Patent Application
20240254789
The present disclosure pertains to a modular shelter structure and method for constructing a modular shelter. More specifically, the disclosure provides a lightweight modular substantially rigid wall system for use in the areas of construction of temporary shelters, storage units, property demarcation, emergency facilities, agricultural facilities, and similar facilities for the military, humanitarian purposes, industrial, recreation, and municipal purposes.
Existing shelter solutions for utilitarian purposes, including tent-type structures, may be configured as short-term solutions, for example, which do not provide the durability, adaptability, security and protection required for the utilitarian purpose. Durable, longer-term shelters can be cost prohibitive and/or require materials, tools, and/or skills which are not available at or readily transportable to the geographic area where the shelter solution is needed. Further, durable, longer-term shelters may be constructed such that they cannot be disassembled for reuse and/or relocation, for example, from one geographic area to another.
Standard methods for the sheltering and storage of people and goods are typically contained within two primary groupings: (1) Soft Wall Structures (tents and the like), and (2) Rigid Wall Structures (shipping containers, framed walls, prefabricated structures, and the like). Each of these solutions solves a problem but introduces a multitude of other problems during their use. Tents and soft sided tarp and canvas structures deteriorate in the elements, provide no, or limited, structural capacity, have essentially no thermal efficiency, are typically ground based (direct contact with the ground), and must be replaced frequently to remain even the least bit effective for providing coverage to people, goods, and/or supplies.
Rigid structures may solve the problems of thermal efficiency and structural capacity, but are currently heavy to move and assemble, are expensive and more complex than a tent to assemble. Additionally, rigid structures are fixed use—i.e., once in place they will stay in place—typically require equipment and power to assemble and are not conducive to rapid deployment in areas without ease of accessibility, power, or a skilled workforce capable of lifting, maneuvering, and assembling these heavy rigid structures.
A lightweight modular shelter, and method for assembling a modular shelter, are provided. The shelter includes a first panel and a first panel connector, which has a panel edge channel operatively connected to a side of the first panel, and a connector plug and a connector socket. The shelter includes second panel and a second panel connector, which has a panel edge channel operatively connected to a side of the second panel, and a connector plug and a connector socket. The connector plug of the first panel connector is inserted into the connector socket of the second panel connector, such that the first panel and the second panel are operatively connected. The lightweight modular shelter may also include a bottom track. The first panel, the second panel, the first panel connector, and the second panel connector are mated to the bottom track.
The method of assembling the shelter includes laying a plurality of bottom tracks on a substantially flat surface: connecting a plurality of wall panel connectors to a plurality of wall panels via panel edge channels in the wall panel connectors; and connecting a plurality of corner connectors to the bottom tracks. The wall panel connectors and the plurality of wall panels are connected to the bottom tracks: the adjacent wall panel connectors are connected by inserting a connector plug of one wall panel connector into a connector socket of another wall panel connector; and the wall panel connectors are connected to one of the corner connectors by inserting the connector plug of one wall panel connector into a connector socket of the corner connector and by inserting a connector plug of the corner connector into the connector socket another wall panel connector. Therefore, the wall panels, the wall panel connectors, the corner connectors, and the bottom tracks form a freestanding structure having at least four wall assemblies.
The rigid wall modular system disclosed herein can be referred to as a Rapid Wall Building System (RWBS), using RWBS components and methods for constructing lightweight modular shelters from reusable standardized components assembled together such that the shelter can be quickly erected and when required, rapidly disassembled for relocation and/or redeployment. The components are lightweight and sized such that they are readily transportable. No special tools or skills are required to assemble the shelter, such that the shelter can be constructed, for example, by the persons deploying and/or requiring use of the shelter, with minimal or no training of the persons.
The Rapid Wall Building System and methods described herein can be used for constructing shelters for a broad range of utilitarian purposes, including military deployment and use, where the term shelter, as used herein, is intended to be interpreted broadly to include structures which are configured to house, store, secure and/or shelter living beings and/or non-living objects including, for example, persons, animals, equipment, vehicles and transportation equipment, medical equipment and supplies, communication equipment, artillery and ammunition, humanitarian supplies including food and agricultural supplies, etc.
As illustrated by the figures and drawings, the shelter components can be assembled into a plurality of different shelter configurations. One or more shelters have an initial configuration can be easily disassembled and the disassembled components can be recombined and reassembled into one or more shelters of the same or a different configuration.
Advantages and benefits of the RWBS system and method of constructing a rigid wall structure are illustrated by the figures and description. The advantages and benefits include, by way of non-limiting example: fewer and standardized components with easy, ergonomically favorable and standardized connections; easy integration of doors, windows, screens, etc., into panels and structure; significant time savings during assembly and disassembly, due to retractable and removable fasteners and limited use of tools; requires less manpower per structure assembly compared with conventional or permanent type structures; and no measuring, cutting, power, or heavy tools required for assembly.
Additional advantages and benefits include, by way of non-limiting example: lower weight materials with high durability and sustainability; corrosion resistant and water resistant materials; ability to be redeployed, adapted, and reconfigured for dynamic changing in-field requirements; optimized hybrid cost solution between a tent and a traditional rigid structure; and greater versability for use due to modular lightweight, reconfigurable, standardized, componentry suitable for multiple and changing environments.
The above features and advantages, and other features and advantages, of the present teachings are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teachings, as defined in the appended claims, when taken in connection with the accompanying drawings.
A modular utilitarian shelter 100, which may also be referred to as modular shelter 100 or shelter 100, produced with a Rapid Wall Building System (RWBS) including a wall assembly 200 and roof assembly 300 is provided herein. Additionally, a method 500 for assembly the modular utilitarian shelter 100 is provided herein, as described in specification and included schematic representations, and as illustrated by the attached figures. The RWBS components may be used to form a lightweight modular shelter 100.
