1. Field of The Disclosure
The present technology relates generally to portable shelter systems and containers, and more particularly, shelter and container structural elements and assemblies.
2. Related Art
Portable shelters are often used to provide temporary facilities for various purposes, such as military, civilian, and medical applications. Such portable shelters may be used to supplement permanent structures when additional space is desired, or to provide new facilities for temporary use, such as the provision of emergency response services after a disaster. Motorized vehicles, such as vans, buses, and recreational vehicles (RVs), etc., may be used as portable shelters under certain circumstances. While these types of motorized vehicles are able to transport themselves to a desired location, they may provide limited interior space for intended use, while also being relatively expensive.
Some portable shelters are configured to be in the size and shape of a standard International Organization for Standardization (ISO) intermodal shipping container. In this way, such shelters may be shipped by commercial means, such as by railway, boat, or aircraft, including military aircraft.
In one aspect of the present invention, a wall for a shelter is disclosed. The wall comprises: a frame comprising frame segments forming an n-sided closed polygon; at least one wall panel, each wall panel contained within the frame; and a plurality of flats, each flat attached to and overlapping a frame segment and a portion of a wall section, thereby retaining each wall panel within the frame
In a second aspect of the present invention, a shelter is disclosed. The shelter comprises: a plurality of walls, each wall comprising: a frame comprising frame segments forming an n-sided closed polygon; at least one wall panel, each wall panel contained within the frame; and a plurality of flats, each flat attached to and overlapping a frame segment and a portion of a wall section, thereby retaining each wall panel within the frame.
Embodiments of the disclosed technology are described below with reference to the attached drawings, in which:
The technology includes wall sections, wall panels assembled from wall sections, and walls assembled from wall panels. The wall section has a substantially rectangular main body, and two flanges extending in the same direction away from opposing longitudinal sides of the main body—an L flange and a second flange. The L flange includes an L flange perpendicular portion and an L flange parallel portion. The L flange perpendicular portion can have a first longitudinal side at the main body first longitudinal side. The L flange parallel portion extending in width from the second longitudinal side of the L flange perpendicular portion, along a line parallel to the main body, away from the main body interior. The second flange having a width, in a direction parallel to the L flange first portion, substantially equal to the L flange width minus the L flange parallel portion thickness. The second flange including a second flange first portion and a second flange second portion. The second flange first portion extending along its first longitudinal side from the main body, and substantially parallel to the L flange perpendicular portion. The second flange second portion is not coplanar with the second flange first portion, and extends from the second longitudinal side of the second flange first portion, along a line parallel to the main body, more toward the main body interior than the second flange first portion.
Wall panels of the present technology include a plurality of wall sections as described above. The wall sections are arranged with a common orientation, parallel, and substantially coterminal along the longitudinal axis of each wall section. The wall panels further include at least one spacer disposed between a second flange first portion of a first wall section and the mating surface of the first flange perpendicular portion of a second wall section adjoining the first wall section thereby defining a gap. An adhesive substantially fills the gap.
Walls of the present technology include a frame comprising frame segments forming an n-sided closed polygon, at least one wall panel (as described above), and a plurality of flats. Each wall panel is contained within the frame. Each flat attached to and overlapping a frame segment and a portion of a wall section, thereby retaining each wall panel within the frame. In some embodiments, the frame is substantially rectangular, and each wall section is oriented having a wall section longitudinal side parallel to the shortest side of the rectangular frame. In some embodiments, the frame is rectangular and comprises four frame segments. In some embodiments, the wall further comprises at least one support member spanning the interior side of the wall from a first vertical frame segment to a second vertical frame segment. Each support member is attached to each L flange parallel portion outer face of each wall panel. In some embodiments, the frame defines a recess therein, and each wall panel is contained within the frame recess with flanges facing into the recess. In some embodiments each wall panel external face is flush with the frame external face.
Shelters of the technology include a plurality of walls. Each wall includes a frame, at least one wall panel, and a plurality of flats. Each frame includes frame segments forming an n-sided closed polygon. Each wall panel is contained within a frame. The flats are attached to and overlapping each frame segment and a portion of a wall section, thereby retaining each wall panel within the frame.
Both shelters and containers may be exposed to environmental extremes in which the typically metal body is subject to expansion and contraction that can weaken the integrity of the body. Further, conventional structural elements, typically horizontal structural elements, present disadvantages. For example, horizontal structural elements are typically roll formed—requiring specialized expensive capital equipment. Assembly of panels and walls from roll-formed horizontal structural elements, some as long as thirty feet, can be cumbersome. The mechanical fasteners used in typical shelter construction do not allow for sufficient expansion and contraction when the shelter is subject to temperature swings. Routing of utilities and heating, ventilation, and air conditioning (HVAC) elements, medical gases, water, and electricity can be complicated in shelters built primarily from horizontal structural members.
