U.S. patent application number 13/847557 was filed with the patent office on 2013-09-26 for shelter and container structural elements and assemblies.
The applicant listed for this patent is Philip T. Cantin, Rick A. Cochran, Richard S. Pike. Invention is credited to Philip T. Cantin, Rick A. Cochran, Richard S. Pike.
Application Number | 20130247509 13/847557 |
Document ID | / |
Family ID | 49210482 |
Filed Date | 2013-09-26 |
United States Patent
Application |
20130247509 |
Kind Code |
A1 |
Pike; Richard S. ; et
al. |
September 26, 2013 |
SHELTER AND CONTAINER STRUCTURAL ELEMENTS AND ASSEMBLIES
Abstract
Systems for wall sections, wall panels assembled from sections,
walls assembled from panels, and shelters assembled from walls. In
embodiments, a wall for a shelter is disclosed, the wall comprising
a frame comprising frame segments forming an n-sided closed
polygon; at least one wall panel, each wall panel contained within
the frame; and a plurality of flats, each flat attached to and
overlapping a frame segment and a portion of a wall section,
thereby retaining each wall panel within the frame. In embodiments,
a shelter is disclosed, the shelter comprising a plurality of
walls, each wall comprising a frame comprising frame segments
forming an n-sided closed polygon; at least one wall panel, each
wall panel contained within the frame; and a plurality of flats,
each flat attached to and overlapping a frame segment and a portion
of a wall section, thereby retaining each wall panel within the
frame.
Inventors: |
Pike; Richard S.; (Saint
Johnsbury, VT) ; Cantin; Philip T.; (Guildhall,
VT) ; Cochran; Rick A.; (Saint Johnsbury,
VT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pike; Richard S.
Cantin; Philip T.
Cochran; Rick A. |
Saint Johnsbury
Guildhall
Saint Johnsbury |
VT
VT
VT |
US
US
US |
|
|
Family ID: |
49210482 |
Appl. No.: |
13/847557 |
Filed: |
March 20, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61613350 |
Mar 20, 2012 |
|
|
|
Current U.S.
Class: |
52/764 ;
52/630 |
Current CPC
Class: |
E04H 1/1205 20130101;
E04H 3/08 20130101; E04H 2001/1283 20130101 |
Class at
Publication: |
52/764 ;
52/630 |
International
Class: |
E04H 1/12 20060101
E04H001/12 |
Claims
1. A wall for a shelter, the wall comprising: a frame comprising
frame segments forming an n-sided closed polygon; at least one wall
panel, each wall panel contained within the frame; and a plurality
of flats, each flat attached to and overlapping a frame segment and
a portion of a wall section, thereby retaining each wall panel
within the frame.
2. The wall of claim 1, wherein each wall panel comprises: a
plurality of wall sections, each wall section comprising: a
substantially rectangular main body; an L flange: extending in a
first direction away from the main body along a first longitudinal
side of the main body; and comprising an L flange perpendicular
portion, the L flange perpendicular portion having a first
longitudinal side at the main body first longitudinal side; and a
second flange: extending in the first direction away from the main
body along the second longitudinal side of the main body; and the
second flange comprising a second flange first portion extending
along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
wall sections arranged parallel and substantially coterminal along
the longitudinal axis of each wall section; at least one spacer
disposed between a second flange of a first wall section and the
mating surface of the L flange perpendicular portion of a second
wall section adjoining the first wall section thereby defining a
gap; and adhesive substantially filling the gap.
3. The wall of claim 2, wherein: the frame is substantially
rectangular, and each wall section is oriented having a wall
section longitudinal side parallel to the shortest side of the
rectangular frame.
4. The wall of claim 2, wherein, for each wall section: the L
flange is substantially coextensive with the first longitudinal
side of the main body.
5. The wall of claim 2, wherein, for each wall section: the second
flange is substantially coextensive with the second longitudinal
side of the main body.
6. The wall of claim 2, wherein, for each wall section: the wall
section is formed of a bent aluminum sheet.
7. The wall of claim 2, wherein, for each wall section: the second
flange having a width, in a direction parallel to the L flange
first portion, substantially equal to the L flange width minus the
L flange thickness; the second flange being an offset flange
comprising a second flange first portion and a second flange second
portion: the second flange first portion extending along its first
longitudinal side from the main body, and substantially parallel to
the L flange perpendicular portion; a second flange second portion
parallel to, and offset, along a line parallel to the main body,
toward the main body interior from the second flange first
portion.