In the drawings, like reference numbers represent like or similar components throughout the several figures, wherever possible, and the elements shown in the figures are not necessarily to scale or proportion. Accordingly, the particular dimensions and applications provided in the drawings presented herein are not to be considered limiting. Reference numbers may not be presented in order.
When used, the term “substantially” refers to relationships that are ideally perfect or complete, but where manufacturing realties prevent absolute perfection. Therefore, substantially denotes typical variance from perfection. For example, if height A is substantially equal to height B, it may be preferred that the two heights are 100.0% equivalent, but manufacturing realities likely result in the distances varying from such perfection. Skilled artisans will recognize the amount of acceptable variance. For example, and without limitation, coverages, areas, or distances may generally be within 10% of perfection for substantial equivalence. Similarly, relative alignments, such as parallel or perpendicular, may generally be considered to be within 5%.
As used in this specification, the term “or” includes any one, and all, combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items.
The RWBS and modular shelter 100 constructed therefrom is advantaged by comprising a minimal number of standardized components which are attachable to each other with either manual force only, or use of a mallet, hammer, or similar pounding tool capable of providing a pounding or hammering force. As such, the modular shelter 100 can be assembled at any location by persons having minimal and/or no construction experience or skill, with minimal and/or no training and without the need for electrical power or tools other than the pounding tool. Notably, because the modular shelter 100 can be assembled without the use of power tools, the modular shelter 100 can be assembled in locations where electrical power, generators, batteries, etc., are not available.
The various shelter components are lightweight for portability and are connected to each other by detachable means, including, without limitation, a plurality of retractable connectors 64 or ergonomically advantaged T-bolt fasteners, to facilitate both quick assembly and disassembly. Therefore, the modular shelter 100 is capable of reuse of the components in different combinations and configurations, and rapid disassembly and relocation. The modular shelter 100 may be moved or altered, for example, in response to changes in the installed environment, including climatic changes or changes in response to military and/or government actions, food and water accessibility, or other humanitarian needs or conditions.
The non-limiting example method 500 of assembling—such as by constructing or erecting—the modular shelter 100 is illustrated by
The RWBS modular shelter 100 is formed from a number of standardized components, including, without limitation: a plurality of wall panels 10, a plurality of roof panels 12, and a plurality of gable panels 14. Furthermore, a plurality of panel connectors 20 and a plurality of corner connectors 60 may be used to tie or connect each of the different panels together.
Note that the wall panels 10 and the roof panels 12, in particular, may be very similar, such that each is usable for the other purpose and/or may be cut into gable panels 14. Furthermore, the panel connectors 20 may be used as panel connectors 20, roof panel connectors 20, or gable panel connectors 20.
A plurality of tracks, including a wall panel bottom track 50 (or simply bottom track 50), an eave track 70, and a gable track 80 may be used to assemble a plurality of differently shaped shelters 100, as required by a specified application and/or anticipated use. Other configurations of roof assemblies 300 may be used with the wall assembly 200, including, for example, conventional and/or known roofing structures, tarps, including roof coverings configured from materials, including natural materials accessible at and/or harvested from the installation location. It is further understood that the shelter 100 and/or the components comprising the shelter 100 can be adapted for installation of electrical, plumbing, lighting, heating, ventilation, air conditioning, solar power, and communications systems, as required by the specified application and/or anticipated use.
The shelter 100 as described herein is advantaged by its flexibility as a temporary shelter, e.g., by the ability to assemble the shelter 100 in a minimal amount of time, including less than one day. Furthermore, as needed, the shelter 100 may be disassembled in a minimal amount of time, including less than one day, for relocation and reassembly, and/or for reassembly into a differently configured shelter 100. Relocation and reassembly may occur via reconfiguration of the component parts and/or by combination or trading of the disassembled component parts with additional component parts.
The example of a temporary shelter is non-limiting, as the durability of the shelter 100, and its individual components, allows for installation of the shelter 100 as a semi-permanent and/or permanent structure, which can include installing the shelter 100 to a foundation provided to make the shelter 100 more permanent. Additionally, the shelter 100 may be raised off of the ground, such as in areas that are flood prone. Although not illustrated, the modular shelter 100 may include floor panels that are attached to the bottom tracks 50 or that are laid on the ground. Examples of structures that can be replaced by various configurations of the shelter 100 may include, without limitation: L-shaped, T-shape, U-shaped, and multi-level structures. Note that the corner connectors 60 may be turned around relative to their position
The Rapid Wall Building System (RWBS) described herein includes standardized components that may be assembled in various configurations to construct the modular shelter 100. As shown in the drawings and described in further detail herein, the RWBS standardized components, which may be combined in various quantities of the various components to construct various shelters 100, including at least one wall panel 10 and at least one panel connector 20.
The retractable connectors 64 may be used to connect the other elements or components together. The retractable connectors 64 include retractable buttons 66 that are spring loaded such that they are selectively extendable from the retractable connectors 64. For example, the retractable connectors 64 may be used to connect the bottom tracks 50 to the panel connectors 20 or to the corner connectors 60.
All, or some, of the components referred to herein may be collectively referred to as RWBS components, and each of which may be referred to herein as an RWBS component. As shown in the example figures, the different panel members can be provided in different shapes, heights, lengths, and widths to form the plurality of wall panel 10 members, roof panel members 12, and gable panel 14 members, that are used to construct various configurations of the modular shelter 100.
The description may move between the method 500 and the individual components and figures demonstrating the components. Note that additional, or fewer, steps may be included with the method 500 shown in the figures. The RWBS shelter 100 created with the method 500 and the RWBS components described and illustrated herein may have a life span of greater than twenty years.
