Insulated cargo container and methods for manufacturing same using vacuum insulated panels and foam insulated liners

Abstract

An insulated cargo container is composed of an underframe, a floor, a first side wall, a second side wall, a roof, and at least one door being connected together to form an enclosure. At least one insulating liner is mounted to the interior surfaces and exterior surfaces of the enclosure in an amount sufficient to achieve a UA rating of less than about 300 for the cargo container.

1 . An insulated cargo container, comprising:
 an underframe having a top surface and a bottom surface;   a floor connected to said top surface of said underframe;   a first side wall and a second side wall each having an interior surface and an exterior surface and each of said side walls includes a door having an interior surface and an exterior surface;   a first end wall and a second end wall each having an interior surface and an exterior surface;   a roof having an interior surface and an exterior surface, wherein said underframe, said floor, said first and second side walls, said first and second end walls and said roof being connected to form an enclosure; and   one or more insulating liners, each comprising an insulating core disposed between an exterior skin and each of said interior surfaces or each of said exterior surfaces or both said interior surfaces and said exterior surfaces of said enclosure, in an amount sufficient to achieve a UA rating of less than about 300.   
   
   
       2 . The insulated cargo container of  claim 1 , wherein said insulating core comprises a foam material selected from the group consisting of cellular elastomeric foam, cellular glass foam, cellular polystyrene, cellular polyurethane, cellulosic fiber, aldehyde condensed phenols, polyethylene, polyisocyanurate, polyolefin, polyvinyl chloride, polyvinyl fluoride, polyvinyl, vinyl and combinations thereof. 
   
   
       3 . The insulated cargo container of  claim 1 , wherein said insulating core comprises a foam material selected from the group consisting of froth, pour, boardstock and bunstock. 
   
   
       4 . The insulated cargo container of  claim 1 , wherein said exterior skin comprises cold rolled steel. 
   
   
       5 . The insulated cargo container of  claim 1 , wherein said exterior skin comprises a resin material, optionally one or more reinforcing materials, and optionally one or more additives. 
   
   
       6 . The insulated cargo container of  claim 5 , wherein said resin material is a thermoset polymer or a thermoplastic polymer. 
   
   
       7 . The insulated cargo container of  claim 5 , wherein said resin material is selected from the group consisting of polyvinyl, polyethylene, polyvinyl chloride. 
   
   
       8 . The insulated cargo container of  claim 5 , wherein said resin material is selected from the group consisting of urethanes, polystyrenes, polyesters, epoxies and combinations thereof. 
   
   
       9 . The insulated cargo container of  claim 5 , wherein said reinforcing materials are selected from the group consisting of ceramic fibers, fibrous glass, glass cloth, glass fabric, glass fiber, calcium silicate, diatomaceous earth, expanded vermiculite, cellulose fibers, woven fabric, non-woven fabric, compacted powder, compacted fiber, mineral fiber, mineral wool, perlite, refractory materials, wood fibers, polyparaphenylene terephthalamide fibers and combinations thereof. 
   
   
       10 . The insulated cargo container of  claim 5 , wherein said one or more additives are selected from the group consisting of abrasion resistant materials, sweat resistant materials, chemical resistant materials, blackbody materials, fire resistant materials, fire retardant materials, intumescent materials, water vapor retardant materials, mold resistant materials, mildew resistant materials, solvent resistant materials, caustic resistant materials, freeze-thaw resistant materials, water resistant materials and combinations thereof. 
   
   
       11 . The insulated cargo container of  claim 1 , wherein said insulation liner is disposed flush to said interior surfaces and said exterior surfaces of said enclosure. 
   
   
       12 . The insulated cargo container of  claim 1 , further comprising a mechanical fastener designed to fasten said insulation material to each of said interior surfaces and said exterior surfaces of said enclosure. 
   
   
       13 . The insulated cargo container of  claim 1 , further comprising a rub rail disposed on said exterior skin where an edge of each of said insulating liners makes contact with an edge of each of said interior surfaces and an edge of each of said exterior surfaces of said enclosure. 
   
   
       14 . A method for insulating a boxcar to achieve a UA rating of less than 300, the boxcar comprising an underframe having a top surface and a bottom surface; a floor connected to said top surface of said underframe; a first side wall and a second side wall each having an interior surface and an exterior surface, and each of said side walls includes a door having an interior surface and an exterior surface; a first end wall and a second end wall each having an interior surface and an exterior surface; a roof having an interior surface and an exterior surface; wherein said underframe, said floor, said first and second side walls, said first and second end walls and said roof being connected to form an enclosure, comprising the steps of:
 attaching one or more insulating liners to the interior surfaces or the exterior surfaces or both the interior surfaces and the exterior surfaces of the enclosure, of the side walls, wherein said one or more insulating liners substantially cover the surfaces of the side walls;   attaching one or more insulating liners to the interior surfaces or the exterior surfaces or both the interior surfaces and the exterior surfaces of the enclosure, of the end walls, wherein said one or more insulating liners substantially cover the surfaces of the end walls;   attaching one or more insulating liners to the interior surface or the exterior surface or both the interior surface and the exterior surface of the enclosure, of the roof, wherein said one or more insulating liners substantially cover the surfaces of the roof;   attaching one or more insulating liners to the floor, wherein said one or more insulating liners substantially cover the floor;   installing at least one closure on the boxcar to cover a portion of an exterior surface of the boxcar not covered by said one or more insulating liners; and   applying an insulating material to the bottom surface of the underframe.   
   
   
       15 . The method of  claim 14 , wherein attaching each of said insulating liners comprises the steps of:
 affixing an insulating core flush to each surface and to each other;   disposing an exterior skin flush to said insulating core; and   disposing optionally a rub rail at a juncture where an edge of each exterior skin and an edge of each interior surface or an edge of each exterior surface or all of said edges of the interior surfaces and the exterior surfaces of the enclosure, make contact.   
   
   
       16 . The method of  claim 15 , wherein affixing comprises mechanically fastening or chemically bonding said insulating liners flush to each of the surfaces of the enclosure. 
   
   
       17 . The method of  claim 15 , wherein disposing said exterior skin comprises mechanically fastening or chemically bonding said exterior skin flush to said insulating liners and double bonding each of said exterior skins together where each make contact. 
   
   
       18 . The method of  claim 15 , wherein disposing optionally said rub rail comprises mechanically fastening said rub rail. 
   
   
       19 . The method of  claim 14 , wherein attaching each of said insulating liners comprises the steps of:
 affixing said insulating liner flush to each surface and to each other;   mechanically fastening said insulating liner to each surface; and   disposing optionally a rub rail at a juncture where an edge of each insulating liner and an edge of each interior surface or an edge of each exterior surface or all of said edges of the interior surfaces and the exterior surfaces of the enclosure, make contact.   
   
   
       20 . The method of  claim 14 , wherein attaching each of said insulating liners comprises the steps of:
 affixing said insulating liner flush to each surface and to each other;   chemically bonding said insulating liner to each surface; and   disposing optionally a rub rail at a juncture where an edge of each insulating liner and an edge of each interior surface or an edge of each exterior surface or all of said edges of the interior surfaces and the exterior surfaces of the enclosure, make contact.