US20130067846A1

US20130067846A1 - Building system and method

Info

Publication number: US20130067846A1
Application number: US13/619,546
Authority: US
Inventors: Kevin Kvols; Daniel J. Hertel
Original assignee: Diversified Fixtures Inc
Current assignee: Diversified Fixtures Inc
Priority date: 2011-09-16
Filing date: 2012-09-14
Publication date: 2013-03-21

Abstract

A building system can comprise wall, floor, and/or ceiling panels. A first profile with two cavities extending along different sides of the profile can be used to connect similar panels together. A second profile can be used to connect dissimilar panels. A plurality of fastening clips can be used to lockingly engage a wall panel at one end and one of either a wall panel, a floor panel, or a ceiling panel at the other end. The building system can be configured to not require other fasteners besides the clips and profiles to hold the panels together.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Application No. 61/535,785, filed Sep. 16, 2011, entitled “BUILDING SYSTEM AND METHOD,” which is incorporated by reference herein in its entirety and is to be considered a part of this specification.

BACKGROUND

1. Field
Certain embodiments disclosed herein relate generally to building systems, in particular to modular building systems. The buildings systems can be collapsible and reusable and can be used for many different purposes. The building systems can employ a unique fastening system to connect, combine, and hold in the place the various components or modular units of the building system.
2. Description of the Related Art
Portable building systems are used in many different situations and locals as varied as classrooms, bathrooms, sheds, construction sites, and emergency relief hubs. Many portable building systems are manufactured and assembled in one location, and then shipped in whole or in half to the needed location. It is often impracticable to assemble on site, whether to assemble entirely or primarily on site. This prevents the use of portable building systems in some situations in which they would be ideal or forces people to use tent-like-structures that may not adequately address the needs of the users. For example, it may be impossible or impractical to transport a pre-assembled building into the backcountry and/or to a disaster area where shelter for whatever purpose is needed.

SUMMARY

Accordingly, there is in the need of the art for improvements to portable building systems, including improvements to fastening systems to connect, combine, and hold in the place the various components or modular units of the building system. These improved systems may solve or address some of the problems described above.
Preferably, a building system includes a plurality of walls, a ceiling and a floor. The walls, ceiling and floor can be held together via profiles or extrusions and clips that engage with a wall at one end and either the ceiling or floor at the other end. One or more inserts can also be used that fit within a groove or notch in a wall, ceiling, or floor. In such embodiments, the clips can have engagement portions (e.g., crimped ends, protrusions, hooks, etc.) that connect to and/or fit within the inserts.
A building system of some embodiments can comprise wall, floor, and/or ceiling panels. A first profile with two cavities extending along different sides of the profile can be used to connect similar panels together. A second profile can be used to connect dissimilar panels. A plurality of fastening clips can be used to lockingly engage a wall panel at one end and one of either a wall panel, a floor panel, or a ceiling panel at the other end. The building system can be configured to not require other fasteners besides the clips and profiles to hold the panels together.
In some embodiments, a building system can comprise, a series a wall panels, a series of floor panels, and a series of ceiling panels. Each panels can have one or more of a respective wall slot, floor slot, and ceiling slot. A first profile can comprise two cavities extending along different sides of the profile, each cavity configured to receive a panel from the same series together. A second profile can be for connecting panels from one series to another series together, the second profile having a shape different from the first profile and comprising two cavities positioned essentially perpendicular with one another, the first cavity configured to receive at least one of either the floor panels or the ceiling panels, and the second cavity configured to receive at least one of the wall panels such that in the assembled configuration the wall panel will rest on and be above the at least one floor panel or the ceiling panel will rest on and be above the wall panel. A plurality of fastening clips can be used where each clip is configured to lockingly engage a wall slot at one end and one of either a wall slot, a floor slot, and a ceiling slot at the other end, wherein the building system does not require other fasteners besides the clips and profiles to hold the panels together.
According to some embodiments, a building system can comprise a series a wall panels, a series of floor panels, a series of ceiling panels, a first profile being in the shape of an I-beam for connecting panels for connecting panels from the same series together, a second profile, and a plurality of clips. The second profile can be for connecting panels from one series to another series together. The plurality of clips can be configured to lockingly engage a wall panel at one end and one of either the wall panels, floor panels, and ceiling panels at the other end. The building system can be made to not require other fasteners besides the clips and profiles to hold the panels together.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the inventions, in which like reference characters denote corresponding features consistently throughout similar embodiments.

FIG. 1 is a perspective view of a building.

FIG. 2 is a view of the bottom of the building of FIG. 1.

FIG. 3 shows a view of a floor unit.

FIGS. 4 and 4A illustrate a profile.

