U.S. patent application number 13/619546 was filed with the patent office on 2013-03-21 for building system and method.
This patent application is currently assigned to DIVERSIFIED FIXTURES, INC.. The applicant listed for this patent is Daniel J. Hertel, Kevin Kvols. Invention is credited to Daniel J. Hertel, Kevin Kvols.
Application Number | 20130067846 13/619546 |
Document ID | / |
Family ID | 47879309 |
Filed Date | 2013-03-21 |
United States Patent
Application |
20130067846 |
Kind Code |
A1 |
Kvols; Kevin ; et
al. |
March 21, 2013 |
BUILDING SYSTEM AND METHOD
Abstract
A building system can comprise wall, floor, and/or ceiling
panels. A first profile with two cavities extending along different
sides of the profile can be used to connect similar panels
together. A second profile can be used to connect dissimilar
panels. A plurality of fastening clips can be used to lockingly
engage a wall panel at one end and one of either a wall panel, a
floor panel, or a ceiling panel at the other end. The building
system can be configured to not require other fasteners besides the
clips and profiles to hold the panels together.
Inventors: |
Kvols; Kevin; (Steamboat
Springs, CO) ; Hertel; Daniel J.; (Colorado Springs,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kvols; Kevin
Hertel; Daniel J. |
Steamboat Springs
Colorado Springs |
CO
CO |
US
US |
|
|
Assignee: |
DIVERSIFIED FIXTURES, INC.
Colorado Springs
CO
|
Family ID: |
47879309 |
Appl. No.: |
13/619546 |
Filed: |
September 14, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61535785 |
Sep 16, 2011 |
|
|
|
Current U.S.
Class: |
52/586.1 |
Current CPC
Class: |
E04B 2001/6195 20130101;
E04B 1/34315 20130101; E04B 1/6116 20130101; E04B 2001/34389
20130101; E04H 1/1205 20130101 |
Class at
Publication: |
52/586.1 |
International
Class: |
E04B 1/38 20060101
E04B001/38; E04C 1/00 20060101 E04C001/00 |
Claims
1. A building system comprising: a series a wall panels, each
having one or more wall slot; a series of floor panels each having
one or more floor slot; a series of ceiling panels each having one
or more ceiling slot; a first profile comprising two cavities
extending along different sides of the profile, each cavity
configured to receive a panel from the same series together; a
second profile for connecting panels from one series to another
series together, the second profile having a shape different from
the first profile and comprising two cavities positioned
essentially perpendicular with one another, the first cavity
configured to receive at least one of either the floor panels or
the ceiling panels, and the second cavity configured to receive at
least one of the wall panels such that in the assembled
configuration the wall panel will rest on and be above the at least
one floor panel or the ceiling panel will rest on and be above the
wall panel; and a plurality of fastening clips, each clip
configured to lockingly engage a wall slot at one end and one of
either a wall slot, a floor slot, and a ceiling slot at the other
end, wherein the building system does not require other fasteners
besides the clips and profiles to hold the panels together.
2. The building system of claim 1, wherein the first profile has an
I-beam shape with the two cavities being on opposite sides of the
first profile.
3. The building system of claim 1, wherein the two cavities of the
first profile are angled at about 135 degrees with respect to one
another.
4. The building system of claim 1, wherein the second profile has
an "L" shape defining two cavities position essentially
perpendicular with one another.
5. The building system of claim 2, wherein the second profile has
an "L" shape defining two cavities position essentially
perpendicular with one another.
6. The building system of claim 1, further comprising a third
profile configured to form a corner between two wall panels, the
third profile having a central channel that runs along the length
of the profile and two cavities with openings perpendicular to one
another running along the length of the central channel.
7. The building system of claim 1, wherein the second profile is
configured to form a corner between two wall panels.
8. The building system of claim 1, further comprising a plurality
of inserts each configured to be placed within the one of a wall
slot, a floor slot, or a ceiling slot.
9. The building system of claim 8, wherein the each clip of the
plurality of clips is configured to be positionable within two
inserts at opposite ends of each clip.
10. A building system comprising: a series a wall panels; a series
of floor panels; a series of ceiling panels; a first profile being
in the shape of an I-beam for connecting panels for connecting
panels from the same series together; a second profile for
connecting panels from one series to another series together, the
second profile having an "L" shape defining two cavities position
essentially perpendicular with one another, the first cavity
configured to receive at least one of either the floor panels or
the ceiling panels, and the second cavity configured to receive at
least one of the wall panels such that in the assembled
configuration the wall panel will rest on and be above the at least
one floor panels or the ceiling panel will rest on and be above the
wall panel; a plurality of clips configured to lockingly engage a
wall panel at one end and one of either the wall panels, floor
panels, and ceiling panels at the other end, wherein the building
system does not require other fasteners besides the clips and
profiles to hold the panels together.
11. The building system of claim 10, further comprising a third
profile configured to form a corner between two wall panels, the
third profile having a central channel that runs along the length
of the profile and two cavities with opening perpendicular to one
another running along the length of the central channel.
12. The building system of claim 10, wherein the second profile is
also configured to form a corner between two wall panels.
