Patent application title:

DOOR FLASHING SYSTEM FOR SHIPPING CONTAINERS

Publication number:

US20260109535A1

Publication date:
Application number:

18/920,902

Filed date:

2024-10-20

Smart Summary: A new system is designed to improve the doors of shipping containers. It includes a top part called the header that connects to the upper door and extends outward and downward. There is also a bottom part called the footer that connects to the lower door and extends outward and upward. Two side pieces connect the header and footer, creating a space where insulation can be added. The side pieces have flanges that help attach them to the header and footer securely. 🚀 TL;DR

Abstract:

A flashing system for a shipping container door, having: a header with a rearward portion connecting to an upper portion of the door, a horizontal portion extending outwardly from the door, and a forward portion extending downwardly; a footer with a rearward portion connecting to a lower portion of the door, a horizontal portion extending outwardly from the door, and a forward portion extending upwardly; and two opposed side members, each having a rearward portion engaging with a side of the door, a portion extending between the header and the footer, and a forward portion parallel to the door, the forward portions of the header and the footer connecting to the forward portions of the side members; the header, footer, and side members defining a space for insulation. Each of the side members includes flanges for connection to the horizontal portions of the header and the footer.

Inventors:

Assignee:

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Classification:

B65D90/008 »  CPC main

Component parts, details or accessories for large containers Doors for containers, e.g. ISO-containers

B65D88/121 »  CPC further

Large containers rigid specially adapted for transport ISO containers

B65D90/00 IPC

Component parts, details or accessories for large containers

B65D88/12 IPC

Large containers rigid specially adapted for transport

Description

FIELD OF THE INVENTION

The present invention relates generally to door flashing systems for shipping containers.

BACKGROUND OF THE INVENTION

Shipping containers are widely used for various applications, including storage, logistics, and as foundational structures for residential and commercial spaces. Modifications to these containers frequently necessitate the integration of insulation and finishing systems, particularly around access points such as doorways. Traditional modification techniques involve the use of welded steel frames, wood studs, or steel framing systems to support interior finishes on container doors; however, these methods introduce inherent challenges, such as dimensional inconsistencies that lead to misalignment, resulting in compromised door functionality and closure. Additionally, an alternative prior art approach involves the application of spray polyurethane foam directly onto the door's surface to enhance thermal insulation, and while this method provides insulation, it can result in operational deficiencies over time such as creaking or warping attributed to the foam's non-uniform application and thermal expansion, ultimately affecting the container's structural integrity and user experience.

In some existing prior art solutions, installation procedures may be inefficient, as such systems necessitated the manual alignment and assembly of multiple discrete components. The lack of integrated reference points for precise placement of these parts introduced significant variability, often leading to user error during installation. Each component required independent positioning and securing without predefined guides or datum references, increasing installation time and reducing dimensional accuracy. This fragmentation in the assembly process frequently resulted in misalignment, adversely impacting door operability and compromising the thermal integrity of the overall system.

SUMMARY OF THE INVENTION

According to a first broad aspect of the present invention, there is provided a flashing system for an inner surface of a door of a shipping container, the system comprising:

    • a header member comprising: a rearwardly disposed vertical portion configured for connection to an upper portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending downwardly relative to the horizontal portion of the header member;
    • a footer member comprising: a rearwardly disposed vertical portion configured for connection to a lower portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending upwardly relative to the horizontal portion of the footer member; and
    • two opposed side members, each side member comprising: a rearwardly disposed portion configured for engagement with a side portion of the door; a laterally disposed vertical portion configured to extend outwardly from the inner surface of the door between the header portion and the footer portion; and a forwardly disposed vertical portion extending inwardly and parallel to the inner surface of the door at an outer extent of the laterally disposed vertical portion of the side member, the forwardly disposed vertical portions of the header member and the footer member configured for connection to the forwardly disposed vertical portion of the side member;
    • wherein the horizontal portion and forwardly disposed vertical portion of the header member, the horizontal portion and forwardly disposed vertical portion of the footer member, and the laterally disposed vertical portions and forwardly disposed vertical portions of the side members together are configured to define a space for receipt of an insulating material therein; and
    • wherein each of the side members further comprises upper and lower horizontal flanges extending inwardly for connection to the horizontal portions of the header member and the footer member.

