SYSTEM OF PREFABRICATED STRUCTURES ARRANGED IN A COMPLEMENTARY LAYOUT
A system of cooperating prefabricated structures arranged in a complementary layout comprises a set of prefabricated structures having substantially the same dimensions. The set of prefabricated structures each include a shell and an extension deployed out from a nested position within the shell. A first deck extends from a first shell. A second deck extends from a second deck, wherein the first prefabricated structure is arranged opposite the second prefabricated structure so that the first deck abuts the second deck. A third deck extends from a third shell, wherein the third prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure so that the third deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure. A fourth deck extends from a fourth shell, wherein the fourth prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure and opposite the third prefabricated structure so that the fourth deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure. The first deck, the second deck, the third deck, and the fourth deck form a common walkway.
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This application claims benefit to the following U.S. Provisional patent application:
U.S. Provisional Patent Application No. 61/084,532, entitled “Deployable Prefabricated Structure,” by James D. Pope, Attorney Docket No. POPE-01000US0, filed Jul. 29, 2008
CROSS-REFERENCE TO RELATED PATENT APPLICATIONSThis application incorporates by reference the following co-pending patent applications:
U.S. patent application Ser. No. ______, entitled “Deployable Prefabricated Structure with a Nested Extension Structure,” by James D. Pope, Attorney Docket No. POPE-01000US1, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Method of Deploying a Prefabricated Structure,” by James D. Pope, Attorney Docket No. POPE-01000US2, filed concurrently.
U.S. patent application Ser. No. ______, entitled “System of Cooperating Prefabricated Structures,” by James D. Pope, Attorney Docket No. POPE-01000US3, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Method for Deploying Cooperating Prefabricated Structures,” by James D. Pope, Attorney Docket No. POPE-01000US4, filed concurrently.
U.S. patent application Ser. No. ______, entitled “System and Method to Stabilize a Deployable Structure,” by James D. Pope, Attorney Docket No. POPE-01000US5, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Deployable Prefabricated Structure with an Extension Structure and a Deployable Floor” by James D. Pope, Attorney Docket No. POPE-01000US6, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Deployable Prefabricated Structure with an Extension Structure That is Sealable to the Prefabricated Structure Upon Deployment from the Prefabricated Structure,” by James D. Pope, Attorney Docket No. POPE-01000US7, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Deployable Prefabricated Structure with an Extension Structure and Interlocking Elements,” by James D. Pope, Attorney Docket No. POPE-01000US8, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Method of Deploying and Redeploying a Prefabricated Structure,” by James D. Pope, Attorney Docket No. POPE-01000US9, filed concurrently.
U.S. patent application Ser. No. ______, entitled “Method for Deploying Prefabricated Structures Arranged in a Complementary Layout,” by James D. Pope, Attorney Docket No. POPE-01001US1, filed concurrently.
BACKGROUNDRecent catastrophic events, such as Hurricane Katrina and the Boxing Day Tsunami of 2004 have demonstrated a persisting need for prefabricated structures that can be easily and quickly deployed to disaster sites that do not necessarily have access to preexisting utilities and that can provide multiple logistical services to victims. Prefabricated structures suited for easy and quick deployment can further be used in other settings where preexisting utilities may not be present for temporary use such as at construction sites, or for more permanent use, such as at remote, undeveloped homestead.
Common reference numerals are used throughout the drawings and detailed description to indicate like elements; therefore, reference numerals used in a drawing may or may not be referenced in the detailed description specific to such drawing if the associated element is described elsewhere.
Embodiments of a prefabricated structure and a system of cooperating prefabricated structures in accordance with the present invention can be quickly and efficiently anchored and deployed to reduce setup time, set up expense, and site preparation. Such embodiments can benefit structures intended for permanent use, emergency use such as for disaster relief, and/or for planned temporary use such as for classroom facilities and construction site administration.
Referring to
The prefabricated structure 100 can be substantially self-contained, in that it need not be connected to preexisting electrical grids, water and/or sewage service lines. The prefabricated structure 100 includes a service pack comprising one or more batteries (shown below) providing electrical power for lighting and appliances, as well as for electrical tools and gadgets accessorizing the living space. The one or more batteries are recharged by a solar panel 108 connected with a roof of the extension 103. The service pack further comprises a generator for providing electrical power to the prefabricated structure 100 and/or supplementally recharging the one or more batteries. The generator can be driven by propane, or some other liquid or gas fuel.