13. The building system of claim 10, wherein: the series of wall
panels further comprises one or more wall slot on each wall panel;
the series of floor panels further comprises one or more floor slot
on each floor panel; the series of ceiling panels further comprises
one or more ceiling slot on each ceiling panel; and each clip of
the plurality of clips is configured to lockingly engage a wall
slot at one end and one of either a wall slot, a floor slot, and a
ceiling slot at the other end.
14. The building system of claim 13, further comprising a plurality
of inserts configured to be positionable within the one of the wall
slots, floor slots, or ceiling slots wherein each of the clips of
the plurality of clips is configured to be positionable within two
inserts at opposite ends of each individual clip.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S.
Provisional Application No. 61/535,785, filed Sep. 16, 2011,
entitled "BUILDING SYSTEM AND METHOD," which is incorporated by
reference herein in its entirety and is to be considered a part of
this specification.
BACKGROUND
[0002] 1. Field
[0003] Certain embodiments disclosed herein relate generally to
building systems, in particular to modular building systems. The
buildings systems can be collapsible and reusable and can be used
for many different purposes. The building systems can employ a
unique fastening system to connect, combine, and hold in the place
the various components or modular units of the building system.
[0004] 2. Description of the Related Art
[0005] Portable building systems are used in many different
situations and locals as varied as classrooms, bathrooms, sheds,
construction sites, and emergency relief hubs. Many portable
building systems are manufactured and assembled in one location,
and then shipped in whole or in half to the needed location. It is
often impracticable to assemble on site, whether to assemble
entirely or primarily on site. This prevents the use of portable
building systems in some situations in which they would be ideal or
forces people to use tent-like-structures that may not adequately
address the needs of the users. For example, it may be impossible
or impractical to transport a pre-assembled building into the
backcountry and/or to a disaster area where shelter for whatever
purpose is needed.
SUMMARY
[0006] Accordingly, there is in the need of the art for
improvements to portable building systems, including improvements
to fastening systems to connect, combine, and hold in the place the
various components or modular units of the building system. These
improved systems may solve or address some of the problems
described above.
[0007] Preferably, a building system includes a plurality of walls,
a ceiling and a floor. The walls, ceiling and floor can be held
together via profiles or extrusions and clips that engage with a
wall at one end and either the ceiling or floor at the other end.
One or more inserts can also be used that fit within a groove or
notch in a wall, ceiling, or floor. In such embodiments, the clips
can have engagement portions (e.g., crimped ends, protrusions,
hooks, etc.) that connect to and/or fit within the inserts.
[0008] A building system of some embodiments can comprise wall,
floor, and/or ceiling panels. A first profile with two cavities
extending along different sides of the profile can be used to
connect similar panels together. A second profile can be used to
connect dissimilar panels. A plurality of fastening clips can be
used to lockingly engage a wall panel at one end and one of either
a wall panel, a floor panel, or a ceiling panel at the other end.
The building system can be configured to not require other
fasteners besides the clips and profiles to hold the panels
together.
[0009] In some embodiments, a building system can comprise, a
series a wall panels, a series of floor panels, and a series of
ceiling panels. Each panels can have one or more of a respective
wall slot, floor slot, and ceiling slot. A first profile can
comprise two cavities extending along different sides of the
profile, each cavity configured to receive a panel from the same
series together. A second profile can be for connecting panels from
one series to another series together, the second profile having a
shape different from the first profile and comprising two cavities
positioned essentially perpendicular with one another, the first
cavity configured to receive at least one of either the floor
panels or the ceiling panels, and the second cavity configured to
receive at least one of the wall panels such that in the assembled
configuration the wall panel will rest on and be above the at least
one floor panel or the ceiling panel will rest on and be above the
wall panel. A plurality of fastening clips can be used where each
clip is configured to lockingly engage a wall slot at one end and
one of either a wall slot, a floor slot, and a ceiling slot at the
other end, wherein the building system does not require other
fasteners besides the clips and profiles to hold the panels
together.
[0010] According to some embodiments, a building system can
comprise a series a wall panels, a series of floor panels, a series
of ceiling panels, a first profile being in the shape of an I-beam
for connecting panels for connecting panels from the same series
together, a second profile, and a plurality of clips. The second
profile can be for connecting panels from one series to another
series together. The plurality of clips can be configured to
lockingly engage a wall panel at one end and one of either the wall
panels, floor panels, and ceiling panels at the other end. The
building system can be made to not require other fasteners besides
the clips and profiles to hold the panels together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Various embodiments are depicted in the accompanying
drawings for illustrative purposes, and should in no way be
interpreted as limiting the scope of the inventions, in which like
reference characters denote corresponding features consistently
throughout similar embodiments.
[0012] FIG. 1 is a perspective view of a building.
[0013] FIG. 2 is a view of the bottom of the building of FIG.
1.
[0014] FIG. 3 shows a view of a floor unit.
[0015] FIGS. 4 and 4A illustrate a profile.
[0016] FIGS. 5 and 5A illustrate another profile.
[0017] FIG. 6 illustrates a partially assembled building including
a floor and walls of the building.
[0018] FIGS. 7 and 7A illustrate another profile.
[0019] FIGS. 7B and 7C illustrate cross-sections of addition
embodiments of profiles.
[0020] FIG. 8 shows a clip and corresponding inserts.
[0021] FIG. 9 is a cross-sectional view showing an assembled clip
and corresponding inserts.
