U.S. patent application number 13/481442 was filed with the patent office on 2012-11-29 for systems and methods for constructing temporary, re-locatable structures.
Invention is credited to James G. Quinn.
Application Number | 20120297700 13/481442 |
Document ID | / |
Family ID | 47217790 |
Filed Date | 2012-11-29 |
United States Patent
Application |
20120297700 |
Kind Code |
A1 |
Quinn; James G. |
November 29, 2012 |
SYSTEMS AND METHODS FOR CONSTRUCTING TEMPORARY, RE-LOCATABLE
STRUCTURES
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.
Inventors: |
Quinn; James G.; (Arnold,
MD) |
Family ID: |
47217790 |
Appl. No.: |
13/481442 |
Filed: |
May 25, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61489748 |
May 25, 2011 |
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Current U.S.
Class: |
52/105 ;
52/285.1; 52/588.1 |
Current CPC
Class: |
E04B 1/34321
20130101 |
Class at
Publication: |
52/105 ;
52/588.1; 52/285.1 |
International
Class: |
E04B 1/343 20060101
E04B001/343; E04B 1/38 20060101 E04B001/38; E04G 21/00 20060101
E04G021/00 |
Claims
1. A system for constructing a temporary structure, comprising: a
plurality of wall panels; a plurality of roof panels; a plurality
of floor panels; at least one door panel; and one or more 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; wherein the first track has a first surface with an
indentation and a flat second surface; and wherein 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.
2. The system of claim 1, further comprising a plurality of
fasteners, wherein each fastener is adapted to couple at least two
of a wall panel, a roof panel, a floor panel, and a door panel.
3. The system of claim 1, further comprising a plurality of
coupling devices.
4. The system of claim 3, wherein at least one coupling device is
adapted to couple a wall panel to a floor panel.
5. The system of claim 3, wherein at least one coupling device is
adapted to couple a wall panel to a roof panel.
6. The system of claim 3, wherein at least one coupling device is
adapted to couple two wall panels perpendicularly.
7. The system of claim 3, further comprising at least one roof
support beam, wherein the coupling device is adapted to couple two
wall panels and a roof support beam.
8. The system of claim 1, wherein the wall panels, the roof panels,
the floor panels, and the at least one door panel are
identical.
9. The system of claim 1, further comprising a coating on the
surface of at least one panel.
10. The system of claim 1, wherein each wall panel, roof panel,
floor panel, and door panel has two first tracks and two second
tracks.
11. The system of claim 10, wherein the two first tracks are
coupled adjacent to each other and the two second tracks are
coupled adjacent to each other.
12. The system of claim 1, wherein the system is adapted to be
assembled and disassembled into the original components on
location.
13. The system of claim 12, wherein the system is adapted to be
re-located and reassembled after being disassembled.
14. The system of claim 1, wherein the first track and the second
track are coupled to parallel edges.
15. The system of claim 1, further comprising adhesive to adjoin
panels.
16. A structure, comprising: a plurality of wall panels; a
plurality of roof panels; a plurality of floor panels; at least one
door panel; and one or more 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; wherein the
first track has a first surface with an indentation and a flat
second surface; and wherein 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.
17. The structure of claim 16, further comprising a plurality of
fasteners, wherein each fastener couples at least two of a wall
panel, a roof panel, a floor panel, and a door panel.
18. The structure of claim 16, further comprising a plurality of
coupling devices.
19. The structure of claim 18, wherein at least one coupling device
couples a wall panel to a floor panel.
20. The structure of claim 18, wherein at least one coupling device
couples a wall panel to a roof panel.
21. The structure of claim 18, wherein at least one coupling device
couples two wall panels perpendicularly.
22. The structure of claim 18, further comprising at least one roof
support beam, wherein the coupling device couples two wall panels
and a roof support beam.
23. The structure of claim 16, wherein the wall panels, the roof
panels, the floor panels, and the at least one door panel are
identical.
24. The structure of claim 16, further comprising a coating on the
surface of at least one panel.
25. The structure of claim 16, wherein each wall panel, roof panel,
floor panel, and door panel has two first tracks and two second
tracks.