8. The wall of claim 2, wherein, for each wall section: the second
flange having a width, in a direction parallel to the L flange
first portion, substantially equal to the L flange width minus the
L flange thickness; a second flange first portion and a second
flange second portion: the second flange first portion extending
along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
second flange second portion oblique to the second flange first
portion, and extending, along a line parallel to the main body,
toward the main body interior.
9. The wall of claim 2, wherein, for each wall section: the L
flange parallel portion extends in the direction along a line
parallel to the main body, more toward the main body interior than
the second flange second portion.
10. The wall of claim 1, wherein: the frame is rectangular and
comprises four frame segments.
11. The wall of claim 1, further comprising: at least one support
member spanning the interior side of the wall from a first vertical
frame segment to a second vertical frame segment, and each support
member attached to each L flange parallel portion outer face of
each wall panel.
12. The wall of claim 1, wherein: the frame defines a recess
therein, and each wall panel is contained within the frame recess
with flanges facing into the recess.
13. The wall of claim 12, wherein: each wall panel external face is
flush with the frame external face.
14. A shelter, the shelter comprising: a plurality of walls, each
wall comprising: a frame comprising frame segments forming an
n-sided closed polygon; at least one wall panel, each wall panel
contained within the frame; and a plurality of flats, each flat
attached to and overlapping a frame segment and a portion of a wall
section, thereby retaining each wall panel within the frame.
15. The shelter of claim 14, wherein each wall panel comprises: a
plurality of wall sections, each wall section comprising: a
substantially rectangular main body; an L flange: extending in a
first direction away from the main body along a first longitudinal
side of the main body; and comprising an L flange perpendicular
portion, the L flange perpendicular portion having a first
longitudinal side at the main body first longitudinal side; and a
second flange: extending in the first direction away from the main
body along the second longitudinal side of the main body; and the
second flange comprising a second flange first portion extending
along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
wall sections arranged parallel and substantially coterminal along
the longitudinal axis of each wall section; at least one spacer
disposed between a second flange of a first wall section and the
mating surface of the L flange perpendicular portion of a second
wall section adjoining the first wall section thereby defining a
gap; and adhesive substantially filling the gap.
16. The shelter of claim 15, wherein: the frame is substantially
rectangular, and each wall section is oriented having a wall
section longitudinal side parallel to the shortest side of the
rectangular frame.
17. The shelter of claim 15, wherein, for each wall section: the L
flange is substantially coextensive with the first longitudinal
side of the main body.
18. The shelter of claim 15, wherein, for each wall section: the
second flange is substantially coextensive with the second
longitudinal side of the main body.
19. The shelter of claim 15, wherein, for each wall section: the
wall section is formed of a bent aluminum sheet.
20. The shelter of claim 15, wherein, for each wall section: the
second flange having a width, in a direction parallel to the L
flange first portion, substantially equal to the L flange width
minus the L flange thickness; the second flange being an offset
flange comprising a second flange first portion and a second flange
second portion: the second flange first portion extending along its
first longitudinal side from the main body, and substantially
parallel to the L flange perpendicular portion; a second flange
second portion parallel to, and offset, along a line parallel to
the main body, toward the main body interior from the second flange
first portion.
21. The shelter of claim 15, wherein, for each wall section: the
second flange having a width, in a direction parallel to the L
flange first portion, substantially equal to the L flange width
minus the L flange thickness; a second flange first portion and a
second flange second portion: the second flange first portion
extending along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
second flange second portion oblique to the second flange first
portion, and extending, along a line parallel to the main body,
toward the main body interior.
22. The shelter of claim 15, wherein, for each wall section: the L
flange parallel portion extends in the direction along a line
parallel to the main body, more toward the main body interior than
the second flange second portion.
23. The shelter of claim 14, wherein: the frame is rectangular and
comprises four frame segments.
24. The shelter of claim 14, further comprising: at least one
support member spanning the interior side of the wall from a first
vertical frame segment to a second vertical frame segment, and each
support member attached to each L flange parallel portion outer
face of each wall panel.
25. The shelter of claim 14, wherein: the frame defines a recess
therein, and each wall panel is contained within the frame recess
with flanges facing into the recess.
26. The shelter of claim 25, wherein: each wall panel external face
is flush with the frame external face.
