling inserts, FIGS. 14E and 14F the wall inserts and FIG. 14G the floor inserts. Other voids not used for conduits are created by the profiled panel modules for components such as heating and/or air conditioning delivery and return ducts in the ceiling and floor.

FIG. 14B shows the interior customization of a small or large shipping container with dunnage walls. This container is divided into four cargo sections. The tops and bottoms of both sections are buffered with a soft material such as foam attached to hollow wall inserts, which can optionally be used as cooling or heating ducts where needed. The sides of both sections are similarly buffered, but with an air inflatable material, only inflated when the fragile cargo is in place. The cargo is gently, but securely, held in place during travel.

FIG. 14H shows the panel walls before insertion of the dunnage material. The container sleeve assembly includes interior panel module 1410 with retainer channels on both its longitudinal sides. FIG. 14I details how panels 1410 are held in place by four interior linear panel connectors 1412 and one interior hub panel connector 1414. Connector 1414 braces four panels 1410 from four directions against each other.

FIG. 14C shows the interior customization of a container with fixed shelving. Dimensional lumber inserts in some of the panels, as well as inserts in some of the linear connectors, serve as blocking for the top, bottom and sidewalls of the container. This blocking in turn allows attachment of the horizontal and vertical shelving walls. FIGS. 14J, 14K and 14L detail such inserts and shelving attachments thereto. Once assembled, this shelving unit can be inserted and retracted as an integrated unit.

Other obvious interior modifications include sliding supports for drawers and sliding shelves and for vertical storage surfaces, such as pegboards, slat walls and louvered panels. Examples of those are shown in later FIG. 21A through FIG. 21H.

FIGS. 15A through 15F are perspective views of container sleeve interior customization.

FIGS. 15A, 15B and 15C are perspective views of FIGS. 14A, 14B and 14C, respectively. FIG. 15D details the hollow inserts in the top and side walls of FIG. 15A. FIG. 15E details the dunnage inserts in the top and side walls of FIG. 15B. Finally, FIG. 15F details the insertion of the pre-assembled integrated shelving unit of FIG. 15C.

FIGS. 15A through 15C are only three of many interior customizations possible in containers and container-like products. The latter include shop, exhibition and retail fixtures as well as much larger shipping containers and lightweight easy-to-move buildings. Manufacturers and other third party suppliers can benefit from integrating their products with the current system inserts so they are ready-made for insertion into container sleeves assembled with profiled panel modules.

Operation—Container Sleeve Exterior Customization—FIGS. 16A Through 19F

FIGS. 16A through 16G are orthogonal views of container sleeves with exterior rails.

FIG. 16A shows a container sleeve customized with rails in all four directions. Rails are most economically lumber double expanded sliding inserts in panel channels. That multidirectional use of rails is used for assemblies of container sleeve clusters. A cluster attaches other sleeves with exterior channels to the exterior rails of this sleeve. FIG. 16D details a corner hereof with double expanded inserts in exterior facing channels. FIG. 16B is a more common use where containers are attached to each other horizontally. FIG. 16E details such interconnection of container sleeves and their finished containers. FIG. 16C is a vertical container interconnection. FIGS. 16F and 16G detail this connection.

Sliding interconnection of containers is structurally superior to bolting, screwing or riveting. The structural stress is not concentrated, but spread over the full length of both containers. Further, the connection is easily reversible, and does not leave unsightly holes or scars. A connecting container sleeve has exterior rails already inserted into its exterior channels. It can have its end framing installed before connecting to other container sleeves. A connected container sleeve has empty exterior channels to accept the rails of the connecting container. It can only accept end framing after this connection is in place. With such end framing in place, the containers are longitudinally locked together. Easily reversible container interconnections can be achieved with cutouts in the front or rear frames of the connected container sleeves, such cutouts matching the rail profiles.

FIGS. 17A through 17H are orthogonal and corresponding perspective views of exterior customizations of container sleeves with inserts serving various purposes.

