PALLETIZED SHELTER SYSTEM
20180163391 ยท 2018-06-14
Inventors
- Braden Roy King (Seattle, WA, US)
- Amy Michelle King (Seattle, WA, US)
- Zane Harry Geel (Seattle, WA, US)
- Troy Kristin Oakes (Aberdeen, WA, US)
Cpc classification
E04B1/34384
FIXED CONSTRUCTIONS
E04H1/02
FIXED CONSTRUCTIONS
International classification
Abstract
A palletizable shelter that is easy to deliver, quick and easy to set up with no tools required, easily moveable (light), that can provide sleeping shelter for up to four adults, provide a very modest amount of living space during the day, provide a modest level of storage in a secure (lockable) structure, easily cleaned, can be disassembled with no tools, packaged and stored in a very small volume, and readily deliverable to the next site quickly and easily. A community in a container model is provided that includes multiple palletizable shelters in a collapsed configuration, a common cooking and meeting place, laundry facilities, and a shared bathroom facility that would include toilets, sinks and showers.
Claims
1. A palletizable shelter, comprising: a rigid base; four rigid walls attachable to the base, the four rigid walls comprising a front wall, a rear wall, a first side wall, and a second side wall; a roof attachable to the four walls, the roof comprising first and second roof panels; and a rigid framework comprising individual vertical frame members on each of the four walls and joist frame members on the roof, the vertical frame members on the first side wall are sized and shaped to be received within vertical frame members on the second wall when the first and second side walls are in an abutting face-to-face and rotated in a 180 degree relationship, and the joist frame members on the first roof panel are received within the joist frame members on the second roof panel when the first and second roof panels are in an abutting and rotated in a 180 degree face-to-face relationship; and the shelter having a deployed configuration in which the base, the four walls, the roof are attached together via the rigid framework to form a shelter that defines an enclosed interior, the shelter having a palletized configuration in which the first and second walls, the front wall, the rear wall, and the first and second roof panels are layered on the rigid pallet and in which the first and second side walls are in the abutting face-to-face and rotated in a 180 degree relationship with the vertical frame members of the first side wall received within the vertical frame members of the second side wall, and further in which the first and second roof panels are in the abutting face-to-face and rotated in a 180 degree relationship with the joist frame members on the first roof panel receiving within them the joist frame members on the second roof panel.
2. The shelter of claim 1 wherein the vertical frame members on the second wall and the joist frame members on the second roof panel have a U-shaped cross-sectional configuration with a channel that is sized and shaped to receive the vertical frame members of the first wall and the joist frame members of the first roof panel, respectively, in the U-shaped channel.
3. The shelter of claim 1 wherein the vertical frame members on each of the four walls have a first end structured to be coupled to the rigid base and a second end structured to be attached to the joist members on each of the first and second roof panels, the second end of the vertical frame members structured to be attached to the joist members on the first roof panel comprising a saddle sized and shaped to receive the joist members on the first roof panel, and the transvers members of the second roof panel comprising a saddle sized and shaped to receive the joist members of the second roof panel.
4. The shelter of claim 1 comprising at least two bunk bed brackets and two pivot pins for each one of the at least two bunk bed brackets, the at least two bunk bed brackets each having a yoke and an extension leg, the yoke structured to be pivotally attached to a respective vertical frame member by a first one of the two pivot pins extending through the yoke and the respective vertical frame member, and the yoke further structured to pivot into a deployed configuration in which the respective extension leg is substantially horizontal and the second one of the two pivot pins holds the yoke of the bracket to the respective vertical frame member in the deployed configuration, and the yoke further structured to rotate into a stored configuration in which the second pivot pin is removed from the yoke and the respective extension leg pivots to abut the respective vertical frame member.
5. The device of claim 1 comprising a corner flashing at each corner formed by the intersection of two of the four walls, the corner flashing having a first longitudinal leg extending from a second longitudinal leg at substantially a right angle, the first longitudinal leg having a first joist width, and the second longitudinal leg having a second joist width that is longer than the first joist width, the first longitudinal leg capable of being attached to a first one of the two walls so that the second longitudinal leg is spaced from the first one of the two walls to form a channel between the second longitudinal leg and the first one of the two walls that is sized and shaped to receive the second one of the at least two walls.
6. A system for storing and deploying transitional housing in a community setting, the system comprising: a container having four walls, a bottom panel, and a top panel connected together to define an enclosed interior, the container structured to be shippable by rail, sea, or land; and at least one shelter that includes: a rigid base; four rigid walls attachable to the base, the four rigid walls comprising a front wall, a rear wall, a first side wall, and a second side wall; a roof attachable to the four walls, the roof comprising first and second roof panels; and a rigid framework comprising individual vertical frame members on each of the four walls and joist frame members on the roof, the vertical frame members on the first side wall are sized and shaped to be received within vertical frame members on the second wall when the first and second side walls are in an abutting face-to-face and rotated 180 degree relationship, and the joist frame members on the first roof panel are received within the joist frame members on the second roof panel when the first and second roof panels are in an abutting face-to-face and rotated 180 degree relationship; and the shelter having a deployed configuration in which the base, the four walls, the roof are attached together via the rigid framework to form a shelter that defines an enclosed interior, the shelter having a palletized configuration in which the first and second walls, the front wall, the rear wall, and the first and second roof panels are layered on the rigid pallet and in which the first and second side walls are in the abutting face-to-face and rotated 180 degree relationship with the vertical frame members of the first side wall received within the vertical frame members of the second side wall, and further in which the first and second roof panels are in the abutting face-to-face and rotated 180 degree relationship with the joist frame members on the first roof panel receiving within them the joist frame members on the second roof panel.