Certain aspects and embodiments of the present technology address(es) some of the above-cited disadvantages and offers other advantages, at least in part through the use of vertical wall sections more amenable to fabrication and assembly than horizontal wall sections. For example, embodiments of the wall sections of the present technology can be assembled into wall panels without the need for mechanical fasteners and in a fashion that allows for expansion and contraction with less likelihood of oil-canning or warping. Fabrication of embodiments of the wall sections of the present technology can be accomplished with more readily-available equipment and in more readily-available facilities, and can present simpler material handling tasks. Shelters assembled from wall built of wall panels using vertical wall sections of the present technology can be more amenable to assembly and offer more flexible routing of utilities than those assembled from horizontal wall sections.
Referring to
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In the illustrated embodiment, the second flange second portion 134 is an offset portion. The offset portion 134 can add rigidity to the wall section 100 when the wall section is subject to end loading, e.g., when the wall section is used as a vertical element in a wall panel. Generally, the second flange portion 134 can be any portion extends from the second flange first portion generally in the direction of the main body interior, and is not coplanar with the second flange first portion, e.g., as described below in connection with
Wall section 100 can be formed by manufacturing methods such as using a press brake on sheet aluminum, to create bends, e.g., bend 140, and to create the offset between the second flange first portion 132 and the second flange second portion 134, thereby avoiding the disadvantages of methods such a roll forming. Bends 140 are substantially right angle bends along each side of the main body at the L flange 120 and the second flange 130, and along the length of the L flange perpendicular portion and the L flange parallel portion. For instance, bends 140 can be ⅛″ radius bends.
Referring to
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Spacers 200 are shown as applied to the exterior surface of the L flange perpendicular portion 122A corresponding to the exterior of the second flange first portion 132B. Spacers 200 also can be applied to the exterior of the second flange first portion 132B. Preferably, spacers are applied before applying an adhesive, as described below.
In some embodiments, spacer 200 is a durable, resilient elastomer that resists drying, rotting, or embrittling, such as Bumpon™ from 3M™. Spacer 200 can include an adhesive backing, e.g., of acrylic, natural rubber, synthetic rubber. Spacers 200 can facilitate having uniformly thick bond lines throughout the assembly, and promote regular and uniform curing of the adhesive that is desirable for final assembly of the sections into panels and panels into walls. Preferably, spacer 200 has a high coefficient of friction to resist skidding on most surfaces. Preferably, spacer is of width on the order of magnitude of 1″ (with 3/16″ squares being preferred), and of thickness to maintain separation between the upper portion of wall section L flange 120A and wall section second flange first portion 132B. The separation is determined by that distance desired to allow adhesive 300 to properly bond wall section 100A to wall section 100B. In some embodiments, the thickness of spacer 200 is 0.030″. While
Adhesive 300, while shown in
The use of spacers and adhesive may allow a wall panel, and walls and other structural elements built therefrom, to expand and contract with less stress on the wall section than in other panel and wall configurations.
Referring to
This adhesive joint can expand and contract with changes in temperature more readily than the wall sections can. This property gives a shelter or container built using wall, ceiling, or floor elements in accordance with the present technology an advantage over the same structures assembled with fasteners such as rivets, screws, clips, welding, and nuts and bolts.
Referring to
For the leftmost and center wall sections, spacers, such as spacers 200, are affixed to the L flange perpendicular portion 120 at a position corresponding to the mating second flange first portion 130 of the next wall section (Step 720), e.g., as shown in
The three wall sections, now joined by spacers and adhesive into a wall panel, are now clamped together, and the panel is allowed to cure (Step 740).
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The wall panels 800 can be held in a frame built from frame segments 992, with the flange side of each wall section 100 facing the interior, thereby presenting a substantially co-planar surface to the exterior. The frame can form a recess, as shown in section D-D, such that the wall panels 800 present an exterior face substantially flush with the face of the frame. The frame segments 992 can be formed from various materials, e.g., extruded aluminum. Wall panels 800 can be secured in the frame using a metal-to-metal bonding such as SEM® 39537 weld bond. While the frame of
Perimeter flats 994 can be affixed to cover the abutment between each frame segment 992 and the wall sections 100, with a first portion of each flat 994 covering a portion of each wall section 100, and the remainder of each flat 994 covering a portion of the frame segment 992.
Referring to
While various embodiments of the present technology have been described above, it should be understood that they have been presented by way of example only, and not limitation. For instance, while the wall sections disclosed herein have been disclosed in the context of vertical wall sections that can be assembled in to panels and walls of a shelter, the wall sections can be used as ceiling and floor elements in those applications, along with applications such as aircraft, ships, rail cars, modular buildings, and fixed construction. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the technology. For instance, features described as part of one implementation can be used on another implementation to yield a still further implementation. Thus, the breadth and scope of the present technology should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
This application claims the benefit of U.S. Provisional Application No. 61/613,350, entitled “SHELTER AND CONTAINER STRUCTURAL ELEMENTS AND ASSEMBLIES”, filed on Mar. 20, 2012.
Number | Date | Country | |
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61613350 | Mar 2012 | US |