[0022] FIG. 10 shows a partially assembled building from the top
looking down.
[0023] FIG. 11 is an illustration of parts of the roof section
and/or ceiling of a building.
[0024] FIG. 12 illustrates a cross-section of a building.
[0025] FIG. 13 shows a partially assembled shipping container.
[0026] FIG. 14 illustrates a shipping container that can be used as
a building.
[0027] FIG. 15 shows another embodiment of a building system.
[0028] FIG. 16 shows a beam construction.
[0029] FIG. 17 shows a view looking inside a building.
[0030] FIG. 18 is a detail view of an embodiment of a roof and
ceiling structure.
[0031] FIG. 19 is a partially expanded view of the building system
of FIG. 15.
[0032] FIG. 20 illustrates a corner of a building system.
DETAILED DESCRIPTION
[0033] A building system and method can include a collapsible
reusable building. The building system can include a plurality of
panels that can be connected together to form the building. The
panels can include a variety of different sizes such that the
building can also take many forms. The building can also include a
number of profiles used to connect and seal the spaces in between
the panels. The building system can also include clips or fasteners
that can be used to connect and secure the panels together,
including the profiles.
[0034] Certain examples of the building systems and methods are
outlined below. A collapsible reusable building can also be
portable such that all the components can be shipped together for
easy and simple assembly on site. In some embodiments, the building
system can be assembled into a building in a short amount of time,
such as 30 minutes, and with limited to no tools. Advantageously,
the building system can comprise a series of modular units that can
be combined in different configurations. The components of the
building system can also be modular, such that they are easily
interlockable and do not require the use of tools for assembly. As
one example which will be explained in more detail below, the roof
system can include a series of individual units which can be
connected to form the roof.
[0035] Looking now to FIG. 1, a building 10 is shown. The building
can be used for any of many purposes, such as being a shed, storage
facility, living quarters, bathroom, dining facility, sleeping
quarters, refrigerator, medical unit, ice fishing shack, etc. For
ease of discussion, the building unit 10 will be described in three
sections; namely, a discussion of the base unit or foundation 3,
the walls 5 and the roof 7. It will be understood that any and all
of the components of the building system 10 can be used
individually or separately, or in combination with other features
and systems. For example, the roof 7 can be used on other
structures and with other building systems. In addition, the walls
5 can be used with other styles and designs and systems of roofs 7
and foundations 3. The foundation 3, walls 5 and roof 7 can also be
other shapes than those shown, including round, triangular,
octagon, curved, etc. There may also be layers, levels, steps,
etc.
[0036] Looking now to FIGS. 2 and 3, the base or foundation 3 will
be described. It will be understood that the base of foundation 3
can take many forms. The base or foundation 3 generally forms the
bottom of the building to which the walls 5 can be attached. The
foundation 3 can be made up of a series of one or more floor units
30. Each floor unit can be combined with other floor units to
create the floor of a building. Each floor unit 30 can also be used
individually. As can be seen in FIG. 3, each floor unit 30 can be
made up of a floor panel 36 and a system of joists and/or beams 32
to raise the floor panel off of the ground. The joists and/or beams
32 may or may not be attached to the floor panel(s) 36. In
addition, the joists and/or beams 32 may or may not be
interconnected. With the floor panels raised off the ground, access
is provided to the bottom of the floor panels. Among other
benefits, this can allow one or more clips to be attached to the
floor panel and a wall panel, as will be described in more detail
below. The joists 32 can be made of any of many different
materials, such as metal and wood. In a preferred embodiment, the
joists 32 are made of metal. In some embodiments, joists 32 or
other materials can be used to level the floor panels or further
raise the floor panels off of the ground, such as to allow water to
pass under the building.
[0037] As can be seen with reference to FIG. 2, the floor panels 30
can be held together with one or more joining bridges 34. The
joining bridges 34 can be made to easily assemble and disassemble
from the joists 32 of the individual floor panels 30. For example,
a system of screws and wing nuts can be used to secure the joining
bridges 34 to the joists 32.
[0038] The floor panels 30 can also be held together with a system
or series of profiles 12. FIG. 4 illustrates a cross-section of one
of the profiles 12. The profile 12, similar to other profiles
described herein, can secure the panels together and also provide
waterproofing and other sealing functions to seal the spaces
in-between the panels such that the elements from the environment
cannot pass through. As can be seen, the cross-section of the
profile 12 is generally in the form of an I-beam, or the shape of
an H, although other configurations are also possible. Another way
to describe the cross-section is that of two C-pockets or cavities
21 that are on opposite sides of the profile. The profile 12,
similar to the other profiles described herein, can be formed such
that the panel fits within the profile in the C-pocket or cavity 21
in a snug or snap-fit type connection. Alternatively, there may be
a small gap between the panel and the profile on one or more sides
of the connection between the profile and the panel. In some
embodiments, the profiles can be made of plastic, such as ABS or
PVC. Other materials such as fiber glass can also be used. The
profiles may be manufactured by extrusion or pultrusion, among
other methods.