Panels 114,115,117 can be mated with the shell frame 102 and extension frame 104 to provide exterior walls and to seal the prefabricated structure 100 from moisture and suppress undesirable heat exchange with the environment. Panels can be selected based on the function or configuration of structures within the prefabricated structure 100. For example, the prefabricated structure of
Referring to
The roofs of the extension 203 and shell 201 of the prefabricated structure 200 of
Referring to
Referring to
The embodiments of prefabricated structures shown in
Referring to
In a preferred embodiment the outer portion is fabricated from aluminum or an aluminum alloy and the inner portion is fabricated from steel or a steel alloy. The components of the inner portion and the outer portion can be welded, riveted, bonded or otherwise fixedly connected. In other embodiments, the inner portion and outer portion can be fabricated from the same material. Further, the slotted beam 128a,b can comprise the floor beams 128a2,b2 of the inner portion welded to a separate pair of beams 128a1,b2, or alternatively, the slotted beam can be fabricated from a single piece of material of a single composition. One of ordinary skill in the art in view of the teachings contained herein will appreciate the myriad different techniques for fixedly connecting the components of the shell frame, and the various tradeoffs in strength and weight for using different materials in fabricating the shell frame.
Referring to
It can be desirable to seal the prefabricated structure from environmental elements at least in a deployed configuration, and preferably in both a deployed configuration and a nested configuration. In a preferred embodiment of a prefabricated structure in accordance with the present invention, a T-flange can extend from structures along the perimeter of the extension. The T-shaped flange can extend inward from the extension-side columns 124b,d and the extension-side roof beam 120b. Referring to
Referring to
Referring to
Referring again to
The shell frame 102 and extension frame 104 can provide channels for communicating one or both of electrical wiring and water ducts.
Vertical structures of both the shell frame 102 and the extension frame 104,504 can comprise C-channels adapted to receive L-channels 372a,372b fixedly embedded in panels 314a or fixedly connected with panels 314, as shown in
In alternative embodiments, the prefabricated structure may be suspended by way of cables attached to eyehooks over a designated deployment site. The prefabricated structure may be held suspended over the site by a crane or other device while support posts are extended from columns of the shell and anchored in position at the site. Once the support posts are extended, the extension can be deployed from the shell. After deployment of the extension, support posts of the extension can be lowered an anchored in position at the site. In still further embodiments, the prefabricated structure can be positioned over a site by a forklift. The prefabricated structure may be held suspended over the site by the forklift while support posts are extended from columns of the shell and anchored in position at the site. As above, once the support posts are extended, the extension can be deployed from the shell. After deployment of the extension, support posts of the extension can be lowered an anchored in position at the site.
It should be noted, and will be apparent upon review of
Embodiments of methods of using prefabricated structures and systems of cooperating prefabricated structures in accordance with the present invention can be applied to provide potential logistical solutions to multiple logistical challenges, for example encountered at a disaster area. The system can comprise two or more cooperating prefabricated structures, each prefabricated structure including a shell and a deployable extension. The prefabricated structures can cooperate in one or more ways. Cooperation can be simple, for example, the prefabricated structures can include decks that are sufficiently close to one another so as to combine to form a common walkway. Alternatively, cooperation can determine a selection of panels (e.g., window height, entry positioning and type) for the shell and extension, and the type of amenities and furniture contained within the prefabricated structures. For example, referring to
Referring again to
As shown in
Further, an additional, dedicated water filtering unit (“ERU-WFSS”) is shown which can provide a common supply water collection, filtration and distribution facility, as well as a grey water processing and dump facility. A water filtering unit can increase an overall volume of water available and provide more efficient processing of supply water that may be collected from rain water or bottled water provided by relief agencies, etc., by providing a larger and more flexible space for including equipment. Likewise, grey water can be collected from use, treated and dumped, for example in a ditch or cesspool (although the water may be sterile and usable for example for growing foods). One or more of the prefabricated structures can be connected with the water filtering unit so that the prefabricated structures combine to provide a shared water system. Such an arrangement can potentially increase an overall available amount of water by allowing dedication of water tanks in some of the prefabricated structures to supply water, for example, while the water filtering unit quickly filters and disposes of grey water.