Step 510: Prepare Foundation. In the example method 500 for constructing the modular shelter 100 using the RWBS components illustrated in
In a non-limiting example, the shelter 100 may be attached to the foundation, for example, by attachment of the bottom tracks 50 to the foundation by fasteners, adhesives, cement and/or by other attachment members configured for that purpose. The examples of foundations given herein are non-limiting, and it would be understood, for example, that the shelter 100 can be constructed on any surface suitable for supporting the wall panel bottom tracks in the configuration required, for example, a square or rectangular arrangement, to receive the wall assemblies 200 and corner connectors 60, and to support the shelter 100 built thereon. In a non-limiting example, the shelter 100 can be constructed without a foundation, by placing the bottom tracks 50 directly on the ground, on a gravel, asphalt, or concrete paved surface such as a road or runway, or on another structure, such as the roof of a building, the deck of a ship, etc. Skilled artisans will recognize numerous options for foundations upon which modular shelters 100 may be placed.
Step 512: Position Bottom Tracks. At step 512, the wall panel bottom tracks 50 are positioned in the configuration of the shelter 100 to be constructed, which in the example shown in
Referring to
Furthermore, and without limitation, the bottom tracks 50 may be formed of a polymer-based material, polymer composite, or carbon fiber reinforced material, such as a nylon-based material, PVC-based material, or high strength polymer, for example, by extrusion or molding. As shown in
The bottom track 50 includes a plurality of receiver apertures or apertures 58 positioned to align with the retractable buttons 66 of the retractable connectors 64 of the panel connectors 20. Therefore, when a panel assembly is inserted into the bottom track 50, the retractable connector 64 engages the receiver aperture 58 to retain the wall panel assembly to the bottom track 50. The bottom track 50 may include a step—which is a lowered portion of the bottom track 50, and is best shown in
In one example, the bottom track 50 can include one or more weep holes 59 formed through one or more walls of the bottom track 50 and distributed along the length of the bottom track 50, which can also be referred to herein as drain holes, to provide for drainage of fluid out of the track channel 54 of bottom track 50, including, for example, drainage of rain water or other run-off from the roof assembly 300 or wall panels 10 which may collect in the track channel 54. The bottom track 50 may include, particularly within the track channel 54, one or more seals, such as bulb seals, along the length of the bottom track 50. The seals may limit incursion of water or other liquids into the bottom track 50, such that less water is drained through the weep holes 59.
Step 514: Connect Corner Connectors. At step 514 of the method 500, the corner connector 60 is inserted into and connected to the bottom tracks 50 at one or more of the respective corners of the shelter 100. Similar to the panel connectors 20, the corner connectors 60) include retractable connectors 64 located in connector portions 26 extending orthogonally from a corner channel 62 of the corner connector 60, as illustrated in
As illustrated in
Alternatively, and without limitation, the corner connector 60 can be formed of a polymer-based material, polymer composite, or carbon fiber reinforced material, such as a nylon-based material, PVC-based material, or high strength polymer, for example, by extrusion or molding. One preferred material may be glass filled nylon, which has high strength and stiffness, and excellent melt strength, such that it is well suited for extrusion and blow molding. This material may be molded but is also beneficial when extruded. The glass filled nylon corner connectors 60 may be lighter in weight than metal-based materials and may also have reduced costs.
As shown in
For example, and without limitation, the corner connector 60 may have connector portions 26 extending from the corner channel 62 to define a 108-degree angle therebetween, which could be used to assemble a pentagonal shaped wall assemblies 200; or the corner connector may have connector portions 26 defining a 120-degree angle therebetween could be used to assemble a hexagon shaped wall assemblies 200, and the like. Further, combinations of corner connectors 60 having different included angles could be used to connect bottom tracks 50 to assemble a wall assembly 200 having an irregular polygon shaped perimeter.
Advantageously, the RWBS including standard components including the panel connectors 20 and the corner connectors 60, as described herein, are configured to assemble wall assemblies 200 having various perimeter shapes and perimeter sizes, and can be disassembled and recombined to form wall assemblies 200 of other perimeter shapes and perimeter sizes. Such that the wall assemblies 200 provide flexibility and reusability of the RWBS components as needs change, relocation or reconfiguration is desired, or combinations thereof, for the shelters 100.
Referring again to the corner connector 60 shown in
As shown in the figures, each of the panel connectors 20 shown in
In the installed position, the connector slot 28 can be located on an outwardly facing surface (exterior to the shelter 100 as installed) of the panel connector 20 or the corner connector 60 for attachment of various exterior components to the shelter 100. The types and configurations of exterior components that may be connected to the exterior of the wall assembly 200, gable, the roof assembly 300, or combinations thereof, of the shelter 100 using the connector slots 28 is unlimited. The exterior components, include, without limitation: brackets, hangers, shelving, storage containers, awnings, electrical and/or plumbing conduit, lighting fixtures, communication equipment, other utility components, water collection reservoirs, solar panels, perimeter fencing, wall extensions, and other exterior components recognizable to skilled artisans.
In the installed position, the connector slot 28 can be located on an inwardly facing surface (interior to the shelter 100 as installed) of the panel connectors 20 or the corner connectors 60, for attachment of interior components to the shelter 100. The types and configurations of interior components that may be connected to the interior of the wall assembly 200, gable, and/or the roof assembly 300 of the shelter 100 using the connector slots 28 included in the connectors is unlimited. The interior components, include, without limitation: brackets, hangers, shelving, storage containers, electrical and/or plumbing conduit, equipment, lighting fixtures, communication equipment, other utility components, work tables or desks, plumbing fixtures, beds, cots, bunks, storage shelving, containers, interior walls and/or wall extensions, and other interior components recognizable to skilled artisans.