7. The system of claim 6 wherein the vertical frame members on the second wall and the joist frame members on the second roof panel have a U-shaped cross-sectional configuration with a channel that is sized and shaped to receive the vertical frame members of the first wall and the first roof panel, respectively, in the U-shaped channel.
8. The system of claim 7 wherein the vertical frame members on each of the four walls have a first end structured to be coupled to the rigid base and a second end structured to be attached to the joist members on each of the first and second roof panels, the second end of the vertical frame members structured to be attached to the joist members on the first roof panel comprising a saddle sized and shaped to receive the joist members on the first roof panel, and the transvers members of the second roof panel comprising a saddle sized and shaped to receive the joist members of the second roof panel.
9. The shelter of claim 6 comprising at least two bunk bed brackets and two pivot pins for each one of the at least two bunk bed brackets, the at least two bunk bed brackets each having a yoke and an extension leg, the yoke structured to be pivotally attached to a respective vertical frame member by a first one of the two pivot pins extending through the yoke and the respective vertical frame member, and the yoke further structured to pivot into a deployed configuration in which the respective extension leg is substantially horizontal and the second one of the two pivot pins holds the yoke of the bracket to the respective vertical frame member in the deployed configuration, and the yoke further structured to rotate into a stored configuration in which the second pivot pin is removed from the yoke and the respective extension leg pivots to abut the respective vertical frame member.
10. The device of claim 6 comprising a corner flashing at each corner formed by the intersection of two of the four walls, the corner flashing having a first longitudinal leg extending from a second longitudinal leg at substantially a right angle, the first longitudinal leg having a first joist width, and the second longitudinal leg having a second joist width that is longer than the first joist width, the first longitudinal leg capable of being attached to a first one of the two walls so that the second longitudinal leg is spaced from the first one of the two walls to form a channel between the second longitudinal leg and the first one of the two walls that is sized and shaped to receive the second one of the at least two walls.
11. The system of claim 6 wherein the container is a high cube container sized and shaped to store at least 14 shelters in palletized configuration and standing on end.
12. The system of claim 11 further comprising at least one portable toilet to be stored in the container.
13. The system of claim 12 further comprising at least one portable laundry with washer and dryer to be stored in the container.
14. The system of claim 13 further comprising removable walls in the container to enable accommodation of at least three portable toilets and at least one portable laundry in individual rooms in the container.
15. The system of claim 14 further comprising plumbing for the at least one portable laundry and at least three portable toilets and electrical wiring for the at least one portable laundry, the plumbing and electrical wiring structured to be stored in the container.
16. The system of claim 14 further comprising a yurt structured to be stored in the container and to be deployed as a community shelter.
17. The system of claim 16 further comprising one or more of a refrigerator, a range, and one or more cabinets to be stored in the container and deployed inside the deployed yurt.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The foregoing and other features and advantages of the present disclosure will be more readily appreciated as the same become better understood from the following detailed description when taken in conjunction with the accompanying drawings, wherein:
[0008]
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
DETAILED DESCRIPTION
[0038] In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures or components or both associated with the use of ISO containers, laundry facilities and equipment, toilets, water and electrical supplies have not been shown or described in order to avoid unnecessarily obscuring descriptions of the implementations.
[0039] Unless the context requires otherwise, throughout the specification and claims that follow, the word comprise and variations thereof, such as comprises and comprising are to be construed in an open inclusive sense, that is, as including, but not limited to. The foregoing applies equally to the words including and having.
[0040] Reference throughout this description to one implementation or an implementation means that a particular feature, structure, or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearance of the phrases in one implementation or in an implementation in various places throughout the specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.
[0041] By way of general description, the present disclosure provides shelters that are small, compact dwelling structures, built with light-weight, strong, and relatively inexpensive materials, into a structure that, through the design of the structure itself, further increase the strength of the dwelling unit by nature of the design of the structural elements into a whole that is stronger than the sum of the pieces.
[0042] The basic materials of the dwelling unit include honeycomb polypropylene structural sheets with a thin fiberglass skin on both sides, aluminum rectangular structural elements or frame members, and a thin walled polycarbonate sheet that provides both structure integrity to the roof while providing waterproofing and allowing solar energy in to the interior of the shelter for solar heating.