As mentioned above, the water filtering unit can collect rain water and filter the water for use by the prefabricated structures. Referring to
Embodiments of methods of distributing a prefabricated structure in accordance with the present invention can be applied to manage construction and deployment costs associated with the prefabricated structures and systems of cooperating prefabricated structures. A method can comprising providing a prefabricated structure for use at a first site, the prefabricated structure including a shell with a shell frame, a plurality of wall panels mated with the shell frame, and a plurality of floor panels mated with the shell frame, and an extension with an extension frame, a plurality of wall panels mated with the extension frame, and a plurality of floor panels mated with the extension frame. The prefabricated structure can be used at a site, such as a disaster relief site, and then recovered from the site for refurbishment. Recovery can comprise a series of steps approximately reversed from the steps of deployment. For example, a prefabricated structure can be recovered by retracting the support posts of the extension into the extension, nesting the extension within the shell, retracting a first set of supports posts of the shell into the shell, joining a rollers to columns of the shell, urging a transport surface so that the set of roller is positioned on the transport surface and can roll on the surface. One of the transport surface and the shell is urged in stages at each pair of columns so that the support posts can be retracted within the column and replaced with rollers that can transfer weight of the prefabricated structure to the transport surface, until the prefabricated structure is wholly received on the transport surface. The prefabricated structure can then be transported back to a refurbishment facility and refurbished. Refurbishment may include replacing one or more floor panels and/or wall panels, amenities and/or furniture. Prefabricated structures can be refurbished so as to support a different use or the same use. It is generally believed that the shell frame extension frame is likely to be undamaged, enabling multiple uses of the prefabricated structure at multiple sites.
The foregoing description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to practitioners skilled in this art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
Claims
1. A system of cooperating prefabricated structures arranged in a complementary layout comprising:
- a set of prefabricated structures having substantially the same dimensions, the set of prefabricated structures including: a first prefabricated structure including a first shell and a first extension deployed out from a nested position within the first shell; a first deck hingedly connected with the first shell, the first deck extending away from the first shell so that a width of the first prefabricated structure and the first deck is about the size of half the length of the prefabricated structures; a second prefabricated structure including a second shell and a second extension deployed out from a nested position within the second shell; a second deck hingedly connected with the second shell, the second deck extending away from the second shell so that a width of the second prefabricated structure and the second deck is about the size of half the length of the prefabricated structures; wherein the first prefabricated structure is arranged opposite the second prefabricated structure so that the first deck abuts the second deck; a third prefabricated structure including a third shell and a third extension deployed out from a nested position within the third shell; a third deck hingedly connected with the third shell, the third deck extending away from the third shell so that a width of the third prefabricated structure and the third deck is about the size of half the length of the prefabricated structures; wherein the third prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure so that the third deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure; a fourth prefabricated structure including a fourth shell and a fourth extension deployed out from a nested position within the fourth shell; and a fourth deck hingedly connected with the fourth shell, the fourth deck extending away from the fourth shell so that a width of the fourth prefabricated structure and the fourth deck is about the size of half the length of the prefabricated structures; wherein the fourth prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure and opposite the third prefabricated structure so that the fourth deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure; and wherein the first deck, the second deck, the third deck, and the fourth deck form a common walkway.
2. The system of claim 1, wherein:
- the prefabricated structures further include: electrical wiring, a supply water duct, and a grey water duct; and
- the electrical wiring of the prefabricated structures is connected so that the prefabricated structures share a common electrical system;
- the supply water ducts of the prefabricated structures are connected so that the prefabricated structures share a supply water system; and
- the grey water ducts of the prefabricated structures are connected so that the prefabricated structures share a grey water system.
3. The system of claim 2, further comprising:
- a canopy connected across the first deck and the second deck;
- a gutter associated with the canopy for collecting water from the canopy; and
- wherein the gutter is communicatively connected with the supply water system.
4. The system of claim 3, wherein a water purification device is positioned between the gutter and the supply water tank to purify collected water for introduction to the supply water system.