The space may be configured to receive both the insulating material and an inwardly-disposed interior surface finishing material.

In some exemplary systems, the rearwardly disposed vertical portions of the header member and the footer member comprise horizontal flanges configured to extend rearwardly to engage upper and lower surfaces of the door.

The rearwardly disposed vertical portions of each of the header member and the footer member and the upper and lower horizontal flanges of the side members are preferably configured to abut the inner surface of the door.

Each of the side member may comprise at least two side member parts connectable at the horizontal flanges of the side members.

In shipping containers where the door comprises a hollow tube frame, the header member, the footer member, and the side members are preferably connected to the door by mechanical fasteners extending into but not through the hollow tube frame.

Exemplary systems preferably further comprise pre-drilled holes in the header member, the footer member, and the side members to allow mechanical fastening thereof.

The header member, the footer member, and the side members may be composed of metal, plastic, composite, or a combination thereof. Further, the header member, the footer member, and the side members may be connected to the door by means of mechanical fastening, adhering, welding, or a combination thereof. The header member, the footer member, and the side members are preferably configured for assembly before mounting on the door.

According to a second broad aspect of the present invention, there is a provided a method for installing flashing on a door of a shipping container, the method comprising the steps of:

    • a. forming a header member comprising: a rearwardly disposed vertical portion configured for connection to an upper portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending downwardly relative to the horizontal portion of the header member;
    • b. forming a footer member comprising: a rearwardly disposed vertical portion configured for connection to a lower portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending upwardly relative to the horizontal portion of the footer member;
    • c. forming two opposed side members, each side member comprising: a rearwardly disposed portion configured for engagement with a side portion of the door; a laterally disposed vertical portion configured to extend outwardly from the inner surface of the door between the header portion and the footer portion; and a forwardly disposed vertical portion extending inwardly and parallel to the inner surface of the door at an outer extent of the laterally disposed vertical portion of the side member, the forwardly disposed vertical portions of the header member and the footer member configured for connection to the forwardly disposed vertical portion of the side member, wherein each of the side members further comprises upper and lower horizontal flanges extending inwardly for connection to the horizontal portions of the header member and the footer member;
    • d. connecting the side members and the upper and lower horizontal flanges of the side members to the header member and the footer member to form a flashing frame defining a space; and
    • e. positioning the flashing frame against the door, and securing the flashing frame thereto such that the rearwardly disposed vertical portions of each of the header member and the footer member and the upper and lower horizontal flanges of the side members abut the inner surface of the door.

In some exemplary embodiments, the method comprises the step of forming the two opposed side members including connecting at least two side member components to form each of the side members.

In some exemplary embodiments, the method further comprises a step, during or after step d, of introducing an interior finishing material into the space.

The rearwardly disposed vertical portions of the header member and the footer member may comprise horizontal flanges configured to extend rearwardly, with step e further comprising engaging the horizontal flanges with upper and lower surfaces of the door.

In shipping containers where the door comprises a hollow tube frame, step e preferably further comprises connecting the header member, the footer member, and the side members to the door by mechanical fasteners extending into but not through the hollow tube frame.

Some exemplary embodiments further comprise a step, during or after step d, of introducing an insulating material to the space.

In some embodiments of the present invention, the system encompasses a pre-assembled, modular door flashing assembly specifically designed to define the X, Y, and Z planes corresponding to the interior wall covering position, insulation thickness, and the parallel alignment to the container door frame, thereby helping to ensure accurate alignment and mitigating installer uncertainty. Some exemplary systems comprise two symmetrical, mirror-image side flashings per side of each container door, with each side flashing equipped with inward-bent structural flanges and reference apertures. These features are intended to help facilitate precise alignment and vertical interconnection of the side flashings, with the goal of a continuous, robust structural interface for each side of the door. The modular nature of exemplary systems helps enable simplified installation while maintaining the structural integrity and dimensional consistency of the door frame.

