CONTAINER CONVERSION SYSTEM AND METHOD

Abstract

A temporary wall system for use in temporarily converting a shipping container, such as a standard or high-cube intermodal container, into a living space or workspace, the shipping container having a substantially rectangular access opening having a perimeter, wherein the wall system comprises a wall having exterior dimensions suitable to allow the perimeter of the wall to at least substantially mate with the perimeter of the container's access opening, wherein the wall defines an access opening that is sized to allow an adult human to pass from one side of the wall to the other through the access opening, and the wall comprises a door that is mounted so that the door can be selectively moved between an open and a closed position; and a power hookup for powering one or more accessories supported by the wall.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/464,869, filed May 8, 2023, entitled “MULTIPURPOSE RELOCATABLE STRUCTURE CONVERSION SYSTEM AND METHOD” and is a continuation-in-part of U.S. patent application Ser. No. 17/675,845, filed Feb. 18, 2022, now U.S. Pat. No. 11,767,162, issued Sep. 26, 2023, entitled “MODULAR FACILITY FORMATION SYSTEM AND SHIPPING METHOD,” which is a continuation of Ser. No. 16/824,941, filed Mar. 20, 2020, now U.S. Pat. No. 11,254,494, issued Feb. 22, 2022, entitled “MODULAR FACILITY FORMATION SYSTEM AND SHIPPING METHOD,” which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/827,831, filed Apr. 1, 2019, entitled “MODULAR CONTAINER INSERT SYSTEM AND SHIPPING METHOD,” the disclosures of which are hereby incorporated by reference herein in their entirety.

BACKGROUND

Temporary workspaces and living spaces are in high demand in numerous situations—from disaster relief, to remote activities, to on site operations or even military activity. The best facilities for these uses are ideally transportable in quantity, affordable, capable of set up with minimal equipment and labor, durable and functional. However, most current options fit only some of these categories. Tent-like structures can be very mobile and easily set up. But unless the product is extremely expensive, these tend not to be very functional or durable. Modular housing can be highly durable and functional, but is generally expensive, hard to set up and very hard to transport in quantity.

Accordingly, there is a great need for a product that offers a balance of all of these qualities. Various embodiments of the subject product may be used to create a living space or workspace that is highly functional (having lights, electricity, climate control and/or high security), while also being able to be moved to a site in quantity. Various embodiments are also long-lasting, relatively inexpensive and, after movement to the site, capable of setup rapidly (e.g., within under an hour) with human labor and simple hand tools.

SUMMARY

It should be appreciated that this summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter.

A method of converting a container into a workspace or shelter, according to a particular embodiment, comprises providing a container comprising: (1) a substantially planar container bottom; (2) a substantially planar container top spaced apart from and co-facing the planar container bottom; (3) a first, substantially planar side wall extending between respective first lateral sides of the container top and container bottom; (4) a second, substantially planar side wall extending between respective second lateral sides of the container top and container bottom; (5) a substantially planar rear wall extending between respective first end sides of the container top, container bottom, first side wall, and second side wall. The container top, container bottom, first side wall, second side wall, and rear wall may define an enclosure that is substantially in the shape of a rectangular prism, the enclosure defining an interior and a front access opening. The container, which may be an intermodal container (having a width of about 8 feet and a height of about 8.5 feet, or about 9.5 feet, if the intermodal container is a “high-cube” intermodal container), may further comprise one or more doors that are mounted adjacent the container so that they are moveable between a closed position in which the one or more doors at least substantially cover the container's front opening, and an open position in which the one or more doors don't substantially cover the container's front opening. The method may further comprise providing a temporary wall that is adapted to be temporarily attached adjacent the container's front opening to selectively prevent individuals from entering the container via the front opening, the temporary wall defining a door opening and comprising a door that is positioned adjacent the door opening and that is adapted to be selectively moved between: (1) a first, closed position in which the door is positioned within the door opening so that the door prevents passage of individuals through the door opening and into the interior of the container; and (2) a second, open position in which the door is positioned to allow passage of individuals through the door opening and into the interior of the container.