FIGS. 5 and 5A illustrate another profile.

FIG. 6 illustrates a partially assembled building including a floor and walls of the building.

FIGS. 7 and 7A illustrate another profile.

FIGS. 7B and 7C illustrate cross-sections of addition embodiments of profiles.

FIG. 8 shows a clip and corresponding inserts.

FIG. 9 is a cross-sectional view showing an assembled clip and corresponding inserts.

FIG. 10 shows a partially assembled building from the top looking down.

FIG. 11 is an illustration of parts of the roof section and/or ceiling of a building.

FIG. 12 illustrates a cross-section of a building.

FIG. 13 shows a partially assembled shipping container.

FIG. 14 illustrates a shipping container that can be used as a building.

FIG. 15 shows another embodiment of a building system.

FIG. 16 shows a beam construction.

FIG. 17 shows a view looking inside a building.

FIG. 18 is a detail view of an embodiment of a roof and ceiling structure.

FIG. 19 is a partially expanded view of the building system of FIG. 15.

FIG. 20 illustrates a corner of a building system.

DETAILED DESCRIPTION

A building system and method can include a collapsible reusable building. The building system can include a plurality of panels that can be connected together to form the building. The panels can include a variety of different sizes such that the building can also take many forms. The building can also include a number of profiles used to connect and seal the spaces in between the panels. The building system can also include clips or fasteners that can be used to connect and secure the panels together, including the profiles.
Certain examples of the building systems and methods are outlined below. A collapsible reusable building can also be portable such that all the components can be shipped together for easy and simple assembly on site. In some embodiments, the building system can be assembled into a building in a short amount of time, such as 30 minutes, and with limited to no tools. Advantageously, the building system can comprise a series of modular units that can be combined in different configurations. The components of the building system can also be modular, such that they are easily interlockable and do not require the use of tools for assembly. As one example which will be explained in more detail below, the roof system can include a series of individual units which can be connected to form the roof.
Looking now to FIG. 1, a building 10 is shown. The building can be used for any of many purposes, such as being a shed, storage facility, living quarters, bathroom, dining facility, sleeping quarters, refrigerator, medical unit, ice fishing shack, etc. For ease of discussion, the building unit 10 will be described in three sections; namely, a discussion of the base unit or foundation 3, the walls 5 and the roof 7. It will be understood that any and all of the components of the building system 10 can be used individually or separately, or in combination with other features and systems. For example, the roof 7 can be used on other structures and with other building systems. In addition, the walls 5 can be used with other styles and designs and systems of roofs 7 and foundations 3. The foundation 3, walls 5 and roof 7 can also be other shapes than those shown, including round, triangular, octagon, curved, etc. There may also be layers, levels, steps, etc.
Looking now to FIGS. 2 and 3, the base or foundation 3 will be described. It will be understood that the base of foundation 3 can take many forms. The base or foundation 3 generally forms the bottom of the building to which the walls 5 can be attached. The foundation 3 can be made up of a series of one or more floor units 30. Each floor unit can be combined with other floor units to create the floor of a building. Each floor unit 30 can also be used individually. As can be seen in FIG. 3, each floor unit 30 can be made up of a floor panel 36 and a system of joists and/or beams 32 to raise the floor panel off of the ground. The joists and/or beams 32 may or may not be attached to the floor panel(s) 36. In addition, the joists and/or beams 32 may or may not be interconnected. With the floor panels raised off the ground, access is provided to the bottom of the floor panels. Among other benefits, this can allow one or more clips to be attached to the floor panel and a wall panel, as will be described in more detail below. The joists 32 can be made of any of many different materials, such as metal and wood. In a preferred embodiment, the joists 32 are made of metal. In some embodiments, joists 32 or other materials can be used to level the floor panels or further raise the floor panels off of the ground, such as to allow water to pass under the building.
As can be seen with reference to FIG. 2, the floor panels 30 can be held together with one or more joining bridges 34. The joining bridges 34 can be made to easily assemble and disassemble from the joists 32 of the individual floor panels 30. For example, a system of screws and wing nuts can be used to secure the joining bridges 34 to the joists 32.
The floor panels 30 can also be held together with a system or series of profiles 12. FIG. 4 illustrates a cross-section of one of the profiles 12. The profile 12, similar to other profiles described herein, can secure the panels together and also provide waterproofing and other sealing functions to seal the spaces in-between the panels such that the elements from the environment cannot pass through. As can be seen, the cross-section of the profile 12 is generally in the form of an I-beam, or the shape of an H, although other configurations are also possible. Another way to describe the cross-section is that of two C-pockets or cavities 21 that are on opposite sides of the profile. The profile 12, similar to the other profiles described herein, can be formed such that the panel fits within the profile in the C-pocket or cavity 21 in a snug or snap-fit type connection. Alternatively, there may be a small gap between the panel and the profile on one or more sides of the connection between the profile and the panel. In some embodiments, the profiles can be made of plastic, such as ABS or PVC. Other materials such as fiber glass can also be used. The profiles may be manufactured by extrusion or pultrusion, among other methods.