[0039] Referring now to FIG. 4A, the profile 12 can include one or
more notches 18. The notch 18 can comprise an area of the profile
where some of the material of the profile has been removed. As
shown in FIG. 4A, one end of the profile 12 has a notch removing
all but the bottom side of the profile at one end. In some
embodiments, the profile may have one or more notches 18. For
example, both ends may have notches 18. In addition or
alternatively, a notch may be located along the length of the
profile. Referring back to FIG. 2, it can be seen that in the
illustrate embodiment, notches 18 are found on both ends of the
profile 12 in the floor or foundation 3.
[0040] The base or foundation 3 can also include a second profile
14 (FIG. 2). The profile 14 can be used to connect the base or
foundation 3 with the walls 5. Referring now to FIGS. 5 and 5A, one
example of the second profile 14 is shown. It will be understood
that the description of the profile 14 in relation to the
foundation or base 3 and the walls is or can be equally applicable
to the connection between the walls and the roof 7. As can be seen
in FIG. 5, the profile 14 can include two C-pockets or cavities,
identified herein as a first cavity 20 and a second cavity 22. The
first and second cavities can be aligned with openings that are
perpendicular to one another. Also as shown, the cavity 20 can be
positioned below the cavity 22. This can allow for the cavity 20 to
be slid onto or connected to the floor panel 36. This way, the
floor panel can also serve as support for the wall sections which
will be slid into or connected to the cavity 22. Although not
shown, the profile 14 may also include one or more notches 18.
[0041] After the base or foundation 3 has been assembled and at
least one profile 14 attached, a user can begin construction of the
wall section 5. The walls can be constructed placing one panel
within the cavity or channel 22 followed by additional profiles and
panels, as will be described. FIG. 6 shows a building with a
partially constructed wall section 5. As can be seen, the wall
section is made up of a series of wall panels 50. The wall panels
can be different sizes, can serve different purposes, and can
include any number of different features. For example, the wall
panel 50 may include one or more cavities or holes 52, 54, 56. The
cavity 52 may serve as a door cavity. The cavity 54 can serve as a
window, and the cavity 56 can receive other features, such as an
air conditioning unit, heating unit, ventilation, or other features
which require a hole or cavity to pass through the panel 50.
[0042] As can be seen, the wall panels 50 are connected through a
series of profiles. As has been described, a profile 12 can be used
to connect the wall panels 50, similar to the manner in which the
profile 12 connects the floor panels 36. In some embodiments, of
the wall section 5, the profiles 12 may include one or more notches
18. For example, the profile 12 may have a notch 18 located at the
top of the profile 12. A third profile 16 can also be used at the
corners of the wall unit 5.
[0043] Referring to FIGS. 7 and 7A, the third profile 16 will now
be described. The profile 16 can include two cavities or channels
24 which are aligned perpendicular to one another. The profile 16
also includes a cavity 26. As can be seen, cavity 26 forms the
corner of the wall unit and also the corner of the profile 16.
Other configurations are also possible. For example, the profile 14
can be used instead of the profile 16 to form the corners of the
wall unit 5. As can be seen in FIG. 7A, the profile 16 can include
one or more notches 18.
[0044] Though three designs of profiles 12, 14, and 16 have been
described, it will be understood that the profiles can take on one
of many different shapes. In their basic configuration, a profile
has two C-pockets or cavities that are connected to thereby connect
two separate panels. As has been mentioned, those panels can
include at least wall panels, floor panels, and ceiling panels. The
relationship between the two C-pockets or cavities can vary
greatly. For example, referring to FIG. 7, an angle Alpha (.alpha.)
can be used to define this relationship. In FIG. 7, .alpha. is
equal to about 90 degrees. This is in contrast to FIG. 4, where
alpha is not shown because it is equal to about 0 degrees. FIGS. 7B
and 7C show the cross-sections of two additional embodiments of
profiles 16' and 14'. In FIG. 7B, .alpha.' is shown as being less
than 90 degrees and in FIG. 7C, .alpha.'' is shown as being greater
than 90 degrees. A profile similar to profile 16' could be used,
for example, when forming a circular, octagon, pentagon, hexagon,
etc. shaped building. In some embodiments, .alpha. can be equal to
about 30, 45, 60, 75, 90, 100, 120, 135, and 150 degrees A profile
similar to profile 14' could be used for example, when forming a
triangular, parallelogram, trapezoid, etc. shaped building. Various
shaped profiles can also allow for the creation of distinct shapes,
alcoves, nooks, etc. It will be understood that the panels can also
be shaped to allow the building to be shaped as such. Thus, the
wall panels may be rounded or curved and then floor and ceiling
panels may be larger one end as compared to another, such as in a
trapezoid, or a piece of pizza shape. The other shapes can also be
used.
[0045] Other features shown in the profile 16' includes a rounded
back side 27 and a gap 29 in one of the walls 31 of the cavity 24.
It ill be understood that any of the profiles could also include
these features. Another feature shown in the profile 14' is that
the cavity 20' does not extend out as far as the cavity 20 in
profile 14 shown in FIG. 5.
[0046] As has been mentioned, the panels can be connected to one
another with a series of fasteners or clips 28 such as that shown
in FIG. 8. The fasteners or clips 28 can be the same or similar to
those described in application Ser. Nos. 13/558,162 filed on Jul.
