Abstract:
A system and method for constructing a temporary structure is disclosed. The system comprises a plurality of wall panels, a plurality of roof panels, a plurality of floor panels, at least one door panel, and each wall panel, roof panel, floor panel, and door panel comprising at least one edge coupled to a first track and at least one edge coupled to a second track. The first track has a first surface with an indentation and a flat second surface. The second track has an angled hemmed tab extending therefrom that is adapted to mate with the indentation of the first track and a straight hemmed tab extending therefrom that is adapted to abut the flat second surface of the first track.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. provisional Application Ser. No. 61/489748, filed May 25, 2011, entitled “Systems and Methods for Constructing Temporary, Re-locatable Structures,” which is hereby specifically and entirely incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The invention is directed to systems and methods of constructing temporary or re-locatable structures and, in particular, systems and methods of constructing temporary structures to be energy efficient using insulated panels. 
         [0004]    2. Background of the Invention 
         [0005]    Global warming, high energy costs, lack of reusable sources of energy, and diminishing resources of fossil fuels are all reasons, among others, to improve the energy efficiency of structures. Traditional temporary structures, such as tents, collapsible fabric or metal structures, or plastic structures, are usually energy inefficient, losing hot and/or cool air though the various surfaces, walls, roofs, windows, doors, gaps, and other components. 
         [0006]    In order to improve the energy efficiency of these temporary buildings it is often necessary to retrofit the building with energy efficient materials, for example with spray-on insulation. Such upgrading is costly, time consuming, and can ruin the structure or re-locatable. Furthermore, existing temporary structures often are difficult to assemble, having multiple parts that must be sorted, organized and installed. 
         [0007]    Therefore, it is desirable to have systems and methods of constructing a temporary structure that is cost effective, easy to install, and provides energy efficiency. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention overcomes the problems and disadvantages associated with current strategies and designs and provides new systems and methods of constructing temporary or re-locatable structures. 
         [0009]    A system and method for constructing a temporary or re-locatable structure is disclosed. The system comprises a plurality of side panels and a plurality of roof and floor panels and a plurality of a first track and a plurality of a second track, the first track having an indentation and the second track having a hemmed tab that is adapted to mate with the indentation of the first track. Each side panel has a first edge coupled to a first track and a second, parallel edge coupled to a second track, while each roof and floor panel has two edges coupled to two first tracks and two edges coupled to two second tracks. 
         [0010]    Other embodiments and advantages of the invention are set forth in part in the description, which follows, and in part, may be obvious from this description, or may be learned from the practice of the invention. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention is described in greater detail by way of example only and with reference to the attached drawings, in which: 
           [0012]      FIG. 1  depicts an embodiment of a wall of side panels. 
           [0013]      FIG. 2  depicts an embodiment of interlocking tracks. 
           [0014]      FIG. 3  depicts an embodiment of top and bottom tracks. 
           [0015]      FIG. 4  depicts another embodiment of a wall of side panels. 
           [0016]      FIG. 5  depicts a plan for an embodiment of a temporary structure. 
           [0017]      FIG. 6  depicts an embodiment of coupling perpendicular side panels. 
           [0018]      FIG. 7  depicts an embodiment of roof and floor panels. 
           [0019]      FIG. 8  depicts an embodiment of an exterior wall. 
           [0020]      FIGS. 9   a - b  depict an embodiment of coupling a wall panel to a floor panel. 
           [0021]      FIGS. 10   a - b  depict an embodiment of coupling a wall panel to a roof panel. 
           [0022]      FIGS. 11   a - b  depict an embodiment of coupling a wall panel to a roof panel. 
           [0023]      FIGS. 12   a - b  depict an embodiment of coupling two roof panels and a roof beam. 
           [0024]      FIGS. 13   a - b  depict an embodiment of coupling a wall panel to a floor panel. 
           [0025]      FIGS. 14   a - b  depict an embodiment of coupling a wall panel to a floor panel. 
           [0026]      FIGS. 15   a -b depict an embodiment of the elements of an exemplary structure contained within a standard shipping container. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0027]    As embodied and broadly described herein, the disclosures herein provide detailed embodiments of the invention. However, the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, there is no intent that specific structural and functional details should be limiting, but rather the intention is that they provide a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
         [0028]    A problem in the art capable of being solved by the embodiments of the present invention is constructing a temporary, re-locatable structure that is energy efficiency. It has been surprisingly discovered that by using interlocking brackets and insulating panels an energy efficient temporary structure can be constructed more easily and quickly than a traditional temporary structure. 
