Patent Publication Number: US-8978333-B2

Title: Structure formed from panels joined with universal clamping brackets

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. provisional patent application Ser. No. 61/684,065, filed on Aug. 16, 2012, the disclosure of which is hereby incorporated by reference. 
    
    
     FIELD 
     The present disclosure relates to shelters and, more particularly, to a shelter formed from modular components including universal brackets and planar members such as autoclaved aerated concrete panels, structural insulated panels, plywood and the like. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Autoclaved Aerated Concrete (AAC) panels are known to be lightweight, fire resistant, and sound insulative. These panes can also be very strong and can hear a significant amount of weight for use in the construction of various structures and shelters, such as homes, hotels, etc. Typically, a plurality of AAC panels are attached together to construct the structure. Similarly, Structural Insulated Panels (“SIP&#39;s”) formed of a foam core that usually has an exterior and interior surface material applied thereto are also used to form floor, walls and roofs. 
     Although these structures have functioned adequately for their intended purposes, there are problems that remain. For instance, attaching the AAC and SIP panels can be difficult and time consuming. Also, the resulting joint between individual panels may not be sufficiently strong in certain uses and/or weather conditions. Specifically, conventional joints between AAC and SIP panels and other panels of material such as plywood and the like may not be able to withstand high winds, etc, occurring during severe weather conditions, such as hurricanes, typhoons, etc. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     A shelter is disclosed that is constructed from a plurality of AAC, or SIP panels or other panels such as plywood or the like. The shelter also includes brackets or joint members that connect at least two panels together. The brackets include a first flange that extends over and overlaps a first side of the at least two panels and a second flange that extends over and overlaps a second side of the at least two panels. At least one clamping element extends from the bracket into the panel and a fastener extends through bracket into the clamping element thereby clamping the clamping element toward a flange, thereby strongly joining the panels together. 
     Other features of the shelter include corner bracket assemblies that attach at least two panels disposed at an angle relative to each other. The corner bracket assembly can include a bracket with flanges operable to attach to at least one of the panels, a tubular retainer that is fixed to the bracket, and a threaded rod that is received in the retainer and that extends partially out of the bracket. The threaded rod can be attached to a foundation on one end, and the rod can compress a roof panel toward the foundation to thereby secure the shelter to the foundation. 
     The shelter can include one or more doors and windows. Also, the shelter can be modular such that the shelter can selectively include one or more rooms and floors. Also, the shelter can be configured into a pet shelter for sheltering a pet or other animal. 
     The shelter can include various features that allow the shelter to withstand high winds, precipitation, flying debris, and other hazards of a hurricane, typhoon, tornado, or other event. Thus, the shelter can protect occupants in a wide variety of conditions. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summery are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is an isometric view shelter according to various teachings of the present disclosure; 
         FIG. 2  is an isometric view of an exemplar bracket used to join two panels together to form the shelter of  FIG. 1 ; 
         FIG. 3  is an enlarged isometric view of a bracket joining two panels together to form a planar wall in accordance with an embodiment of the present invention; 
         FIG. 4  is an enlarged, isometric view of a bracket joining two panels to form a corner of the shelter of  FIG. 1  and a second bracket joining two panels together to form a planar wall of the shelter in accordance with an embodiment of the present invention; 
         FIG. 5  is an enlarged cross sectional view of the bracket of  FIG. 3 ; 
         FIG. 6  is an enlarged ground mounting bracket showing possible mounting of a panel to the ground in accordance with an embodiment of the present invention. 
         FIG. 7  is a cross-section of a corner mounting bracket in accordance with an embodiment of the present invention. 
         FIG. 8  is a cross-section of an alternative possible bracket in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross-section of an alternative possible planar mounting bracket in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-section of the planar mounting bracket of  FIG. 3  sowing possible cross-sections of panels mounted thereto. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings.  FIGS. 1-10  disclose a preferred shelter  109  formed of modular panel  12  and bracket  14  components. Each of these embodiments is discussed in greater detail below. 
     Referring initially to  FIG. 1 , a shelter  10  is illustrated according to venous exemplary embodiments. The shelter  10  can generally include a plurality of panels  12  that can be formed of suitable materials such as Autoclaved Aerated Concrete (AAC). Structural Insulated Panels (“SIP&#39;s”), plywood, or the like that are joined together edge-to-edge via a plurality of brackets  14  (i.e. joints or fleshing) and that are supported atop a foundation  16 . As will be discussed, the shelter  10  can provide protection from the elements. Also, in some embodiments, the shelter  10  can withstand high winds, heavy precipitation, flying debris, and other effects of hurricanes, typhoons, tornadoes, or other extreme weather conditions. 
     As shown in  FIG. 1  the panels  12  can be substantially flat panels that are elongate. As is known, the AAC panels  12  can be manufactured by combining ground silica sand, Portland cement, lime, water, and an expanding agent (e.g., ground aluminum powder), which is molded. During formation in a mold, the aluminum can react with the lime to produce hydrogen bubbles therein. The AAC panels  12  can be then cut into a desired shape from the bulk, molded material. The AAC panels  12  can be relatively lightweight and, yet, can bear significant loads. Also, the AAC panels  12  can be fire resistant and can be sound insulative. 
