U.S. patent application number 10/117560 was filed with the patent office on 2003-10-09 for method for constructing modular shelters using recycled land/sea shipping containers.
Invention is credited to Cote, Edward E. JR..
Application Number | 20030188507 10/117560 |
Document ID | / |
Family ID | 28674228 |
Filed Date | 2003-10-09 |
United States Patent
Application |
20030188507 |
Kind Code |
A1 |
Cote, Edward E. JR. |
October 9, 2003 |
Method for constructing modular shelters using recycled land/sea
shipping containers
Abstract
A method of constructing modular, multi-use, enclosed shelters
by recycling modular shipping containers, including the steps of
determining a desired type of enclosed shelter module compatible
with the dimensions of a modular shipping container, determining
structural and functional components necessary for the selected
type of enclosed shelter module, packing the structural and
functional components into the modular shipping container,
transporting the packed shipping container to a site selected for
the enclosed shelter module, unpacking the structural and
functional components from the shipping container, and assembling
the structural and functional components into and onto the shipping
container to convert the shipping container into the desired type
of enclosed shelter module. Modular, multi-use enclosed shelters
may be constructed by assembling a plurality of shipping containers
converted into one or more types of enclosed shelter modules into a
multi-element structure, wherein each element of the structure is
comprised of a converted shipping container and the shipping
containers are joined by means of the mechanisms normally provided
to interlock multiple modular shipping containers during
shipping.
Inventors: |
Cote, Edward E. JR.; (New
Hampton, NH) |
Correspondence
Address: |
DAVIS & BUJOLD, P.L.L.C.
FOURTH FLOOR
500 N. COMMERCIAL STREET
MANCHESTER
NH
03101-1151
US
|
Family ID: |
28674228 |
Appl. No.: |
10/117560 |
Filed: |
April 4, 2002 |
Current U.S.
Class: |
52/741.1 ;
52/143; 52/79.1; 52/79.9 |
Current CPC
Class: |
E04B 1/3483 20130101;
E04B 2001/34892 20130101 |
Class at
Publication: |
52/741.1 ;
52/79.1; 52/79.9; 52/143 |
International
Class: |
E04H 001/00; E04H
003/00; E04H 005/00; E04H 006/00; E04H 009/00; E04H 014/00; E04H
001/12 |
Claims
What is claimed is:
1. A method for recycling modular shipping containers, comprising
the steps of: determining a type of enclosed shelter compatible
with the standardized, modular dimensions of a shipping container;
determining structural and functional components necessary for the
selected type of enclosed shelter; packing the structural and
functional components into the shipping container; transporting the
packed shipping container to a site selected for the enclosed
shelter; unpacking the structural and functional components from
the shipping container; and assembling the structural and function
components into and onto the shipping container to convert the
shipping container into the desired type of enclosed shelter.
2. The method of claim 1 for recycling modular shipping containers,
further comprising the steps of: assembling a plurality of shipping
containers converted into one or more types of enclosed shelters
into a multi-element structure, wherein each element of the
structure is comprised of a converted shipping container and the
shipping containers are joined by means of the mechanisms normally
provided to interlock multiple shipping containers during
shipping.
3. A method of constructing modular, multi-use enclosed shelters,
comprising the steps of: determining a desired type of enclosed
shelter module compatible with the dimensions of a modular shipping
container; determining structural and functional components
necessary for the selected type of enclosed shelter module; packing
the structural and functional components into the modular shipping
container; transporting the packed shipping container to a site
selected for the enclosed shelter module; unpacking the structural
and functional components from the shipping container; and
assembling the structural and function components into and onto the
shipping container to convert the shipping container into the
desired type of enclosed shelter module.
4. The method of claim 3 for constructing modular, multi-use
enclosed shelters, further comprising the steps of: assembling a
plurality of shipping containers converted into one or more types
of enclosed shelter modules into a multi-element structure, wherein
each element of the structure is comprised of a converted shipping
container and the shipping containers are joined by means of the
mechanisms normally provided to interlock multiple modular shipping
containers during shipping.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] 1. Field of the Invention
[0002] The present invention is directed to a method for
constructing modular shelters, such as residences or offices using
recycled sea/land shipping containers for both the transportation
of residential or office module building supplies and as the basic
structure for a residential or office module and wherein various
modules may be assembled to provide multiple interconnected
residential or office spaces.