5. The system of claim 3, wherein the gutter is mounted on a vertical support structure of the shell frame.
6. The system of claim 1, further comprising:
- another set of prefabricated structures having substantially the same dimensions as prefabricated structures of the set, the another set of prefabricated structures including: a fifth prefabricated structure including a fifth shell and a fifth extension deployed out from a nested position within the fifth shell; a fifth deck hingedly connected with the fifth shell, the fifth deck extending away from the fifth shell so that a width of the fifth shell and the fifth deck is about the size of half the length of the prefabricated structures; wherein the fifth prefabricated structure is arranged transverse to the third prefabricated structure so that the fifth deck abuts the third deck and extends along approximately half the length of the second extension of the second prefabricated structure; a sixth prefabricated structure including a sixth shell and a sixth extension deployed out from a nested position within the sixth shell; a sixth deck hingedly connected with the sixth shell, the sixth deck extending away from the sixth shell so that a width of the sixth shell and the sixth deck is about the size of half the length of the prefabricated structures; wherein the sixth prefabricated structure is arranged transverse to the fourth prefabricated structure so that the sixth deck abuts the fourth deck and the fifth deck and extends along approximately half the length of the second extension of the second prefabricated structure; a seventh prefabricated structure including a seventh shell and a seventh extension deployed out from a nested position within the seventh shell; a seventh deck hingedly connected with the seventh shell, the seventh deck extending away from the seventh shell so that a width of the seventh shell and the seventh deck is about the size of half the length of the prefabricated structures; wherein the seventh prefabricated structure is arranged transverse to the third prefabricated structure so that the seventh deck abuts the third deck and extends along approximately half the length of the first extension of the first prefabricated structure; a eighth prefabricated structure including a eighth shell and a eighth extension deployed out from a nested position within the eighth shell; and a eighth deck hingedly connected with the eighth shell, the eighth deck extending away from the eighth shell so that a width of the eighth shell and the eighth deck is about the size of half the length of the prefabricated structures; wherein the eighth prefabricated structure is arranged transverse to the fourth prefabricated structure so that the eighth deck abuts the fourth deck and the seventh deck and extends along approximately half the length of the first extension of the first prefabricated structure; and wherein the fifth deck, the sixth deck, the seventh deck, and the eighth deck form a common walkway.
7. The system of claim 6, wherein the system is substantially square in layout.
8. The system of claim 6, wherein the first deck, the second deck, the third deck, the fourth deck, the fifth deck, the sixth deck, the seventh deck, and the eighth deck form a common walkway.
9. The system of claim 6, wherein:
- a prefabricated structure from the first set of prefabricated structures provides an administration unit;
- a prefabricated structure from the first set of prefabricated structures provides a commissary unit;
- a prefabricated structure from the second set of prefabricated structures provides a communication unit; and
- a prefabricated structure from the second set of prefabricated structures provides a bunk unit.
10. The system of claim 9, wherein:
- a prefabricated structure from the first set of prefabricated structures provides a medical unit; and
- a prefabricated structure from the second set of prefabricated structures provides a water filtering unit.
11. The system of claim 10, wherein:
- the prefabricated structures further include: electrical wiring, a supply water duct, and a grey water duct; and
- the electrical wiring of the prefabricated structures is connected so that the prefabricated structures share a common electrical system;
- wherein the communication unit controls distribution of electricity;
- the supply water ducts of the prefabricated structures are connected so that the prefabricated structures share a supply water system; and
- the grey water ducts of the prefabricated structures are connected so that the prefabricated structures share a grey water system;
- wherein the water filtering unit treats grey water and purifies collected water for introduction to the supply water system.
12. A system of cooperating prefabricated structures arranged in a complementary layout comprising:
- a set of prefabricated structures having substantially the same dimensions, the set of prefabricated structures including: a first prefabricated structure including a first shell and a first extension deployed out from a nested position within the first shell; a first deck hingedly connected with the first shell, the first deck extending away from the first shell; a second prefabricated structure including a second shell and a second extension deployed out from a nested position within the second shell; a second deck hingedly connected with the second shell, the second deck extending away from the second shell; wherein the first prefabricated structure is arranged opposite the second prefabricated structure so that the first deck abuts the second deck; a third prefabricated structure including a third shell and a third extension deployed out from a nested position within the third shell; a third deck hingedly connected with the third shell, the third deck extending away from the third shell; wherein the third prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure so that the third deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure; a fourth prefabricated structure including a fourth shell and a fourth extension deployed out from a nested position within the fourth shell; and a fourth deck hingedly connected with the fourth shell, the fourth deck extending away from the fourth shell; wherein the fourth prefabricated structure is arranged transverse to the first prefabricated structure and the second prefabricated structure and opposite the third prefabricated structure so that the fourth deck abuts and extends along the width of the first prefabricated structure and the second prefabricated structure; and wherein the first deck, the second deck, the third deck, and the fourth deck form a common walkway.
