Patent Publication Number: US-2013247509-A1

Title: Shelter and container structural elements and assemblies

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     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. 
    
    
     BACKGROUND 
     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. 
     SUMMARY 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the disclosed technology are described below with reference to the attached drawings, in which: 
         FIG. 1  illustrates a wall section of the present technology in a projection view; 
         FIG. 2  illustrates a wall section of the present technology in front and side views; 
         FIG. 3  illustrates the wall section of the present technology in side and section views illustrating a first flange and a second flange; 
         FIG. 4  illustrates an alternative embodiment of the second flange of the present technology; 
         FIG. 5  is an expanded partial cross-section view illustrating a wall panel at the joint between wall sections of  FIG. 1 ,  FIG. 2 , and  FIG. 3  in accordance with the present technology; 
         FIG. 6  is an expanded top view of the joint of a wall panel between wall sections in accordance with the present technology; and 
         FIG. 7  is a flow chart describing assembly of a wall panel from wall sections. 
         FIG. 8  is a perspective view of a wall panel in accordance with the present technology. 
         FIG. 9  illustrates wall panels of the present technology assembled in a frame to form a wall in accordance with the present technology. 
         FIG. 10A  illustrates wall panels in an eight-sided frame as part of forming a wall with a portal of the present technology. 
         FIG. 10B  illustrates wall panels in an eight-sided frame having flats securing the wall panels within the frame to form a wall with a portal of the present technology. 
         FIG. 11  illustrates a shelter built using sections and panels of the present technology. 
     
    
    