[0003] 2. Background of the Invention
[0004] There is a present and historic need for sturdy, relatively
inexpensive, readily shippable, enclosed, human inhabitable
shelters having one or more interior spaces for housing, offices or
other purposes that may be readily constructed by either skilled or
unskilled labor, that may be adapted to a wide range of purposes,
sites and environments and that can readily survive the rigors of
transportation under a wide range of conditions. It is also
preferable that such shelters be at least capable of assuming a
modular form having one or more sets of standardized dimensions for
facility in shipping. The reuse or recycling of elements,
structures or materials, including those originally intended for
other purposes is also desirable for economic and environmental
reasons.
[0005] Such shelters may be employed for a wide range of purposes,
such as vacation homes, hunting and fishing lodges, wilderness
shelters and temporary or long term laboratory/medical/housing
facilities, particularly in remote sites, and low cost housing and
office space. Other exemplary applications include emergency
housing, office and laboratory facilities for areas effected by
natural or man-made disasters and short or long term housing,
office and laboratory facilities in developing areas.
[0006] Another and apparently unrelated problem arises from the
very common situation of trade shipment imbalances between
countries or even between areas of a country. That is, certain
countries or locales, often those offering low labor costs, tend to
be sources of goods, most often including consumers goods such as
vehicles, cars, furniture, electronic components and products, food
and flowers, while other countries or locales tend to be importers
of such goods and to ship a relatively smaller volume of goods in
return. Such situations commonly result in a shipping imbalance
wherein "empties", that is, the means by which the goods are
shipped, either accumulate at the receiving locale or shipped back
empty to the source locale. The return of empty shipping containers
is often regarded as uneconomical, whether the "empties" are
packing containers, trucks, rail cars or ships. Therefore, and
unless the involved industry has developed a specific method to
deal with the costs of returning empties, such as carrying the
return costs as part of the original shipping costs or developing a
return market to minimize the volume of empty shipping, the
"empties" tend to merely accumulate at the receiving end. It will
be recognized, therefore, that the non-return and accumulation of
"empties" represents a significant lost investment in raw materials
and construction costs.
[0007] For example, a very common method of shipping goods by sea,
rail or truck is the use of "sea/land" containers, which are
rugged, standardized containers that are typically multiples of 20
in length by 8 feet wide and high with a pair of bolt latched doors
at one end. The containers include interlock mechanisms at each
corner, thereby allowing the containers to be stacked or otherwise
securely joined to one another on, for example, the deck of a ship,
on a railcar or on a truck, and are typically constructed of heavy
gauge steel. The accumulation of empty, unreturned sea/land
shipping containers is a particularly significant problem as the
containers are manufactured in significant quantities and are
sufficiently inexpensive to be commonly used in "one way" trades
but, because of the number of containers involved in such trades,
represent significant unrecovered value in both raw materials and
construction costs
[0008] The present invention provides a solution to the apparently
unrelated problems, and to other similar and related problems of
the prior art.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a method for recycling
modular shipping containers to provide shelters wherein the methods
includes the steps of determining a type of enclosed shelter
compatible with the standardized, modular dimensions of a shipping
container, determining structural and functional components
necessary for the selected type of enclosed shelter, packing the
structural and functional components into the shipping container,
transporting the packed shipping container to a site selected for
the enclosed shelter, unpacking the structural and functional
components from the shipping container, and assembling the
structural and function components into and onto the shipping
container to convert the shipping container into the desired type
of enclosed shelter.
[0010] The method of the present invention may further include the
assembly of a plurality of shipping containers converted into one
or more types of enclosed shelters into a multi-element structure,
wherein each element of the structure is comprised of a converted
shipping container and the shipping containers are joined by means
of the mechanisms normally provided to interlock multiple shipping
containers during shipping.
[0011] The present invention is also directed to a method of
constructing modular, multi-use enclosed shelters, including the
steps of determining a desired type of enclosed shelter module
compatible with the dimensions of a modular shipping container,
determining structural and functional components necessary for the
selected type of enclosed shelter module, packing the structural
and functional components into the modular shipping container,
transporting the packed shipping container to a site selected for
the enclosed shelter module, unpacking the structural and
functional components from the shipping container, and assembling
the structural and function components into and onto the shipping
container to convert the shipping container into the desired type
of enclosed shelter module.