27. A wall panel for a shelter, the wall panel comprising: a
plurality of wall sections, each wall section comprising: a
substantially rectangular main body; an L flange extending in a
first direction away from the main body along a first longitudinal
side of the main body; and comprising an L flange perpendicular
portion, the L flange perpendicular portion having a first
longitudinal side at the main body first longitudinal side; and a
second flange extending in the first direction away from the main
body along the second longitudinal side of the main body; and the
second flange comprising a second flange first portion extending
along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
wall sections arranged parallel and substantially coterminal along
the longitudinal axis of each wall section; at least one spacer
disposed between a second flange of a first wall section and the
mating surface of the L flange perpendicular portion of a second
wall section adjoining the first wall section thereby defining a
gap; and adhesive substantially filling the gap.
28. The wall panel of claim 27, wherein, for each wall section: the
L flange is substantially coextensive with the first longitudinal
side of the main body.
29. The wall panel of claim 27, wherein, for each wall section: the
second flange is substantially coextensive with the second
longitudinal side of the main body.
30. The wall panel of claim 27, wherein, for each wall section: the
wall section is formed of a bent aluminum sheet.
31. The wall panel of claim 27, wherein, for each wall section: the
second flange having a width, in a direction parallel to the L
flange first portion, substantially equal to the L flange width
minus the L flange thickness; the second flange being an offset
flange comprising a second flange first portion and a second flange
second portion: the second flange first portion extending along its
first longitudinal side from the main body, and substantially
parallel to the L flange perpendicular portion; a second flange
second portion parallel to, and offset, along a line parallel to
the main body, toward the main body interior from the second flange
first portion.
32. The wall panel of claim 27, wherein, for each wall section: the
second flange having a width, in a direction parallel to the L
flange first portion, substantially equal to the L flange width
minus the L flange thickness; a second flange first portion and a
second flange second portion: the second flange first portion
extending along its first longitudinal side from the main body, and
substantially parallel to the L flange perpendicular portion; the
second flange second portion oblique to the second flange first
portion, and extending, along a line parallel to the main body,
toward the main body interior.
33. The wall panel of claim 27, wherein, for each wall section: the
L flange parallel portion extends in the direction along a line
parallel to the main body, more toward the main body interior than
the second flange second portion.
34. A wall section for a shelter, the wall section comprising: a
substantially rectangular main body of thickness substantially less
than width; an L flange: extending in a first direction away from
the main body along a first longitudinal side of the main body, and
comprising an L flange perpendicular portion and an L flange
parallel portion, the L flange perpendicular portion having a first
longitudinal side at the main body first longitudinal side, and the
L flange parallel portion extending from the second longitudinal
side of the L flange perpendicular portion, along a line parallel
to the main body, away from the main body interior; and a second
flange: extending in the first direction away from the main body
along the second longitudinal side of the main body; having a
width, in a direction parallel to the L flange first portion,
substantially equal to the L flange width minus the L flange
parallel portion thickness; and comprising a second flange first
portion and a second flange second portion: the second flange first
portion extending along its first longitudinal side from the main
body, and substantially parallel to the L flange perpendicular
portion; the second flange second portion: not coplanar with the
second flange first portion, and extending from the second
longitudinal side of the second flange first portion, along a line
parallel to the main body, more toward the main body interior than
the second flange first portion.
35. The wall section of claim 34, wherein: the L flange is
substantially coextensive with the first longitudinal side of the
main body.
36. The wall section of claim 34, wherein: the second flange is
substantially coextensive with the second longitudinal side of the
main body.
37. The wall section of claim 34, wherein: the wall section is
formed of a bent aluminum sheet.
38. The wall section of claim 34, wherein the second flange is: an
offset flange comprising: a second flange second portion parallel
to, and offset, along a line parallel to the main body, toward the
main body interior from the second flange first portion.
39. The wall section of claim 34, wherein the second flange the
second flange second portion is oblique to the second flange first
portion, and the second flange second portion extends, along a line
parallel to the main body, toward the main body interior.
40. The wall section of claim 34, wherein: the L flange parallel
portion extends in the direction along a line parallel to the main
body, more toward the main body interior than the second flange
second portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/613,350, entitled "SHELTER AND CONTAINER
STRUCTURAL ELEMENTS AND ASSEMBLIES", filed on Mar. 20, 2012.
