Expandable Portable Shelter and Structures of Multiple Expandable Portable Shelters

Abstract

A multicon structure comprising six or twelve expandable portable shelters (EPSs) characterized by equal depth dimensions extending in the direction of the structure length, and each EPS having two faces that are transverse to the structure length. Each EPS comprises two sets of panels, each set of panels including a floor panel, a ceiling panel, side panels, and an end panel. Each set of panels folding out from a corresponding face. Each EPS may be characterized by a depth that is a unit fractional amount of an intermodal shipping container length. Each EPS having corner post assemblies comprising a tubular stiffening structure, a hinge mount feature, and a panel interface feature. The outer panel having a gasket positioned such that, when the EPS is in a collapsed state, a watertight seal is formed between the gasket and the panel interface feature.

Claims

1. A multicon structure characterized by a structure length, structure width and structure height, the structure comprising: six or twelve expandable portable shelters (EPSs), characterized by equal depth dimensions extending in the direction of the structure length and each EPS having two faces that are transverse to the structure length, each EPS comprising two sets of panels, each set of panels comprising a floor panel, a ceiling panel, side panels, and an end panel, for each EPS each set of panels folding out from a corresponding one of the faces.

2. The multicon structure of claim 1, wherein the faces have a same face width and a same face height as one another, and wherein each panel has a width substantially equal to the face width and a height substantially equal to the face height.

3. The multicon structure of claim 1, wherein the floor panels or the ceiling panels are outer panels of each of the EPSs.

4. The multicon structure of claim 3, wherein each EPS comprises a frame and the outer panels form a watertight seal with the frame.

5. The multicon structure of claim 3, wherein each EPS comprises a frame having a frame top and a frame bottom, wherein each floor panel is rotatably coupled to the frame bottom, and each ceiling panel is rotatably coupled to the frame top.

6. The multicon structure of claim 5, wherein the frame comprises corner posts extending between the frame top and the frame bottom and each of the side panels is rotatably coupled to one of the corner posts.

7. The multicon structure of claim 1, wherein the structure length equals 20 feet or 40 feet.

8. The multicon structure of claim 1, wherein the structure width is 8 feet and the structure height equals 8.0 feet, 8.5 feet or 9.5 feet.

9. The multicon structure of claim 1, wherein each EPS has an expanded state, in which an enclosed area for human activity or equipment storage is defined in-part by the EPS's two sets of panels.

10. An expandable portable shelter (EPS) characterized by a depth that is a unit fractional amount of an intermodal shipping container length and having two faces that are transverse to the depth, the EPS comprising two sets of panels, each set of panels comprising a floor panel, a ceiling panel, side panels, and an end panel, each set of panels folding out from a corresponding one of the two faces.

11. The EPS of claim 10, wherein the faces have a same face width and a same face height as one another, and wherein each panel has a width substantially equal to the face width and a height substantially equal to the face height.

12. The EPS of claim 10, wherein the floor panels or the ceiling panels are outer panels of the EPSs.

13. The EPS of claim 12, wherein the EPS comprises a frame and the outer panels form a watertight seal with the frame.

14. The EPS of claim 12, wherein the EPS comprises a frame having a frame top and a frame bottom, wherein the floor panel is rotatably coupled to the frame bottom, and the ceiling panel is rotatably coupled to the frame top.

15. The EPS of claim 14, wherein the frame comprises corner posts extending between the frame top and the frame bottom and each of the side panels is rotatably coupled to one of the corner posts.

16. The EPS of claim 10, wherein the depth equals about 3.3 feet.

17. The EPS of claim 10, wherein the EPS has a width of about 8.0 feet and a height of about 8.0 feet, 8.5 feet or 9.5 feet.

18. The EPS of claim 10, wherein the EPS has an expanded state in which an interior area for human activity or equipment storage is defined in-part by the EPS's two sets of panels.