[0012] Again, this method may be used to construct modular,
multi-use enclosed shelters by assembling a plurality of shipping
containers converted into one or more types of enclosed shelter
modules into a multi-element structure, wherein each element of the
structure is comprised of a converted shipping container and the
shipping containers are joined by means of the mechanisms normally
provided to interlock multiple modular shipping containers during
shipping.
[0013] Other features, objects and advantages of the present
invention will be understood by those of ordinary skill in the
relevant arts after reading the following descriptions of a
presently preferred embodiment of the present invention, and after
examination of the drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a general diagram of a Container 10, such as a
sea/land shipping container;
[0015] FIG. 2 is a flow diagram illustrating the recycling of
Containers 10 into shelters;
[0016] FIG. 3A is a plan of a container recycled into an exemplary
shelter; and
[0017] FIGS. 3B and 3C are side plan views of containers recycled
into exemplary shelters.
DESCRIPTION OF THE INVENTION
[0018] Referring to FIG. 1, therein is shown a diagrammatic
representation of a Sea/Land Shipping Container (Container) 10
having two Side Walls (Sides) 10S, two End Walls (Ends) 10E, a Top
Wall (Top) 10T and a Bottom Wall (Bottom) 10B. As is well known in
the art, a Container 10 is typically of standardized dimensions,
such as multiple of 20 feet in length by 8 feet wide and 8 feet
high, to permit the stacking and interlocking of multiple
Containers 10, and is typically provided with Interlocks 101 at
each corner to allow stacked or otherwise arranged Containers 10 to
be securely joined one to another. Also, one End 10E is typically
comprised of a pair of hinged Doors 10D securable by Lock Bolts
(Bolts) 10L. Containers 10 are typically constructed of heavy gauge
steel and are thereby structurally strong and rugged and, together
with the facility for securely locking the Containers 10 by means
of Doors 10D and Bolts 10L, provide secure protection to the
contents of a Container 10 against a wide range of environmental
and physical rigors, including physical force, water and fire.
[0019] As illustrated in FIG. 2, the present invention provides a
method by which Containers 10 are recycled to provide sturdy,
relatively inexpensive, shippable, enclosed, modular shelters that
may be used, for example, for housing, offices or other purposes,
that may be readily constructed by skilled or unskilled labor, that
may be adapted to a wide range of purposes, sites and environments,
and that can readily survive the rigors of transportation under a
wide range of conditions. Such shelters may typically be designed
and constructed for functions or purposes requiring that they be
human inhabitable for brief or extended periods, or may be designed
and constructed for purposes whose primary requirement is other
than human inhabitability, such as remote or local equipment
shelters or storage facilities. It will also be noted that a
shelter or structure based upon one or more Containers 10 do not
require extensive foundations, such as concrete foundations, due to
the inherent structural strength of the Containers 10. That is,
Containers 10 do not require concrete or similar foundation walls
as a primary component of the structural strength of the
structure.
[0020] According to the present invention, and as described further
in the following, a Container 10 that has fulfilled its initial
purpose; that is, the shipping of goods from one locale to another,
is modified into a Shippable Module 12 wherein the Container 10 is
used both as the Basic Structure 14 of a Shelter Module 16, that
is, to provide the walls, roof and floor of the Shelter Module 16,
and as the shipping Container 10 for all Components 18 required to
fit the Basic Structure 14, that is, the Container 10, to the
desired purposes as a Shelter Module 16.
[0021] Components 18 may include, for example, door or window
units, exterior siding, interior wall and insulation panels, floor
coverings, fixtures such as cabinets, sanitary facilities and so
on, and utility components such as wiring and plumbing elements.