         [0029]      FIG. 1  depicts an exemplary exterior wall  100 . In the preferred embodiment, wall  100  is comprised of a plurality of panels  105 . As shown in  FIG. 1 , panels  105  are 8 feet wide by 8.5 feet tall; however other size panels can be used. Preferably each panel  105  is comprised of a polystyrene core; however, other insulating materials such as, but not limited to, fiberglass, urea-formaldehyde, cellulous, and polyethylene can be used. Additionally, panels  105  may be coated with FRP (fiberglass reinforced plastic) boards, film coverings (e.g. graphical image film coverings or heat dissipating film coverings), spray coatings (e.g. insulating spray coatings or fire retardant spray coatings), Strongwell&#39;s Safe Plates, or other materials. Panels  105  are preferably also made of a fire retardant material. Preferably, panels  105  have a thickness of either 3.5 inches, 5.5 inches, or 7.5 inches; however other thicknesses are possible. In the preferred embodiment, panels  105  weigh no more than 1.625 pounds per square foot; however other weights are possible. 
         [0030]      FIG. 2  depicts exemplary interlocking tracks  210   a  (labeled A in the figures) and  210   b  (labeled B in the figures). In the preferred embodiment, each panel  105  has one track  210   a  coupled to a first edge and one track  210   b  coupled to a second, parallel edge. In the preferred embodiment, tracks  210   a  and  210   b  are coupled to the long sides of panels  105 , however, depending on the structure, the short sides of panels  105  can be coupled to tracks  210   a  and  210   b.  Furthermore, in certain embodiments each panel can have two tracks  210   a  and two tracks  210   b.  Preferably in embodiments with tracks on each edge of the panel  105 , the two tracks  210   a  are adjacent to each other and the two tracks  210   b  are adjacent to each other such that opposing edges have different tracks. Track  210   a  has indented or recessed portion  215  along its outer edge, into which angled hemmed tab  220  of track  210   b  mates. On the opposite edge of track  210   b  from angled hemmed tab  220  is straight hemmed tab  225 . As can be seen from  FIG. 2 , both angled and straight hemmed tabs  220  and  225  extend from the outer edge of track  210   b . In a preferred embodiment a foam seal or other insulation is placed between track  210   a  and track  210   b  as they coupled. Furthermore, in a preferred embodiment, a fastener  230  (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener) is used to secure track  210   a  to track  210   b  once the two tracks are coupled together. Both tracks  210   a  and  210   b  are preferably made of 20 or 24 gage steel, however other materials can be used.  FIG. 3  depicts an embodiment of bottom tracks  335  and top tracks  340 . In a preferred embodiment, bottom track  340  is coupled to the bottom edge of each panel  105  and top track  340  is coupled to the top edge of each panel  105 . Preferably, both bottom track  335  and top track  340  are “C” shaped double tracks. Bottom track  335  and top track  340  preferably couple to panel  105  with fasteners  345  (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener). Bottom track  335  and top track  340  preferably also couple to the floor and roof with fasteners. 
         [0031]      FIG. 4  depicts another embodiment of an exterior wall  450 . Exterior wall for example may be comprised of two panels  105  and entrance  455 . Another number of panels  105  and entrances  455  can be used in any order. Entrance  455  is preferably made of the same material as panels  105 , however, entrance  455  also includes a door or other entranceway. In  FIG. 4 , entrance  455  is shown as 4 feet wide by 8.5 feet tall, however another size panel can be used. Preferably, entrance  455  has the same height as panels  105 . 
         [0032]      FIG. 5  depicts an example of a temporary structure floor plan. As can be seen in the figure, the floor plan is a rectangular structure having two parallel long walls made up of four panels  105  each and two parallel short walls made up of two panels  105  and one entrance  455  each. The configuration shown in  FIG. 5  is merely exemplary and another number of panels  105  and entrances  455  can be used to define the structure. Additionally, structures can be assembled in multiples or stacked as needed. Furthermore, structures need not be rectangular, but can have another shape. 
         [0033]      FIG. 6  depicts the self-locking corner  660  used to couple perpendicular sections of wall. Self-locking corner  660  is preferably used to couple a track  210   b  of a first panel  105  to a track  210   a  of a second, perpendicular panel  105 . Self-locking corner  660  is preferably coupled to tracks  210   a  and  210   b  with a fastener (for example, a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener). A foam seal or other insulation can be used between tracks  210   a  and  210   b  to improve the insulation of the structure. 
         [0034]      FIG. 7  depicts roof and floor panels  765 . Preferably roof and floor panels  765  are made of the same materials as panels  105 . As shown in  FIG. 7 , roof and floor panels  765  are preferably 8 feet by 10 feet, however other dimensions can be used. In the preferred embodiment, each roof and floor panel  765  is coupled on two sides with track  210   a  and on two sides with track  210   b,  however other configurations can be utilized. Preferably, the roof is supported by beams. The beams preferably span the  20  foot section of the structure and are placed at 4 foot or 8 foot intervals, however other distributions and sizes of the beams can be used. 
         [0035]      FIG. 8  depicts exterior wall sections  870  with cross beam roof supports at intervals. Exterior wall sections  870  are the same as panels  105 , except exterior wall section  870  are able to be coupled to roof beams  875 . In the preferred embodiment, wall sections  870  are installed down both sides of the temporary structure. Numerous configurations can be implemented to divide the structure into rooms by using panels such as section  870 . Additional temporary structures can be coupled to the first temporary structure to create longer, wider, or stacked (e.g. two story) structures. The additional temporary structures can be coupled to the first temporary structure either side by side, end to end, or one on top of another. 