As shown in the figures, the connector slots 28 extend the full length of the corner connector 60 and the full length of the panel connector 20, such that attachment can be made to the connector slot 28 at any position along the length of the panel connectors 20 or corner connectors 60. This allows for flexibility of use, easy repositioning of components, or both. The connectors slots 28 can be formed during extrusion and/or molding of the panel connectors 20 or corner connectors 60, such that the fabrication cost of the connector slots 28 is minimal.
The example is non-limiting, and other means for forming the connector slots, including machining, stamping, etc., could be used. In the non-limiting example shown, the connector slot 28 has a generally T-shaped cross-section such that a T-bolt end of a fastener can be inserted at any position along the length of the slot and rotated to retain the T-bolt end within the connector slot 28. The example is non-limiting, such that it would be anticipated within the scope of this disclosure that other slot shapes and/or configurations could be formed in the panel connectors 20 or corner connectors 60 to provide attachment means for attachment of interior and exterior components and/or wall extensions to the panel connectors 20) or corner connectors 60.
Referring again to the corner connector 60 shown in
As shown in
As shown in
Non-limiting example configurations of the plug seal include bulb seals, D-shaped seals, O-shaped seals, etc. In one example, the panel connectors 20 or corner connectors 60 are provided with the plug seal pre-applied to the socket channel. In another example, the panel connectors 20 or corner connectors 60 and plug seals are provided as separate components and the plug seal is attached to the socket channel during assembly of the shelter 100. In a non-limiting example, the plug seal can be adhered to the socket channel by an adhesive or other fastening means, and/or the plug seal can include an adhesive strip for adhering the plug seal to the socket channel.
Referring again to the corner connector 60 shown in
As shown in the figures, the connector portion 26 has the retractable connector 64, including the retractable button 66, inserted to each end of the panel connectors 20. As such, in an installed position the connector portions 26 of the panel connectors 20, and also the corner connectors 60, are attached at a first end (lower end, as installed) to the bottom tracks 50 by engaging the retractable buttons 66 of the retractable connectors 64 in the receiver apertures 58 of the bottom tracks 50, to form the wall assembly 200 of the shelter 100 shown in
As illustrated in
Referring to
The extrusion example is non-limiting, and other methods of forming, including bending and stamping, can be used to form the panel connectors 20. The metal-based panel connectors 20, in addition to the other components, can be surface treated for corrosion protection, for example, by anodizing, e-coating, painting, galvanizing, plating, or other suitable means for inhibiting and/or prevention corrosion of environment attack on the panel connector 20. In a non-limiting example, the panel connector 20 can be formed of a polymer-based material, polymer composite, or carbon fiber reinforced material, such as a nylon-based material, PVC-based material, or high strength polymer, for example, by extrusion or molding.
One preferred material may be glass filled nylon, which has high strength and stiffness, and excellent melt strength, such that it is well suited for extrusion and blow molding. This material may be molded but is also beneficial when extruded. The glass filled nylon panel connectors 20 may be lighter in weight than metal-based materials and may also have reduced costs. In one example, the wall, roof, and gable panel connectors 20 are formed of the same material, which in a preferred example is extruded and/or molded in a continuous length which can then be cut to the lengths required for each of the respective wall, roof and gable panel connectors 20.
Alternatively, the wall panel connectors 20 may be made of a different material than the roof panel connectors 20 or gable panel connectors 20, according to the use requirements of the shelter 100 including these components. For example, the panel connectors 20 may be made of a metal-based material according to the rigidity or column strength requirements of the wall assembly 200, and the roof panel connectors 20 may be made of a lighter non-metallic or polymer-based material where sufficient for supporting the roof loading requirements, to provide a lighter weight roof panel 12 for ease of lifting and placement during assembly of the roof assembly 300. The examples are non-limiting and other combinations made be used.
As shown in
Further, the wall panel connectors 20, roof panel connectors 20, and gable panel connectors 20, in the preferred example shown, have the same cross-sectional shape and size, such that all of the panel connectors 20 can be cut to length from a standardized extrusion or molded blank, reducing manufacturing and tooling costs. Standardization of the cross-sectional shape of the extrusion or molded blank can also be beneficial, for example, where in-field repairs are required and/or to simplify spare parts supply and management. For example, the longest of the panel connectors 20 can be provided as a standard repair part, which can be shortened, if needed, to the length required for the panel connector 20 being replaced in the field, minimizing spare parts inventory and complexity. The panel connectors 20 may also be cut at angles, such as when used as gable panels connectors 20.
Optional Step 516: Install Door. At optional step 516, and as illustrated in the non-limiting examples shown in
Optional Step 518: Install Window(s). Similarly, at optional step 518, and as illustrated in the non-limiting examples shown in
These examples are illustrative and non-limiting, and it would be understood that other configurations of wall panels 10 can be included in the shelter 100. Alternative wall panels 10, include, without limitation, those having a panel frame and a panel insert. The panel frame can be configured to be received into the track channel 54 of the bottom track 50. The panel insert which may be of various configurations as required by the use of the shelter 100. For example, and without limitation, the panel insert may be configured for surveillance and composed of a reinforced, tinted, and/or bullet resistance material. Additional example panel inserts may be made of a screen or mesh material for ventilation of the shelter 100. Additional panels, including the roof panels 12 and gable panels 14, can include panels having a panel frame and/or panel insert.
In an illustrative example, one or more roof panels 12 include a panel insert configured as a window panel or skylight for receiving light into the shelter 100. Other configurations are possible, for example, installing window and/or screen inserts into the gable panels for lighting and/or ventilation. In a non-limiting example, steps 516 and/or 518 are completed prior to transporting the wall panels 10 or roof panels 12 to the location where the shelter 100 is to be constructed. In a non-limiting example, steps 516 and/or 518, and/or the assembly of panel frames and panel inserts can be performed at the location where the shelter 100 is to be assembled. Additionally, the doors 112, windows 114, and/or materials for the panel frames and inserts may be locally sourced, e.g., provided proximate to the assembly location of the shelter 100, and installed to the panels.