13. The system of claim 12, wherein:
- the prefabricated structures further include: electrical wiring, a supply water duct, and a grey water duct; and
- the electrical wiring of the prefabricated structures is connected so that the prefabricated structures share a common electrical system;
- the supply water ducts of the prefabricated structures are connected so that the prefabricated structures share a supply water system; and
- the grey water ducts of the prefabricated structures are connected so that the prefabricated structures share a grey water system.
14. The system of claim 13, further comprising:
- a canopy connected across the first deck and the second deck;
- a gutter associated with the canopy for collecting water from the canopy;
- wherein the gutter is communicatively connected with the supply water system; and
- wherein a water purification device is positioned between the gutter and the supply water tank to purify collected water for introduction to the supply water system.
15. The system of claim 12, further comprising:
- another set of prefabricated structures having substantially the same dimensions as prefabricated structures of the set, the another set of prefabricated structures including: a fifth prefabricated structure including a fifth shell and a fifth extension deployed out from a nested position within the fifth shell; a fifth deck hingedly connected with the fifth shell, the fifth deck extending away from the fifth shell; wherein the fifth prefabricated structure is arranged transverse to the third prefabricated structure so that the fifth deck abuts the third deck and extends along approximately half the length of the second extension of the second prefabricated structure; a sixth prefabricated structure including a sixth shell and a sixth extension deployed out from a nested position within the sixth shell; a sixth deck hingedly connected with the sixth shell, the sixth deck extending away from the sixth shell; wherein the sixth prefabricated structure is arranged transverse to the fourth prefabricated structure so that the sixth deck abuts the fourth deck and the fifth deck and extends along approximately half the length of the second extension of the second prefabricated structure; a seventh prefabricated structure including a seventh shell and a seventh extension deployed out from a nested position within the seventh shell; a seventh deck hingedly connected with the seventh shell, the seventh deck extending away from the seventh shell; wherein the seventh prefabricated structure is arranged transverse to the third prefabricated structure so that the seventh deck abuts the third deck and extends along approximately half the length of the first extension of the first prefabricated structure; a eighth prefabricated structure including a eighth shell and a eighth extension deployed out from a nested position within the eighth shell; and a eighth deck hingedly connected with the eighth shell, the eighth deck extending away from the eighth shell; wherein the eighth prefabricated structure is arranged transverse to the fourth prefabricated structure so that the eighth deck abuts the fourth deck and the seventh deck and extends along approximately half the length of the first extension of the first prefabricated structure; and wherein the fifth deck, the sixth deck, the seventh deck, and the eighth deck form a common walkway.
16. The system of claim 15, wherein the system is substantially square in layout.
17. The system of claim 15, wherein the first deck, the second deck, the third deck, the fourth deck, the fifth deck, the sixth deck, the seventh deck, and the eighth deck form a common walkway.
18. The system of claim 15, wherein:
- a prefabricated structure from the first set of prefabricated structures provides an administration unit;
- a prefabricated structure from the first set of prefabricated structures provides a commissary unit;
- a prefabricated structure from the second set of prefabricated structures provides a communication unit; and
- a prefabricated structure from the second set of prefabricated structures provides a bunk unit.
19. The system of claim 18, wherein:
- a prefabricated structure from the first set of prefabricated structures provides a medical unit; and
- a prefabricated structure from the second set of prefabricated structures provides a water filtering unit.
20. The system of claim 19, wherein:
- the prefabricated structures further include: electrical wiring, a supply water duct, and a grey water duct; and
- the electrical wiring of the prefabricated structures is connected so that the prefabricated structures share a common electrical system;
- wherein the communication unit controls distribution of electricity;
- the supply water ducts of the prefabricated structures are connected so that the prefabricated structures share a supply water system; and
- the grey water ducts of the prefabricated structures are connected so that the prefabricated structures share a grey water system;
- wherein the water filtering unit treats grey water and purifies collected water for introduction to the supply water system.
Type: Application
Filed: Oct 13, 2008
Publication Date: Feb 4, 2010
Applicant: GREEN HORIZON MANUFACTURING LLC (San Francisco, CA)
Inventor: James D. Pope (San Francisco, CA)
Application Number: 12/250,493
International Classification: E04H 1/02 (20060101); E04C 2/52 (20060101);