Referring now to FIG. 4A, the profile 12 can include one or more notches 18. The notch 18 can comprise an area of the profile where some of the material of the profile has been removed. As shown in FIG. 4A, one end of the profile 12 has a notch removing all but the bottom side of the profile at one end. In some embodiments, the profile may have one or more notches 18. For example, both ends may have notches 18. In addition or alternatively, a notch may be located along the length of the profile. Referring back to FIG. 2, it can be seen that in the illustrate embodiment, notches 18 are found on both ends of the profile 12 in the floor or foundation 3.
The base or foundation 3 can also include a second profile 14 (FIG. 2). The profile 14 can be used to connect the base or foundation 3 with the walls 5. Referring now to FIGS. 5 and 5A, one example of the second profile 14 is shown. It will be understood that the description of the profile 14 in relation to the foundation or base 3 and the walls is or can be equally applicable to the connection between the walls and the roof 7. As can be seen in FIG. 5, the profile 14 can include two C-pockets or cavities, identified herein as a first cavity 20 and a second cavity 22. The first and second cavities can be aligned with openings that are perpendicular to one another. Also as shown, the cavity 20 can be positioned below the cavity 22. This can allow for the cavity 20 to be slid onto or connected to the floor panel 36. This way, the floor panel can also serve as support for the wall sections which will be slid into or connected to the cavity 22. Although not shown, the profile 14 may also include one or more notches 18.
After the base or foundation 3 has been assembled and at least one profile 14 attached, a user can begin construction of the wall section 5. The walls can be constructed placing one panel within the cavity or channel 22 followed by additional profiles and panels, as will be described. FIG. 6 shows a building with a partially constructed wall section 5. As can be seen, the wall section is made up of a series of wall panels 50. The wall panels can be different sizes, can serve different purposes, and can include any number of different features. For example, the wall panel 50 may include one or more cavities or holes 52, 54, 56. The cavity 52 may serve as a door cavity. The cavity 54 can serve as a window, and the cavity 56 can receive other features, such as an air conditioning unit, heating unit, ventilation, or other features which require a hole or cavity to pass through the panel 50.
As can be seen, the wall panels 50 are connected through a series of profiles. As has been described, a profile 12 can be used to connect the wall panels 50, similar to the manner in which the profile 12 connects the floor panels 36. In some embodiments, of the wall section 5, the profiles 12 may include one or more notches 18. For example, the profile 12 may have a notch 18 located at the top of the profile 12. A third profile 16 can also be used at the corners of the wall unit 5.
Referring to FIGS. 7 and 7A, the third profile 16 will now be described. The profile 16 can include two cavities or channels 24 which are aligned perpendicular to one another. The profile 16 also includes a cavity 26. As can be seen, cavity 26 forms the corner of the wall unit and also the corner of the profile 16. Other configurations are also possible. For example, the profile 14 can be used instead of the profile 16 to form the corners of the wall unit 5. As can be seen in FIG. 7A, the profile 16 can include one or more notches 18.
Though three designs of profiles 12, 14, and 16 have been described, it will be understood that the profiles can take on one of many different shapes. In their basic configuration, a profile has two C-pockets or cavities that are connected to thereby connect two separate panels. As has been mentioned, those panels can include at least wall panels, floor panels, and ceiling panels. The relationship between the two C-pockets or cavities can vary greatly. For example, referring to FIG. 7, an angle Alpha (α) can be used to define this relationship. In FIG. 7, α is equal to about 90 degrees. This is in contrast to FIG. 4, where alpha is not shown because it is equal to about 0 degrees. FIGS. 7B and 7C show the cross-sections of two additional embodiments of profiles 16′ and 14′. In FIG. 7B, α′ is shown as being less than 90 degrees and in FIG. 7C, α″ is shown as being greater than 90 degrees. A profile similar to profile 16′ could be used, for example, when forming a circular, octagon, pentagon, hexagon, etc. shaped building. In some embodiments, α can be equal to about 30, 45, 60, 75, 90, 100, 120, 135, and 150 degrees A profile similar to profile 14′ could be used for example, when forming a triangular, parallelogram, trapezoid, etc. shaped building. Various shaped profiles can also allow for the creation of distinct shapes, alcoves, nooks, etc. It will be understood that the panels can also be shaped to allow the building to be shaped as such. Thus, the wall panels may be rounded or curved and then floor and ceiling panels may be larger one end as compared to another, such as in a trapezoid, or a piece of pizza shape. The other shapes can also be used.