The side flashings are interfaced at the upper section by a header and at the lower section by a footer, utilizing a uniform flange design that helps ensure seamless integration and precise alignment during installation. The mirrored side flashings are designed to interlock with high precision through laser-cut alignment holes, which may be calibrated to correspond with matching holes on the header and footer. This configuration helps establish a rigid, continuous framing system across each door, enhancing structural integrity and minimizing tolerances during assembly.

In some exemplary embodiments, complete pre-assembly of the system may be completed on a planar surface prior to installation. The assembled flashing frame is then elevated and positioned as a unified structure onto the container door. The integrated flanges can engage with the interior door surface, providing a definitive contact point, or positive stop, to maintain consistent dimensional tolerance across all three critical planes—height, width, and depth. This helps ensure precise alignment and flush closure of the door, thereby preserving its structural integrity. The pre-assembly process notably reduces installation time by streamlining the procedure, enhances accuracy by reducing variances during on-site assembly, and obviates the requirement for specialized tools or advanced installer training. This approach may optimize the efficiency and reliability of the installation process.

Exemplary systems may comprise two principal components: a pair of mirrored side flashings and a pair of mirrored header/footer flashings, each designed for integration using standard mounting hardware. In certain embodiments, each component incorporates inward-facing flanges on the side flashing members, which fulfill several critical functions. These flanges facilitate the mechanical connection between adjacent flashings, ensuring structural continuity, while also serving as physical reference points for accurate alignment during installation.

The header and footer components are preferably precision-crafted, mirrored elements designed to interface seamlessly with the side flashing components, utilizing an identical inward-bent flange architecture. These components are positioned at the upper and lower extremities of each door side. Each structural frame assembly requires one header, one footer, and two side flashings per vertical side of the door, resulting in four side flashings in total. Both the header and footer components are preferably fabricated with laser-cut alignment reference points, to help ensure exact positioning during installation. When assembled, the header, footer, and side flashings coalesce to form a rigid, rectangular frame with desirable tolerances, conforming to the internal geometry of the shipping container door. This configuration can facilitate a robust connection and helps ensure optimal insulation and sealing integrity.

The individual components of the flashing system may be pre-fabricated and assembled at ground level to form a fully integrated frame. Once this assembly is complete, the entire unit is hoisted and positioned as a single unit, allowing for alignment with the container door. The pre-calibrated reference points and precision-located fastening interfaces help ensure that the unit is accurately positioned without the need for manual part-by-part alignment during installation. This method may significantly minimize installation time, mitigate complexity, and ensure consistent installation accuracy across all mounting points.

Pre-assembly and single-piece configuration can streamline the installation process by significantly reducing both setup time and labor intensity. The mirrored components, integrated with inward-bent flanges, can provide precise alignment across all critical planes, helping to mitigate or reduce installation errors. This system incorporates a defined channel or space to accommodate insulation, helping prevent the formation of thermal bridges that could compromise energy efficiency. Furthermore, the flashing system is designed to retain the original structural integrity and operational functionality of the container doors, ensuring the original opening and closing mechanisms remain unaffected.

In some exemplary embodiments, the inward-bent flanges are formed with precise reference holes, ensuring that the assembled frame achieves a positive stop against the surface of the door panel. Additionally, multiple laser-cut holes along the door flashing system may facilitate the attachment of other structural systems near the container door. This feature helps maintain uniform spacing and dimensional stability, ensuring consistent alignment across all three primary structural planes—lateral, longitudinal, and vertical. Furthermore, in certain embodiments, the door flashing system can be fastened, adhered, or welded to the structural hollow members of the container door frame. By seeking to define these planes with high precision, the assembly helps ensure that the door panel maintains a flush fitment upon closure, promoting an optimal seal and preventing misalignment or operational wear over time.