Step 520: Assemble Wall Panels. At step 520, the panel connectors 20 may be assembled, attached, or otherwise joined to the wall panels 10. Note that this may be considered an optional step. In many situations, the wall panels 10 will come with the panel connectors 20 pre-attached, such as from the factory or assembly facility, which may simplify construction of the shelter 100 at the installation site.
The wall panels 10, roof panels 12, and gable panels 14, which may collectively be referred to as panel members, are fabricated as lightweight panels for easy transport and handling during assembly of the shelter 100. In a non-limiting example, the panel members, have opposing panel faces defining a panel thickness PT therebetween, opposing panel side edges defining a panel width PW, and upper and lower edges defining a panel height PH. The upper and lower edges of the panel members may be defined relative to the installed position of the respective panel member, but note that in many configurations, the upper and lower edges may be reversible.
In the examples shown in the figures, the wall panels 10 and the roof panels 12 are generally rectangular in shape. The panel members can be formed or fabricated, for example, by trimming or cutting, in other shapes as required to assemble the shelter 100. For example, the gable panels can be formed in triangular shapes. In an illustrative example, the panel members include a core member and having panel faces made of a sheathing material attached to opposing sides of the core member to form a composite or laminate panel member. For example, and without limitation, the panel member is formed of one or more materials selected such that the panel member is lightweight for portability while providing an R-value of at least 2, such that the shelter 100 formed therefrom has better insulative properties than a tent-type structure. In one example, the panel member is characterized by an R-value in the range of about 4 to 10, and in another example, the panel member is characterized by an R-value of 9 or greater, to provide thermal efficiency to the shelter 100 formed therefrom.
For example, and without limitation, the core may formed of a rigid foam material such as a polystyrene-based material. In one example, the rigid foam is a graphene infused polystyrene to provide an insulating core member having an R-value of 9 or greater, and in a preferred example, having an R-value of at least 10 to provide thermal efficiency while maintaining the lightweight characteristics of the panel member. One, or both, of the core member and the sheathing material on the faces are preferably formed of a water resistant, water repelling, and/or hydrophobic materials, to form the modular shelter 100 which is resistant to water ingression. For example, and without limitation, the panel faces are made of a sheathing material attached to opposing sides of the core member, for example, by an adhesive, where the sheathing material forming the panel faces are made of a polymer material such as a fiberglass reinforced polymer (FRP), a polyethylene based polymer, a high density polyethylene elastomer (HDPE), a polyamide, a vinyl based material, or a nylon based polymer material, to provide additional rigidity, strength, and water resistance to the panel member.
In a non-limiting example, the panel member can be formed by laminating the sheathing material to the form core, including applying an adhesive, such as a cold spread glue or spray on adhesive, to one or both of the core member and the sheathing material prior to laminating the layers together to form a panel member. Alternatively, heat may be applied to bond or laminate the sheathing members to the core member, or an expanding foam core may be placed between sheathing members, such that the expanding foam bonds directly to the sheathing members. In a non-limiting example, the foam core construction of the wall panels 10 provides an advantage of being readily modified for installation of doors 112, windows, 114, etc., with minimal hand tools such as a hand saw, knife, or other manual cutting tool, e.g., without the use of specialty or power tools.
One or more of the panel height PH, panel width PW, panel thickness PT and/or the shape of the panel member can be varied to meet the use requirements of the shelter 100 being assembled from the respective panel members. Various configurations and combinations of a core layer and/or one or more panel faces can be used to construct a panel member as needed to meet the use requirements of the shelter 100 formed from the panel member, and/or to provide selective characteristics or properties to the panel member.
For example, and without limitation, the panel member can be configured for intrusion and/or ballistic resistance, fire and/or smoke resistance, water resistance, wind resistance, insulative or other thermal properties, electrical properties, appearance characteristics—including camouflage, light reflecting, light absorbing—or decorative appearance characteristics, etc. The combination of sheathing and core materials may be varied, for example, to provide various configurations of panel members. In one example the panel faces and core member can be formed as a unitary homogeneous structure defining the panel member. In another example, the core member can be formed of multiple layers to provide the desired properties, such as the core member including a ballistic insert, a reinforcement or rigidity insert, for example, for wind resistance and/or load dissipation, etc.
In a non-limiting example, the panel member can include opposing panel faces made of different materials and/or configured to contribute differing properties to the panel member. In a non-limiting, illustrative, example, a panel member can include an exterior (as installed) panel face having weather resistant, camouflage, and/or ballistic properties, and an interior (as installed) panel face having thermally insulative and/or decorative characteristics. All of these examples are illustrative and non-limiting, and it would be understood that panel members comprising other combinations of materials and configured layers would be possible within the scope of the description.
In one non-limiting example, an adhesive can be applied to the channel interior surfaces of the panel edge channel 22, and/or to the panel side edge and/or to the portions of the panel face being inserted into the panel edge channel 22, to adhere the panel member to the channel interior surfaces, thereby attaching the panel connector 20 to the panel member to form the wall panel 10. In one example, the adhesive can be configured as a sealant, and distributed and/or applied to the panel member and/or to the channel interior surfaces to seal the joint between the panel member and panel edge channel 22, to impede and/or prevent fluid flow (water, liquids, air, etc.) through this joint.