Other features shown in the profile 16′ includes a rounded back side 27 and a gap 29 in one of the walls 31 of the cavity 24. It ill be understood that any of the profiles could also include these features. Another feature shown in the profile 14′ is that the cavity 20′ does not extend out as far as the cavity 20 in profile 14 shown in FIG. 5.
As has been mentioned, the panels can be connected to one another with a series of fasteners or clips 28 such as that shown in FIG. 8. The fasteners or clips 28 can be the same or similar to those described in application Ser. Nos. 13/558,162 filed on Jul. 25, 2012 and 61/511,951, filed on Jul. 26, 2011 which are both incorporated by reference herein and made a part of this specification. The panels, such as the floor panels, wall panels or, as will be described below, the ceiling panels, can include one or more slots or cavities 38 (FIGS. 3, 6, 10) into which a clip 28 can fit into. The clips 28 can be sized and shaped to engage with slots or cavities 38. The fastener can be L-shaped such that one end will connect to a first panel, such as a wall panel, and the other end can connect to a second panel, such as a floor panel. The fastener can use a spring force to secure the panels together.
Inserts 130 can be configured to at least partially fit within the slots or cavities 38. An insert 130 can also be placed within the slot to further seal and help secure the fastener in the fastened position. Preferably, the clips 28 are configured to engage with inserts 130 installed in the slots or cavities 38. Engagement between the clips 28 and the inserts 130 and/or slots 38 can secure adjacent panels to each other and enable secure construction of the building system. The inserts 130 can be the same or similar to those described in application Ser. Nos. 13/558,162 filed on Jul. 25, 2012 and 61/511,951, filed on Jul. 26, 2011 which are both incorporated by reference herein and made a part of this specification.
FIG. 8 illustrates a clip 28 and two corresponding inserts 130. Each insert 130 can include a base 132 and a flange portion 134. The back side of the base 132 can be configured to fixedly and/or releasably engage with a slot 38 in a panel. The front side of the base 132 can be configured to engage with and receive one of the engagement features 152, 154 of the clip 28.
The clip 28 has a first engagement feature 152 configured to engage with an insert 130 and/or with a slot 38 in the panel. The clip 28 can have a second engagement feature 154 configured to engage with an insert 130 and/or with a slot 38 in another panel. In some embodiments, one of the first and second engagement features 152, 154 is configured to engage with an insert 130 and the other is configured to engage directly with a slot 38 in a panel. It will be understood that though a particular style of clip is described, any of number of different clips could be used. For example a CLIP-LOK Brand clip or other type of clip could be used. In addition the building system could use one or more different styles or types of clips. Inserts may or may not be used with any of the clips.
One or both of the first engagement feature 152 and second engagement feature 154 can include one or more clip release features 156. In some embodiments, the clip release feature 156 comprises one or more protrusions, tongues, or lips, which may include flat unbent portions on the end of the first and/or second clip portions 152, 153. The clip release feature 156 can be used to assist with the removal of the subject clip 28 and/or with removing already assembled clips 28. The clip release feature 156 is shown extending from the end of the clip, between the two U- or V-shaped engagement features 154. The clip release feature 156 can have one of many different shapes.
As shown, the clip release feature 156 has a low profile and extends over the slot 38 and/or over the inner cavity of the insert 130. As can be seen with reference to FIG. 9, the clip release feature 156 can extend into the opening in the insert, but preferably does not extend past, or completely cover the opening. This allows a user to release the clip by engaging the clip release feature 156 with one of a variety of levers. This can be done without the use of any special tools. For example, another clip, a screwdriver, a shovel, a crowbar, etc. can be advanced under the clip release feature 156 into the groove or insert and then used as a lever to pop the clip out of engagement with the groove or insert. It will be understood that the clip release feature 156 can function in other or similar ways, at different locations. For example, the clip release feature 156 can be located near the end of the clip, but not extending over an opening. The clip release feature 156 can be structured and/or positioned such that a lever can still be placed under the clip release feature 156 and the clip pried off. In other embodiments, the clip release feature 156 can be pulled away from the container to release the clip.
As mentioned, the clip can use a spring force to secure the panels together. Returning to FIG. 8, an angle θ between the first clip portion 151 and the second clip portion 153 can be greater than about 45° and/or less than about 135° when the clip 28 is in a disconnected state (e.g., not engaged with inserts 130 or slots 38). In some embodiments, the angle θ is approximately 75° when the clip 150 is in the disconnected state. As illustrated in FIG. 9, clips 28 can be used to adjoin two sides 110 of an object at an angle β. Preferably, the angle θ between the first and second clip portions 151, 153 for a given clip 28 is less than the angle β between the two sides 110 of the object being connected by such a clip 28. In such cases, the clip 28 must be widened (e.g., the angle θ must be increased) in order to fit the clip 28 onto the two sides 110. As such, the bending stress in the clip 28 due to the widening of the clip 28 can bias the first and second engagement features 152, 154 into the slots 38 and/or inserts 130 on the adjoining sides 110. Such a biasing force helps the clip 150 to stay in place and secure the two sides 110 to each other.