The integrated reference holes, combined with the symmetrical design of the mirrored parts, helps ensure precise alignment during assembly, reducing the potential for misalignment. Upon installation, the inward-bent flanges create a controlled and uniform channel, optimizing the spacing for insulation placement. Additionally, the interior flange provides a structurally reliable mounting surface for subsequent interior finishes, accommodating materials such as drywall, plywood, or other panel systems. This configuration not only enhances thermal efficiency but also facilitates ease of installation for post-insulation interior cladding.

The present invention may provide a high-precision, easily installable door flashing system specifically designed for shipping containers, with a focus on enhancing insulation and finishing while maintaining the original operational functionality of the container doors. The approach obviates the need for conventional framing techniques, which frequently result in misalignment or compromised door closure. Exemplary embodiments of the present invention may offer the following technical advantages:

    • a. The system may be formed for rapid installation, utilizing a pre-assembled, single-piece configuration that reduces installation time, complexity, and potential points of failure compared to traditional multi-component systems.
    • b. The system's mirrored parts can be precision-engineered with inward-bent flanges, ensuring exact alignment during installation, thereby mitigating variability and human error. This configuration helps ensure uniformity in placement and enhances structural stability.
    • c. The system may be designed to create a controlled gap between the door and the insulation material, allowing for integration of insulation while reducing the risk of thermal bridging. This helps ensure superior thermal performance, making the system desirable for temperature-sensitive environments.
    • d. By maintaining the original door mechanisms, the exemplary flashing system helps ensure that the doors retain their stock functionality, including smooth opening and closing without obstruction, even after insulation and finishing have been applied.
    • e. The system is adaptable for a variety of container types, including but not limited to, commercial and industrial containers where precise alignment and enhanced thermal insulation are critical. It is equally effective in residential container modifications, such as container homes, where it delivers both an aesthetically clean finish and reliable door operation. The system is also suitable for climate-controlled storage units, offering enhanced insulation properties without compromising door functionality or structural integrity.

Material selection can be optimized by incorporating advanced manufacturing processes such as extrusion or injection molding, utilizing lightweight plastics, composite materials or other materials to minimize the thermal bridging. This could not only reduce the overall weight of the system but also enhance ease of installation.

In some exemplary embodiments, laser-cut metal components can be employed that are folded to precise angles, helping ensure accurate hole alignment and flange positioning. The entire assembly is designed for ease of manufacturing using standard sheet metal fabrication techniques, making it cost-effective for both small-scale and mass production.

A detailed description of exemplary embodiments of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as being limited to these embodiments. The exemplary embodiments are directed to particular applications of the present invention, while it will be clear to those skilled in the art that the present invention has applicability beyond the exemplary embodiments set forth herein.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which illustrate exemplary embodiments of the present invention:

FIG. 1 is a front perspective view of an exemplary fully assembled door flashing system, showing the side flashings, header, and footer connected, with inward-bent flanges ensuring structural alignment.

FIG. 2 is an exploded view of the modular door flashing assembly of FIG. 1, including symmetrical side flashings, header, and footer, which interlock to form a rigid frame.

FIG. 3 is a front perspective view of the pre-assembled door flashing system positioned near a shipping container door, illustrating the installation method.

FIGS. 4A, 4B, 4C illustrates front elevation, top plan, and side elevation views of the fully assembled system, highlighting the alignment provided by reference holes and inward-bent flanges.

FIG. 4D illustrates a rear elevation view showing the continuous frame created by the connected side flashings, header, and footer, emphasizing thermal efficiency and alignment.

FIG. 5 is a side sectional view of the top portion of the flashing system installed on a door, showing the defined space for insulation and improved thermal performance.

FIG. 6 is a side sectional view of the bottom portion of the flashing system, illustrating the secure seal between the footer and the door threshold.

FIG. 7 is a side sectional view of the top portion of the flashing system with wall covering placement, ensuring thermal efficiency.