Step 522: Connect Panels to Tracks. Referring again to the method shown in
At step 522, the panel assemblies are connected to each other and to the corner connectors 60, as shown in
As previously described, the panel connectors 20 and corner connectors 60 include the connector portion 26 for connecting to an adjacent panel connector 20 and corner connector 60 as the wall assembly 200 is assembled, by insertion of the connector plug 30 into the connector socket 40 to provide a sealed connection between each panel assembly and the adjacent panel assembly or the corner connector 60. In one example, the plug seal, which may be a bulb seal, may be installed along the socket channel, and compressed by insertion of the connector plug 30 into the socket channel, to provide additional sealing of the joints between the wall panel assemblies, and to further prevent airflow through the joints for insulating and sealing purposes. Any of the components of the RWBS shelters 100 described herein may include sealing elements to, for example and without limitation, minimize incursion of water, allow removal of water via specific pathways, or minimize airflow through the components.
Each of the panel connectors 20 includes at least one retractable connector 64 positioned in the panel connector 20, as shown in
For example, the freestanding wall assembly 200 can be used as an open top structure to house livestock or store supplies. In one example, a roof covering such as a tarp, netting, etc., or covering made of non-RWBS roofing materials, for example, locally sourced materials—including thatch, bamboo, wood, etc. —could be applied to cover the freestanding wall assemblies 200. In one example, the roof covering may be attached via tie downs or ropes connected to the wall assembly 200 via the connector slots 28. In a non-limiting example, a conventional roof, such as a wooden truss and shingle roof, can be installed to the wall assembly 200 to form a complete shelter. In the example shown in
Step 524: Connect Gable Tracks. At step 524, gable tracks 80 are attached to the upper ends of the panel connectors 20 and corner connectors 60 of the wall assembly 200. As shown in
Each of the first panel channels 92 and second panel channels 94 include receiver apertures 58 formed therethrough and positioned to receive and engage the retractable buttons 66 of the retractable connectors 64 of the panel connectors 20 and corner connectors 60 inserted into the channels. One or more seals, such as bulb seals, may be incorporated into any channel of the gable track 80. In particular, the second panel channel 94 may have seals, such that liquid is prevented from entering the second panel channel 94.
In some configurations, the modular shelter 100 may have more than one floor, such that the gable tracks 80 may be used for assembling an upper wall assembly 200 to a lower wall assembly 200, as would be recognized by skilled artisans. The gable tracks 80 are installed to the upper edges of the wall panels 10 and corner connectors 60 forming the lower wall assembly 200, and the second panel channels 94 of the gable tracks 80 function as the bottom track channels to receive and connect to the corner connectors 60 and the panel connectors 20 of the upper wall assembly 200, and to receive and connect to the lower edges of the wall panels 10 forming the upper wall assembly 200.
As shown in
The gable track 80, or the gable track 81, may include a plurality of weep holes 59 extending through any wall of the gable track 80, or between the first panel channels 92 and second panel channels 94, to provide drainage of fluid, including rainwater, which may run off the upper wall assembly 200 and collect in the second panel channel 94, functioning as previously described for the weep holes 59 of the bottom tracks 50. Therefore, if water enters the gable track 80 or the gable track 81, such as by passing the optional seals, it is allowed to drain therefrom. The gable track 80 may be formed, without limitation, of similar materials, or by similar production methods, as the bottom tracks 50, the panel connectors 20, or the corner connectors 60.
Optional Step 526: Install Upper Wall Assembly. At step 526, the corner connectors 60, panel connectors 20, and wall panels 10 of an upper wall assembly 200 are installed to the second panel channel 94 of the gable track 80. This may include installing panels with doors 112 and/or windows 114. The wall structure including the lower wall assemblies 200 and upper wall assemblies 200 form a rigid, freestanding structure of increased height, which may be useful, for example, for the storage of supplies and/or equipment which exceeds the height of the lower wall assembly 200. As described previously, the freestanding structure including upper and lower wall assemblies 200 can be used as an open top structure. Alternatively, any of the roof structures previously discussed can be installed to the upper wall assembly 200.
Optional Step 528: Install Floor or Floor Assembly. Referring again to the method 500, at step 528 floor joists and a floor can be installed to the example shelter 100 to separate the upper and lower wall assemblies 200 and provide a second story interior space within the shelter 100. In a non-limiting example, the floor joists can be configured as cross members attached via brackets to the gable tracks 80. The descriptor “floor joist” is non-limiting, and it would be understood that the many cross members could also be used, for example, to install and/or attach a ceiling above the first floor of the shelter 100.
Note that the example method 500 is non-limiting, such that it would be understood that steps could be repeated to assemble a plurality of wall assemblies 200 stacked and connected via gable tracks 80 to construct shelters 100 of additional height and/or multiple floors.
Optional Step 530: Install Upper Level Access. At step 530 some sort of access to the upper floor may be installed. For example, and without limitation, stairs, a ladder, or an opening in the interior floor, may be installed to grant access to the upper level. Skilled artisans will recognize numerous configurations for access to the upper level.
Step 532: Connect Eave Tracks. At step 532, the RWBS roof assembly 300 begins to be installed to the wall assemblies 200. Referring to the method 500, one or more eave tracks 70 are attached to the upper ends of the panel connectors 20 and the corner connectors 60 of the eave sides of the wall assembly 200. The term “eave side” is used to denote a side of the wall assembly 200 which joins with a lower edge of the roof panel 12. The eave tracks 70 are illustrated in
The roof panel channel 74 of the eave track 70 includes an offset fascia leg 82 and two soffit legs 84, which cooperate to receive the lower end of the roof panel 12. As shown in
The eave track 70 may include additional fastener apertures formed in the soffit legs 84 and distributed along the length of the eave track 70. These faster apertures may be positioned to align with the connector slots 28 of roof panel connectors 20. During assembly of the roof assembly 300 to the wall assembly 200, as illustrated by the non-limiting examples described herein, a T-bolt may be positioned in the connector slot 28 of the roof panel connector 20 such that the threaded end of the T-bolt is received by and extends through the fastener aperture of the lower soffit leg 84 of the eave track 70. A knob of the T-bolt fastener may be threaded onto the threaded end of the T-bolt and tightened to connect the panel connectors 20 and/or the roof panel 12 to the eave track 70. The knob can also be referred to herein as a T-bolt handle.