It will be understood that the clips 28 can be attached to the building at any point after the various panels have been put together. Preferably, the clips are attached after the corresponding panels have been placed next to one another and within the respective profile. If inserts are used, they can be inserted at any time prior to attachment of the clips.
Once the base or foundation 3 has been assembled and the walls 5 have further been assembled onto the foundation or base 3, the roof and/or ceiling 7 can then be assembled. In some embodiments, another building unit can be attached to the assembled walls and base so that both units can share the same roof.
Returning to FIG. 6, it can be seen that in some embodiments, the tops of some of the wall panels 50 can include one or more slots or channels 58. A beam can be placed within corresponding slots on opposite wall panels 50. The beam can provide additional structural support for the ceiling and roof.
Looking now at FIG. 10, it can be seen that the ceiling panels 72 have been placed on the wall unit 5. It can also be seen that profiles 14 have been used to connect the ceiling panels to the wall unit 5. Although not shown, profiles 12 or other styles of profiles can also be used to connect the individual ceiling panels 72 to one another. The ceiling panels can be open as shown with holes passing therethrough or closed. Preferably, the ceiling panels 72 provide a surface around the top perimeter of the walls unit 5. This provides structural support to the building and also provides a surface to connect the clips between the wall panels and the ceiling panels.
The configuration shown in FIG. 10 provides many benefits. For example, the cube or rectangular structure with panels on each side has great structural integrity. In addition, a base unit, as shown in FIG. 10 can utilize a variety of different style roofs. For example, a solid, angled roof can be used as is illustrated elsewhere herein. Alternatively, a flat solid roof; a flat vinyl, a plastic, a foam, or other material and or shape roof, can be used. In addition, the roof can be transparent to allow sun light into the building. In some embodiments, the panels 72 can serve as both the ceiling and the roof. In addition, in some embodiments, the panels 72 can be provided with additionally preassembled roofing material such that installing the ceiling and the roof is performed simultaneously. It will be understood that many different types and styles of roofs can be used.
FIG. 10 illustrates the fasteners or clips 28 that have been secured to the panels 72 and 50 as was discussed previously. As can be seen, a slot or cavity 38 in the panels 72 and 50 is used to connect the two ends of the clip or fastener 28. Although only a limited number of clips 28 are shown, it should be understood that clips 28 can be used throughout the assembly, such as to hold the panels 50 together at the corners, and also the panels 50 and panels 36 at the wall and base or floor. In some embodiments, the clips 28 connect on top of or over the profiles 14 and/or 16 and/or other profiles.
The ceiling panels 72 can include one or more holes or cavities 74. The holes or cavities 74 can be used to attach to or provide additional features in the ceiling. For example, a ceiling plug can be attached to or within the space 74. The ceiling plug may include lights, fan units, ventilation, or other features. In some embodiments, the ceiling plug can be thin ABS material that is thermo formed to the desired shape.
Turning to FIGS. 11 and 12, another embodiment of a roof and/or ceiling section 7 is shown. In this embodiment, it can be seen that the ceiling plugs 76 and 78 are illustrated. Ceiling plug 76 can simply plug the hole or space 74, whereas ceiling plug 78 includes one or more lighting units 80. The lighting units can include any type of lighting system, such as LED, fluorescent, or incandescent. The lighting units 80 can also be powered with various different types of systems, including batteries, solar power, and electrical connections to a separate electrical source, such as city power.
The roof and/or ceiling section 7 can include a roof unit 82. The roof unit 82 can be a preassembled unit including shingles or other roof outer covering surfaces, awnings, one or more trusses, flashings, and other ceiling members. In some embodiments, the roof unit can have a polyurea coating on an outer surface. In some embodiments, the roof unit 82 can be formed such that one side has a flashing 83 that extends past the rest of the unit so that when combined with another roof unit 82, the flashing will overlap with the second unit, creating a sealed and waterproofed roof structure.
The roof unit 82 can also include a hole or cavity 84. In the assembled condition, the hole 84 can be lined up above the hole 74 on the ceiling panel. This can allow the ceiling plugs, such as 76 and 78, to also connect to the roof unit 82. As has been mentioned, the ceiling plugs can provide many different features.
The roof unit can be secured to the ceiling panel 72 in many different ways. For example, as just mentioned, the ceiling plug 76 or 78 can be used to secure the roof unit 82 to the ceiling panel 72. In some embodiments, a clip or fastener 28 can be used to secure the roof unit 82 and the ceiling panel 72. For example, one end of the fastener 28 can fit within a channel or slot 38 and the other end can wrap around to contact the bottom of the ceiling panel 72, as can be seen in FIG. 12. As can also be seen in FIG. 12, the roof and/or ceiling section 7 can also include a series of beams 86. As discussed with reference to FIG. 6, the wall panels 50 can include one or more slots or channels 58 and the beams 86 can be placed within corresponding slots on opposite wall panels 50 to provide structural support for the ceiling and roof. The size of the beams 86 can depend on many features including potential snow-load.