25, 2012 and 61/511,951, filed on Jul. 26, 2011 which are both
incorporated by reference herein and made a part of this
specification. The panels, such as the floor panels, wall panels
or, as will be described below, the ceiling panels, can include one
or more slots or cavities 38 (FIGS. 3, 6, 10) into which a clip 28
can fit into. The clips 28 can be sized and shaped to engage with
slots or cavities 38. The fastener can be L-shaped such that one
end will connect to a first panel, such as a wall panel, and the
other end can connect to a second panel, such as a floor panel. The
fastener can use a spring force to secure the panels together.
[0047] Inserts 130 can be configured to at least partially fit
within the slots or cavities 38. An insert 130 can also be placed
within the slot to further seal and help secure the fastener in the
fastened position. Preferably, the clips 28 are configured to
engage with inserts 130 installed in the slots or cavities 38.
Engagement between the clips 28 and the inserts 130 and/or slots 38
can secure adjacent panels to each other and enable secure
construction of the building system. The inserts 130 can be the
same or similar to those described in application Ser. Nos.
13/558,162 filed on Jul. 25, 2012 and 61/511,951, filed on Jul. 26,
2011 which are both incorporated by reference herein and made a
part of this specification.
[0048] FIG. 8 illustrates a clip 28 and two corresponding inserts
130. Each insert 130 can include a base 132 and a flange portion
134. The back side of the base 132 can be configured to fixedly
and/or releasably engage with a slot 38 in a panel. The front side
of the base 132 can be configured to engage with and receive one of
the engagement features 152, 154 of the clip 28.
[0049] The clip 28 has a first engagement feature 152 configured to
engage with an insert 130 and/or with a slot 38 in the panel. The
clip 28 can have a second engagement feature 154 configured to
engage with an insert 130 and/or with a slot 38 in another panel.
In some embodiments, one of the first and second engagement
features 152, 154 is configured to engage with an insert 130 and
the other is configured to engage directly with a slot 38 in a
panel. It will be understood that though a particular style of clip
is described, any of number of different clips could be used. For
example a CLIP-LOK Brand clip or other type of clip could be used.
In addition the building system could use one or more different
styles or types of clips. Inserts may or may not be used with any
of the clips.
[0050] One or both of the first engagement feature 152 and second
engagement feature 154 can include one or more clip release
features 156. In some embodiments, the clip release feature 156
comprises one or more protrusions, tongues, or lips, which may
include flat unbent portions on the end of the first and/or second
clip portions 152, 153. The clip release feature 156 can be used to
assist with the removal of the subject clip 28 and/or with removing
already assembled clips 28. The clip release feature 156 is shown
extending from the end of the clip, between the two U- or V-shaped
engagement features 154. The clip release feature 156 can have one
of many different shapes.
[0051] As shown, the clip release feature 156 has a low profile and
extends over the slot 38 and/or over the inner cavity of the insert
130. As can be seen with reference to FIG. 9, the clip release
feature 156 can extend into the opening in the insert, but
preferably does not extend past, or completely cover the opening.
This allows a user to release the clip by engaging the clip release
feature 156 with one of a variety of levers. This can be done
without the use of any special tools. For example, another clip, a
screwdriver, a shovel, a crowbar, etc. can be advanced under the
clip release feature 156 into the groove or insert and then used as
a lever to pop the clip out of engagement with the groove or
insert. It will be understood that the clip release feature 156 can
function in other or similar ways, at different locations. For
example, the clip release feature 156 can be located near the end
of the clip, but not extending over an opening. The clip release
feature 156 can be structured and/or positioned such that a lever
can still be placed under the clip release feature 156 and the clip
pried off. In other embodiments, the clip release feature 156 can
be pulled away from the container to release the clip.
[0052] As mentioned, the clip can use a spring force to secure the
panels together. Returning to FIG. 8, an angle .theta. between the
first clip portion 151 and the second clip portion 153 can be
greater than about 45.degree. and/or less than about 135.degree.
when the clip 28 is in a disconnected state (e.g., not engaged with
inserts 130 or slots 38). In some embodiments, the angle .theta. is
approximately 75.degree. when the clip 150 is in the disconnected
state. As illustrated in FIG. 9, clips 28 can be used to adjoin two
sides 110 of an object at an angle .beta.. Preferably, the angle
.theta. between the first and second clip portions 151, 153 for a
given clip 28 is less than the angle .beta. between the two sides
110 of the object being connected by such a clip 28. In such cases,
the clip 28 must be widened (e.g., the angle .theta. must be
increased) in order to fit the clip 28 onto the two sides 110. As
such, the bending stress in the clip 28 due to the widening of the
clip 28 can bias the first and second engagement features 152, 154
into the slots 38 and/or inserts 130 on the adjoining sides 110.
Such a biasing force helps the clip 150 to stay in place and secure
the two sides 110 to each other.
[0053] It will be understood that the clips 28 can be attached to
the building at any point after the various panels have been put
together. Preferably, the clips are attached after the
corresponding panels have been placed next to one another and
within the respective profile. If inserts are used, they can be
inserted at any time prior to attachment of the clips.
[0054] Once the base or foundation 3 has been assembled and the
walls 5 have further been assembled onto the foundation or base 3,
the roof and/or ceiling 7 can then be assembled. In some
embodiments, another building unit can be attached to the assembled
walls and base so that both units can share the same roof.