Sleeves in FIGS. 17A through 17H all have exterior bottom rails, which are double expanded dimensional lumber inserts. They generally serve to lift container above ground to allow it to be loaded by a tow motor or a forklift truck. Additionally, they protect container bottoms from direct contact with the ground. They may also serve to let containers slidingly attach onto in-vehicle retention panels, to be securely retained during travel as shown in later FIGS. 20A through 23C. In FIGS. 17A and 17B, bottom rail inserts alternatively serve as anchors that hold straight wheel assemblies.

FIGS. 17A and 17B show two types of handles mounted on the sides of a container sleeve on double expanded inserts or rails. They are slid into in the exterior channels of double side single deep panel modules. FIGS. 17C and 17D show forklift pockets similarly mounted, but using two inserts each for additional strength.

FIGS. 17E and 17F is the same container sleeve shown in previous FIGS. 14B and 15B, but here furnished with exterior bottom rails. Similarly, FIGS. 17G and 17H is the same container sleeve shown in previous FIGS. 14C and 15C, but here also furnished with exterior bottom rails.

FIGS. 18A through 18G are perspective and orthogonal views and details of sliding and hinged doors and lids to further customize containers or container-like products.

FIG. 18A shows a container shell with sliding doors on both its sides and a closed wall rear frame and an open front frame. FIG. 18B is the orthogonal version seen from the front. FIG. 18C details the lower of two rail guides 1810 retaining the left door to the container. The guides are mounted to panel inserts in the top and bottom side panel module channels.

FIG. 18D is a container with a closed wall end frame and an open front frame with a hinged door. FIG. 18E is a same size container shell, but with a hinged and closed top lid. In FIG. 18F its lid is open. FIG. 18G details the attachment of the stationary hinge half 1812 to one of the two a panel inserts in the outside channels of the container top that define the opening.

FIGS. 19A through 19F are perspective views and details of container rolling means and views of lumber inserts that support a range of different interior mechanical components.

FIG. 19A shows an open ended container with double expanded rail inserts fixed in channels in two double side single deep panel modules in the bottom wall of the container. Attached to these rails are four casters, one of which is further detailed in FIG. 19B. Only the bottom member 1910 of the rail can be seen, with the upper member hidden in the panel module channel.

FIG. 19C shows a container with two drawers and a sliding shelf accessible from the front. It has extendable legs on roller balls. The legs are telescoped in housings attached to modified end frames. Legs are extended and retracted by spur gears that cooperate with gear racks on the legs protruding out through longitudinal cuts in their housings. In this container, rotational power is applied with a battery powered hand drill to shafts with hexagonal ends. Power can be applied to either the front legs, the rear legs, or with a hand operated coupling mechanism, to both pairs simultaneously.

With extendable legs, the container can be positioned at a height that is most convenient for loading and unloading it. With its legs fully retracted, the container can rest on its horizontally extendable rails with casters. That position gives it a lower and more stable center of gravity for routine movement. The extendable rails slide in exterior channels of the bottom container shell wall and are also hand drill operated. Detailed FIG. 19D shows an extended rail wherein both the bottom rail member 1910 and the upper member 1912 can be seen. The gear rack on the leg is also clearly visible.

In fact, FIG. 19C shows a self-loading container that is currently the subject of a patent application by the present inventor.

FIG. 19E shows the open container bottom to demonstrate a number of cost saving lumber inserts that support a range of different interior mechanical components. As such, detailed FIG. 19F again shows the extendable horizontal rails where both the bottom rail members 1910 and the upper members 1912 can be seen. Sidewall shaft support lumber inserts 1914 have a specially routed profile that runs the full length of the container, retained in inward facing channels in the bottom of both sidewalls. Inserts 1914 retain, without any welding required, several flanged bearings, squeezably inserted, for shafts running crosswise in the container bottom.

Where shafts and their bearings cannot be supported by container sidewall inserts, or where additional interior shaft support is needed, lumber insert combos are used in container bottom channels. Bottom shaft support member 1916 is retained in an interior-facing channel of the container bottom. Top shaft support member 1918 is screwed onto member 1916. The member combo is thereby tightened around the retainer wings of the channel to secure it in place, again without welding needed. Member 1918, shorter than member 1916, supports its lengthwise running shaft in two flanged bearings on its opposite ends. The bearings are in turned retained by straps screwed to member 1918.