         [0036]      FIGS. 9   a - b  depict an embodiment of a coupling device  909  for coupling a wall panel coupled to track  210   a  to a floor panel coupled to track  210   b.  Coupling device  909  is substantially “C” shaped. As can be seen in  FIG. 9   b , the upper portion of coupling device  909  mates with track  210   a  and there is a flange that couples to straight hemmed tab  225  of track  210   b.  Coupling device  909  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener  908  engages coupling device  909  and track  210   a  securely coupling the wall panel to the floor panel. Fastener  908  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0037]      FIGS. 10   a - b  depict an embodiment of a coupling device  1011  for coupling a wall panel coupled to track  210   b  to a roof panel coupled to track  210   b.  Coupling device  1011  is substantially “C” shaped. As can be seen in  FIG. 10   b , the upper portion of coupling device  1011  has a flange that mates with the angled hemmed tab of the track  210   b  of the roof panel while the lower portion of coupling device  1011  mates with track  210   b  of the wall panel. Coupling device  1011  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener  1012  engages coupling device  1011  and track  210   b  of the wall panel securely coupling the wall panel to the roof panel. Fastener  1012  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0038]      FIGS. 11   a - b  depict an embodiment of a coupling device  1116  for coupling a wall panel coupled to track  210   b  to a roof panel coupled to track  210   a.  Coupling device  1116  is substantially “C” shaped. As can be seen in  FIG. 11   b , the upper portion of coupling device  1116  surrounds track  210   a  of the roof panel, while the lower portion of coupling device  1116  abuts with track  210   b  of the wall panel. Coupling device  1116  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners  1117  engage coupling device  1116  and both track  210   b  of the wall panel and track  210   a  of the roof panel, securely coupling the wall panel to the roof panel. Fasteners  1117  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0039]      FIGS. 12   a - b  depict an embodiment of a coupling device  1221  for coupling two roof panels to a beam  1223 . Coupling device  1221  is substantially “A” shaped. As can be seen in  FIG. 11   b , the upper portion of coupling device  1221  fits within the indented portion  215  of track  210   a  and over angled hemmed tab  220  of track  210   b,  while the lower portion abuts beam  1223 . Coupling device  1221  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment a fastener  1222  engages coupling device  1221  and beam  1223 , securely coupling the roof panels to the beam  1223 . Fastener  1222  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0040]      FIGS. 13   a - b  depict an embodiment of a coupling device  1333  for coupling two perpendicular wall panels at a corner. Coupling device  1333  is substantially “C” shaped. As can be seen in  FIG. 13   b , the left portion of coupling device  1333  mates with track  210   a  of a first wall panel, while the right portion of coupling device  1333  abuts track  210   b  of the second wall panel. Coupling device  1333  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners  1334  engage coupling device  1333  and both track  210   a  of the first wall panel and track  210   b  of the second wall panel, securely coupling the wall panels. Fasteners  1334  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0041]      FIGS. 14   a -b depict an embodiment of a coupling device  1442  for coupling two perpendicular wall panels at a corner. Coupling device  1442  is substantially “C” shaped. As can be seen in  FIG. 14   b , the upper portion of coupling device  1442  mates with track  210   a  of a first wall panel, while the lower portion of coupling device  1442  abuts track  210   b  of the second wall panel. Coupling device  1442  is preferably made of 20 or 24 gage steel, however other materials can be used. In the preferred embodiment fasteners  1443  engage coupling device  1442  and both track  210   a  of the first wall panel and track  210   b  of the second wall panel, securely coupling the wall panels. Fasteners  1442  can be a turn polycarbonate fastener, a rivet, a bolt, a screw, a brad, glue, adhesive, double-stick tape, or another fastener. 
         [0042]    In the preferred embodiment, each of the components of the temporary structure is manufactured off-site, and then the components are delivered to the site of the temporary structure where they are assembled. Preferably, the temporary structure can be assembled and disassembled with minimum effort and tools. Furthermore, the components can be reused so that the structure is re-locatable. Preferably, during assembly, each fastener is installed either from the inside of the structure or from the roof of the structure. 
         [0043]      FIGS. 15   a - b  depict all of the components for an approximately 20′×40′ temporary structure fit within a standard 20 foot shipping container for transportation. In locations where wind is an issue, traditional anchors and tie downs can be used to secure the temporary structure. In the preferred embodiment, the roof can support at least a 40 lb load, however in other embodiment the roof can support greater loads. 
         [0044]    Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all publications, U.S. and foreign patents and patent applications, are specifically and entirely incorporated by reference. It is intended that the specification and examples be considered exemplary only with the true scope and spirit of the invention indicated by the following claims. Furthermore, the term “comprising” includes the terms “consisting of” and “consisting essentially of,” and the terms comprising, including, and containing are not intended to be limiting.