In various embodiments: (1) the temporary wall comprises at least one attachment mechanism (e.g., a tab, retractable pin assembly or other suitable attachment mechanism) that is adapted for use in temporarily attaching the temporary wall adjacent the container's front opening; (2) the at least one attachment mechanism comprises a plurality of attachment mechanisms, each of the attachment mechanisms extending from a different position along an outer perimeter of the temporary wall; (3) the plurality of attachment mechanisms comprise a first attachment mechanism that is disposed on a first lateral side of the temporary wall and a second attachment mechanism that is disposed on a second lateral side of the temporary wall; (4) each of the plurality of attachment tabs comprises a substantially planar distal portion that extends substantially perpendicularly to a side of the temporary wall that is positioned facing the interior of the enclosure when the temporary wall is attached adjacent the container's front opening; (5) the temporary wall includes at least one power receptacle for use in providing power to one or more powered accessories disposed adjacent the temporary wall; (6) at least one of the one or more powered accessories is an environmental control unit that is configured to regulate a temperature of air within the interior of the container; (7) at least one of the one or more powered accessories is a light that is disposed on a side of the temporary wall that is positioned facing the interior of the enclosure when the temporary wall is attached adjacent the container's front opening; (8) the temporary wall is configured and/or dimensioned to facilitate attaching an environmental control unit adjacent the wall; (9) the temporary wall is dimensioned so as to allow it to fit within the interior of a standard height intermodal container, and be able to be manually secured (e.g., releasably without damage or advance modification to the container) to the interior of the container when the temporary wall is positioned at least substantially perpendicular to a longitudinal axis of the container so that it selectively blocks access to the container's interior; (10) the temporary wall comprises a gasket disposed adjacent a perimeter of the temporary wall for creating a substantially weatherproof seal between the temporary wall and the container adjacent the container's front opening—in various embodiments, the gasket may extend around at least about 70%, at least about 80%, at least about 90% and/or substantially the entire perimeter of the temporary wall; (11) the wall has a width of about 8 feet and a height of about 8.5 feet or 9.5 feet; (12) the wall has a width and height that is between about 90% and about 100% (e.g., between about 95% and about 100%) of the width, and between about 90% and about 100% (e.g., between about 95% and 100%) of the height of a standard or high-cube intermodal shipping container; and/or (13) the wall is dimensioned to allow the wall to be operatively positioned within the shipping container while one or more exterior doors associated with the shipping container are closed to prevent access to the wall from outside the shipping container.

A temporary wall system, according to various embodiments, for use in temporarily converting a shipping container into a living space or workspace (where the shipping container has a substantially rectangular access opening having a perimeter) comprises: (1) a wall having exterior dimensions suitable to allow the perimeter of the wall to at least substantially mate with the interior perimeter of the container's access opening, the wall defining an access opening that is sized to allow an adult human to pass from one side of the wall to the other through the access opening, and the wall comprising a door that is mounted so that the door can be selectively moved between: (a) a first position in which the door obstructs the access opening to prevent passage of individuals through the access opening; and (b) a second position in which the door does not sufficiently obstruct the access opening to prevent passage of individuals through the access opening; and (2) a power hookup (e.g., incorporated into the wall) to facilitate powering one or more accessories supported by the wall (e.g., from an electrical power source).

In particular embodiments: (1) the power hookup is attached adjacent the wall; (2) the wall defines an environmental control opening that is dimensioned for receiving a heating/air-conditioning unit, and the wall comprises a shelf/boxed holding structure disposed adjacent a bottom portion of the opening and that is configured for supporting the heating/air-conditioning unit so that an output portion of the heating/air-conditioning unit is at least substantially aligned with the environmental control opening; (3) the wall comprises a light that is mounted adjacent the wall, the light being adapted to be powered by power supplied by the power hookup; (4) the wall comprises a power outlet that is mounted adjacent the wall, the power outlet being adapted to be powered by power from the power hookup; (5) the shipping container is an ISO intermodal container; and (6) the shipping container has a length selected from a group consisting of about 10 feet, about 20 feet, and about 40 feet, or any other suitable length.