FIG. 8 is an enlarged top perspective view of laser-cut reference holes and connections between the side flashing and header, demonstrating structural integrity and weatherproofing.

FIG. 9 is a perspective view of the door in a closed position, showing how the flashing system preserves door functionality while enhancing thermal efficiency and weatherproofing.

FIG. 10A illustrates a detailed top perspective view of the connection between the header and side flashings, ensuring precise alignment at the top of the door.

FIG. 10B illustrates a detailed bottom perspective view of the connection between the footer and side flashings, preventing gaps and maintaining structural integrity at the bottom of the door.

FIG. 10C illustrates a detailed perspective view of the vertical connection between adjacent side flashings, illustrating precision and alignment along the vertical sides.

Exemplary embodiments will now be described with reference to the accompanying drawings.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Throughout the following description, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. The following description of examples of the invention is not intended to be exhaustive or to limit the invention to the precise form of any exemplary embodiment. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense. The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.

Turning now to the drawings, exemplary embodiments of the present invention are illustrated. FIG. 1 illustrates an exemplary embodiment of a system 10 in a perspective view, showing the fully assembled door flashing system 10. The side flashings 12 are shown interconnecting with the header 14 and footer 16. Both the header 14 and footer 16 are equipped with precision laser-cut reference holes 28 (shown in FIG. 2) that align with corresponding holes 26 in the side flashings, facilitating connections between all components. The inward-bent flanges 18 on the side flashings 12 provide structural alignment, ensuring the system defines the X, Y, and Z planes with precision. This configuration allows for a flush door closure after installation, eliminating installer guesswork and enabling more rapid assembly while maintaining dimensional tolerances for improved structural integrity and insulation performance.

FIG. 2 depicts an exploded view 20 of the modular door flashing assembly 10 of FIG. 1, comprising side flashings 12, a header 14, and a footer 16. The side flashings 12 are symmetrical, mirror-image components, each featuring inward-bent flanges 18 that establish structural connections and serve as attachment points for both insulation and interior finishes. The inward-bent flanges 18 allow for interlocking of the components, ensuring integration while maintaining structural integrity, dimensional stability, and accurate alignment along the X, Y, and Z axes. The laser-cut reference holes 26, 28 in the flashing components 12, 14, 16 allow for easy attachment to the door, facilitating a quick and efficient installation process. Additionally, this creates a controlled gap between the door panel and the flashing system, reducing the risk of thermal bridging and optimizing insulation efficiency.

FIG. 3 illustrates a perspective view 30 of the fully assembled door flashing system 10 positioned near the shipping container door 24, ready for installation. FIG. 3 aids in understanding the installation method, showing how the pre-assembled flashing system, consisting of the side flashings 12, header 14, and footer 16, is aligned with the container door 24 prior to mounting. The header 14 and footer 16 are similarly mirrored components positioned at the upper section 32 and lower section 36 of the door 24 frame, respectively. When assembled, these components form a rigid, rectangular frame that conforms to the internal perimeter of the shipping container door 24. The inward-bent flanges 18 are used to ensure alignment with the door 24 frame during installation, defining the X, Y, and Z planes. The assembled system 10 can be lifted and positioned as a single unit, helping to ensure a seamless fit without the need for part-by-part alignment during installation or adjustments on-site.

FIGS. 4A, 4B, and 4C illustrate a front elevation view 40, a top plan view 44, and a right side elevation view 46 of the fully assembled door flashing system 10. The laser-cut reference holes 28 in the header 14 and the footer 16 facilitate precise alignment and fitment with the side flashings 12 ensuring accurate positioning of all components. The inward-bent flanges 18 provide structural continuity by interlocking the components, while also creating a defined channel for insulation placement between the door panel and interior finish/wall covering. This configuration helps prevent thermal bridging, optimizing thermal efficiency. Additionally, the assembly may enhance weatherproofing by forming a continuous barrier that protects against drafts, moisture ingress, and other environmental elements, ensuring the door's operational integrity and long-term performance.

