MODULAR STRUCTURE SYSTEMS
20230211943 · 2023-07-06
Inventors
Cpc classification
B65D88/522
PERFORMING OPERATIONS; TRANSPORTING
B65D2590/0008
PERFORMING OPERATIONS; TRANSPORTING
B65D7/12
PERFORMING OPERATIONS; TRANSPORTING
B65D88/022
PERFORMING OPERATIONS; TRANSPORTING
B65D88/129
PERFORMING OPERATIONS; TRANSPORTING
E04B2001/34892
FIXED CONSTRUCTIONS
International classification
Abstract
A method for joining shipping containers together to create a modular structure includes providing a first shipping container and a second shipping container; removing a wall of the side of the first shipper container to create a first opening; removing a wall of the side of the second shipping container to create a second opening; positioning the first opening adjacent and opposite to the second opening; aligning the first opening with the second opening; after the aligning, securing the first shipping container to the second shipping container to create the modular structure; and securing an inner flashing around an inner periphery of the first opening.
Claims
1. A method for joining shipping containers together to create a modular structure, the method comprising: providing a first shipping container and a second shipping container, each shipping container defining a side with four corners and an inner volume, wherein each corner comprises a corner casting; removing a wall of the side of the first shipping container to create a first opening; removing a wall of the side of the second shipping container to create a second opening; positioning the first opening adjacent and opposite to the second opening; aligning the first opening with the second opening such that each corner casting of the first container is adjacent and opposite to a respective corner casting of the second shipping container, the aligning defining a peripheral gap between the sides of the first and second shipping containers; after the aligning, securing the first shipping container to the second shipping container to create the modular structure by securing each corner casting of the first shipping container to the respective corner casting of the second shipping container to constrain a width of the peripheral gap; securing an inner flashing around an inner periphery of the first opening, wherein, when the first and second shipping containers are secured, the inner flashing extending into the second opening and covering the peripheral gap to define a portion of an enclosure of the modular structure comprising the inner volumes of the first and second shipping containers.
2. The method of claim 1, wherein securing each corner casting of the first shipping container to the respective corner casting of the second shipping container comprises securing each adjacent pair of corner castings with an adjustable fastener, the adjustable faster enabling the width of the peripheral gap to be adjusted by operating the adjustable fasteners.
3. The method of claim 2, further comprising securing an outer flashing around the an outer periphery of the second opening, wherein, when the first and second shipping containers are secured, the outer flashing extending around the first shipping container and covering the peripheral gap to define a portion of an exterior of the modular structure.
4. The method of claim 3, wherein the peripheral gap defines a gasket volume between the inner and outer flashings, the method further comprising disposing a gasket material in the gasket volume, the gasket material creating a seal between the inner and outer flashing to seal the enclosure modular structure at the location of the gap.
5. The method of claim 4, further comprising: after filling the sealing volume with the gasket material and securing the first shipping container to the second shipping container with the adjustable fastener, operating the adjustable fastener to reduce the width of the gap; and reducing, by operating the adjustable fastener, the gasket volume between the inner and outer flashings to fill the gasket volume with the gasket material; sealing, by reducing the gasket volume, the modular structure at the gap.
6. The method of claim 1, further comprising: providing a third shipping container that defines a side with four corners and an inner volume, wherein each corner comprises a corner casting; removing a wall of another side of the first shipping container to create a third opening; removing a wall of the side of the third shipping container to create a fourth opening; and positioning the third opening adjacent and opposite to the fourth opening.
7. The method of claim 6, further comprising: aligning the third opening with the fourth opening such that each corner casting of the first container is adjacent and opposite to a respective corner casting of the third shipping container, the aligning defining a peripheral gap between the sides of the first and third shipping containers; after the aligning, securing the first shipping container to the third shipping container to enlarge the modular structure by securing each corner casting of the first shipping container to the respective corner casting of the third shipping container to constrain a width of the peripheral gap between the sides of the first and third shipping containers; and securing an inner flashing around an inner periphery of the third opening, wherein, when the first and third shipping containers are secured, the inner flashing extending into the fourth opening and covering the peripheral gap to define a portion of an enclosure of the modular structure comprising the inner volumes of the first and third shipping containers.
8. The method of claim 6, further comprising: providing a fourth shipping container that defines a side with four corners and an inner volume, wherein each corner comprises a corner casting; removing a wall of a ceiling of the first shipping container to create a fifth opening; removing a wall of a bottom of the fourth shipping container to create a sixth opening; and positioning the fifth opening adjacent and opposite to the sixth opening.
9. The method of claim 8, further comprising: aligning the fifth opening with the sixth opening such that each corner casting of the first container is adjacent and opposite to a respective corner casting of the fourth shipping container, the aligning defining a peripheral gap between the ceiling and the bottom, respectively, of the first and fourth shipping containers; after the aligning, securing the first shipping container to the fourth shipping container to enlarge the modular structure by securing each corner casting of the first shipping container to the respective corner casting of the fourth shipping container to constrain a width of the peripheral gap between the ceiling and the bottom, respectively, of the first and fourth shipping containers; and securing an inner flashing around an inner periphery of the fifth opening, wherein, when the first and fourth shipping containers are secured, the inner flashing extending into the sixth opening and covering the peripheral gap to define a portion of an enclosure of the modular structure comprising the inner volumes of the first and fourth shipping containers.