A method, according to various embodiments, of converting a shipping container (e.g., an ISO intermodal container) into a temporary living space or temporary workspace comprises: (1) providing a temporary wall system for use in temporarily converting an ISO intermodal container into a temporary living space or workspace, the container having a substantially rectangular access opening having a perimeter, wherein the wall system comprises a wall having exterior dimensions suitable to allow the perimeter of the wall to at least substantially mate with the perimeter of the container's access opening, wherein: (a) the wall defines an access opening that is sized to allow an adult human to pass from one side of the wall to the other through the access opening, (b) the wall comprises (i) a door that is mounted so that the door can be selectively moved between a first position in which the door obstructs the access opening to prevent passage of individuals through the access opening and a second position in which the door does not sufficiently obstruct the access opening to prevent passage of individuals through the access opening, and (ii) a power hookup disposed adjacent (e.g., incorporated into) the wall for powering one or more accessories supported by the wall; (2) positioning the temporary wall system adjacent the container's access opening so that the perimeter of the wall substantially mates with the perimeter of the container's access opening; (3) connecting the power hookup to a power source; and (4) using power from the power hookup to power an environmental control unit adjacent the wall, the environmental control unit being adapted for selectively providing heated or cooled air to an interior of the container.

According to yet another aspect of the disclosure, a method of converting a container into a workspace comprises: (1) opening one or more doors of the container; (2) lifting the conversion system; (3) inserting the conversion system into the container; (4) aligning the conversion system such that the gasket abuts an interior surface of the container; (5) connecting a power supply line to the power receptacle; (6) initiating power supply via the power supply line; and (7) initiating operation of the environmental control unit.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are described below. In the course of this description, reference will be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIGS. 1 and 2 are perspective views of an intermodal container into which a wall assembly according to various embodiments has been operatively installed.

FIG. 3 is a wall assembly according to a particular embodiment.

FIG. 4 is a front perspective view of an intermodal container into which a wall assembly according to a further embodiment has been operatively installed.

FIG. 5A is a front perspective view of an intermodal container into which a wall assembly according to another embodiment has been operatively installed.

FIG. 5B is a front perspective view of an intermodal container into which a wall assembly according to another embodiment has been operatively installed.

FIGS. 6A and 6B illustrate a conversion system that includes an interior module defining a framework along with a wall assembly that is selectively operably attachable to the module.

FIG. 6B is a cutaway view with the container's top shown removed.

FIG. 7A is a flowchart illustrating a conversion process according to various embodiments.

FIG. 7B is a flowchart illustrating a conversion system manufacturing process according to particular embodiments.

FIGS. 8A-8E are, respectively, front (exterior) perspective, rear (interior), right side, left side and top views of a wall assembly of a conversion system for a container according to a particular embodiment.

FIGS. 9A-9E are, respectively, front (exterior) perspective, front, rear (interior), and left and right side views of a first embodiment of a wall assembly of a conversion system according to an alternative embodiment.

FIGS. 10A-10D are respectively, perspective, left side, top and front views of a sliding bolt attachment mechanism according to various embodiments.

DETAILED DESCRIPTION

Various embodiments now will be described more fully hereinafter with reference to the accompanying drawings. It should be understood that the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

As noted above, there is currently a need for improved systems and methods for providing permanent or temporary living spaces or workspaces in situations, for example, where many of such living spaces or workspaces are needed to be deployed and assembled rapidly. As discussed in greater detail below, and elsewhere herein, one solution to this, according to various embodiments, comprises providing a powered wall assembly having a door (e.g., a lockable door) and that is configured to be attached to the open end of a shipping container, such as an ISO intermodal container. In particular embodiments, the wall assembly is adapted to operably support an environmental control unit, such as a window-mounted heating/air-conditioning unit and to provide power to the environmental control unit.

After the wall assembly is attached to an open end of the shipping container, the environmental control unit may be powered on and used to control the temperature of air within the interior of the shipping container. In particular embodiments, the perimeter of the wall assembly substantially mates with the perimeter of the open end of the shipping container so that there is no or minimal air leakage from the interior of the container to outside of the container. In particular embodiments, the wall assembly includes one or more gaskets (e.g., made of a flexible material such as rubber) that extend along at least about 70%, about 80%, about 90% and/or about 100% of the outer perimeter of the wall assembly to reduce or eliminate air flow out of the container.