     DETAILED DESCRIPTION 
     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  FIG. 1 , a wall section  100  of the present technology is show in projection. In some embodiments of the technology, wall sections  100  can be formed from metal sheets, e.g., 3000 series aluminum. In other embodiments of the technology the wall section  100  can be formed from materials such as plastics, polymers (e.g., fiberglass fiber reinforced polymer), and composites. The wall section includes a main body  110  of width substantially less than length. For example, the width can be 10″-12″ while the length can be 96″-120″. The wall section profile geometry (section width, overall height), material type, and material thickness can be determined by the structural requirements of the particular application, e.g., a shelter conforming in overall dimensions to the ISO container standard. The wall section  100  can be formed from a sheet of uniform thickness substantially less than the wall main body  110  width. For example, the wall section  100  thickness can be 0.080″. The wall section  100  includes an “L” flange  120  and a second flange  130 . 
     Referring to  FIG. 2 , in which the wall section  100  is shown in front and side views, the L flange  120  includes a perpendicular portion  122  and a parallel portion  124 , where “perpendicular” and “parallel” are in reference to the wall section  100  main body  110 . The perpendicular portion  122  is of width less than the width of the main body  110 , but substantially greater than the material thickness. For example, the perpendicular portion  122  can be 1.75″ wide. The perpendicular portion  122  of the L flange  120  is formed substantially perpendicular to, and (in most embodiments) substantially coextensive with, a first long side of the main body  110 . The parallel portion  124  is of width less than the width of the main body  110 , but substantially greater than the material thickness. For example, the parallel portion  124  can be 1.5″ wide. The parallel portion  124  of the L flange  120  is substantially perpendicular to, formed at, and (in most embodiments) substantially coextensive with the side of the perpendicular portion  124  not adjoining the main body  110 . The parallel portion  124  extends away from the main body  110 . 
     Referring to  FIG. 3 , the wall section  100  of the present technology is shown in a side view and in section views illustrating the first flange  120  and a second flange  130 . The second flange  130  includes a second flange first portion  132  and a second flange second portion  134 . The overall width W 4  of the second flange  130  can be substantially equal to the overall width W 2  of the L flange  110 , minus the material thickness T. As described below, this relationship can facilitate assembly of wall panels and walls, and allows panels and walls assembled from wall sections to present a substantially co-planar surface on the non-flange side of the wall panels, walls, and shelters. For example, the overall width W 4  of the second flange  130  can be 1.670″. The second flange first portion  132  is formed substantially perpendicular to, and (in most embodiments) substantially coextensive with, a second long side of the main body  110 . 
     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  FIG. 4 . 
     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  FIG. 4 , an alternative embodiment of the second flange  130  is illustrated as flange  430 . In this embodiment the overall width W 6  of the second flange  430  can be substantially equal to the overall width W 2  of the corresponding L flange  110 , minus the material thickness T. For example, the overall width W 6  of flange  430  can be 1.5″. The flange first portion  432  is substantially similar to flange first portion  132 . Flange  430  second portion  434 , instead of being parallel to, but offset from, first portion  432 , is oblique to first portion  432  at an angle A. The flange  430  of  FIG. 4  can find use in ceiling sections. The embodiment illustrated in  FIG. 4  also can find use when mechanical fasteners are used to connect wall sections in to wall panels and walls. In embodiments employing mechanical fasteners for joining wall sections, maximizing the parallel surface area between the surfaces to be connected is not as critical as when adhesives are used. 
     Referring to  FIG. 5 , an expanded partial cross-section view illustrating a wall panel at the joint between wall sections  100 A and  100 B, each similar to wall section  100  of  FIG. 1 ,  FIG. 2 , and  FIG. 3 , is illustrated. Both wall sections  100 A,  100 B are oriented with flanges in the same direction, i.e., down in  FIG. 5 . 
     Spacers  200  are shown as applied to the exterior surface of the L flange perpendicular portion  122 A corresponding to the exterior of the second flange first portion  132 B. Spacers  200  also can be applied to the exterior of the second flange first portion  132 B. 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  120 A and wall section second flange first portion  132 B. The separation is determined by that distance desired to allow adhesive  300  to properly bond wall section  100 A to wall section  100 B. In some embodiments, the thickness of spacer  200  is 0.030″. While  FIG. 5  illustrates a vertical distribution of spacers  200 , and  FIG. 6 , described below, illustrates longitudinal distribution of the spacers, various other distributions are possible to facilitate proper bonding between the wall sections using the adhesive  300 . 
     Adhesive  300 , while shown in  FIG. 5  as uniformly distributed, can be applied in one or more beads around the spacers on one or both of the surfaces to be joined, as known to those of skill in the relevant art. In some embodiments, adhesive  300  is a single component, high strength, elastomeric sealant. For example, Hybrid adhesive sealant  760  from 3M™. The adhesive  300  is applied in sufficient quantity to substantially fill the space between the second flange first portion  132 B of wall section  100 B to the depth of the spacer  200 . 