     Similarly, and as best shown in  FIGS. 3-5 , the panels  14  can be SIP&#39;s that are formed and constructed with conventional materials and methods. For example, the SIP can include a rigid polymer foam  60  sandwiched between two layers  62  of structural board, such as sheet metal, plywood, cement, oriented strand board. The polymer foam  60  can be expanded polystyrene foam (EPS), extruded polystyrene foam (XPS), polyisocyanurate foam, polyurethane foam or the like. An additional layer of other material  61  ( FIG. 8 ), such as ballistic insulation, or the like may also be positioned within the SIP or operably secured to an exterior surface of the SIP as desired. In addition, an exterior surface material  210  ( FIG. 10 ), such as plaster, stucco, paint or the like may be applied to the SIP as desired. 
     The shelter  10  can include any number of panels  12  of any suitable shape. Also, the shelter  10  can include one or more panels  12  that collectively define upright, vertical walls and other panels  12  that collectively define a roof. It will be appreciated that the shelter  10  could also include panels  12  made out a material other than those described herein in some embodiments of the present disclosure. 
     Moreover, the brackets  14  can nave a number of varieties. In some embodiments shown in  FIGS. 2 ,  3 , and  5 , two panels  12  can be joined by a bracket to form an elongate planar structure such as a wall, roof, floor or the like. Alternatively, in some embodiments shown in  FIGS. 4 ,  7 , and  8 , the brackets can be configured so as to join two panels  12  together to define a corner. The joint members  18 ,  20  can be made from bent sheet metal, such as steel and/or Aluminum, or they may be molded or extruded using conventional fabrication methods. On known material that works particularly well in this application is commonly known as Aluminum 6061. 
     The brackets  14  can each include a base  20  that wraps around a respective edge of the panels  12  and flanges  22 ,  24  extends perpendicularly away from the base  20  and capture the edge of the panel  14  therein as best shown in  FIG. 5 . Elongate protrusions  26   a ,  26   b  extend perpendicularly from the base and are parrallelly aligned and spaced apart from the flanges  22 ,  24 . Fastener mounting holes are aligned to as to allow a fastener, such as a screw fastener to extend through a flange  22 ,  24  and be threadably received through holes  54  in the elongate protrusions  26   a ,  26   b  as best shown in  FIG. 5 . The faster extends through a portion of the panel, and mating recesses are preferably provided in the edge of the panel  14  so as to allow the protrusion to be received therein. Accordingly, can be appreciated that tightening the fastener draws the distal end  28  of the protrusion  26   a ,  26   b  toward its adjacent flange  24 ,  22 , thereby allowing the protrusion to essentially clamp a portion of the panel  12  to the bracket  14 . This clamping action allows the structure formed with these brackets to be quickly assembled while also being particularly strong and wind resistant. 
     Referring to  FIGS. 7 &amp; 8 , the brackets  14  also include a corner joint assembly that connects at least two panels  12  at an angle (e.g., ninety degrees). The bracket  14  can include a hollow for receiving cables  112  or the like therein. The cables can include steel securing cables that around mounted to the ground for holding the structure in place during high winds or the like. In addition other items, such as electrical wiring and the like can be extended through the hollow as needed. 
     A layout of a one-room shelter  10  is illustrated in  FIG. 1 . In some embodiments, the shelter  10  can be approximately 7′4″ by 7′4″. This layout can be sized to be useful as a home, a shed, a medical care facility, a latrine (i.e., housing a toilet, sink, etc.), a school or for other uses. In other embodiments, the size of the shelter  10  can be reduced to house and protect a pet or other animal (e.g., a doghouse). The components of the present invention may be combined as needed to build multiple story structures. 
     Moreover, the panels  12  can be arranged to include windows and doors (hinged or sliding doors) with frames made out of metal or other materials. 
     Also, a coating, such as Stucco, can be applied on the outer surfaces of the panels  12  for aesthetic purposes and to further protect the shelter  10  against the elements. Moreover, the shelter  10  can include an interior flooring The flooring can be wooden planks that are arranged edge-to-edge, a cement slab, etc. The flooring can be an exposed portion of the foundation  16  in some embodiments, or the flooring can be separate and can overlay the foundation  16 . The flooring can also include a mat, such as a rubber mat that is laid over the foundation  16 . 
     The shelter  10  can also include certain modular features. For instance, the shelter  10  can be configured to include optional rooms, wings, or other features. For instance, the brackets  14  can be configured to join a plurality of panels  12  into a variety of optional rooms or wings. It will be appreciated that a set of panels  12  and joints  14  can be included in a kit, and the user can earl decide whether to assemble the panels  12  and joints  14  of the kit into a one-room or multiple room shelter  10 . In some embodiments, a number of different floor plans can be built from the same amount of panels  12  and joints  14 . Also, in some embodiments, the user can attach additional rooms or wings to an already-standing shelter  10 . Furthermore, in some embodiments, multiple individual one-room shelters  10  can be connected for increased modularity. 
     The materials for the sheet  10  (i.e., panels  12 , joints  14 , fasteners etc.) can be transported in a disassembled state on one or more standard pallets. Also, in some embodiments, a plurality (e.g. twenty) of sets of materials (e.g., enough for twenty shelters  10 ) can be palletized and fit inside a standard 20′ shipping container. Thus, the materials can be transported across large distances, for instance, to areas of the word that experience typhoons, hurricanes, or other extreme weather events. Because the materials of the shelter  10  are highly portable, many shelters  10  can be provided in a relatively short amount of time to people that are at risk from these weather events. 
     Accordingly, the shelter  10  can provide protection against harsh winds (e.g., up to 185 mph winds), heavy precipitation, flying debris, etc. Also the shelters  10  can be quickly and easily assembled and disassembled. Moreover, the shelters  10  can be modular and adaptable according to the needs of the users. Furthermore, the materials for the shelters  10  can be palletized and relatively easily transported to almost any place in the world. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.