BACKGROUND
[0002] 1. Field of The Disclosure
[0003] The present technology relates generally to portable shelter
systems and containers, and more particularly, shelter and
container structural elements and assemblies.
[0004] 2. Related Art
[0005] Portable shelters are often used to provide temporary
facilities for various purposes, such as military, civilian, and
medical applications. Such portable shelters may be used to
supplement permanent structures when additional space is desired,
or to provide new facilities for temporary use, such as the
provision of emergency response services after a disaster.
Motorized vehicles, such as vans, buses, and recreational vehicles
(RVs), etc., may be used as portable shelters under certain
circumstances. While these types of motorized vehicles are able to
transport themselves to a desired location, they may provide
limited interior space for intended use, while also being
relatively expensive.
[0006] Some portable shelters are configured to be in the size and
shape of a standard International Organization for Standardization
(ISO) intermodal shipping container. In this way, such shelters may
be shipped by commercial means, such as by railway, boat, or
aircraft, including military aircraft.
SUMMARY
[0007] In one aspect of the present invention, a wall for a shelter
is disclosed. The wall comprises: a frame comprising frame segments
forming an n-sided closed polygon; at least one wall panel, each
wall panel contained within the frame; and a plurality of flats,
each flat attached to and overlapping a frame segment and a portion
of a wall section, thereby retaining each wall panel within the
frame
[0008] In a second aspect of the present invention, a shelter is
disclosed. The shelter comprises: a plurality of walls, each wall
comprising: a frame comprising frame segments forming an n-sided
closed polygon; at least one wall panel, each wall panel contained
within the frame; and a plurality of flats, each flat attached to
and overlapping a frame segment and a portion of a wall section,
thereby retaining each wall panel within the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of the disclosed technology are described below
with reference to the attached drawings, in which:
[0010] FIG. 1 illustrates a wall section of the present technology
in a projection view;
[0011] FIG. 2 illustrates a wall section of the present technology
in front and side views;
[0012] FIG. 3 illustrates the wall section of the present
technology in side and section views illustrating a first flange
and a second flange;
[0013] FIG. 4 illustrates an alternative embodiment of the second
flange of the present technology;
[0014] FIG. 5 is an expanded partial cross-section view
illustrating a wall panel at the joint between wall sections of
FIG. 1, FIG. 2, and FIG. 3 in accordance with the present
technology;
[0015] FIG. 6 is an expanded top view of the joint of a wall panel
between wall sections in accordance with the present technology;
and
[0016] FIG. 7 is a flow chart describing assembly of a wall panel
from wall sections.
[0017] FIG. 8 is a perspective view of a wall panel in accordance
with the present technology.
[0018] FIG. 9 illustrates wall panels of the present technology
assembled in a frame to form a wall in accordance with the present
technology.
[0019] FIG. 10A illustrates wall panels in an eight-sided frame as
part of forming a wall with a portal of the present technology.
[0020] FIG. 10B illustrates wall panels in an eight-sided frame
having flats securing the wall panels within the frame to form a
wall with a portal of the present technology.
[0021] FIG. 11 illustrates a shelter built using sections and
panels of the present technology.
DETAILED DESCRIPTION
[0022] The technology includes wall sections, wall panels assembled
from wall sections, and walls assembled from wall panels. The wall
section has a substantially rectangular main body, and two flanges
extending in the same direction away from opposing longitudinal
sides of the main body--an L flange and a second flange. The L
flange includes an L flange perpendicular portion and an L flange
parallel portion. The L flange perpendicular portion can have a
first longitudinal side at the main body first longitudinal side.
The L flange parallel portion extending in width from the second
longitudinal side of the L flange perpendicular portion, along a
line parallel to the main body, away from the main body interior.
The second flange having a width, in a direction parallel to the L
flange first portion, substantially equal to the L flange width
minus the L flange parallel portion thickness. The second flange
including a second flange first portion and a second flange second
portion. The second flange first portion extending along its first
longitudinal side from the main body, and substantially parallel to
the L flange perpendicular portion. The second flange second
portion is not coplanar with the second flange first portion, and
extends from the second longitudinal side of the second flange
first portion, along a line parallel to the main body, more toward
the main body interior than the second flange first portion.