Alternative top shaft support member 1922 similarly supports its crosswise running shaft, but at a higher level. It is screwed onto alternative bottom shaft support member 1920 and is similarly tightened in place around the retainer wings of another bottom channel.

The lumber insert shaft supports described above are easily customized and more economical than metal shaft supports. In addition, the latter are only available in a limited number of standard sizes. As already mentioned, lumber inserts do not need welding, and are easily repositioned and totally removable without leaving unsightly scars.

Operation—in-Vehicle Storage Containers—FIGS. 20A Through 23C

FIG. 20A is an orthogonal view of a retention panel on plywood for an SUV cargo area. FIGS. 20B through 20H are perspective views of containers retained by the panel.

FIG. 20A shows the retention panel attached to the insertable cargo floor. The panel is a lateral or linear interconnection of double side single deep panel modules.

FIG. 20B details channels 2010 that will slidably retain the bottom rails of inserted containers first shown in FIGS. 17A through 17H. Compressed insert combos 2012 and 2014 are screwed onto the plywood where they serve to hold the retention panel that is also slidably inserted.

FIG. 20C is the schematic representation of the cargo area in an SUV. The plywood sheet under the retention panel is cut to fit around the wheel wells to be secured in place. The sheet with the retention panel is laid on the vehicle floor to fit around the wheel wells. If too heavy for the operator, the sheet goes in first, then the retention panel is slid in place. FIG. 20D details the panel end with channels ready to accept containers with bottom rails. FIG. 20E shows inserted container units with bottom rails from earlier FIGS. 17G and 17E. FIG. 20F is a detail of it. FIG. 20G shows an inserted container with two drawer banks. FIG. 20H is a detail of it. All three units were inserted through the rear door of the SUV.

FIGS. 21A through 21H are orthogonal and perspective views of a tool container inserted in a cargo van. The unit holds sliding shelves, drawers, sliding slatwall and pegboard inserts.

FIG. 21A is an orthogonal view and FIG. 21B a perspective view of the tool container with bottom rails slidably inserted in a retainer panel in a cargo van. FIG. 21C shows the tool container itself with extra long bottom rails extended backwards. Long rails allow the container to be extended outside of the van rear door, when needed for better access. FIG. 21D shows such rearwards extension. FIG. 21E and detailed FIG. 21F show the pegboard storage panel attached to container exterior, best reached when extended.

FIG. 21G is a detailed perspective view of the container. In addition to the fixed pegboard on the container exterior, its interior holds both pegboards and slatwall storage panels as well as sliding shelves and drawers. They are all accessible by sliding them out like drawers, using U channels attached to inserts in the interior container shell walls. FIG. 21H is a perspective view of the slatwall, otherwise partly hidden in the other Figs.

Containers and container-like products shown in previous FIGS. 20C through 21H are all accessible only from the rear of the cargo area of a vehicle. Many vans need container-like products accessible from inside the cargo area. Such products may be for commercial use, others for recreational use. The following Figs. demonstrate such examples.

FIGS. 22A through 22C are perspective views of commercial container-like products with lengthwise modified bottom rails inserted into a cargo van retention floor.

FIG. 22A is a perspective view of two long and narrow shelving units slid onto the retention panel. The units are located flush with both sides of the van's cargo space, facing each other, with room left to access and walk between them.

FIG. 22B shows a similar placement. However here, two shelving units have been vertically interconnected with double expanded inserts to achieve twice the height. Also, a floor or retention panel cover sheet has been installed between the two opposing double shelving units to prevent dirt from accumulating in channels and to improve foot access.

FIG. 22C shows drawer and shelving units accessible through the rear door of the van. At the same time, a desk is created by dropping a tabletop onto two drawer and sliding shelf units that are also slidably attached to the panel retention floor of the van.

FIGS. 23A through 23C are perspective views of recreational container-like products with lengthwise modified bottom rails inserted into a cargo van retention floor.

The recreational world is full of homemade van conversions for camping purposes. One of the most popular and frequently shown on social media is a van with storage and seating facilities that can be converted into sleeping accommodations when camping.

FIG. 23A shows opposing shelving units in a recreational van conversion. A floor surface has been added between the shelving units. On top of each shelving unit a flat seating surface has been added with hinged rear retainers for seating cushions.