19. An expandable portable shelter (EPS) characterized by a depth, a width and a height, the EPS having (I.) a collapsed state in which two outer rigid panels, a plurality of inner rigid panels and two doors are supported by a frame such that the outer rigid panels and two doors define a four-sided perimeter, the two outer rigid panels rotatably coupled to the frame and forming a first set of opposing sides of the perimeter and the doors forming a second set of opposing sides of the perimeter, and (II.) an expanded state to provide area for human activity or equipment storage defined in-part by the outer rigid panels and the inner rigid panels, the frame comprising four vertical, corner post assemblies, each of the four corner post assemblies connected to a frame top by a corresponding corner casting, and each of the four corner post assemblies connected to a frame bottom by a corresponding corner casting, in a plane transverse to the height of the EPS, each of the corner post assemblies comprising (A.) a tubular stiffening structure, (B.) a hinge mount feature which, when the EPS is in the collapsed state, has a first segment that extends from the tubular stiffening structure in a direction transverse a plane defined by an outer surface of one of the doors and a second segment that extends in a direction parallel to the plane defined by the outer surface of one of the doors, and (C.) a panel interface feature which, when the EPS is in the collapsed state, has a first segment that extends from the tubular stiffening structure in a direction parallel to a plane defined by an outer surface of one of the outer rigid panels and a second segment forming a vertex with the first segment, the second segment extending transverse to the plane defined by the outer surface of the one of the outer rigid panels, the second segment of the panel interface feature having an interface surface defining, in-part, an opening in which the one of the outer rigid panels is disposed, the one of the outer rigid panels having a gasket attached thereto positioned such that, when the one of the outer rigid panels is in the collapsed state, a watertight seal is formed between the gasket and the interface surface.

20. The EPS of claim 19, wherein the tubular stiffening structure has a closed shape in the plane.

21. The EPS of claim 19, wherein the first segment of the hinge mount feature extends from the tubular stiffening structure in a direction perpendicular to the plane defined by an outer surface of one of the doors.

22. The EPS of claim 19, wherein the first segment of the hinge mount and the second segment of the hinge mount extend perpendicular to one another.

23. The EPS of claim 19, wherein the hinge mount has an L-shape in the plane.

24. The EPS of claim 23, wherein the first segment of the hinge mount and the second segment of the hinge mount are joined together by a curved portion.

25. The EPS of claim 19, wherein the second segment of the panel interface feature extends from the tubular stiffening structure in a direction perpendicular to the plane defined by an outer surface of the outer rigid panel.

26. The EPS of claim 19, wherein the first segment of the panel interface feature and the second segment of the panel interface feature extend perpendicular to one another.

27. The EPS of claim 19, wherein the panel interface feature has an L-shape in the plane.

28. The EPS of claim 19, wherein the first segment of the panel interface feature and the second segment of the panel interface feature are joined by a curved portion.

29. The EPS of claim 19, wherein the watertight seal extends from a corner casting at the frame top to one of the corner castings at the frame bottom.

30. The EPS of claim 19, wherein the second segment of the panel interface feature has an incurvation located more distally to the vertex than the interface surface, the incurvation forming a concave surface facing toward the opening.

31. The EPS of claim 30, wherein one of the inner rigid panels is coupled to the door interface feature by a hinge located in the incurvation.

32. The EPS of claim 30, wherein in the plane, the hinge mount feature, the panel interface feature and at least a portion of the tubular stiffening structure are formed of a single piece of material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] FIG. 1A is a schematic illustration of a conventional EPS in a collapsed state having dimension of a conventional intermodal shipping container;

[0036] FIG. 1B is a schematic illustration of the EPS of FIG. 1A in an expanded state;

[0037] FIG. 2A is a schematic, perspective view of an example of a multicon structure according to aspects of the present invention, in a collapsed state;

[0038] FIG. 2B is a schematic, first side view of the collapsed multicon structure of FIG. 2A;

[0039] FIG. 2C is a schematic, second side view of the collapsed multicon structure of FIG. 2A;

[0040] FIG. 3A is a schematic cross-sectional view of an example of an EPS (i.e., a representative EPS from the multicon structure shown in FIGS. 2A-2C) according to aspects of the present invention, in a collapsed state, with a cross-section taken along line 3A-3A in FIG. 2C;

[0041] FIG. 3B is a schematic, projection view of the EPS of FIG. 3A, in an expanded state;

[0042] FIG. 4 is a schematic illustration of a portion of the EPS of FIG. 3 with the outer panels and doors opened, and with inner portions of the EPS and the ceiling panel omitted to more clearly show the frame;

[0043] FIG. 5A is a cross-sectional view of one side of a EPS including a door (the door in a closed position) and illustrating corner post assemblies according to aspects of the present invention; and

[0044] FIG. 5B is a cross-sectional view of one corner post assembly of FIG. 5B in greater detail.

DETAILED DESCRIPTION

[0045] The invention will be further illustrated with reference to the following specific examples. It is understood that these examples are given by way of illustration and are not meant to limit inventions beyond language set forth in the claims.