[0043] Further strength is achieved through the design of the aluminum structure or frame in to a protective cage with the polypropylene skin providing a barrier to the weather but not required for structural strength. Further strength is achieved through the careful placement of connections between floor-to-wall, wall-to-wall and wall-to-roof sub-assemblies. Speed of assembly and disassembly is achieved through the use of quick connect pins at each of the above connection points so that the assembly and disassembly is quick, straight forward, and without requiring any tools. Because of this unique design, the wear and tear on the components during the assembly and disassembly process is minimized.
[0044] The design of the subassemblies, such as wall panels and roof panels is such that when disassembled they interlock or mesh with each other in a nesting relationship to reduce the virtual thickness of the combined packaged unit and increase the structural integrity of the packaged panels during shipping. The size of the final packaged pallet shelter units is such that they can fit into a 20 foot high cube shipping container, and only standing on edge, with maximum utilization of the interior volume of the container. By utilizing a standard shipping container, the full container can also be shipped to anywhere in the world utilizing the benefits of the standardized container for truck, rail, ship or air transport.
[0045] Finally, the shelter is one of the basic building blocks of the community model in which the basic building blocks of the community are selected and sized so as to fit within the same shipping container all of the necessary elements to support a full community. This very compact design enables the basic building blocks to be delivered to the site in one package that is easily unloaded and easily assembled. When the community needs to be moved, it can be quickly cleaned, broken down, repackaged, stored, and then shipped to the new location.
[0046] In accordance with one aspect of the present disclosure there is provided a custom made corner flashing that has two sides of different widths. It is installed on the front wall and back wall corners during fabrication of the front and back wall subassemblies in order to create the gap that the side walls slide in to at the point of final field install assembly. More particularly, the corner flashing is installed at each corner formed by the intersection of two of the four walls. The corner flashing has a first longitudinal leg extending from a second longitudinal leg at substantially a right angle, the first longitudinal leg having a first width, and the second longitudinal leg having a second width that is longer than the first width. The first longitudinal leg is capable of being attached to a first one of the two walls so that the second longitudinal leg is spaced from the first one of the two walls to form a channel between the second longitudinal leg and the first one of the two walls that is sized and shaped to receive the second one of the at least two walls.
[0047] Referring initially to
[0048] A rigid framework 77 shown more clearly in
[0049] The vertical frame members 78 on each of the four walls 56, 58, 60, 62 have a first end 90 structured to be coupled to the rigid base 52 and a second end 92 structured to be attached to the joist members 80 on each of the first and second roof panels 66, 68. Preferably the second end 92 of the vertical frame members 78 is structured to be attached to the joist members 86 on the first roof panel 66 with a saddle 92 sized and shaped to receive the joist frame members 86 on the first roof panel 86 as shown in
[0050]
[0051] Each shelter 50 can include one or more bunk assemblies 102 that include the planar bunk panel 104 and a frame 106 that is pivotally connected to the vertical frame members 78 as shown in
[0052]
[0053] A center support 128 is also shown (see
[0054] In use, the shelter 50 has a deployed configuration as shown in
[0055] Referring next to
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
[0063]
[0064]
[0065] As will be readily appreciated from the foregoing, the shelter and system of the present disclosure provide many novel features, including without limitation:
[0066] Design of a structural aluminum cage or framework that is lightweight, strong, and has key connection points, i.e., wall-to-floor connection, wall-to-wall connection, and roof-to-wall connections, with quick connect pins that eliminate the need for hand tools. In addition, the quick connect pin receivers minimize wear and tear while also controlling cost. The carefully shaped and placed structural elements within the subassemblies reduce the unassembled palletized package size and increase the structural integrity of the palletized shelter as a shipping unit for storage and transport. In addition, the design of the disassembled and palletized shelter maximizes the volume and enables standardization for use with a high cube shipping container
[0067] The design and sizing of the community building blocks allow everything needed for the community model to be fit within the same shipping container for storage and shipment. The community system can be quickly and easily unpacked and deployed, and the shipping container can be converted to a useable shared bathroom and laundry facility.
[0068] The various implementations described above can be combined to provide further implementations. Aspects of the implementations can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further implementations. For example, the aluminum material can be replaced with many other structural materials such as wood, but at the cost of increasing weight and reducing longevity through multiple assemblies and disassembles. Next to wood, aluminum is the most effective, light-weight, inexpensive structural material available. Similarly, the Plascore (honeycomb polypropylene) could be replaced with standard plywood, but again the weight would increase, the durability would decrease, the resistance to insects would be very poor.
[0069] In addition to the foregoing, the quick connectors could be replaced with nuts and bolts, although the assembly and disassembly would be slower and would require tools. Additional connection points could be provided, but it would be unnecessary overkill in terms of structural strength of the assembled unit. Likewise, the thin walled polycarbonate could be replaced with any of a variety of materials that are weather proof, but this would increase weight and lose the solar advantage.
[0070] The intermeshing of the structural frame members when palletizing the sub-assemblies could be eliminated but at the cost of increased thickness of the palletized disassembled components and the structural integrity would be reduced. One could choose to ship the shelters in any truck, but this would lose the use of the shipping container to convert to the shared bathroom and laundry facility.
[0071] These and other changes can be made to the implementations in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific implementations disclosed in the specification and the claims, but should be construed to include all possible implementations along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.