As noted above, in particular embodiments, the wall assembly is powered. For example, the wall assembly may include a power hookup, such as an electrical hookup that may be connected to a power source and that may be used to power one or more electrical accessories adjacent to (e.g., on) the wall assembly. As discussed in greater detail below, in particular embodiments, such electrical accessories include: (1) one or more lights supported adjacent an interior and/or exterior of the wall assembly and optionally controlled by one or more switches mounted to the wall assembly; (2) one or more power outlets supported adjacent an interior and/or exterior of the wall assembly and optionally controlled by one or more switches mounted to the wall assembly; (3) one or more environmental control units for controlling one or more environmental conditions (e.g., temperature, air quality, humidity levels) within the container; and/or (4) any other suitable electrical accessories. Various embodiments of such conversion systems are discussed in greater detail below.

FIGS. 1-2 are perspective views of an intermodal container 1100A having a wall assembly 3000A operatively installed within its interior adjacent its access doors 1200. As may be understood from FIG. 2, the wall assembly 3000A is attached (e.g., via suitable fasteners) to a module 2000A that includes a support framework as described in U.S. Pat. No. 11,034,511, which, as noted above, is incorporated herein by reference. One or more additional modules 2000B may also be stored within the container 1100A.

In this embodiment, the module 2000A to which the wall assembly 3000A may, for example, be positioned within the interior of the container 1100A so that the wall assembly 3000A is disposed adjacent the container's access opening (also referred to herein as its “front opening”) and so that the wall assembly forms a substantially weather and/or airtight seal with an interior portion of the container 1100A. As discussed in greater detail below, this may allow a user to control the temperature and/or humidity within the container using, for example, a heating/air-conditioning unit mounted to the wall assembly 3000A. This may also allow users to selectively restrict access to the container's interior by, for example, closing and locking the wall assembly's access door 3010A (See FIG. 3).

FIG. 3 is a front perspective view of the wall assembly 3000A of the conversion system of FIGS. 1 and 2. As discussed in greater detail below, the wall assembly 3000A may include an access door 3010A, one or more accessories, weather sealing, power source, etc., for use in converting an intermodal container into a living space or workspace. The wall assembly 3000A may provide these features to a container reversibly (e.g., without significant alteration of the container structure).

In various embodiments, such as the embodiment shown in FIG. 8A, the wall assembly 3000E comprises a perimeter frame 3001E made of a plurality of perimeter frame elements. For example, the perimeter frame 3001E may include two substantially vertical frame elements 3003E and two substantially horizontal frame elements 3004E. Each of the two substantially horizontal frame elements 3004E may be respectively secured to extend between respective ends of the two substantially vertical frame elements 3003E. In this manner, the vertical frame elements 3003E and the horizontal frame elements 3004E may, in various embodiments, substantially form a parallelogram (e.g., a rectangle). The perimeter frame 3001E (e.g., which may define the wall assembly's outer perimeter) may have dimensions at least substantially corresponding to the dimension of the interior walls of standard ISO containers (1AA, 1BB, 1CC, or a 1A, 1B, 1C or 1D under the ISO 668 classification) (e.g., substantially the same width and substantially the same height). Accordingly, in particular embodiments, when the wall assembly 3000E is installed within the container, each side of the perimeter frame 3001E may abut an inside portion of a respective container wall. This may allow the wall assembly 3000E to be held fixedly in place by friction between the outer walls of the perimeter frame 3001E and the interior walls of the container.

In some embodiments, the wall assembly's perimeter frame 3001E may have dimensions that are slightly less than the dimensions of the respective interior walls of a standard ISO intermodal container. In such embodiments, the perimeter frame 3001E may include one or more fastening mechanisms (e.g., selectively extendable/retractable pins or screws) to hold the wall assembly 3000E in place within its respective intermodal container (e.g., using frictional contact between the fastening mechanisms (e.g., when the fastening mechanisms are in an extended position) and the interior walls of the container).

As shown in FIG. 3, the perimeter frame may include a base feature such that a portion of the perimeter base supports the wall assembly, while a portion of the perimeter base is raised above a ground level. Accordingly, the perimeter frame 3001A comprises a recessed portion 3012A that is configured to allow a forklift to pass under the wall portion and engage with forklift apertures that may be selectively disposed by the forklift into a structure rearward of the wall assembly 3000A.