FIG. 4D presents a rear elevation view 48 of the fully assembled door flashing system 10, highlighting the continuous frame for surrounding the shipping container door. The mirrored side flashings 12 are connected to the header 14 and the footer 16, through laser-cut reference holes 26, 28 forming a rigid, structurally sound frame. This frame is designed to support thermal efficiency by minimizing heat transfer and preventing thermal bridging. The system 10 maintains structural integrity across all three planes (X, Y, Z), helping ensure that the container doors 24 close flush and remain properly aligned, reducing any risk of misalignment that could affect functionality or sealing performance.

FIG. 5 provides an upper sectional view 50 of the header 14 connected to the hollow structure 38 of the container door 24 (the door 24 frame being composed of hollow tubing), illustrating a defined gap or space 22 for insulation (not shown) or other interior wall coverings. Placement of insulating material and interior finish/wall covering in the space 22 may occur during or after formation of the flashing frame. The inward-bent flanges 18 contribute to structural stability by maintaining dimensional consistency and providing a controlled channel 22 for insulation placement. The flanges 18 create a positive stop where they contact the door panel 24, ensuring alignment along the X, Y, and Z planes. This may enhance thermal efficiency by preventing the formation of thermal bridges, helping ensure optimal insulation performance while preserving the door's original operational functionality. The top edge 82 of the header 14 is also rearwardly bent to form a feature that mates with an upper surface of the door 24.

FIG. 6 provides a lower sectional view 52 of the flashing system 10 at the bottom threshold 42 of the container door 24, illustrating the interaction between the footer 16 and the door threshold 42. The view highlights how the footer 16 aligns with the door's threshold 42 and side flashing 12, creating a seal to reduce the risk of moisture and drafts entering the system 10. The inward-bent flange 18 design helps ensure dimensional consistency throughout the assembly, helping prevent misalignment or gaps that could compromise the space 22 for insulation or sealing integrity of the door 24. The bottom edge 84 of the footer 16 is also rearwardly bent to form a feature that mates with a lower surface of the door 24.

FIG. 7 provides an upper sectional view 54 of the flashing system 10 with a wall covering 34 and illustrates how the system 10 creates a controlled-dimension gap 22 adjacent the structural hollow member 38 of the container door 24 and facilitates the desired placement of interior finish or wall coverings 34. The inward-bent flanges 18 serve as structural reference points between the header 14 and the side flashings 12, ensuring proper alignment of the components. This configuration may enhance thermal efficiency by providing a consistent and insulated barrier, and it can accommodate various interior finishes, such as drywall or plywood and other suitable coverings, without the need for additional support structures.

FIG. 8 provides a top perspective view 56 showing the laser-cut reference holes 26, 28 and the connection points between the side flashings 12 and the header 14. The header 14 is also provided with holes 80 for use in connecting the header 14 to the top hollow structural frame member 38 of the door 24. The inward-bent flange 18 is positioned under the horizontal portion of the header 14 such that the reference holes 26 in the flange 18 align with the reference holes 28 in the header 14, allowing the side flashing 12 and the header 14 to be secured together, forming a rigid frame without the need for external alignment tools. The header 14 comprises a downward-bent section aligning with the side flashing 12, with alignment of the reference holes 26, 28 allowing securing of the components, to create a continuous, enclosed corner, reducing any potential gaps. This configuration not only reinforces structural integrity but also significantly enhances the weatherproofing of the system by reducing the risk of air and moisture infiltration.

FIG. 9 provides a perspective view 60 of the shipping container door 24 in its closed position, demonstrating how the installed flashing system 10 maintains the original functionality of the door 24 without interference. The alignment of the system 10 helps ensure normal operation of the door 24, allowing the door 24 to open and close without obstruction while retaining its original sealing capabilities. The integrated inward-bent flanges 18 effectively connect the side flashings 12, the header 14, and the footer 16 to help prevent thermal bridging and ensure consistent alignment, thereby protecting against drafts and moisture intrusion.