[0055] Returning to FIG. 6, it can be seen that in some
embodiments, the tops of some of the wall panels 50 can include one
or more slots or channels 58. A beam can be placed within
corresponding slots on opposite wall panels 50. The beam can
provide additional structural support for the ceiling and roof.
[0056] Looking now at FIG. 10, it can be seen that the ceiling
panels 72 have been placed on the wall unit 5. It can also be seen
that profiles 14 have been used to connect the ceiling panels to
the wall unit 5. Although not shown, profiles 12 or other styles of
profiles can also be used to connect the individual ceiling panels
72 to one another. The ceiling panels can be open as shown with
holes passing therethrough or closed. Preferably, the ceiling
panels 72 provide a surface around the top perimeter of the walls
unit 5. This provides structural support to the building and also
provides a surface to connect the clips between the wall panels and
the ceiling panels.
[0057] The configuration shown in FIG. 10 provides many benefits.
For example, the cube or rectangular structure with panels on each
side has great structural integrity. In addition, a base unit, as
shown in FIG. 10 can utilize a variety of different style roofs.
For example, a solid, angled roof can be used as is illustrated
elsewhere herein. Alternatively, a flat solid roof; a flat vinyl, a
plastic, a foam, or other material and or shape roof, can be used.
In addition, the roof can be transparent to allow sun light into
the building. In some embodiments, the panels 72 can serve as both
the ceiling and the roof. In addition, in some embodiments, the
panels 72 can be provided with additionally preassembled roofing
material such that installing the ceiling and the roof is performed
simultaneously. It will be understood that many different types and
styles of roofs can be used.
[0058] FIG. 10 illustrates the fasteners or clips 28 that have been
secured to the panels 72 and 50 as was discussed previously. As can
be seen, a slot or cavity 38 in the panels 72 and 50 is used to
connect the two ends of the clip or fastener 28. Although only a
limited number of clips 28 are shown, it should be understood that
clips 28 can be used throughout the assembly, such as to hold the
panels 50 together at the corners, and also the panels 50 and
panels 36 at the wall and base or floor. In some embodiments, the
clips 28 connect on top of or over the profiles 14 and/or 16 and/or
other profiles.
[0059] The ceiling panels 72 can include one or more holes or
cavities 74. The holes or cavities 74 can be used to attach to or
provide additional features in the ceiling. For example, a ceiling
plug can be attached to or within the space 74. The ceiling plug
may include lights, fan units, ventilation, or other features. In
some embodiments, the ceiling plug can be thin ABS material that is
thermo formed to the desired shape.
[0060] Turning to FIGS. 11 and 12, another embodiment of a roof
and/or ceiling section 7 is shown. In this embodiment, it can be
seen that the ceiling plugs 76 and 78 are illustrated. Ceiling plug
76 can simply plug the hole or space 74, whereas ceiling plug 78
includes one or more lighting units 80. The lighting units can
include any type of lighting system, such as LED, fluorescent, or
incandescent. The lighting units 80 can also be powered with
various different types of systems, including batteries, solar
power, and electrical connections to a separate electrical source,
such as city power.
[0061] The roof and/or ceiling section 7 can include a roof unit
82. The roof unit 82 can be a preassembled unit including shingles
or other roof outer covering surfaces, awnings, one or more
trusses, flashings, and other ceiling members. In some embodiments,
the roof unit can have a polyurea coating on an outer surface. In
some embodiments, the roof unit 82 can be formed such that one side
has a flashing 83 that extends past the rest of the unit so that
when combined with another roof unit 82, the flashing will overlap
with the second unit, creating a sealed and waterproofed roof
structure.
[0062] The roof unit 82 can also include a hole or cavity 84. In
the assembled condition, the hole 84 can be lined up above the hole
74 on the ceiling panel. This can allow the ceiling plugs, such as
76 and 78, to also connect to the roof unit 82. As has been
mentioned, the ceiling plugs can provide many different
features.
[0063] The roof unit can be secured to the ceiling panel 72 in many
different ways. For example, as just mentioned, the ceiling plug 76
or 78 can be used to secure the roof unit 82 to the ceiling panel
72. In some embodiments, a clip or fastener 28 can be used to
secure the roof unit 82 and the ceiling panel 72. For example, one
end of the fastener 28 can fit within a channel or slot 38 and the
other end can wrap around to contact the bottom of the ceiling
panel 72, as can be seen in FIG. 12. As can also be seen in FIG.
12, the roof and/or ceiling section 7 can also include a series of
beams 86. As discussed with reference to FIG. 6, the wall panels 50
can include one or more slots or channels 58 and the beams 86 can
be placed within corresponding slots on opposite wall panels 50 to
provide structural support for the ceiling and roof. The size of
the beams 86 can depend on many features including potential
snow-load.
[0064] One advantage of the above described roof design is that by
having the roof panel 82 and the ceiling panel 72 clamped together,
whether by a fastener 28 or otherwise secured, this also helps
further ensure that the connection between the wall panel 50 and
the ceiling panel 72 stays secure. This is because the roof panel
82 presses down on the fastener 28 and profile 14 on the ceiling
panel 72. This is turn prevents the fastener 28 and the profile 14
that are on the ceiling panel 72 and connected to the wall panel 50
from moving.