The wall assembly 3000A may further comprise one or more internal vertical frame element(s) 3003A and one or more internal horizontal frame element(s) 3004A each being disposed in an area defined by the perimeter frame. The internal vertical frame element(s) 3003A and the internal horizontal frame element(s) 3004A may provide attachment points for conversion system features and/or panels, as well as reinforcing the perimeter frame 3001A. In some embodiments, the wall assembly 3000A may include at least one substantially vertical door frame element 3003A secured within the area defined by the perimeter frame. The door frame may be configured to support a door 3010A. In some embodiments, the door 3010A may be attached (e.g., rotatably connected via one or more hinges) to a portion of the perimeter frame 3001A (e.g., a suitable vertical frame element 3003A).

Further, the door 3010A may also include a smaller access hole 3011A dimensioned to allow a person to egress through the access hole 3011A (e.g., about 24 inches by about 30 inches). A second door (e.g., an escape hatch) may be disposed adjacent the access hole 3011A. In various embodiments, the escape hatch may include at least one release handle configured to selectively open the escape hatch. The access hole 3011A may be used by a worker to safely escape the structure in the event that the door 3010A is obstructed.

In various embodiments, the wall assembly may further comprise one or more supports for an accessory unit, such as an environmental control unit. In further embodiments, the wall assembly may include one or more openings that is selectively obstructed by one or more panels attached adjacent the wall assembly. This may allow an operator to selectively remove the panel to: (1) permit access to one or more components (e.g., wiring, duct work, etc.) inside the container; or (2) provide access to an air-transfer opening for an environmental control unit, such as a heating/air-conditioning unit.

As may be understood from FIGS. 8A and 8B, in various embodiments, the wall assembly 3000E may comprise a plurality of attachment tabs 3070E extending rearwardly from the perimeter frame 3001E from various positions about the wall assembly's perimeter frame 3001E. As shown in FIG. 23B, the wall assembly 3000E may comprise, for example, a plurality of (e.g., two to eight) attachment tabs 3070E. The attachment tabs 3070E-3070E may each include one or more fastening apertures allowing a suitable screw, bolt, or other fastener to secure the wall assembly 3000E to a framework or a module. Other attachment tab arrangements are also envisioned (e.g., different placements, such as at the top, bottom, front, etc. of the wall assembly 3000E, or more/fewer attachment tabs) so that, for example, the wall assembly 3000E can be secured to the interior of an intermodal container by tension.

FIG. 4 illustrates a conversion system installed in a container 1100B according to various embodiments. Although other components of the conversion system are hidden from view in FIG. 4, the wall assembly 3000B remains visible and is shown installed adjacent the container's access opening (“front opening”). As stated above, the container 1100B may be constructed to ISO 668 standard, or may be another structure that may or may not comply with ISO 668 dimensions and/or strength and construction requirements but that, for example, may have the same interior dimensions. The wall assembly 3000B may substantially mate with an interior surface of the container 1100B as shown. In some embodiments, the material of the wall assembly's perimeter frame (e.g., metal) may contact the material of the container (e.g., a metal-on-metal abutment). Alternatively, in some embodiments, a gasket (e.g., a rubberized gasket) may cover the perimeter frame (e.g., partially or completely cover vertical perimeter frame elements and a top horizontal perimeter frame element but, in some embodiments, not perimeter frame elements supporting the weight of the wall assembly 3000B, etc.) and abut a surface of the container. In such embodiments, the perimeter frame may be slightly undersized (e.g., have dimensions that are 95%, 96%, 97%, 98%, 99%, etc. of the respective dimensions of the opening in which the wall assembly 3000B will be installed), thereby, in some embodiments, providing a gap to accommodate the gasket. Further, an operator may find it easier and quicker to place a wall assembly in a door of a container when the wall assembly frame is undersized and can therefore be installed without high precision, and in a container that may be misshapen due to damage or manufacturing tolerances. Further still, a gasket may fill gaps between the perimeter frame and the container to help prevent dust and water intrusion and also provide a climate-controlled workspace.