[0046] FIGS. 2A-2C are schematic illustrations of an example of a multicon structure 200 according to aspects of the present invention, in a collapsed state. Multicon structure 200 is characterized by a structure length L, structure width W, and structure height H. Structure 200 comprises six expandable portable shelters (EPSs) 210a-210f. In the illustrated embodiment, structure length L is about 20 feet (i.e., a length as specified by ISO 1C or 1CC or 1CCC). As described below, EPSs 210a-210f allow for increased ratio of enclosed area for human activity and/or storage of equipment when the EPSs are in an expanded state to the area of the collapsed multicon structure footprint, as compared to conventional EPSs.

[0047] Each EPS 210 is characterized by a depth D extending in the direction of the structure length L. Typically, all of the EPSs have the same depth D. In the illustrated embodiment, each EPS has a depth of about 3.3 feet. It will be appreciated that dividing a multicon structure (20-feet in length) into a greater number of EPSs may be precluded by a need for allowing adequate enclosed area for electrical and mechanical appliances E (shown in FIG. 4) when the EPSs are in the collapsed state. Advantageously, a single EPS is relatively small compared to conventional EPS thereby allowing for one person to collapse and expand the EPS, and two EPSs placed side-by-side have a depth equal to a conventional TRICON EPS allowing for handling similar to a conventional TRICON EPS.

[0048] While the illustrated example shows a 20-foot structure divided into 6 EPSs, a structure may have a structure length L of about 40 feet (i.e., a length as specified by ISO 1A or 1AA or 1AAA), with the structure comprising twelve EPSs. Similar to the illustrated embodiment, in such a configuration, each EPS has a depth of about 3.3 feet; and such a construction results in a ratio of enclosed area for human activity and/or storage of equipment when the EPSs are in an expanded state to the area of the collapsed multicon structure footprint that is the same as for the 6-EPS structure.

[0049] Each EPS 210 has a width W.sub.U and a height H.sub.U corresponding to (and equal to) structure width W and structure height H, and two faces that are transverse (and in the illustrated embodiment perpendicular) to structure length L, although only a single face F is shown (i.e., the face of EPS 210f). Each face is defined by an EPS side exclusive of the frame (i.e., the opening outlined by the frame). Each face is characterized by a face height h and face width w. Face height h and face width w are reduced from the structure height H and structure width W due to the shape and dimension of components of frame FR. An example of corner post construction of frame FR is discussed in greater detail, below, with reference to FIGS. 4 and 5.

[0050] In the collapsed state, as shown in FIG. 3A for a representative one of EPSs 210a-210f, two outer rigid panels (floor panels 212f) and two doors 214a, 214b define a four-sided perimeter. As illustrated in FIGS. 2A-2C, the outer surfaces of the doors may be contoured but they define identifiable planar surfaces. The outer rigid panels form the faces of EPS 210 with the edges of the outer panels forming watertight seals with the frame, as is discussed in greater detail below.

[0051] In the collapsed state, each of the two outer rigid panels covers a plurality of inner rigid panels (the inner panels are visible in FIG. 3B). In the collapsed state, the two outer rigid panels, the plurality of inner rigid panels and the two doors 214a, 214b are supported by frame FR. In the collapsed state, the two outer rigid panels form a first set of opposing sides of the perimeter which are rotatably coupled to frame FR. The doors form a second set of opposing sides of the perimeter. For example, the outer panels may be latched to the frame using a cam lock 216 or other suitable latching mechanism thereby maintaining the outer panels as well as the inner rigid panels in the collapsed state.

[0052] FIG. 3B is a schematic illustration of representative EPS 210 according to aspects of the present invention, in an expanded state. As set forth above, each EPS 210 has two sets of panels 212. As is visible in FIG. 3B, each set of panels 212 folds out from a corresponding one of faces F. Each set of panels 212 includes a floor panel 212.sub.f (shown more completely in FIG. 4), a ceiling panel 212.sub.c, multiple side panels 212.sub.s, and an end panel 212.sub.e. In the illustrated embodiment, the sets of panels at each face F are the same. In the illustrated embodiment, the floor panel constitutes an outer panel (shown for example in FIG. 2C), and the ceiling panel 212.sub.c, side panels 212.sub.s, and an end panel 212.sub.e constitute a set of inner panels Although in the illustrated embodiment, the two outer rigid panels are floor panels, in other embodiments, the outer rigid panels may be ceiling panels or side panels.

[0053] In the expanded state, EPS 210 provides interior area for human activity and/or storage of equipment that is defined in-part (and predominantly) by the outer panels and the inner rigid panels; however, a relatively small portion of the enclosed area is defined by the top, bottom and sides of the original collapsed structure.