As shown in
Additionally, some configurations of the roof assembly 300 may include an eave seal (not shown) positioned, most likely, on the lower soffit leg 84 along the length of the eave track 70, in contact with the interior panel faces of the roof panels 12. Other eave seals may be incorporated. In one example, the eave seal is made of an elastomer, polymer, or rubber-based material which is compressible such that the eave seal is compressed during assembly of the roof panel 12 to the eave track 70, thus creating a continuous seal along the length of the eave track 70 between the surface of the soffit leg 84 and the interior panel face. In the event that water collects in the roof panel channel 74 at a rate or in a quantity that is not gravity drained through weep holes, then the eave seal may seal the flange to the roof panel interface and prevent water ingression along the lower soffit leg 84 to the interior of the shelter 100.
If water is present in sufficient quantity, the eave seal may pressurize the collected water to force the water out of the roof panel channel 74 via the weep holes. Non-limiting example configurations of the eave seal include bulb seals, D-shaped seals, O-ring seals, etc., to provide a seal the joint between the abutting connector portions 26. In one example, the eave track 70 may be provided with the eave seal pre-applied to the lower soffit leg 84. In another example, the eave track 70 and eave seal are provided as separate components and the eave seal is attached to the lower soffit leg 84 during assembly of the shelter 100. In a non-limiting example, the eave seal can be adhered to the lower soffit leg 84 by an adhesive or other fastening means, and/or the eave seal can include an adhesive strip for adhering the eave seal to the lower soffit leg 84.
Step 534: Assemble Gables. At step 534, the RWBS roof assembly 300 assembles the gable portions from, at least, gable panels 14 and gable panel connectors 20. The gable tracks 80 may have already been attached to the wall panel 10 and the wall panel connectors 20 and the corner connectors 60 along the gable sides of the wall assembly 200, with the gable tracks 80 being attached by engagement of the retractable buttons 66 in the receiver apertures 58 of the gable tracks 80.
At step 534, gable panel connectors 20 are attached to gable panel 14 to form gable panel assemblies, as shown in
The gable panels 14 may be inserted to the second panel channel 94 (the upper channel) of the gable track 80 to form the gable assembly, in the example shown in
Note that alternative gable constructions may be used. For example, and without limitation, the roof assembly 300 may have a single span along a single pitch angle PA, such that the gable panels 14 are substantially right triangles, which may be single, solid panels. This may also include one side having an upper layer, likely shorter, wall assembly 200 attached to an additional gable track 80.
Step 536: Assemble Roof Panels. At step 536, roof panel connectors 20 are attached to the roof panels 12 to form roof assemblies 300, as shown in
Step 538: Gable End Closures. At step 538, the gable end track 120 is attached to the gable panels 14, by insertion of the upper edge of the gable panel 14 into a gable panel channel of the gable end track 120, which may also be referred to herein as the gable closure. The gable end track 120 generally includes two channel slots, a gable channel slot and a roof channel slot, at substantially right angles to one another.
The gable end track 120, which is best viewed in
Step 540: Connect Cross Members. In step 540, one or more cross members 130 can be connected the eave tracks 70, to provide additional rigidity to the wall assembly 200, truss support for the roof assembly 300, or both. The cross member 130, and elements connected thereto, are best viewed in
In a non-limiting example, the eave tracks 70 include a cross channel 76 having receiver apertures 58 defined therein, as best viewed in
The cross member 130 can include a web member 132 operatively connected to the cross member 130 and functional as a truss element to support portions of a ridge track 110 or ridge track assembly 110 (shown in
As shown in
The web member 132 can be positioned in the folded position, adjacent to the cross member 130, for efficiency of packaging and shipment, such that the cross members 130 with the web members 132 in the folded position can be more closely nested to each other during transport. The upper end of the web member 132 includes one or more retractable connectors 64 and retractable buttons 66, which can be engaged with receiver apertures 58 of the ridge track assembly 110, to connect the web member 132 to the ridge track assembly 110 in a truss configuration, as shown in
Step 542: Assemble Ridge Track Portions. At step 542 of the method 500, portions of the ridge track assembly 110 are assembled. As shown in
Assembly of the ridge track assembly 110 may occur in various orders, and the order suggested herein is only one example, as are the remainder of the steps of the method 500. After the cross members 130 are installed and the web members 132 rotated upward, the lower track 118 may be attached to the web members 132 via retractable connectors 64 and retractable buttons 66 engaged with receiver apertures 58 in a web channel of the lower track 118. The elements of the ridge track assembly 110, including the upper tracks 116 and the lower tracks 118, may be formed, without limitation, of similar materials, or by similar production methods, as the bottom tracks 50, the panel connectors 20, the corner connectors 60, the gable tracks 80, or the eave tracks 70, and other components of the shelter 100. In some configurations, there may be seals, for example bulb seals, between the upper track 116 and the roof panels 12.
In some configurations, multiple lower tracks 118 will be aligned and connected via at least one ridge splice 90, as viewed in
Additional fasteners may be used for transportation, assembly, or both, of any of the components of the modular shelter 100. For example, and without limitation, the ridge splice 90 may pivot about a bolt or pivot pin, which may later be removed, or may be retained within the assembled shelter 100.