FIGS. 5A and 5B illustrate conversion systems with one or more accessories installed in a container 1100C according to various embodiments. Beginning with FIG. 5A, a conversion system may include one or more accessories such as an electrical connector interface 3040C (e.g., which may include a power hookup). The electrical connector interface 3040C may be angled and recessed behind the wall assembly 3000C, as described above, or may be rearward of at least one outer surface of the wall assembly 3000C, such that the electrical connector interface 3040C may be surrounded by a protective covering protruding from the front of the wall assembly 3000C. Further, the wall assembly 3000C may include wiring and outlets on its interior side to allow users to supply power to various workplace components (e.g., chargers, computers, fans, lights, tools, etc.). Alternatively, the electrical connector interface 3040C may include an open aperture allowing a power cord to penetrate the wall assembly 3000C. In some embodiments, the aperture may include a gasket to substantially seal the opening against a penetrating cord.

The wall assembly 3000C may also or alternatively include an environmental control unit 3017C. The environmental control unit 3017C may include, for example, a heat pump, air conditioner and/or air filter, etc., configured to provide a temperate and clean workspace inside of the container 3000C. The environmental control unit 3017C may be secured in an aperture of the wall assembly 3000C. As described above, the environmental control unit 3017C, in some embodiments, may be configured to move between a retracted shipping position, relative to a surface of the wall assembly 3000C, and an extended operating position, relative to the surface of the wall assembly 3000C.

FIG. 5B illustrates an alterative configuration of a wall assembly 3000C, wherein the electrical connector interface 3040C and the environmental control unit 3017C are on the left side of the wall assembly 3000C, as opposed to the right side as shown in FIG. 5A. Accordingly, the wall assembly 3000C may be selectively reconfigurable according to user needs. For instance, in some embodiments, the wall assembly 3000C may have welded internal frame elements. A user may install accessories as desired (e.g., an environmental control unit, electrical connector interface, communications interfaces such as routers, etc.), and install filler panels as to close open areas of the wall assembly 3000C. Accessories and panels may be secured by suitable fasteners (e.g., screws, clips, bolts, etc.). In some cases, an end user may specify a desired configuration, and a manufacturer may weld or otherwise permanently attach accessories and panels. Further still, in some cases, internal frame elements may be reconfigurable as well, and reconfigurably secured to the perimeter frame (e.g., using fasteners, brackets, etc.).

FIGS. 6A and 6B illustrate a conversion system including a support structure 2000D installed in a container 1100D according to various embodiments. Thus, in addition to a wall assembly 3000D, the conversion system may further include a support structure 2000D enabling the wall assembly 3000D to be placed within the container 2000D and remain stable without requiring a mechanical connection between the wall assembly 3000D and the container 1100D. The support structure 2000D may comprise one or more horizontal members dimensioned to fit into the container and to abut an interior surface of the container, and the wall assembly 3000D may be fastened adjacent (e.g., to) the support structure 2000D. For example, the support structure 2000D may comprise a substantially planar horizontal platform 2604, and the wall assembly 3000D may be attached to the platform 2604 at a substantially right angle. Thus, the conversion system may slide into the container 1100D and abut the interior of the container 1100D, while remaining substantially self-supporting. In this manner, the conversion system may, in various embodiments, be used with a container 1100D without modification to the container 1100D.

Further, in some embodiments, the support structure 2000D may comprise a framework providing additional support to the wall assembly 3000D, as well as non-destructive attachment mechanisms (e.g., clamps or other pressure fasteners) to further secure the wall assembly 3000D and one or more accessories adjacent the container 2000D. For example, as shown in FIG. 6A, the support structure 2000D may include a plurality of (e.g., four) substantially vertical support elements extending upwardly from the platform and a plurality of (e.g., four) substantially horizontal support elements. Each substantially horizontal support element may be secured to extend between respective distal ends of each of a respective pair of substantially vertical support elements. Thus, the framework may be substantially shaped as a rectangular prism. Other framework shapes for the support structure 2000D are also envisioned, such as triangular braces, etc.

In addition, the platform of the support structure may include a pair of forklift apertures. These forklift apertures may be dimensioned to allow a user to quickly lift and insert the conversion system into a container 1100D, as illustrated in FIG. 6B showing the conversion system installed in the container 1100D (with the top of the container 1100D being cut away to reveal the container's interior).

FIG. 7 is a flowchart illustrating a container conversion process 2700 according to various embodiments. The conversion process 2700 may be used by an end user, for instance in a deployed environment, to convert any suitable (e.g., appropriately dimensioned) container or other container into a workplace and/or shelter.