FIG. 23B shows the shelving units on slidable support framing, here slid halfway towards each other

FIG. 23C shows the shelving units here slid together to form a sleeping surface. One or both of the supporting shelving units could be converted to longitudinal shelving units accessible from the rear door. The shelves could then hold the rollably stored seating and mattress materials.

The van containerizations shown in previous FIGS. 22A through 23C are only minor examples of the container-like products that can be assembled with the current system for insertion onto the floors of work and recreational vans. There already is a major market segment involved in customizing work vans for specific trades and recreational uses with permanently attached fixtures. The present system allows reversible customization and future rearrangement and/or expansion of such fixtures. In addition, the present system allows temporarily insertable and retractable fixtures without permanent attachment and drilling into or welding onto van interior walls and floors. This has advantages, such as:

• • (i) Temporary and reversible fixturing in rented or leased vans
  • (ii) One van can have many concurrent uses, commercial and/or family, rather than being dedicated to one particular use only, which requires owning other vehicles for other uses.
  • (iii) The ability to port existing fixturing to a new van from a traded-in van.
  • (iv) A higher trade-in value for a van without conversion scars.

Self-Loading Containers and Container-Like Products

Containers and container-like products shown in previous FIGS. 20A through 23C are only the first step of in-vehicle customizations possible with the present assembly system. Using retainer floors as shown above is most useful for one or several containers that are hand or machine loadable and intended to stay in the vehicle for longer periods.

Alternatively, larger customizations may include among many others: Mobile units for manufacturing, distribution, work shops, retail, catering, exhibitions, delivery, market stands, travel, recreation, camping, hunting, fishing, etc. They are generally meant to be loaded and unloaded more frequently or even routinely. As such they require a loading floor mechanism that is more forgiving than the exact fit needed of container bottom rails into the vehicle floor retainer panels.

Furthermore, such larger container customizations are likely to need non-manual, exterior lifting equipment available in both the loading and the unloading locations. The need for exterior loading equipment can be eliminated by self-loading/unloading abilities added to the container. All containers and container-like products demonstrated herein can have self-loading versions. With self-loading, size and weight of container customizations will not be limited.

Self-loading containers and compatible self-loading vehicle flooring is the subject of a current patent application by the present inventor.

While the invention herein disclosed fulfills the objects stated above, and while examples of alternative ramifications and embodiments have been shown, it will be appreciated that numerous other modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention.

Claims

1. A customizable container shell assembly system comprising:

a. A four-sided container sleeve having two open ends, said sleeve assembled by slidably interconnecting and laterally interlocking four sleeve walls at right angles, each said wall comprising at least one elongated panel module having a cross sectional profile with longitudinal edges adapted to slidingly interconnect and laterally interlock, at right angles with matching edges of same length corner panel connectors, and at straight angles with matching edges of same length linear panel connectors.

b. Two end frames, each having a front face aligned with the plane of said open ends, with the outer peripheral edges of said face incorporating two parallel flanges perpendicular to said face, said flanges aligned with said sleeve walls and oriented toward the interior of said sleeve and configured to encase and retain both ends of said four sleeve walls of claim 1a, so that when said end frames are crosswise aligned with and abutted to said open ends, and attached to said four sleeve walls, a six-sided container shell assembly is created.

c. Means to attach said end frames to said container sleeve.

whereby a container shell is defined, that is customizable as to its cross sectional height and width by the number and width of the interconnected elongated panel modules and panel connectors that are included in its sleeve walls, and customizable as to its length by the length to which said panel modules and panel connectors are cut, and said container shell being further customizable by the choice of alternative cross sectional profiles of said panel modules to which interior and exterior attachments can be slidingly attached and by the choice of alternative end frame configurations.

2. The elongated panel module of claim 1a, wherein it has a crosswise profile that between its said longitudinal edges additionally incorporates a section or surface that is straight and oriented both towards the interior and the exterior of said container sleeve.

3. The elongated panel module of claim 1a, wherein it has a crosswise profile that between its said longitudinal edges additionally incorporates at least one longitudinal channel with a bottom and two T shaped sides that end in opposing, but spaced apart retainer wings at its top, configured to laterally retain elongated objects that are slidingly and longitudinally inserted into said channel while leaving the greater part of one side of said objects visible between said retainer wings and accessible from that side of said panel module that is oriented towards the interior of said container sleeve.