[0023] Wall panels of the present technology include a plurality of
wall sections as described above. The wall sections are arranged
with a common orientation, parallel, and substantially coterminal
along the longitudinal axis of each wall section. The wall panels
further include at least one spacer disposed between a second
flange first portion of a first wall section and the mating surface
of the first flange perpendicular portion of a second wall section
adjoining the first wall section thereby defining a gap. An
adhesive substantially fills the gap.
[0024] Walls of the present technology include a frame comprising
frame segments forming an n-sided closed polygon, at least one wall
panel (as described above), and a plurality of flats. Each wall
panel is contained within the frame. Each flat attached to and
overlapping a frame segment and a portion of a wall section,
thereby retaining each wall panel within the frame. In some
embodiments, the frame is substantially rectangular, and each wall
section is oriented having a wall section longitudinal side
parallel to the shortest side of the rectangular frame. In some
embodiments, the frame is rectangular and comprises four frame
segments. In some embodiments, the wall further comprises at least
one support member spanning the interior side of the wall from a
first vertical frame segment to a second vertical frame segment.
Each support member is attached to each L flange parallel portion
outer face of each wall panel. In some embodiments, the frame
defines a recess therein, and each wall panel is contained within
the frame recess with flanges facing into the recess. In some
embodiments each wall panel external face is flush with the frame
external face.
[0025] Shelters of the technology include a plurality of walls.
Each wall includes a frame, at least one wall panel, and a
plurality of flats. Each frame includes frame segments forming an
n-sided closed polygon. Each wall panel is contained within a
frame. The flats are attached to and overlapping each frame segment
and a portion of a wall section, thereby retaining each wall panel
within the frame.
[0026] Both shelters and containers may be exposed to environmental
extremes in which the typically metal body is subject to expansion
and contraction that can weaken the integrity of the body. Further,
conventional structural elements, typically horizontal structural
elements, present disadvantages. For example, horizontal structural
elements are typically roll formed--requiring specialized expensive
capital equipment. Assembly of panels and walls from roll-formed
horizontal structural elements, some as long as thirty feet, can be
cumbersome. The mechanical fasteners used in typical shelter
construction do not allow for sufficient expansion and contraction
when the shelter is subject to temperature swings. Routing of
utilities and heating, ventilation, and air conditioning (HVAC)
elements, medical gases, water, and electricity can be complicated
in shelters built primarily from horizontal structural members.
[0027] Certain aspects and embodiments of the present technology
address(es) some of the above-cited disadvantages and offers other
advantages, at least in part through the use of vertical wall
sections more amenable to fabrication and assembly than horizontal
wall sections. For example, embodiments of the wall sections of the
present technology can be assembled into wall panels without the
need for mechanical fasteners and in a fashion that allows for
expansion and contraction with less likelihood of oil-canning or
warping. Fabrication of embodiments of the wall sections of the
present technology can be accomplished with more readily-available
equipment and in more readily-available facilities, and can present
simpler material handling tasks. Shelters assembled from wall built
of wall panels using vertical wall sections of the present
technology can be more amenable to assembly and offer more flexible
routing of utilities than those assembled from horizontal wall
sections.
[0028] Referring to FIG. 1, a wall section 100 of the present
technology is show in projection. In some embodiments of the
technology, wall sections 100 can be formed from metal sheets,
e.g., 3000 series aluminum. In other embodiments of the technology
the wall section 100 can be formed from materials such as plastics,
polymers (e.g., fiberglass fiber reinforced polymer), and
composites. The wall section includes a main body 110 of width
substantially less than length. For example, the width can be
10''-12'' while the length can be 96''-120''. The wall section
profile geometry (section width, overall height), material type,
and material thickness can be determined by the structural
requirements of the particular application, e.g., a shelter
conforming in overall dimensions to the ISO container standard. The
wall section 100 can be formed from a sheet of uniform thickness
substantially less than the wall main body 110 width. For example,
the wall section 100 thickness can be 0.080''. The wall section 100
includes an "L" flange 120 and a second flange 130.
[0029] Referring to FIG. 2, in which the wall section 100 is shown
in front and side views, the L flange 120 includes a perpendicular
portion 122 and a parallel portion 124, where "perpendicular" and
"parallel" are in reference to the wall section 100 main body 110.
The perpendicular portion 122 is of width less than the width of
the main body 110, but substantially greater than the material
thickness. For example, the perpendicular portion 122 can be 1.75''
wide. The perpendicular portion 122 of the L flange 120 is formed
substantially perpendicular to, and (in most embodiments)
substantially coextensive with, a first long side of the main body
110. The parallel portion 124 is of width less than the width of
the main body 110, but substantially greater than the material
thickness. For example, the parallel portion 124 can be 1.5'' wide.