One advantage of the above described roof design is that by having the roof panel 82 and the ceiling panel 72 clamped together, whether by a fastener 28 or otherwise secured, this also helps further ensure that the connection between the wall panel 50 and the ceiling panel 72 stays secure. This is because the roof panel 82 presses down on the fastener 28 and profile 14 on the ceiling panel 72. This is turn prevents the fastener 28 and the profile 14 that are on the ceiling panel 72 and connected to the wall panel 50 from moving.
The entire building unit 10, in some embodiments, can be assembled with a minimal number of people and require minimal to no tools for assembly. In addition, the building unit 10 can be assembled in a minimal amount of time, such as 30 minutes.
The many panels described, such as the ceiling panels, the walls panels, the roof panels, and the floor panels, can be made from various different materials. For example, the panels can be made up of a series of different materials, such as having a foam core sandwiched between two pieces of plywood. The panels can be structural insulated panels or structural insulating panels (SIPs) or other types of composite building materials. In some embodiments the panels can be made up of a single material, such as solid plywood. In addition, the panels can be coated with various different materials, such as a coating on the inside or what will be the inside of the building and a separate or the same coating on the outside or what will be the outside of the building. For example, the panel can be made with a phenolic skin or other resin-impregnated kraft paper, fiberboard siding, high impact plastic, metal, fiber reinforced plastic (FRP), etc. Some surfaces of the panels may also be covered with a polyurethane or polyurea coating. Other coatings can also be used.
As will be understood, the building units 10 can be assembled such that multiple building units can be combined to create a larger structure, or the building unit can be used or combined with other structures.
It should also be understood that the profiles 12, 14, 16 can be any desired length. For example, profile 14 can extend the entire length of a side of the wall section 5, or multiple profiles 14 can be used. Advantageously, all components of the building system 10 can be sized so that they can be shipped together. For example, the profiles 12, 14, 16 can be as long as or shorter than the panels 36, 50, 72.
Turning now to FIGS. 13 and 14, a shipping container or crate 40 is shown. The crate 40 can include a number of the panels 42, 44 that can be connected to one another by various methods. For example, the panels can have a series of slots 38 and be connected to one another with a series of fasteners or clips 28 as described in Application 61/511,951, filed on Jul. 26, 2011. Inserts can be placed within the slots as also described in Application 61/511,951, filed on Jul. 26, 2011. Again, as before, only a limited number of clips 28 are shown, but it should be understood that all of the slots 30 can include a clip 28 and, in some embodiment an insert. It will be understood that clips of other types and designs can also be used. The crate can be assembled, disassembled and stacked as also described therein. The crate can be any type of crate but is preferably a crate as described in Application 61/511,951, filed on Jul. 26, 2011. One or more profiles 12, 14, 16 can also be used in the assembly of the crate 40. As shown in FIG. 14, a profile 12 can be used to connect two panels 42, 44 together. Each side of the crate 40 can use a single panel 42, 44, or more than one panel.
The building system 10 can be shipped within the crate 40. As can be seen in FIG. 13, the building system 10 is shown disassembled and stacked within the crate 40. Additional features, such as air conditioning units can also be shipped with the building system 10. The crate 40 can be sized and shaped according to the dimensions of the components of the desired building system 10 when disassembled. Though it cannot be seen, the crate 40 can include a pallet type feature on the bottom of the crate or other transport structure or feature to facilitate the handling and moving of the crate 40. The transport structure or feature can support the crate in a stable fashion while being lifted by a forklift, pallet jack, front loader, hoist, crane, etc.
In some embodiments, after the building system 10 has emptied from the crate 40, the crate 40 can also be used as a building. For example, the crate 40 can be used as a shelter, a shed, a bathroom, an out building, etc. As shown in FIG. 14, the crate 40 can be provided with a panel 44 that includes a door 46. The panel 44 can form a part of the shipping container 40 during shipping. Alternatively, an extra panel 44 with a door 46 can be shipped inside the crate 40 to later replace one of the panels 42. After replacement, the crate can be used as a building or structure that has a door. Of course, it will be understood that the crate 40 can also be used as a building or structure by simply removing one or more panels.
FIGS. 15-20 show another embodiment of a building system 10′. Numerical reference to components is the same as previously described, except that one or more prime symbols (′) have been added to each reference numeral. Where such references occur, it is to be understood that the components are the same or substantially similar to previously-described components. It should be understood that the illustrated building system includes each of the features designated by the numbers used herein. However, as emphasized repeatedly herein, these features need not be present in all embodiments.