10. The method of claim 9, further comprising installing a staircase that extends in the inner volume of the first shipping container toward the sixth opening.
11. The method of claim 10, wherein the staircase extends through the sixth opening.
12. The method of claim 1, further comprising installing one or more utility connections within at least one of the inner volume of the first or second shipping containers.
13. The method of claim 12, wherein the one or more utility connections extend within the inner volume of each of the first and second shipping containers.
14. The method of claim 12, wherein the one or more utility connections comprises at least one of an electrical power connection, an HVAC connection, a network connection, or a CPS connection.
15. The method of claim 14, further comprising installing a plurality of solar power assemblies to the modular structure.
16. The method of claim 15, further comprising electrically connecting the plurality of solar power assemblies to the at least one electrical power connection.
17. The method of claim 1, further comprising installing a wing frame extension across an opening defined by barn doors coupled to the first shipping container.
18. The method of claim 17, further comprising installing an interior door to the wing frame extension.
19. The method of claim 18, wherein the interior door defines an airtight or watertight seal of the inner volume of the first shipping container.
20. The method of claim 19, wherein at least one of the barn doors is configured to be open while the interior door is closed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0057] Like reference symbols may refer to like components. Also, features shown or described with reference to a particular modular structure or system may also be included on other modular structures or systems even if such features are not shown on such modular structures or systems.
DETAILED DESCRIPTION
[0058] The present disclosure described modular structure systems and methods therefor. In some implementations, a modular structure system may include a modular structure, such as a shipping container. The shipping container, in some aspects, may be an intermodal shipping container governed by the ISO 6346 standard, otherwise known as an ISO shipping container. In some aspects, each modular structure is an ISO shipping container of a particular, standardized size. Such sizes include, for example, 40′ long by 8′ wide by 8′ tall (Regular 40′ ISO) also referred to as “40′ Container”; 40′ long by 8′ wide by 9.5″ tall (High Cube 40′ ISO) also referred to as “40′ Container”; or 20′ long by 8′ wide by 8′ tall (Regular 20′ ISO) also referred to as “20″ ISO Container.” In some aspects, one or more of the modular structures is a “one-trip” shipping container, e.g., an ISO shipping container that has been transported a single trip.
[0059] Other containers besides ISO shipping containers may form the basis of one or more of the modular structures. For example, any container that may be modified, e.g., by removing what is not needed (sides, roofs, floors, doors, etc.) and adding what is desired (HVAC, electrical connections, Network and Telephone Connections, Potable Water, Grey water, Black Water, Chill Water, and Heated Water/Steam) to construct a modular structure system are contemplated by the present disclosure. In addition, such modular structures, such as ISO shipping containers, may be transported via truck, rail, ship, and helicopter to wherever they are needed.
[0060] One or more modular structures (as described in more detail herein) may include utility connections. In some aspect utility connections includes any combination of the following available utilities that are required in a building, aircraft or other vessel/structure that would be connected/interconnected between any combination of the modular structures in order to accommodate environmental conditions required for humans, as well as other flora, and fauna, or experiments, systems that require specialized environments: power (may be three phase, single phase, DC, or AC, or any combination); HVAC (heating ventilation, air conditioning, filters, back pressure systems); CPS (Collective Protection Systems) for NBC and HAZMAT applications; oxygen generation and distribution systems as well as humidifiers, dehumidifiers, CO.sub.2 scrubbers and other environmental control systems; network (radar and microwave wave guides, low and high voltage Cat5/6, etc. network cabling, fiber optics, telephone, and other network communication systems); piping/tubing for water (e.g., potable, grey, black, contaminated, high pressure, steam, etc.); drainage (for water, other fluids (chemicals, etc.); air and other compressed gases (e.g., oxygen, hydrogen, welding/manufacturing gases, etc.); and physical communication systems (vacuum tubes, messenger chutes, money/mail transfer chutes, etc.).
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[0062] Turning briefly to
[0063] As shown in
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[0066] As shown in
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[0068] In some aspects, the inner door 125 may be used to separate a “dirty” volume of the modular structure from a “clean” volume of the modular structure. For example, a volume between the inner door 125 and doors 102/103 may be considered a “dirty” volume, e.g., a volume fluidly coupled to an ambient environment through the doors 102/103, a volume in which persons or items entering the structure are considered dirty from the ambient environment (due to viral or bacterial or radioactive hazards or other). In some aspects, the inner door 125 may be fluid tight and create two separate and fluidly decoupled plenums within the structure.
[0069] In some aspects, another inner door (not shown) can be installed within the structure to the right of the inner door 125. With two inner doors, three separate plenums (e.g., fluidly decoupled volumes) may be defined within the structure. In some aspects, the plenum between the doors 102/103 and inner door 125 may be considered the “dirty” volume. The plenum between the inner door 125 and another inner door can be considered a “decontamination” volume in which “dirty” items are decontaminated. The plenum to the right of the other door can be considered the “clean” volume, into which decontaminated items may be move.