The parallel portion 124 of the L flange 120 is substantially
perpendicular to, formed at, and (in most embodiments)
substantially coextensive with the side of the perpendicular
portion 124 not adjoining the main body 110. The parallel portion
124 extends away from the main body 110.
[0030] Referring to FIG. 3, the wall section 100 of the present
technology is shown in a side view and in section views
illustrating the first flange 120 and a second flange 130. The
second flange 130 includes a second flange first portion 132 and a
second flange second portion 134. The overall width W4 of the
second flange 130 can be substantially equal to the overall width
W2 of the L flange 110, minus the material thickness T. As
described below, this relationship can facilitate assembly of wall
panels and walls, and allows panels and walls assembled from wall
sections to present a substantially co-planar surface on the
non-flange side of the wall panels, walls, and shelters. For
example, the overall width W4 of the second flange 130 can be
1.670''. The second flange first portion 132 is formed
substantially perpendicular to, and (in most embodiments)
substantially coextensive with, a second long side of the main body
110.
[0031] In the illustrated embodiment, the second flange second
portion 134 is an offset portion. The offset portion 134 can add
rigidity to the wall section 100 when the wall section is subject
to end loading, e.g., when the wall section is used as a vertical
element in a wall panel. Generally, the second flange portion 134
can be any portion extends from the second flange first portion
generally in the direction of the main body interior, and is not
coplanar with the second flange first portion, e.g., as described
below in connection with FIG. 4.
[0032] Wall section 100 can be formed by manufacturing methods such
as using a press brake on sheet aluminum, to create bends, e.g.,
bend 140, and to create the offset between the second flange first
portion 132 and the second flange second portion 134, thereby
avoiding the disadvantages of methods such a roll forming. Bends
140 are substantially right angle bends along each side of the main
body at the L flange 120 and the second flange 130, and along the
length of the L flange perpendicular portion and the L flange
parallel portion. For instance, bends 140 can be 1/8'' radius
bends.
[0033] Referring to FIG. 4, an alternative embodiment of the second
flange 130 is illustrated as flange 430. In this embodiment the
overall width W6 of the second flange 430 can be substantially
equal to the overall width W2 of the corresponding L flange 110,
minus the material thickness T. For example, the overall width W6
of flange 430 can be 1.5''. The flange first portion 432 is
substantially similar to flange first portion 132. Flange 430
second portion 434, instead of being parallel to, but offset from,
first portion 432, is oblique to first portion 432 at an angle A.
The flange 430 of FIG. 4 can find use in ceiling sections. The
embodiment illustrated in FIG. 4 also can find use when mechanical
fasteners are used to connect wall sections in to wall panels and
walls. In embodiments employing mechanical fasteners for joining
wall sections, maximizing the parallel surface area between the
surfaces to be connected is not as critical as when adhesives are
used.
[0034] Referring to FIG. 5, an expanded partial cross-section view
illustrating a wall panel at the joint between wall sections 100A
and 100B, each similar to wall section 100 of FIG. 1, FIG. 2, and
FIG. 3, is illustrated. Both wall sections 100A, 100B are oriented
with flanges in the same direction, i.e., down in FIG. 5.
[0035] Spacers 200 are shown as applied to the exterior surface of
the L flange perpendicular portion 122A corresponding to the
exterior of the second flange first portion 132B. Spacers 200 also
can be applied to the exterior of the second flange first portion
132B. Preferably, spacers are applied before applying an adhesive,
as described below.
[0036] In some embodiments, spacer 200 is a durable, resilient
elastomer that resists drying, rotting, or embrittling, such as
Bumpon.TM. from 3M.TM.. Spacer 200 can include an adhesive backing,
e.g., of acrylic, natural rubber, synthetic rubber. Spacers 200 can
facilitate having uniformly thick bond lines throughout the
assembly, and promote regular and uniform curing of the adhesive
that is desirable for final assembly of the sections into panels
and panels into walls. Preferably, spacer 200 has a high
coefficient of friction to resist skidding on most surfaces.