     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  FIG. 6 , the cross-section view of  FIG. 5  is seen from a top view. In this view it can be seen that the spacers  200  are distributed along the joint between wall section  100 A and wall section  100 B. In assembling a wall panel from wall sections, sections  100 A and  100 B are brought together and clamped for sufficient time to allow the adhesive to bond the sections together. Excess adhesive  400 , e.g., adhesive beyond that needed to substantially fill the gap between wall section  100 B second flange first portion  132  B will flow 1) into the space between wall section  100 B second flange second portion and the corresponding portion of wall section  100 A first flange perpendicular portion  122 A, and 2) out of the top of the joint. Adhesive  400  flowing out of the top of the joint can be removed. 
     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  FIG. 7 , a flow chart describing methods  700  for assembly of wall panels from wall sections is shown. In step  710 , a plurality of wall sections  100  are formed (Step  710 ). For example, wall sections  100  are formed from aluminum sheets using a press brake for bending both an L flange  120  and a second flange  130  into the sheet. For the purpose of this example, three (3) wall sections are formed and aligned with long sides parallel; each wall section oriented as shown in FIG.  1 —with the L flange on the right and the second flange on the left, both flanges facing down. 
     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  FIG. 5  and  FIG. 6 . Adhesive, e.g., adhesive  400 , is applied to the L flange perpendicular portion  120  at a position corresponding to the mating second flange first portion  130  of the next wall section around the spacers (Step  730 ). Preferably, sufficient adhesive is applied to substantially fill the space between the L flange perpendicular portion  120  and the mating second flange first portion  130  of the next wall section. 
     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 ). 
     Referring to  FIG. 8 , a wall panel  800  of the present technology is illustrated. In  FIG. 8 , the wall panel  800  includes three (3) wall sections  100 , and a partial wall section  910 . Partial walls sections can be used when wall length is desired to be other than a multiple of the wall section length. In some embodiments of the technology, a partial wall section is, as shown in  FIG. 8 , simply a wall section  100  terminated before reaching either the L flange or the second flange. In some embodiments, a partial wall section includes both an L flange and a second flange as described above, but has a main body width different than the main body width of other wall sections used in a panel. 
       FIG. 8  also illustrates the L flange parallel portion  124 , including the L flange parallel portion outer face  920 . In some embodiments, the L flange parallel portion extends only as far as required to contact the second flange second portion  134  of the adjoining wall section. In other embodiments, such as the embodiment shown in  FIG. 8 , the L flange parallel portion extends beyond the second flange second portion  134 , providing a broader L flange parallel portion outer face that can be used to secure other structural elements (such as horizontal rails) and finish elements (such as wall board). The space  930  that can be enclosed by finish elements such as wallboard can be used to route utilities (e.g., electrical, communications), water, medical gases, and heating, ventilation, and air conditioning (HVAC) elements. 
     Referring to  FIG. 9 , a wall  990  of the present technology is illustrated. Wall  990  is not shown to scale; features are exaggerated to illustrate the relationship between the elements of the wall  990 . Wall  990  can include a plurality of wall panels  800 . Typically, wall  990  can include ten (10) or more wall panels  800 ; each wall panel  800  can include a number of wall sections  100 , e.g., three (3) full-width wall sections  100  and one (1) partial-width wall section as shown in  FIG. 8 . In preferred embodiments, walls  990  are formed with wall sections  100  of the wall panels  800  oriented vertically, e.g., along the short dimension of the rectangular wall  990  for configurations in which the wall  990  is longer than it is high. 
     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  FIG. 9  is rectangular and has four frame segments  992 , the frame can be any shape, including an n-sided closed polygon.  FIG. 10  illustrates an overall rectangular eight-sided closed polygon assembled as a frame  992 . Zero or more supports  996  can horizontally span the frame, and be secured to each wall section  100  at the L flange parallel portion outer face  920  using a metal-to-metal bonding such as SEM® 39537 weld bond. The horizontal supports  996  can be tack welded to the vertical frame segments  992 . 
     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 .  FIG. 9  illustrates four (4) flats  994  miter joined at the corners. The flats  994  can be secured to each frame segment  992  using various adhesives, e.g., methacrylate-based adhesives. In some embodiments, an adhesive sealant such as a single component, high strength, elastomeric sealant (for example, Hybrid adhesive sealant  760  from 3M™) can be used at the interface between the flats  994  and each wall section  100 . 
     Referring to  FIG. 10A , eight (8) frame segments  992  are illustrated forming an 8-sided closed polygon to frame a shelter wall  1000  including a portal  1010 . While the frame forms an 8-sided polygon, the overall wall shape is rectangular with height less than width. Perimeter flats are not shown in  FIG. 10A . The wall  1000  includes eighteen (18) full wall sections spanning the height of the wall, and four (4) shorter wall sections  100  over the portal  1010 . In  FIG. 10B , eight (8) flats  994  are affixed to the frame segments  992  and the wall sections  100 . Each flat  994  overlaps the abutment between a wall section  100  and a frame segment  992 . Referring to  FIG. 11 , a shelter  1000  formed from walls  990  of the present technology is shown in perspective view. Shelter  1000  includes long wall  990 A and short wall  990 B. Shelter  1000  can be sized to conform to ISO standards for intermodal shipping containers. 
     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.