FIG. 9 also shows the interior view of the flashing system 10 after installation. The modular components connect to the door frame 24 without affecting the operational mechanisms of the door 24 or interacting with the roof 58, side walls 62, 64, and floor 66 of the container. The laser-cut holes 26, 28 along the door flashing system 10 also function as mounting points for insulation, interior finishes and other structural components, helping ensure a flush, gap-free installation. The system 10 helps preserve the structural integrity of the door while enhancing its thermal efficiency and improving weatherproofing by creating a continuous barrier against environmental elements.

FIG. 10A provides a detailed top perspective view 68 showing the connection between the header 14 and the side flashing 12. The laser-cut reference holes 28, along with the inward-bent flange 18, helps ensure a secure and precise fit, maintaining alignment across the top of the door 24. This connection method is consistent across all junctions between the header 14 and the side flashings 12 throughout the entire door flashing system 40, helping ensure structural integrity and uniform alignment across the assembly. Further, holes 80 are provided in the header 14 to enable connection to the top hollow member 38 of the door 24, and unlike the embodiment of FIG. 8, the embodiment of FIG. 10A further comprises holes 80 in the side members 12 for connecting the side members 12 to the side hollow frame members 38 of the door 24.

FIG. 10B provides a detailed bottom perspective view 70 showing the connection between the footer 16 and the side flashing 12, illustrating how the footer 16 engages with the side flashings 12 and inward-bent flanges 18 through laser-cut reference holes 28. This alignment helps ensure a gap-free connection to maintain the structural integrity of the door frame and provide enhanced weather resistance. The connection method is uniform across all junctions between the footer 16 and side flashings 12 throughout the entire door flashing system 40, helping ensure consistent structural integrity and alignment across the entire system. Further, holes 80 are provided in the footer 16 to enable connection to the bottom hollow member 38 of the door 24, and unlike the embodiment of FIG. 8, the embodiment of FIG. 10B further comprises holes 80 in the side members 12 for connecting the side members 12 to the side hollow frame members 38 of the door 24.

FIG. 10C illustrates the vertical connection 72 between vertically adjacent side flashings 12 where two side flashing components are being connected to achieve the full vertical extent, demonstrating how the mirrored components connect using the inward-bent flanges 18. This connection method is uniform between the two side flashings 12 on all vertical sides of the door flashing system 40. As shown, each system 40 is equipped with two side flashings 12 for each vertical edge. The inward-bent flanges 18, in combination with the laser-cut reference holes and other holes along the door flashing system 40, helps ensure a continuous and aligned frame along the vertical edges of the container door 24. This configuration reinforces the structural rigidity of the assembly and helps reduce the risk of misalignment during installation, ensuring proper fitment and maintaining the operational integrity of the door.

The foregoing is considered as illustrative only of the principles of the present invention. The scope of the claims should not be limited by the exemplary embodiments set forth in the foregoing, but should be given the broadest interpretation consistent with the specification as a whole.

Claims

1. A flashing system for an inner surface of a door of a shipping container, the system comprising:

a header member comprising:

a rearwardly disposed vertical portion configured for connection to an upper portion of the door;

a horizontal portion configured for extending outwardly from the inner surface of the door; and

a forwardly disposed vertical portion extending downwardly relative to the horizontal portion of the header member;

a footer member comprising:

a rearwardly disposed vertical portion configured for connection to a lower portion of the door;

a horizontal portion configured for extending outwardly from the inner surface of the door; and

a forwardly disposed vertical portion extending upwardly relative to the horizontal portion of the footer member; and

two opposed side members, each side member comprising:

a rearwardly disposed portion configured for engagement with a side portion of the door;

a laterally disposed vertical portion configured to extend outwardly from the inner surface of the door between the header portion and the footer portion; and

a forwardly disposed vertical portion extending inwardly and parallel to the inner surface of the door at an outer extent of the laterally disposed vertical portion of the side member, the forwardly disposed vertical portions of the header member and the footer member configured for connection to the forwardly disposed vertical portion of the side member;

wherein the horizontal portion and forwardly disposed vertical portion of the header member, the horizontal portion and forwardly disposed vertical portion of the footer member, and the laterally disposed vertical portions and forwardly disposed vertical portions of the side members together are configured to define a space for receipt of an insulating material therein; and

wherein each of the side members further comprises upper and lower horizontal flanges extending inwardly for connection to the horizontal portions of the header member and the footer member.