[0065] The entire building unit 10, in some embodiments, can be
assembled with a minimal number of people and require minimal to no
tools for assembly. In addition, the building unit 10 can be
assembled in a minimal amount of time, such as 30 minutes.
[0066] The many panels described, such as the ceiling panels, the
walls panels, the roof panels, and the floor panels, can be made
from various different materials. For example, the panels can be
made up of a series of different materials, such as having a foam
core sandwiched between two pieces of plywood. The panels can be
structural insulated panels or structural insulating panels (SIPs)
or other types of composite building materials. In some embodiments
the panels can be made up of a single material, such as solid
plywood. In addition, the panels can be coated with various
different materials, such as a coating on the inside or what will
be the inside of the building and a separate or the same coating on
the outside or what will be the outside of the building. For
example, the panel can be made with a phenolic skin or other
resin-impregnated kraft paper, fiberboard siding, high impact
plastic, metal, fiber reinforced plastic (FRP), etc. Some surfaces
of the panels may also be covered with a polyurethane or polyurea
coating. Other coatings can also be used.
[0067] As will be understood, the building units 10 can be
assembled such that multiple building units can be combined to
create a larger structure, or the building unit can be used or
combined with other structures.
[0068] It should also be understood that the profiles 12, 14, 16
can be any desired length. For example, profile 14 can extend the
entire length of a side of the wall section 5, or multiple profiles
14 can be used. Advantageously, all components of the building
system 10 can be sized so that they can be shipped together. For
example, the profiles 12, 14, 16 can be as long as or shorter than
the panels 36, 50, 72.
[0069] Turning now to FIGS. 13 and 14, a shipping container or
crate 40 is shown. The crate 40 can include a number of the panels
42, 44 that can be connected to one another by various methods. For
example, the panels can have a series of slots 38 and be connected
to one another with a series of fasteners or clips 28 as described
in Application 61/511,951, filed on Jul. 26, 2011. Inserts can be
placed within the slots as also described in Application
61/511,951, filed on Jul. 26, 2011. Again, as before, only a
limited number of clips 28 are shown, but it should be understood
that all of the slots 30 can include a clip 28 and, in some
embodiment an insert. It will be understood that clips of other
types and designs can also be used. The crate can be assembled,
disassembled and stacked as also described therein. The crate can
be any type of crate but is preferably a crate as described in
Application 61/511,951, filed on Jul. 26, 2011. One or more
profiles 12, 14, 16 can also be used in the assembly of the crate
40. As shown in FIG. 14, a profile 12 can be used to connect two
panels 42, 44 together. Each side of the crate 40 can use a single
panel 42, 44, or more than one panel.
[0070] The building system 10 can be shipped within the crate 40.
As can be seen in FIG. 13, the building system 10 is shown
disassembled and stacked within the crate 40. Additional features,
such as air conditioning units can also be shipped with the
building system 10. The crate 40 can be sized and shaped according
to the dimensions of the components of the desired building system
10 when disassembled. Though it cannot be seen, the crate 40 can
include a pallet type feature on the bottom of the crate or other
transport structure or feature to facilitate the handling and
moving of the crate 40. The transport structure or feature can
support the crate in a stable fashion while being lifted by a
forklift, pallet jack, front loader, hoist, crane, etc.
[0071] In some embodiments, after the building system 10 has
emptied from the crate 40, the crate 40 can also be used as a
building. For example, the crate 40 can be used as a shelter, a
shed, a bathroom, an out building, etc. As shown in FIG. 14, the
crate 40 can be provided with a panel 44 that includes a door 46.
The panel 44 can form a part of the shipping container 40 during
shipping. Alternatively, an extra panel 44 with a door 46 can be
shipped inside the crate 40 to later replace one of the panels 42.
After replacement, the crate can be used as a building or structure
that has a door. Of course, it will be understood that the crate 40
can also be used as a building or structure by simply removing one
or more panels.
[0072] FIGS. 15-20 show another embodiment of a building system
10'. Numerical reference to components is the same as previously
described, except that one or more prime symbols (') have been
added to each reference numeral. Where such references occur, it is
to be understood that the components are the same or substantially
similar to previously-described components. It should be understood
that the illustrated building system includes each of the features
designated by the numbers used herein. However, as emphasized
repeatedly herein, these features need not be present in all
embodiments.
[0073] The building system 10' is shown with three sections, a base
unit or foundation 3', walls 5' and roof 7'. As has been mentioned,
the base 3' can take many forms. The base 3' can use a system of
modular beams 32' to support the building system 10'. The beams 32'
can raise the floor panel(s) 36' off of the ground. The beams 32'
may or may not be attached to the floor panel(s) 36' and may or may
not be interconnected. The beams 32' can be made of any of many
different materials, such as metal, wood, and composite building
materials. For example, the beams can be made of, but not limited
to, 3/4'' plywood and coated with polyurea.
[0074] Looking now to FIG. 16, it can be seen that the beams 32'
can be modular to provide for any number of different lengths of
beam. The beam sections 62, 64 can individually be the same length
or different lengths. In addition, the beam sections can be the
substantially same length or width as the floor panels 36'. As
shown, the beam section 62 is substantially the same length as the
width of two floor panels, while beam section 64 is as long as one
floor panel is wide. The beam 32' can also include beam section 66,
68 that can be end caps for the beam. The end caps can close and/or
essentially finish the beam, for example so that the height of the
beam is consistent along its length and so that any open cavities
are closed.