The building system 10′ is shown with three sections, a base unit or foundation 3′, walls 5′ and roof 7′. As has been mentioned, the base 3′ can take many forms. The base 3′ can use a system of modular beams 32′ to support the building system 10′. The beams 32′ can raise the floor panel(s) 36′ off of the ground. The beams 32′ may or may not be attached to the floor panel(s) 36′ and may or may not be interconnected. The beams 32′ can be made of any of many different materials, such as metal, wood, and composite building materials. For example, the beams can be made of, but not limited to, ¾″ plywood and coated with polyurea.
Looking now to FIG. 16, it can be seen that the beams 32′ can be modular to provide for any number of different lengths of beam. The beam sections 62, 64 can individually be the same length or different lengths. In addition, the beam sections can be the substantially same length or width as the floor panels 36′. As shown, the beam section 62 is substantially the same length as the width of two floor panels, while beam section 64 is as long as one floor panel is wide. The beam 32′ can also include beam section 66, 68 that can be end caps for the beam. The end caps can close and/or essentially finish the beam, for example so that the height of the beam is consistent along its length and so that any open cavities are closed.
The different sections of the beam 32′ can be attached in many different manners. In some embodiments, the beam sections are slip fit together with a mortise and tenon joint or with a tongue and groove joint. A beam section 62, 64 can have a mortise hole 70 at one end and a tenon 60 at the other end. This can allow any number of beam sections to be connected. In some embodiments, some or all of the beam sections 66, 68 can have only one of a mortise hole and a tenon on one end and the other end can be a closed surface. The closed surface can define the end or end cap of the beam 32′. It will be understood that other configurations can also be used. The beam sections 62, 64, 66, 68 are preferably held to together by friction, but fasteners such as bolts may also be used.
The beams 32′ can be laid out as a foundation for the floor panels 36′. In some embodiments shims can be proved to help level the floor panels. The floor panels are preferable not fastened to the beams and can stay in place by friction. At the same time, certain uses or locations may require a separate anchoring system, for example, if the building system is to be used in a high wind area.
FIGS. 17-20 will now be used to describe the roof and/or ceiling 7′. FIG. 17 shows a modification of the ceiling panels 72′. In particular, rather than having large opening or holes, the ceiling panels 72′ have much smaller holes 74′. These smaller holes can still be used to attach to or provide additional features in the ceiling as has been described. For example, a fastener 28′ can extend through the hole 74′ to attach a ceiling panel 82′ to the ceiling panel 72′. In addition, a ceiling plug or cover can also be used.
FIG. 18 shows another embodiment of a fastening system for use with the ceiling and roof panels. In particular, a bolt 94 and washer or plate 92 can be used to secure roof panel 82″ to the ceiling panel 72′. The bolt can be self threading, or can engage a nut 96 that has been attached to the roof panel 82″.
Turning now to FIG. 19, a partially exploded view of the building system 10′ is shown. FIG. 19 illustrates a cover 88 that can be used to place on top of and/or surrounding the roof panels 82′. Looking back at FIG. 15, it can be seen that the cover 88 can enclose the top of the building system 10′. This can include enclosing all or part of one or more of the roof panels 82′, wall panels 50′, profiles 14″, profiles 12′, profiles 16″, fasteners 28′, and inserts 130′. In some embodiments, the sides of the cover 88 can extend down to the slots 38′ in the wall panels 50′. As shown, the slots 38′ have an insert 130′ placed within them. In some embodiments the cover 88 can be used in addition to or instead of the roof panels 82′. For example, the cover 88 can surround and directly cover the ceiling panels 72′ without the use of separate roof panels 82′. It will be understood that the ceiling panels 72, 72′ can also form the roof without separate roof panels 82, 82′ and/or a cover 88.
The cover 88 can be made of any number of different materials and is preferably waterproof. The cover can be a large sheet of strong, flexible, water-resistant or waterproof material. The cover can be made of cloth, canvas, polyester, polyethylene, polypropylene, etc. In some embodiments the cover can comprise a tarpaulin or tarp.
The cover 88 can be connected to the rest of the building system in many ways. In some embodiments, the cover can form a tight fit over the roof and be held on by friction. Looking to FIG. 20, a rope or cord 90 may also be used to secure the cover 88. As shown, the rope 90 and cover can be configured such that the rope is sewn or otherwise enclosed within the cover. In some embodiments, the rope and extend around the bottom periphery of the cover. The cover 88 can include one or more holes 92 through which the rope can extend. For example, the cover 88 can have one or more holes 92 at the same locations on the buildings where the fasteners. The rope can be secured to one or more fasteners 28′. For example, the rope 90 can engage with the clip release feature 156′ on the fastener 28′.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
Similarly, this method of disclosure, is not to be interpreted as reflecting an intention that any claim require more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