Preferably, spacer is of width on the order of magnitude of 1''
(with 3/16'' squares being preferred), and of thickness to maintain
separation between the upper portion of wall section L flange 120A
and wall section second flange first portion 132B. The separation
is determined by that distance desired to allow adhesive 300 to
properly bond wall section 100A to wall section 100B. In some
embodiments, the thickness of spacer 200 is 0.030''. While FIG. 5
illustrates a vertical distribution of spacers 200, and FIG. 6,
described below, illustrates longitudinal distribution of the
spacers, various other distributions are possible to facilitate
proper bonding between the wall sections using the adhesive
300.
[0037] Adhesive 300, while shown in FIG. 5 as uniformly
distributed, can be applied in one or more beads around the spacers
on one or both of the surfaces to be joined, as known to those of
skill in the relevant art. In some embodiments, adhesive 300 is a
single component, high strength, elastomeric sealant. For example,
Hybrid adhesive sealant 760 from 3M.TM.. The adhesive 300 is
applied in sufficient quantity to substantially fill the space
between the second flange first portion 132B of wall section 100B
to the depth of the spacer 200.
[0038] The use of spacers and adhesive may allow a wall panel, and
walls and other structural elements built therefrom, to expand and
contract with less stress on the wall section than in other panel
and wall configurations.
[0039] Referring to FIG. 6, the cross-section view of FIG. 5 is
seen from a top view. In this view it can be seen that the spacers
200 are distributed along the joint between wall section 100A and
wall section 100B. In assembling a wall panel from wall sections,
sections 100A and 100B are brought together and clamped for
sufficient time to allow the adhesive to bond the sections
together. Excess adhesive 400, e.g., adhesive beyond that needed to
substantially fill the gap between wall section 100B second flange
first portion 132 B will flow 1) into the space between wall
section 100B second flange second portion and the corresponding
portion of wall section 100A first flange perpendicular portion
122A, and 2) out of the top of the joint. Adhesive 400 flowing out
of the top of the joint can be removed.
[0040] This adhesive joint can expand and contract with changes in
temperature more readily than the wall sections can. This property
gives a shelter or container built using wall, ceiling, or floor
elements in accordance with the present technology an advantage
over the same structures assembled with fasteners such as rivets,
screws, clips, welding, and nuts and bolts.
[0041] Referring to FIG. 7, a flow chart describing methods 700 for
assembly of wall panels from wall sections is shown. In step 710, a
plurality of wall sections 100 are formed (Step 710). For example,
wall sections 100 are formed from aluminum sheets using a press
brake for bending both an L flange 120 and a second flange 130 into
the sheet. For the purpose of this example, three (3) wall sections
are formed and aligned with long sides parallel; each wall section
oriented as shown in FIG. 1--with the L flange on the right and the
second flange on the left, both flanges facing down.
[0042] For the leftmost and center wall sections, spacers, such as
spacers 200, are affixed to the L flange perpendicular portion 120
at a position corresponding to the mating second flange first
portion 130 of the next wall section (Step 720), e.g., as shown in
FIG. 5 and FIG. 6. Adhesive, e.g., adhesive 400, is applied to the
L flange perpendicular portion 120 at a position corresponding to
the mating second flange first portion 130 of the next wall section
around the spacers (Step 730). Preferably, sufficient adhesive is
applied to substantially fill the space between the L flange
perpendicular portion 120 and the mating second flange first
portion 130 of the next wall section.
[0043] The three wall sections, now joined by spacers and adhesive
into a wall panel, are now clamped together, and the panel is
allowed to cure (Step 740).
[0044] Referring to FIG. 8, a wall panel 800 of the present
technology is illustrated. In FIG. 8, the wall panel 800 includes
three (3) wall sections 100, and a partial wall section 910.
Partial walls sections can be used when wall length is desired to
be other than a multiple of the wall section length. In some
embodiments of the technology, a partial wall section is, as shown
in FIG. 8, simply a wall section 100 terminated before reaching
either the L flange or the second flange. In some embodiments, a
partial wall section includes both an L flange and a second flange
as described above, but has a main body width different than the
main body width of other wall sections used in a panel.
[0045] FIG. 8 also illustrates the L flange parallel portion 124,
including the L flange parallel portion outer face 920. In some
embodiments, the L flange parallel portion extends only as far as
required to contact the second flange second portion 134 of the
adjoining wall section. In other embodiments, such as the
embodiment shown in FIG. 8, the L flange parallel portion extends
beyond the second flange second portion 134, providing a broader L
flange parallel portion outer face that can be used to secure other
structural elements (such as horizontal rails) and finish elements
(such as wall board). The space 930 that can be enclosed by finish
elements such as wallboard can be used to route utilities (e.g.,
electrical, communications), water, medical gases, and heating,
ventilation, and air conditioning (HVAC) elements.