26. The structure of claim 25, wherein the two first tracks are
coupled adjacent to each other and the two second tracks are
coupled adjacent to each other.
27. The structure of claim 16, wherein the structure is
disassemblable into the original components.
28. The structure of claim 27, wherein the structure is
re-locatable and reassemblable.
29. The structure of claim 16, wherein the first track and the
second track are coupled to parallel edges.
30. The structure of claim 16, further comprising adhesive between
adjoining panels.
31. A panel, comprising: a first track coupled to at least one edge
of the panel; and a second track coupled to at least one other edge
of the panel; wherein the first track has a first surface with an
indentation and a flat second surface; and wherein 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. 9a-b depict an embodiment of coupling a wall panel to
a floor panel.
[0021] FIGS. 10a-b depict an embodiment of coupling a wall panel to
a roof panel.
[0022] FIGS. 11a-b depict an embodiment of coupling a wall panel to
a roof panel.
[0023] FIGS. 12a-b depict an embodiment of coupling two roof panels
and a roof beam.
[0024] FIGS. 13a-b depict an embodiment of coupling a wall panel to
a floor panel.
[0025] FIGS. 14a-b depict an embodiment of coupling a wall panel to
a floor panel.
[0026] FIGS. 15a-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'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 210a (labeled A
in the figures) and 210b (labeled B in the figures). In the
preferred embodiment, each panel 105 has one track 210a coupled to
a first edge and one track 210b coupled to a second, parallel edge.
In the preferred embodiment, tracks 210a and 210b 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 210a and
210b. Furthermore, in certain embodiments each panel can have two
tracks 210a and two tracks 210b. Preferably in embodiments with
tracks on each edge of the panel 105, the two tracks 210a are
adjacent to each other and the two tracks 210b are adjacent to each
other such that opposing edges have different tracks. Track 210a
has indented or recessed portion 215 along its outer edge, into
which angled hemmed tab 220 of track 210b mates. On the opposite
edge of track 210b 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 210b.
In a preferred embodiment a foam seal or other insulation is placed
between track 210a and track 210b 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 210a to track 210b once the two tracks are coupled together.
Both tracks 210a and 210b 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 210b of a first panel 105 to a
track 210a of a second, perpendicular panel 105. Self-locking
corner 660 is preferably coupled to tracks 210a and 210b 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 210a and 210b 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 210a and on two sides with track 210b, 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. 9a-b depict an embodiment of a coupling device 909 for
coupling a wall panel coupled to track 210a to a floor panel
coupled to track 210b. Coupling device 909 is substantially "C"
shaped. As can be seen in FIG. 9b, the upper portion of coupling
device 909 mates with track 210a and there is a flange that couples
to straight hemmed tab 225 of track 210b. 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 210a 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. 10a-b depict an embodiment of a coupling device 1011
for coupling a wall panel coupled to track 210b to a roof panel
coupled to track 210b. Coupling device 1011 is substantially "C"
shaped. As can be seen in FIG. 10b, the upper portion of coupling
device 1011 has a flange that mates with the angled hemmed tab of
the track 210b of the roof panel while the lower portion of
coupling device 1011 mates with track 210b 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 210b 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. 11a-b depict an embodiment of a coupling device 1116
for coupling a wall panel coupled to track 210b to a roof panel
coupled to track 210a. Coupling device 1116 is substantially "C"
shaped. As can be seen in FIG. 11b, the upper portion of coupling
device 1116 surrounds track 210a of the roof panel, while the lower
portion of coupling device 1116 abuts with track 210b 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 210b of the wall panel and track 210a 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. 12a-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. 11b, the upper
portion of coupling device 1221 fits within the indented portion
215 of track 210a and over angled hemmed tab 220 of track 210b,
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. 13a-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.
13b, the left portion of coupling device 1333 mates with track 210a
of a first wall panel, while the right portion of coupling device
1333 abuts track 210b 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 210a of the first wall
panel and track 210b 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. 14a-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.
14b, the upper portion of coupling device 1442 mates with track
210a of a first wall panel, while the lower portion of coupling
device 1442 abuts track 210b 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 210a of the first
wall panel and track 210b 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. 15a-b depict all of the components for an
approximately 20'.times.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.
* * * * *