4. The elongated panel module of claim 1a, wherein it has a crosswise profile that between its said longitudinal edges additionally incorporates at least two adjacent longitudinal channels, each with a bottom and two T shaped sides that end in opposing, but spaced apart retainer wings at their tops, with said wings of one said channel facing in the opposite direction of said wings of the adjacent said channel, said channels configured to laterally retain elongated objects that are slidingly and longitudinally inserted into said channels while leaving in one of said channels the greater part of one side of said objects visible between said retainer wings and accessible from that side of said panel module that is oriented towards the interior of said container sleeve, and while leaving in the adjacent of said channels the greater part of one side of said objects visible between said retainer wings and accessible from that side of said panel module that is oriented towards the exterior of said container sleeve.

5. The end frames of claim 1b, further comprising customizable closure parts and customizable closed end walls.

6. The means of claim 1c to attach said end frames of claim 1b to said container sleeve of claim 1a, wherein said means according to one embodiment includes screws disposed perpendicular to said container sleeve in two locations in each of eight corners of said sleeve through apertures in the outer flanges of said end frames aligned with apertures in said sleeve, with said screws received by bars of a high durometer elastomer encased and retained in both ends of longitudinal corner voids of said sleeve.

7. The means of claim 1c to attach said end frames of claim 1b to said container sleeve of claim 1a, wherein said means according to an alternate embodiment includes four rods with threaded ends, said rods disposed longitudinally in said longitudinal corner voids of said sleeve and through apertures in the front faces of both the front and rear of said end frames of said container shell and with said frames tightened against both ends of said container sleeve by nuts screwed onto said threaded ends of said rods.

8. The at least two adjacent longitudinal channels of claim 4 to laterally retain elongated objects, wherein said channels are shaped and sized to retain a range of standard dimensional lumber cross sections, said range including lumber sizes commonly referred to as 1 by 3, 2 by 3, 2 by 4, 3 by 4, 3 by 6, and 4 by 6.

9. The longitudinal channels of claim 8, wherein the height, width and material thickness or gauge of the crosswise profiles of said channels are stepwise increased as structurally required to support the range of increasing lumber sizes of claim 8 and wherein their matching corner and linear panel connectors and end frames are correspondingly increased.

10. The linear panel connectors of claim 1a, wherein dimensional lumber is longitudinally routed or otherwise modified crosswise to match and slidingly fit into that side of their crosswise profiles that is oriented toward the interior of said container sleeve, for the purpose of bracing said linear panel connectors against the adjacent panel modules that they connect, thereby stiffening and reinforcing the container sleeve and shell walls of which they are part.

10. The four-sided container sleeve of claim 1a, wherein interior panel modules are configured to longitudinally subdivide the interior space of said sleeve, the crosswise profiles of said modules with edges similar to the longitudinal edges of the panel module of claim 1a, that are slidingly connectable to the edges of matching longitudinal interior linear and hub panel connectors of the same length as said interior panel modules, and wherein said interior panel modules have a crosswise profile that between their said longitudinal edges additionally incorporates a section or surface that is straight, and said interior linear panel connectors configured with edges to longitudinally and slidingly interconnect at straight angles with said interior panel modules and said hub panel connectors configured with edges to longitudinally and slidingly interconnect with and brace onto themselves a plurality of said interior panel modules.

11. The four-sided container sleeve of claim 1a, wherein interior panel modules are configured to longitudinally subdivide the interior space of said sleeve, the crosswise profiles of said modules with edges similar to the longitudinal edges of the panel module of claim 1a, that are slidingly connectable to the edges of matching longitudinal interior linear and hub panel connectors of the same length as said interior panel modules, and wherein said interior panel modules have a crosswise profile that between their said longitudinal edges additionally incorporates at least one longitudinal channel with a bottom and two T shaped sides that end in opposing, but spaced apart retainer wings at its top, configured to laterally retain elongated objects that are slidingly and longitudinally inserted into said channel while leaving the greater part of one side of said objects visible between said retainer wings and accessible from their visible side of said panel module, and said interior linear panel connectors configured with edges to longitudinally and slidingly interconnect at straight angles with said interior panel modules and said hub panel connectors configured with edges to longitudinally and slidingly interconnect with and brace onto themselves a plurality of said interior panel modules.