2. The system of claim 1, wherein the rearwardly disposed vertical portions of the header member and the footer member comprise horizontal flanges configured to extend rearwardly to engage upper and lower surfaces of the door.

3. The system of claim 1, wherein the rearwardly disposed vertical portions of each of the header member and the footer member, and the upper and lower horizontal flanges of the side members are configured to abut the inner surface of the door.

4. The system of claim 1, wherein each of the side member comprises at least two side member parts with the horizontal flanges and connectable at the horizontal flanges.

5. The system of claim 1, wherein the door comprises a hollow tube frame, the header member, the footer member, and the side members connected to the door by mechanical fasteners extending into but not through the hollow tube frame.

6. The system of claim 1, wherein the space is configured to receive the insulating material and an inwardly-disposed interior surface finishing material.

7. The system of claim 1, further comprising pre-drilled holes in the header member, the footer member, and the side members to allow mechanical fastening thereof.

8. The system of claim 1, wherein the header member, the footer member, and the side members are composed of metal, plastic, composite, or a combination thereof.

9. The system of claim 1, wherein the header member, the footer member, and the side members are connected to the door by means of mechanical fastening, adhering, welding, or a combination thereof.

10. The system of claim 1, wherein the header member, the footer member, and the side members are configured for assembly before mounting on the door.

11. A method for installing flashing on a door of a shipping container, the method comprising the steps of:

a. forming a header member comprising: a rearwardly disposed vertical portion configured for connection to an upper portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending downwardly relative to the horizontal portion of the header member;

b. forming a footer member comprising: a rearwardly disposed vertical portion configured for connection to a lower portion of the door; a horizontal portion configured for extending outwardly from the inner surface of the door; and a forwardly disposed vertical portion extending upwardly relative to the horizontal portion of the footer member;

c. forming two opposed side members, each side member comprising: a rearwardly disposed portion configured for engagement with a side portion of the door; a laterally disposed vertical portion configured to extend outwardly from the inner surface of the door between the header portion and the footer portion; and a forwardly disposed vertical portion extending inwardly and parallel to the inner surface of the door at an outer extent of the laterally disposed vertical portion of the side member, the forwardly disposed vertical portions of the header member and the footer member configured for connection to the forwardly disposed vertical portion of the side member, wherein each of the side members further comprises upper and lower horizontal flanges extending inwardly for connection to the horizontal portions of the header member and the footer member;

d. connecting the side members and the upper and lower horizontal flanges of the side members to the header member and the footer member to form a flashing frame defining a space; and

e. positioning the flashing frame against the door, and securing the flashing frame thereto such that the rearwardly disposed vertical portions of each of the header member and the footer member and the upper and lower horizontal flanges of the side members abut the inner surface of the door.

12. The method of claim 11, wherein the step of forming the two opposed side members comprises connecting at least two side member components to form each of the side members.

13. The method of claim 11, further comprising a step, during or after step d, of introducing an interior finishing material into the space.

14. The method of claim 11, wherein the rearwardly disposed vertical portions of the header member and the footer member comprise horizontal flanges configured to extend rearwardly, step e further comprising engaging the horizontal flanges with upper and lower surfaces of the door.

15. The method of claim 11, wherein the door comprises a hollow tube frame, step e further comprising connecting the header member, the footer member, and the side members to the door by mechanical fasteners extending into but not through the hollow tube frame.

16. The method of claim 11, further comprising a step, during or after step d, of introducing an insulating material to the space.

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