[0054] In the illustrated embodiment, the outer panel (i.e., the floor panel 212f) is rotatably coupled to the frame bottom B of frame FR (shown in FIG. 4); the ceiling panel 212c is rotatably coupled to the frame top T of frame FR; each side panel 212s is rotatably coupled to a corresponding corner post assembly 220a-220d (shown in FIG. 4); and the end panel 212e is rotatably coupled to one of side panels 212s (e.g., by one or more hinges (not shown)). After the panels are rotated to achieve the expanded state, seems S are present between adjacent panels 212 and latches (not shown) are used to couple adjacent panels at the seams, to form a fixed, closed structure. The order in which the panels 212 are stacked and are stored in the collapsed state is not essential; however, ceiling panel 212c and floor panel 212f will be attached to frame FR using a hinge having a horizontal axis of rotation, and side panels will be attached to the frame using a hinge having a vertical axis of rotation. End panel 212e can be coupled to a side edge of any of the ceiling, floor and side panels by hinge or simply attached to said panels by one or more latches.

[0055] In some embodiments, each panel has panel side-dimensions approximately equal to the face width w and face height h of the faces (shown in FIG. 2C). It is to be appreciated that it typically desirable that panel side dimensions are large as possible; however, some clearance is needed relative to the frame to allow the panels to be rotated into positions to form an expanded state. The face height and face width are less than the structure height and the structure width by an amount determined by construction of corner post assemblies 220a-220d, and the frame top and the frame bottom of frame FR.

[0056] In some embodiments, the rigid outer panels may be made of steel, aluminum or a composite materiel to provide protection to the entire structure when collapsed (such as during transport). The rigid inner panels are typically made of lighter construction such as multiply construction of sheet metal and insulation, with the insulation disposed between the sheet metal plies.

[0057] FIG. 4 is a schematic illustration of a portion of the EPS of FIGS. 3A and 3B with the outer panels (floor panel 212f) and doors 214a, 214b opened, and with inner portions of the EPS (e.g., panels 212c, 212e and 212s) and the top of the original structure omitted, to more clearly show frame FR. The frame comprises four corner post assemblies 220a-220d (an embodiment of which is described in greater detail below with reference to FIGS. 5A and 5B), eight corner castings 230 (only seven are visible), four top posts 240 (forming a frame top T), and four bottom posts 250 (forming a frame bottom B). In the illustrated embodiment, door 214a provides access to the interior of a collapsed and expanded structure, and door 214b provides access to electrical and mechanical equipment E.

[0058] FIG. 5A is a partial cross-sectional view of one side of an EPS (such as EPS 210), including a door 514. The view shows corner post assemblies 520a, 520b according to aspects of the present invention which may be used, for example, to form corner post assemblies 220a-220d in EPS 210 shown in FIG. 4. FIG. 5B shows post assembly 520a in greater detail. The illustrated corner post assemblies efficiently use space needed for panel and door support structure, thereby increasing the space available for panels and the corresponding area for human activity and/or equipment within the expanded structure.

[0059] The cross-section shown in FIG. 5A is taken in a plane transverse to the height of the EPS (e.g., height H.sub.u). Corner post assemblies 520a, 520b are designed to facilitate operation of various panels and doors (e.g., panels 212 and doors 214a, 214b shown in FIGS. 2A-3B). In the plane of the cross-section, each corner post assembly 520a, 520b comprises a tubular stiffening structure 530a, 530b, and each of the corner post assemblies comprises a door hinge mount feature 540a, 540b and a panel interface feature 550a, 550b. In some embodiments, in the plane of the cross-section, the tubular structure forms a closed shape, although the tubular structure may provide the desired stiffening and be less than closed. The closed shape may be square (as illustrated), rectangular, round, oval or any shape providing suitable stiffness.

[0060] Each hinge mount feature 540a, 540b, when the EPS is in the collapsed state, has a first segment 541a, 541b that extends from a corresponding tubular stiffening structure 530a, 530b in a direction transverse to a plane P.sub.door defined by an outer surface of door 514 and a second segment 542a, 542b that extends in a direction parallel to plane P.sub.door. In some embodiments, the first segment 541a, 541b may be perpendicular to plane P.sub.door. In some embodiments the first segments 541a, 541b and second segments 542a, 542b of the hinge mount feature 540a, 540b may extend perpendicular to one another; however, in other embodiments, the segments are other than perpendicular and may be joined by a curved portion (as shown). To extend in a direction parallel to plane P.sub.door, second segment 542a, 542b need not be straight and extend only in a direction parallel; rather, it predominantly extends in such direction and may include some curvature.