12. The four-sided container sleeve of claim 1a, wherein an interior linear panel connector Is configured with edges to longitudinally and slidingly interconnect at straight angles with said interior panel module of claim 11.

13. The four-sided container sleeve of claim 1a, wherein an interior hub panel connector Is configured with edges to longitudinally and slidingly interconnect with and brace onto themselves a plurality of said interior panel modules of claim 11.

14. The interior panel modules of claim 11, the interior linear panel connector of claim 12, and the interior hub panel connector of claim 13, wherein they are configured to have a range of sizes and gauges corresponding to those of claims 8 and 9.

15. The elongated objects of claims 3 and 4, wherein they are hollow ducts, conduits or dimensional lumber or modifications of same for bracing, structural extensions of container sleeves, sliding attachments to and of other surfaces, shorter and longer blocking for attachments, said attachments including additional lumber assemblies and other parts and components of parts.

16. The elongated objects of claims 3 and 4, wherein they are a combination of three lumber parts the same length as the container sleeve of claim 1a, said parts laterally combined to have a cross sectional profile schematically similar to an H-beam, where the exterior two said parts have a cross sectional dimension that allows their sliding longitudinal insertion of either in said outwards facing channels of said elongated panel module of claim 4, and where the middle or center of said three parts has a lesser cross sectional dimension, whereby it fits between the two said retainer wings of said channels, so that the resulting lumber combination will simultaneously fit slidingly into a pair of the panel module of claim 4, positioned adjacent and parallel to each other, thereby enabling said lumber combination to slidingly interconnect sides of assemblies using the present system, including the interconnection of the container shell of claim 1a with other container shells and with horizontal and vertical retention panels or walls comprising a plurality of said panel modules of claim 4, interconnected with said linear panel connectors of claim 1a, said plurality mounted onto a linear surface having a width and length at least equal to the width and length of the adjacently interconnected wall of said container shell.

17. The elongated objects of claims 3 and 4, wherein they are a lateral interconnection of two lumber parts, each generally substantially shorter than the container sleeve of claim 1a, where one, or the connector, of said parts has a cross sectional dimension that allows its sliding longitudinal insertion in said inwards facing channels of said elongated panel modules of claims 3 and 4, and where the second, or the connected, of said two parts has a predetermined thickness, whereby it can support an attached shaft and bearing combination at the cross sectional shaft distance from said elongated panel modules that is needed for a given mechanical assembly, and where said connected part has a width sufficiently exceeding the width of the gap between said two opposing retainer wings of said channels of claims 3 and 4, so when said connected part is sufficiently tightened against said connector part, thus sandwiching said wings between the two, it will cause the longitudinal fixing in place of said lateral interconnection.

18. The corner panel connectors of claim 1a, wherein said connectors have a crosswise profile with two outside facing longitudinal sides, one laterally wider than the other, and wherein said connectors can be positioned in a container sleeve assembly, either with their wider side facing horizontally or vertically outwards from their sleeve wall, whereby the alternate choice of said connector position can slightly vary the height versus the width of said container sleeve and shell assembly for the purpose of fitting said assembly into spaces that have tight limits, either vertically or horizontally.

19. The corner panel connectors of claim 1a, wherein said connectors have a crosswise profile with two outside facing longitudinal sides that are raised by a predetermined dimension to be flush with the outside surfaces of rigid flat panels, having the thickness of the same predetermined dimension, said panels positioned laterally onto each of the four sides of said container sleeve of claim 1a between said raised corner connectors, with the width of said panels being equal to the width between said raised corner connectors and their length being equal to the length of said sleeve, whereby said panels will be retained by the attachment of two said end frames of claim 1b, for the varied purposes of economically customizing exterior container walls with a range of color choices, printed or illustrated messages, or with a surface protecting panel modules for later reuse or against moisture.

20. The lumber parts of claims 8, 9, 10, 15, 16, and 17, wherein they are made with other materials and by other processes including lamination and extrusion.