[0070] The inner door 125 is shown positioned orthogonally to a lengthwise axis of the modular structure. In some aspects, inner doors may be positioned parallel to a lengthwise axis of the modular structure. In example embodiments of modular structure systems in which two or more modular structures (such as the spacer or access modular structures of
[0071] The inner door may actually be part of one of the two barn doors in order to allow for routine man door usage and then allow larger items to pass without constricting width. For example, turning to
[0072] In some aspects, the door assembly (e.g., combination of barn doors 129/130 and interior door 127 mounted to wing frame extension 126) allows for a human door, watertight door, airtight door, scuttle, or other access in order to allow faster and easier entry into the modular structure. Further, such an interior door 127 may allow for a watertight or airtight seal to the modular structure, which may be useful in the event of nuclear, biological, or chemical environments that could be toxic to the inhabitants of the modular structure.
[0073] In some aspects, the illustrated wing frame extension 126 may allow users to quickly and easily access the space within the modular structure by keeping one of the barn doors open at all times (while still maintaining the ability to seal the modular structure by closing both barn doors 129/130), as shown in
[0074] In some aspects, the interior door 127 can be outfitted with any type of locking/security access system (e.g., regular locks, cypher locks, scanners, digilocks, proximity readers, biometric readers). The interior door 127 could be manually or automatically operated. The user can then leave the right barn door 129 open (in this configuration, other configurations may have the wing frame on the right barn door, leaving the left barn door 130 open) and then access the modular structure through the interior door 127. When the door 127 is closed, the wing frame extension 126, if attached to the mounting barn door (i.e., left barn door 130) could be bolted to the closed barn door side of the modular structure in order to provide additional stability to the wing frame. For additional security, the right barn door 129 could be closed and locked without revealing the fact that the container had been modified which may be useful in shipping or during storage
[0075] In some aspects, the wing frame extension 126 could be attached (e.g., welded, fastened, bolted) to either the barn door or to the modular container, as shown in
[0076] In some aspects, an additional wing frame extension 126 could be installed in an interior volume of the modular container, e.g., several feet away from the wing frame extension 126 shown adjacent the barn doors 129/130. In such aspects, a decontamination area may be created and defined between the extensions 126 within the interior volume of the modular container. Thus, there may be a two-stage ingress into the container created by the wing frame extensions 126. A user would enter a decontamination volume first (e.g., between the two wing frame extensions 126) before entering a clean volume (e.g., in the container past the second, interior-mounted wing frame extension 126). Such a set of dual door assemblies may be helpful to create a decontamination zone, or toxic cleanup zone, or to create a clean-room purging, cleaning, or dressing area. Depending on the desired use, additional stages may be added and/or different containers may be used to create separate areas that could be used not just for decontamination but also for other purposes.
[0077] For example, multiple, separated and isolated areas within one or more modular structures that are coupled together may ensure a higher level of cleanliness required for certain applications (e.g., silicon wafer design with separate compartments (8) required for a 1/100,000 pp, clean room that require: initial entrance, dirty changing compartment, shower compartment, drying compartment, clean dressing room, SCBA/PPE outfitting room, testing chamber, entrance to clean area.)
[0078] As another example, multiple, separated and isolated areas within one or more modular structures that are coupled together may create an environment for a desired end use (e.g., decompression, fumigation, imbuing a material with a chemical gas at an elevated temperature like titanium nitride coatings). These additional compartments could be spaces with different temperatures, pressures, in a vacuum, or pressured (filled) up with different gases. This could be for spraying consumables, humanely killing livestock, scientific applications that require different temperatures or pressures but still require a human to enter. In short, these partitions function as a quick acting watertight door such as in a space station.
[0079] In some aspects, a parent modular structure may be a base building block and can be configured for SCIF (Sensitive Compartmented Information Facility) or NBC (Nuclear, Biological, and Chemical) Treatment and Resistant Facility variants by modifying the inner door space and ventilation and access systems. In some aspects, a parent modular structure can handle incoming and outgoing power. In some aspects, a parent modular structure (or also an “all-in-one” unit) can also be used as a base for a “solar hub” or “power units” which is to say, solar, wind, turbine, generator, (or other source of power) with or without energy storage. The generated power may then be distributed from the parent modular structure to child modular structures or to a public power grid (if connected to the grid) or used within a parent container.
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[0083] In some aspects, as shown, the modular structures shown in
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[0085] In some aspects, in a modular structure system, one or more riser (or child) modular structures can be placed orthogonally across an end of multiple modular structures positioned and connected side-by-side. The riser modular structures may include components such as HVAC and power components and provide a “mechanical” space that stretches across at least a portion of the side-by-side modular structures. In some aspects, ingress/egress structures (e.g., doors) may be provided from the riser modular structure spaces into ends of one or more of the side-by-side modular structures (such as the side-by-side modular structures shown in
[0086] In some aspects, the modular structures shown in
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[0097] Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in certain claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results.