[0061] Each panel interface feature 550a, 550b, when the EPS is in the collapsed state, has a first segment 551a, 551b that extends from a corresponding tubular stiffening structure 530a, 530b in a direction parallel to a plane P.sub.RP defined by an outer surface of one of the outer rigid panels 510 and a second segment 552a, 552b forming a vertex V with the first segment 551a, 551b that is transverse to the plane P.sub.RP defined by outer surface of the one of the outer rigid panels 510. Second segment 552a, 552b has an interface surface I. Interface surface I defines, in-part, an opening O in which the one of the outer rigid panels 510 is disposed. (A corresponding opening O′ is shown in FIG. 4 for outer rigid panel (i.e., floor panel 212f)). In some embodiments, as shown in FIGS. 5A and 5B, in the plane of the cross-section, a hinge mount feature (e.g., hinge mount feature 540a), a panel interface feature (e.g., panel interface feature 550a) and at least a portion of a tubular stiffening structure 530a are formed of a single piece of material (i.e., of unitary construction) and a remainder of the stiffening structure 530a′ is attached to the single piece of material. For example, the remainder of the stiffening structure is welded to the single piece of material.

[0062] As shown in FIG. 4, a gasket G is disposed around a perimeter of floor panel 212f. For example, the gasket can be attached by a series of rivets R (a representative rivet is shown in FIG. 4) or adhesive or other suitable technique. Gasket G interfaces with surface I of panel interface feature 550a such that, when the outer rigid panel (i.e., floor panel 212f)) is in a closed position, a watertight seal is formed between the corner post assembly 520a and outer rigid panel 510. For example, gasket G may be made of butyl rubber or other suitable material. In some embodiments, the second segment 552a, 552b may be perpendicular to plane P.sub.RP. In some embodiments the first segments 551a, 551b and second segments 552a, 552b of panel interface feature 550a, 550b may be perpendicular to one another; however, in other embodiments, the segments are other than perpendicular and may be joined by a curved portion (as shown). To extend in a direction parallel to plane P.sub.RP, first segment 551a, 551b need not be straight and need not extend only in a direction parallel to plane P.sub.RP; rather, it predominantly extends in such direction and may include some curvature; however, the second segment is large enough and flat enough to allow application of a gasketing material thereon to form a watertight seal with panel 510 over multiple uses.

[0063] Typically, a rigid outer panel (floor panel 212f) and panel interface features 550a, 550b extend such that the watertight seal extends along the entire height h of the outer rigid panel, and from a corner casting at the frame top to a corner casting at the frame bottom.

[0064] In some embodiments, first segment 541a and the second segment 542a of hinge mount feature 540a constitute a first L-shaped feature; and the first segment 551a and the second segment 552a of panel interface feature 550a constitute a second L-shaped feature; however, the segments may be straight or may include some curvature. Vertex V may be ninety degrees or about ninety degrees or may include a curvature; however, a concavity C is present to maintain a hinge H therein for coupling to a door.

[0065] In the illustrated embodiment, second segments 552a, 552b of panel interface features 550a, 550b have an incurvation 553a, 553b located more distal to vertex V than the interface surface I, within which one or more panel hinges PH (e.g., for a side panel 212s) is attached. (The incurvation forms a concave surface facing toward opening O.) The axis of panel hinge PH extends vertically. Typically, the entire incurvation (and hinge) do not extend beyond the interface surface I into the opening O, to avoid a need to reduce the dimensions of panels (e.g., panels 212 shown in FIG. 3B). Also, typically no portion of a panel interface feature 550a, 550b extends beyond the interface surface I into the opening O.

[0066] In some embodiments, the tubular stiffening structures 530a, 530b extend from one of the corner castings 230 at the frame top to one of the corner castings 230 at the frame bottom (shown in FIG. 4). However, depending on the shape of the tubular stiffening structure and the material selected to form the corner post assembly, the tubular stiffening structures may extend less than from one of the corner castings 230 at the frame top to one of the corner castings 230 at the frame bottom.

[0067] As illustrated, in some embodiments, the panel interface features 550a, 550b further comprise a third segment 554a, 554b extending from the incurvation 553a, 553b in a direction transverse to the plane P.sub.door formed by the outer surface of door 514 thereby forming a stop to prevent the door from rotating toward the interior of the EPS.

[0068] Hinge mount features 540a, 540b may extend from a corner casting 230 at the frame top of the frame FR to a corner casting 230 at the bottom of the frame FR; however, the hinge mount features may only extend over portions of the length of the corner post assembly 520a, 520b where the hinges H are present.

[0069] Although various embodiments have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention and these are therefore considered to be within the scope of the invention as defined in the claims which follow.