What is claimed is:

1. A building system comprising:

a series a wall panels, each having one or more wall slot;

a series of floor panels each having one or more floor slot;

a series of ceiling panels each having one or more ceiling slot;

a first profile comprising two cavities extending along different sides of the profile, each cavity configured to receive a panel from the same series together;

a second profile for connecting panels from one series to another series together, the second profile having a shape different from the first profile and comprising two cavities positioned essentially perpendicular with one another, the first cavity configured to receive at least one of either the floor panels or the ceiling panels, and the second cavity configured to receive at least one of the wall panels such that in the assembled configuration the wall panel will rest on and be above the at least one floor panel or the ceiling panel will rest on and be above the wall panel; and

a plurality of fastening clips, each clip configured to lockingly engage a wall slot at one end and one of either a wall slot, a floor slot, and a ceiling slot at the other end, wherein the building system does not require other fasteners besides the clips and profiles to hold the panels together.

2. The building system of claim 1, wherein the first profile has an I-beam shape with the two cavities being on opposite sides of the first profile.

3. The building system of claim 1, wherein the two cavities of the first profile are angled at about 135 degrees with respect to one another.

4. The building system of claim 1, wherein the second profile has an “L” shape defining two cavities position essentially perpendicular with one another.

5. The building system of claim 2, wherein the second profile has an “L” shape defining two cavities position essentially perpendicular with one another.

6. The building system of claim 1, further comprising a third profile configured to form a corner between two wall panels, the third profile having a central channel that runs along the length of the profile and two cavities with openings perpendicular to one another running along the length of the central channel.

7. The building system of claim 1, wherein the second profile is configured to form a corner between two wall panels.

8. The building system of claim 1, further comprising a plurality of inserts each configured to be placed within the one of a wall slot, a floor slot, or a ceiling slot.

9. The building system of claim 8, wherein the each clip of the plurality of clips is configured to be positionable within two inserts at opposite ends of each clip.

10. A building system comprising:

a series a wall panels;

a series of floor panels;

a series of ceiling panels;

a first profile being in the shape of an I-beam for connecting panels for connecting panels from the same series together;

a second profile for connecting panels from one series to another series together, the second profile having an “L” shape defining two cavities position essentially perpendicular with one another, the first cavity configured to receive at least one of either the floor panels or the ceiling panels, and the second cavity configured to receive at least one of the wall panels such that in the assembled configuration the wall panel will rest on and be above the at least one floor panels or the ceiling panel will rest on and be above the wall panel;

a plurality of clips configured to lockingly engage a wall panel at one end and one of either the wall panels, floor panels, and ceiling panels at the other end, wherein the building system does not require other fasteners besides the clips and profiles to hold the panels together.

11. The building system of claim 10, further comprising a third profile configured to form a corner between two wall panels, the third profile having a central channel that runs along the length of the profile and two cavities with opening perpendicular to one another running along the length of the central channel.

12. The building system of claim 10, wherein the second profile is also configured to form a corner between two wall panels.

13. The building system of claim 10, wherein:

the series of wall panels further comprises one or more wall slot on each wall panel;

the series of floor panels further comprises one or more floor slot on each floor panel;

the series of ceiling panels further comprises one or more ceiling slot on each ceiling panel; and

each clip of the plurality of clips is configured to lockingly engage a wall slot at one end and one of either a wall slot, a floor slot, and a ceiling slot at the other end.

14. The building system of claim 13, further comprising a plurality of inserts configured to be positionable within the one of the wall slots, floor slots, or ceiling slots wherein each of the clips of the plurality of clips is configured to be positionable within two inserts at opposite ends of each individual clip.