Step 544: Install Roof. At step 544 of the method 500, one or more roof panels 12, having panel connectors 20 connected to one or more edges, may be laid onto the assembled portions of the ridge track assembly 110. The installed lower tracks 118, supported by the web members 132, provide a base onto which roof panels 12 and roof panel connectors 20 may be laid during installation. Note that the roof panels 12 were assembled to the roof panel connectors 20 in step 536. However, the installation step 544 may also include assembling the roof panels.
The roof panels 12 may also be inserted into roof panel channels of the gable end tracks 120. Furthermore, the roof panels may be inserted to roof panel channels of the eave track 70. This allows the roof panels 12 and roof panel connectors 20—i.e., portions of the roof assembly 300—to be installed on top of the freestanding structure prior to installing the upper tracks 116 with the LCA 138.
Step 546: Complete Ridge Track. At step 546 of the method 500, the reminder of the ridge track assembly 110 is assembled. As best viewed in
To attach the upper track 116 to the lower track 118, the LCA 138 are attached to the upper track 116, such as with bolts or retractable connectors 64. Then, the pull handles 140, which are rotated substantially 90-degrees relative to the orientations shown in the figures, are pulled through the tray slots 124 in the lower track 118. After pulling through the tray slots 124, the pull handles 140 are rotated 90-degress, to the orientations shown in the figures, and released, such that the internal spring of the LCA 138 pulls the pull handles 140 into engagement with the tray cutouts 122.
The tray cutouts 122 may be difficult to view in
The upper track 116 and the lower track 118 are squeezed by the LCA 138 onto the sides of the roof panels 12 therebetween, as best viewed in
Optional Step 550: Connect Interior Wall Sections. Optional steps 550-556 are provided to install or connect, including, but not limited to, interior components, exterior components, utilities, wall components, or combinations thereof. At step 550, interior wall sections may be attached, such as to the connector slots 28 of the panel connectors 20. Alternatively, any of the additional components may be attached via other mechanisms or means, including, without limitation, brackets attached to the wall panels 10, roof panels 12, gable panels 14, panel connectors 20, or corner connectors 60.
Other components can be installed to the shelter 100, including, without limitation, flooring, ceiling components, lighting, communication equipment, toilets, plumbing, kitchen equipment, and other components recognizable by those having ordinary skill in the art. Note that these components may not be illustrated in the figures, but will be understood skilled artisans.
Optional Step 552: Install Utilities. At step 552, one or more utilities may be installed to the shelter 100. The possible utilities include, without limitation, lighting, electrical wire and/or outlets, HVAC, and plumbing.
Optional Step 554: Connect Interior Components. At step 554, one or more interior components may be installed or connected to the shelter 100. The possible interior components include, without limitation, flooring, ceiling components, shelves, and hooks.
Optional Step 556: Connect Exterior Components. At step 556, one or more exterior components may be installed or connected to the shelter 100. The possible exterior components include, without limitation, air conditioning units, solar power units, and communications systems. The method 500 may end after optional step 556, or additional steps may be provided to further customize or better prepare the modular shelter 100 for the specific needs of specific installation.
The RWBS components described herein, with reference to the method 500 and the other figures, can be configured, combined, and assembled into multiple different configurations of modular shelters 100 for various uses, including recreational, utilitarian, humanitarian, military, and other uses recognizable to those having ordinary skill in the art. The various RWBS components described herein including wall panels 10, roof panels 12, panel connectors 20, corner connectors 60, bottom tracks 50, eave tracks 70, gable tracks 80, and ridge tracks 110, etc. can be adapted and/or modified within the scope of this disclosure for assembling shelters 100 for the various uses.
By way of non-limiting example, the various RWBS components can be modified as appropriate to the intended use of the shelter 100, including modifications to provide desired appearance or functional characteristics, including, without limitation: camouflage, decorative treatments, light reflective properties, ballistic properties, surface texturing and embossment, decorative trim, decal application, etc. as appropriate to the intended use and/or location of the modular shelter 100.
The example of the retractable connector 64 is illustrative and non-limiting, and it would be understood that the use of other types of reusable connectors, including spring-loaded or spring-type connectors or conventional removable and reusable connectors, such as bolts and nuts, etc., is anticipated within the scope of the disclosure. For permanent installations of the modular shelter 100, RWBS components with single use and/or non-reusable connectors, such as rivets, can be provided and are anticipated within the scope of the disclosure.
The Rapid Wall Building System (RWBS) described herein is further advantaged by logistic efficiencies, due to the ability to compactly package and ship the standardized components, many, or all, of which can be nested to each other to substantially reduce empty shipping space. Combined with the lightweight characteristics of the RWBS components, transportation costs and energy savings are significantly lower relative to transportation costs of conventional materials for similarly sized modular shelters 100.
The detailed description and the drawings or figures are supportive and descriptive of the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings defined in the appended claims.
This application claims the benefit of U.S. Provisional Application No. 63/208,949, filed Jun. 9, 2021: U.S. Provisional Application No. 63/187,438, filed May 12, 2021: U.S. Provisional Application No. 63/316,386, filed Mar. 3, 2022: U.S. application Ser. No. 29/834,548, filed Apr. 12, 2022: U.S. application Ser. No. 29/787,993, filed Jun. 9, 2021; U.S. application Ser. No. 29/787,996, filed Jun. 9, 2021: U.S. application Ser. No. 29/787,999, filed Jun. 9, 2021: U.S. Provisional Application No. 63/223,779, filed Jul. 20, 2021: U.S. Provisional Application No. 63/340,537, filed May 11, 2022: all of which are hereby incorporated by reference in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US22/28896 | 5/12/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63340537 | May 2022 | US | |
| 63316386 | Mar 2022 | US | |
| 63223779 | Jul 2021 | US | |
| 63208949 | Jun 2021 | US | |
| 63187438 | May 2021 | US |
