Stackable flat-pack shipping container with segmented roof

Abstract

A modular container is provided having a base. A plurality of panels is coupled to the base to form an enclosure having an internal volume. The plurality of panels substantially defines an outer perimeter, and substantially defines a top circumferential edge of the modular container. At least one door provides access to the internal volume. A roof having a shoebox flange is coupled to the plurality of panels. The shoebox flange circumscribes the roof and defines the outer perimeter of the roof. The shoebox flange fits over the top circumferential edge. The roof comprises a plurality of individual roof panels that are fastenable together. The modular container, when in a disassembled and flat-packed state, fits at least one of horizontally and vertically in an ISO container.

1 . A modular container, comprising:
 a base;   a plurality of panels coupled to the base to form an enclosure having an internal volume, wherein the plurality of panels substantially defines an outer perimeter of the modular container, and substantially defines a top circumferential edge of the modular container;   at least one door that provides access to the internal volume;   a roof coupled to the plurality of panels, wherein the roof comprises a shoebox flange that downwardly protrudes from a top of the roof and circumscribes the roof and defines the outer perimeter of the roof, wherein the shoebox flange fits over the top circumferential edge of the modular container;   wherein the roof comprises a plurality of individual roof panels that are fastenable together;   wherein the modular container, when in a disassembled and flat-packed state, fits at least one of horizontally and vertically in a shipping container.   
     
     
         2 . The modular container of  claim 1 , further comprising a plurality of connection flanges on the roof, wherein each individual roof panel comprises at least one connection flange proximate an outer edge of the roof panel, and wherein the individual roof panels are fastenable to each other by securing the connection flanges together. 
     
     
         3 . The modular container of  claim 1 , wherein each outer edge of each roof panel comprises either a connection flange or a shoebox flange. 
     
     
         4 . The modular container of  claim 1 , comprising a gasket placed between the connection flanges of the plurality of individual roof panels. 
     
     
         5 . The modular container of  claim 1 , comprising a u-channel that is fastened to a junction defined by adjacent flanges of adjacent roof panels, wherein the junction between adjacent panels and the gasket are substantially shielded from external factors by the u-channel. 
     
     
         6 . The modular container of  claim 5 , wherein the u-channel comprises a plate attached to each end of the u-channel. 
     
     
         7 . The modular container of  claim 6 , wherein each plate is attachable to a portion of the modular container proximate the shoebox flange. 
     
     
         8 . The modular container of  claim 1 , comprising a crossmember installed to a portion of the modular container, being disposed beneath a junction defined by adjacent connection flanges of adjacent roof panels, wherein the crossmember comprises a main support that is adjacent to the roof when the roof is installed. 
     
     
         9 . The modular container of  claim 8 , wherein the main support comprises attachment blocks that are received by a portion of at least one of the panels, support panels, or other support member, and couplable thereto. 
     
     
         10 . The modular container of  claim 1 , wherein the base comprises at least one split that defines a junction between at least two base portions being couplable to each other at the junction. 
     
     
         11 . The modular container of  claim 10 , wherein the split of the base comprises a split through at least one of a length of the modular container, a width of the modular container, and both the length and the width of the modular container. 
     
     
         12 . The modular container of  claim 1 , wherein a split of the roof comprises a split through the length of the modular container or the width of the modular container or both the length and width of the container. 
     
     
         13 . The modular container of  claim 1 , comprising a plurality of floor panels, each having a size and dimension that allows the floor panels to fit into an ISO container when at least one of horizontally and vertically flat-packed. 
     
     
         14 . The modular container of  claim 10 , wherein the base portions are at least one of horizontally and vertically flat packable to fit in an ISO container. 
     
     
         15 . The modular container of  claim 1 , comprising a width greater than 7.7 feet and a length greater than 7.7 feet when in an assembled state. 
     
     
         16 . The modular container of  claim 1 , wherein every component of the modular container, when in a disassembled state, is flat-packable and comprises at least one of a horizontally and vertically flat-packed width of less than or equal to 7.7 feet. 
     
     
         17 . The modular container of  claim 1 , wherein every component of the modular container, when in a disassembled state, is flat-packable and comprises at least one of a horizontally and vertically flat-packed width less than or equal to 8.9 feet. 
     
     
         18 . The modular container of  claim 1 , wherein at least one of the plurality of panels is hingedly attached to another portion of the modular container. 
     
     
         19 . A method of assembling a flat-packable modular container comprising:
 coupling a plurality of base members to form a base;   coupling a plurality of panels and/or support panels to the base;   coupling adjacent panels and/or support panels to each other;   coupling at least one crossmember to any two of the panels and/or the support panels such that the at least one crossmember is disposed to be under a seam defined by a roof;   forming the roof by coupling a plurality of roof members together;   coupling the roof to a top circumferential edge defined by the plurality of panels and/or support panels;   coupling a u-channel to a junction formed between the coupled roof members; and   installing at least one door in an opening defined by the plurality of panels and/or support panels.   
     
     
         20 . A method of disassembling a flat-packable modular container comprising:
 providing an assembled flat-packable modular container;   uninstalling at least one door disposed in at least on opening defined by a plurality of panels and/or support panels;   uncoupling a u-channel from a junction formed between at least two coupled roof members that define a roof;   uncoupling the roof from a top circumferential edge defined by the plurality of panels and/or support panels;   uncoupling the at least two coupled roof members;   uncoupling a crossmember from any two of the panels and/or the support panels to which the crossmember is coupled;   uncoupling adjacent panels and/or support panels from each other;   uncoupling the plurality of panels and/or support panels from a base comprising a plurality of base members; and   uncoupling the plurality of base members.