Shipping container and method of construction thereof

Abstract

An intermodal shipping container including one or more improvements such as intermediate gable posts or gable headers adapted to increase an internal width and strength of the container, wherein the gable posts or the gable headers include twin channels having at least two internal flanges welded to a gable post plate or gable header plate, one or more upper castings having an integral top rail ledge, wherein a top rail of a side wall hangs on the integral top rail ledge, “C” channel style beam main frame cross members, a one-piece continuous top plate including an integral lip connecting the top plate and a roof, one or more rear lower castings, wherein the one or more rear lower castings are an integral interlocking interface, a bolster including an integral seating and fastening surface and slots, and/or one or more nested rear corner posts subassemblies, the one or more nested rear corner posts having a notch and protrusion connection, wherein a protrusion in a lower rear casting engages with a corresponding notch in the rear corner post.

What is claimed is: 
     
         1 . An intermodal shipping container comprising one or more intermediate gable posts and/or intermediate gable headers adapted to increase an internal width and strength of the container, wherein the gable posts and/or the gable headers include twin channels having at least two internal flanges welded to a gable post plate and/or gable header plate. 
     
     
         2 . The intermodal shipping container as recited in  claim 1 , wherein the twin channels are one piece and welded to the one or more gable posts or gable headers, wherein the gable post or the gable headers have slots allowing the welding of the one-piece twin channel from the interior. 
     
     
         3 . The shipping container as recited in  claim 2 , wherein wall panel extensions are integrated in the one-piece twin channels, providing a flat interior profile. 
     
     
         4 . The shipping container as recited in  claim 2 , wherein the one-piece twin channel is formed by rolling or pressing. 
     
     
         5 . An intermodal shipping container comprising one or more upper castings having an integral top rail ledge, wherein a top rail of a side wall hangs on the integral top rail ledge. 
     
     
         6 . The intermodal shipping container as recited in  claim 5 , wherein the one or more upper castings have a first protrusion and a second protrusion, the first protrusion engaging with a twin channel intermediate gable post and the second protrusion engaging with an twin channel intermediate gable header. 
     
     
         7 . An intermodal shipping container comprising “C” shaped channel beam main frame cross members. 
     
     
         8 . The intermodal shipping container as recited in  claim 7 , wherein the crossmembers are adapted to provide a web oriented to face a front of the shipping container, the web dimensions of the crossmembers being one continuous length. 
     
     
         9 . The intermodal shipping container as recited in  claim 7 , wherein the crossmembers include a wide uninterrupted flange to receive floor screws. 
     
     
         10 . An intermodal shipping container comprising a one-piece continuous top plate including an integral lip connecting the top plate and a roof. 
     
     
         11 . The intermodal shipping container as recited in  claim 10 , wherein the top plate is a door header top plate. 
     
     
         12 . The intermodal shipping container as recited in  claim 10 , wherein the top plate is a front top plate. 
     
     
         13 . The intermodal shipping container as recited in  claim 11 , further comprising an overhang adapted to shield upper door lock rod keepers. 
     
     
         14 . The shipping container as recited in  claim 10 , the container further comprising rear headers, wherein the rear headers have integral internal gussets. 
     
     
         15 . An intermodal shipping container comprising one or more rear lower castings, wherein the one or more rear lower castings are an integral interlocking interface, wherein a door sill abuts the rear lower casting and a rear corner post, the one or more rear lower castings having an observation hole to externally view a chassis twist lock. 
     
     
         16 . An intermodal shipping container comprising a bolster including an integral seating and fastening surface and slots, the integral seating and fastening surface adapted to fasten and support flooring and the slots used for welding, wherein the bolster is flush with a top surface of flooring. 
     
     
         17 . The shipping container as recited in  claim 16 , wherein the bolster is a front intermediate bolster 
     
     
         18 . The shipping container as recited in  claim 16 , wherein the bolster is a rear intermediate bolster. 
     
     
         19 . The shipping container as recited in  claim 16 , wherein the bolster is a door sill. 
     
     
         20 . The shipping container as recited in  claim 16 , wherein the bolster has integral internal gussets. 
     
     
         21 . An intermodal shipping container comprising one or more nested rear corner posts subassemblies, the one or more nested rear corner posts having a notch and protrusion connection, wherein a protrusion in a lower rear casting engages with a corresponding notch in the rear corner post. 
     
     
         22 . A method of fabricating an intermodal shipping container, the method comprising:
 preparing a sub assembly by welding a top rail onto a side wall panel;   introducing the side wall sub assembly to intermediate gables from above; and   lowering the wall sub assembly until the wall assembly is entirely supported by the intermediate gables.