Any of Components 18 may be provided in a range of forms, depending
upon the skill levels of the anticipated constructors. For example,
as illustrated in FIG. 3A, certain Components 18 may be provided in
fully assembled, modular form, such as windows, doors, cabinets and
sanitary fixtures such as toilets, basins and bath/shower units,
requiring only that the units be put in place, such as in an
appropriate opening cut in a wall, and fixed in place by a means
suitable to the component and the assembler, such as nails, screws,
bolts or adhesives. At least some utilities, such as power wiring
and plumbing, may also be provided and assembled as modular units,
assuming that the layout of the Shelter Module 16 is defined and
known before the Module 12 is assembled. In the same manner,
interior wall, roof, ceiling and floor components and insulation
may be provided as pre-assembled modules requiring only that the
modules be moved into place and installed by, for example, nails,
screws or adhesives. In other instances, certain interior
Components 18, such as flooring, ceiling or wall components maybe
installed when a Module 12 is originally assembled for shipment
and, in other instances, and particularly when more skilled workers
are available, at least some Components 18, such as wiring and
plumbing elements or floor, ceiling and wall elements, may be
provided as "raw materials" or basic components rather than as
modular, preassembled or preformed elements. In summary, the only
fixed requirement imposed on the forms that may be assumed by
Components 18 is that the Components 18 fit within the Module 12.
Otherwise the nature, type and form of Components 18 is determined
by the intended function of the Shelter Module 16, the expected or
defined environmental and site conditions, the skill of the
available work force, and so on.
[0022] As illustrated in FIGS. 3B and 3C, two or more of one or
more types of Shelter Modules 16 may be assembled together using
the corner Interlocks 101 standard on Containers 10, such as
Sea/Land containers, to lock the Shelter Modules 16 into the
desired side-by-side and/or stacked configuration to thereby
construct a Multi-Unit Structure 20 of any desired configuration.
Multi-Unit Structures 20 may include, for example, an office unit
comprised of multiple office units with a kitchen/lounge/sanitary
facilities unit or a housing unit comprised of a kitchen/common
room/sanitary facility and one or more sleeping or residence units.
The addition of one or more laboratory or clinic units to such a
Multi-Unit Structure 20 would, in turn, create a clinic or research
station, and so on, while the addition of Shelter Modules 16 having
other Components 18 could result, for example, in a prison or jail
facility, a communications facility or a store, and so on.
[0023] For example, and as indicated in FIG. 3, when Shelter
Modules 16 are joined on a horizontal plane, interior passages
between Shelter Modules 16 may be provided by suitable matching
openings made in the adjacent Shelter Modules 16 and door or door
frame Components 18 in the openings that mate to provide a passage
sealed against the outside environment. In a like manner, when
Shelter Modules 16 are joined or stacked vertically, interior
passages between vertically joining Shelter Modules 16 may again be
provided by suitable matching openings in the ceiling of the lower
unit and the floor of the upper unit and a stairway Component 18
installed for passage between the Shelter Modules 16. In the
alternative, when desired or necessary, passage between vertically
joining Shelter Modules 16 may be provided by means of exterior
door Components 18 jointed by an exterior stair unit Component 18.
Other facilities connecting between adjoining Shelter Modules 16,
such as plumbing, sanitary connections, power or communications
wiring and connections, heat/ventilation/air conditioning ducting
and so on may be provided in a similar manner, that is, by matching
openings made in the Shelter Modules 16 with appropriate Components
18 to seal the openings as necessary.
[0024] Lastly, a Module 12 may include drawings for assembly into a
Shelter Module 16 and verified according to local codes and
requirements. In an alternative, and particularly in regions
lacking skill labor used to construction, guidelines for the
assembly of a Module 12 into a Shelter Module 16 may be provided
by, for example, stenciling on the interior surfaces to locate and
dimension, for example, window and door openings, the locations of
interior elements, such as wiring, plumbing, interior divider
walls, toilets, and so on. In yet further alternatives, the
required openings, mountings and assemblies may be made by medium
to high level skilled workers using, for example, cutting torches,
power saws and drills and so on. In the instance of relatively low
skill workers or a lack of appropriate assembly tools, some
elements, such as window, door and plumbing openings may be formed
at the assembly of a Module 12 as "knock out" panels, making
appropriate allowance for the rigors of transportation and
assembly.
[0025] In conclusion, while the invention has been particularly
shown and described with reference to preferred embodiments of the
apparatus and methods thereof, it will be also understood by those
of ordinary skill in the art that various changes, variations and
modifications in form, details and implementation may be made
therein without departing from the spirit and scope of the
invention as defined by the appended claims. Therefore, it is the
object of the appended claims to cover all such variation and
modifications of the invention as come within the true spirit and
scope of the invention.
* * * * *