[0046] Referring to FIG. 9, a wall 990 of the present technology is
illustrated. Wall 990 is not shown to scale; features are
exaggerated to illustrate the relationship between the elements of
the wall 990. Wall 990 can include a plurality of wall panels 800.
Typically, wall 990 can include ten (10) or more wall panels 800;
each wall panel 800 can include a number of wall sections 100,
e.g., three (3) full-width wall sections 100 and one (1)
partial-width wall section as shown in FIG. 8. In preferred
embodiments, walls 990 are formed with wall sections 100 of the
wall panels 800 oriented vertically, e.g., along the short
dimension of the rectangular wall 990 for configurations in which
the wall 990 is longer than it is high.
[0047] The wall panels 800 can be held in a frame built from frame
segments 992, with the flange side of each wall section 100 facing
the interior, thereby presenting a substantially co-planar surface
to the exterior. The frame can form a recess, as shown in section
D-D, such that the wall panels 800 present an exterior face
substantially flush with the face of the frame. The frame segments
992 can be formed from various materials, e.g., extruded aluminum.
Wall panels 800 can be secured in the frame using a metal-to-metal
bonding such as SEM.RTM. 39537 weld bond. While the frame of FIG. 9
is rectangular and has four frame segments 992, the frame can be
any shape, including an n-sided closed polygon. FIG. 10 illustrates
an overall rectangular eight-sided closed polygon assembled as a
frame 992. Zero or more supports 996 can horizontally span the
frame, and be secured to each wall section 100 at the L flange
parallel portion outer face 920 using a metal-to-metal bonding such
as SEM.RTM. 39537 weld bond. The horizontal supports 996 can be
tack welded to the vertical frame segments 992.
[0048] Perimeter flats 994 can be affixed to cover the abutment
between each frame segment 992 and the wall sections 100, with a
first portion of each flat 994 covering a portion of each wall
section 100, and the remainder of each flat 994 covering a portion
of the frame segment 992. FIG. 9 illustrates four (4) flats 994
miter joined at the corners. The flats 994 can be secured to each
frame segment 992 using various adhesives, e.g., methacrylate-based
adhesives. In some embodiments, an adhesive sealant such as a
single component, high strength, elastomeric sealant (for example,
Hybrid adhesive sealant 760 from 3M.TM.) can be used at the
interface between the flats 994 and each wall section 100.
[0049] Referring to FIG. 10A, eight (8) frame segments 992 are
illustrated forming an 8-sided closed polygon to frame a shelter
wall 1000 including a portal 1010. While the frame forms an 8-sided
polygon, the overall wall shape is rectangular with height less
than width. Perimeter flats are not shown in FIG. 10A. The wall
1000 includes eighteen (18) full wall sections spanning the height
of the wall, and four (4) shorter wall sections 100 over the portal
1010. In FIG. 10B, eight (8) flats 994 are affixed to the frame
segments 992 and the wall sections 100. Each flat 994 overlaps the
abutment between a wall section 100 and a frame segment 992.
Referring to FIG. 11, a shelter 1000 formed from walls 990 of the
present technology is shown in perspective view. Shelter 1000
includes long wall 990A and short wall 990B. Shelter 1000 can be
sized to conform to ISO standards for intermodal shipping
containers.
[0050] While various embodiments of the present technology have
been described above, it should be understood that they have been
presented by way of example only, and not limitation. For instance,
while the wall sections disclosed herein have been disclosed in the
context of vertical wall sections that can be assembled in to
panels and walls of a shelter, the wall sections can be used as
ceiling and floor elements in those applications, along with
applications such as aircraft, ships, rail cars, modular buildings,
and fixed construction. It will be apparent to persons skilled in
the relevant art that various changes in form and detail can be
made therein without departing from the spirit and scope of the
technology. For instance, features described as part of one
implementation can be used on another implementation to yield a
still further implementation. Thus, the breadth and scope of the
present technology should not be limited by any of the
above-described exemplary embodiments, but should be defined only
in accordance with the following claims and their equivalents.
* * * * *