[0075] The different sections of the beam 32' can be attached in
many different manners. In some embodiments, the beam sections are
slip fit together with a mortise and tenon joint or with a tongue
and groove joint. A beam section 62, 64 can have a mortise hole 70
at one end and a tenon 60 at the other end. This can allow any
number of beam sections to be connected. In some embodiments, some
or all of the beam sections 66, 68 can have only one of a mortise
hole and a tenon on one end and the other end can be a closed
surface. The closed surface can define the end or end cap of the
beam 32'. It will be understood that other configurations can also
be used. The beam sections 62, 64, 66, 68 are preferably held to
together by friction, but fasteners such as bolts may also be
used.
[0076] The beams 32' can be laid out as a foundation for the floor
panels 36'. In some embodiments shims can be proved to help level
the floor panels. The floor panels are preferable not fastened to
the beams and can stay in place by friction. At the same time,
certain uses or locations may require a separate anchoring system,
for example, if the building system is to be used in a high wind
area.
[0077] FIGS. 17-20 will now be used to describe the roof and/or
ceiling 7'. FIG. 17 shows a modification of the ceiling panels 72'.
In particular, rather than having large opening or holes, the
ceiling panels 72' have much smaller holes 74'. These smaller holes
can still be used to attach to or provide additional features in
the ceiling as has been described. For example, a fastener 28' can
extend through the hole 74' to attach a ceiling panel 82' to the
ceiling panel 72'. In addition, a ceiling plug or cover can also be
used.
[0078] FIG. 18 shows another embodiment of a fastening system for
use with the ceiling and roof panels. In particular, a bolt 94 and
washer or plate 92 can be used to secure roof panel 82'' to the
ceiling panel 72'. The bolt can be self threading, or can engage a
nut 96 that has been attached to the roof panel 82''.
[0079] Turning now to FIG. 19, a partially exploded view of the
building system 10' is shown. FIG. 19 illustrates a cover 88 that
can be used to place on top of and/or surrounding the roof panels
82'. Looking back at FIG. 15, it can be seen that the cover 88 can
enclose the top of the building system 10'. This can include
enclosing all or part of one or more of the roof panels 82', wall
panels 50', profiles 14'', profiles 12', profiles 16'', fasteners
28', and inserts 130'. In some embodiments, the sides of the cover
88 can extend down to the slots 38' in the wall panels 50'. As
shown, the slots 38' have an insert 130' placed within them. In
some embodiments the cover 88 can be used in addition to or instead
of the roof panels 82'. For example, the cover 88 can surround and
directly cover the ceiling panels 72' without the use of separate
roof panels 82'. It will be understood that the ceiling panels 72,
72' can also form the roof without separate roof panels 82, 82'
and/or a cover 88.
[0080] The cover 88 can be made of any number of different
materials and is preferably waterproof. The cover can be a large
sheet of strong, flexible, water-resistant or waterproof material.
The cover can be made of cloth, canvas, polyester, polyethylene,
polypropylene, etc. In some embodiments the cover can comprise a
tarpaulin or tarp.
[0081] The cover 88 can be connected to the rest of the building
system in many ways. In some embodiments, the cover can form a
tight fit over the roof and be held on by friction. Looking to FIG.
20, a rope or cord 90 may also be used to secure the cover 88. As
shown, the rope 90 and cover can be configured such that the rope
is sewn or otherwise enclosed within the cover. In some
embodiments, the rope and extend around the bottom periphery of the
cover. The cover 88 can include one or more holes 92 through which
the rope can extend. For example, the cover 88 can have one or more
holes 92 at the same locations on the buildings where the
fasteners. The rope can be secured to one or more fasteners 28'.
For example, the rope 90 can engage with the clip release feature
156' on the fastener 28'.
[0082] Although this invention has been disclosed in the context of
certain preferred embodiments and examples, it will be understood
by those skilled in the art that the present invention extends
beyond the specifically disclosed embodiments to other alternative
embodiments and/or uses of the invention and obvious modifications
and equivalents thereof. In addition, while a number of variations
of the invention have been shown and described in detail, other
modifications, which are within the scope of this invention, will
be readily apparent to those of skill in the art based upon this
disclosure. It is also contemplated that various combinations or
sub-combinations of the specific features and aspects of the
embodiments may be made and still fall within the scope of the
invention. Accordingly, it should be understood that various
features and aspects of the disclosed embodiments can be combined
with or substituted for one another in order to form varying modes
of the disclosed invention. Thus, it is intended that the scope of
the present invention herein disclosed should not be limited by the
particular disclosed embodiments described above, but should be
determined only by a fair reading of the claims that follow.
[0083] Similarly, this method of disclosure, is not to be
interpreted as reflecting an intention that any claim require more
features than are expressly recited in that claim. Rather, as the
following claims reflect, inventive aspects lie in a combination of
fewer than all features of any single foregoing disclosed
embodiment. Thus, the claims following the Detailed Description are
hereby expressly incorporated into this Detailed Description, with
each claim standing on its own as a separate embodiment.
* * * * *