Beginning at step 2705, the conversion process 2700 may include opening doors of the container, such as double doors typically on the end wall of a container. The conversion process 2700, at step 2710, further includes lifting the conversion system described herein, for instance using a forklift. In some cases, the conversion system may be light enough, or modularized into liftable components, such that one or more individuals may manually lift and install the conversion system without assistance of machinery. At step 2715, the conversion process 2700 includes inserting the conversion system into the container. In various embodiments, the conversion system may be inserted sufficiently far into the container such that the doors of the container may freely close without impacting the conversion system. In other words, any accessories (e.g., an environmental control unit) may be far enough into the container that the container's main doors may close, which may allow users to add extra security to the workspace or living space or even ship the container with an installed conversion system in a standard shipping channel. In some embodiments, the conversion system may only extend partially into (or not substantially extend into) the container (or other structure) when installed adjacent the container (or other structure).

The next step, Step 2720 includes aligning the conversion system such that its gasket abuts (e.g., seals against) an interior surface of the container. Step 2720 may include horizontally translating tines on a forklift to obtain a consistent seal and eliminate gaps between the inner walls of the container and the conversion system. Following step 2720, a user may add any suitable mechanical fasteners or connections to further secure the conversion system into the container (e.g., screws, bolts, clamps, latches, etc.).

Continuing, the conversion process 2700 may also include activating any accessories, for instance, by connecting a power supply line to the power receptacle at step 2725 and initiating power supply via the power supply line at step 2730. Further, at step 2735, the conversion process 2700 may include initiating operation of the environmental control unit. In some embodiments, the environmental control unit may be integrated into the same circuitry as the power receptacle. Alternatively, the environmental control unit may receive power via a separate circuit, in which case, step 2735 may further include running a power supply line to the environmental control unit.

FIG. 7B is a flowchart illustrating a conversion system manufacturing method 2800 according to various embodiments. The manufacturing method 2800 may be used to assemble a conversion system as described herein prior to shipment to an end user. Alternatively, components of the conversion system may be shipped to an end user or intermediary assembling entity to be assembled on site, for instance. As used to describe the manufacturing method 2800, the word “fastening” may include the use of any combination of one or more material connections (e.g., welding) or mechanical fasteners (e.g., interference fits, clamps, pins, screws, bolts, hinges, etc.), and may include permanent attachments (e.g., welds) and selectable attachments (e.g., pins).

At step 2805, the manufacturing method 2800 includes fastening each of two substantially vertical elements to a top substantially horizontal element and a bottom substantially horizontal element to form a perimeter frame. Step 2805 may result, for example, in a substantially parallelogram shaped frame. Alternatively, step 2805 may include additional elements to introduce one or more bends or recesses, for instance to accommodate forklift tines.

At step 2810, the manufacturing method 2800 may include fastening an interior substantially vertical element to the top substantially horizontal element to at least partially form a door frame. Step 2810 may also include fastening multiple substantially vertical elements (e.g., a left and a right portion of a door frame) to the top substantially horizontal element. Alternatively, the door frame may be formed between a substantially vertical element of the perimeter frame and an interior substantially vertical element. A door may be fastened to the door frame at step 2815.

Continuing, at step 2820, the manufacturing method 2800 may include fastening an interior substantially horizontal element to at least one of the two substantially vertical elements to at least partially form an interior frame. The interior frame may provide structural support for an accessory, and the manufacturing method 2800 may include fastening an accessory to the interior frame at step 2825, such as an environmental control unit and/or an electrical connector interface. The manufacturing method 2800 may also include fastening a panel at step 2830 to fill a remaining portion of an area defined by the perimeter frame. In some cases, the manufacturing method 2800 may include filling one or more openings (e.g., every opening) with a panel. The panel or panels may be selectively removable, or may be permanently attached.

In some embodiments, additional features of the wall assembly described herein may be installed during the manufacturing method 2800. For example, the manufacturing method 2800 may further include fastening at least one attachment tab to the perimeter frame, or fastening a gasket around an outer surface of the perimeter frame. In some cases, the manufacturing method 2800 may also include fastening at least one lifting point to the perimeter frame, such as a loop, anchor, etc. Alternatively, or additionally, the lifting point may be an aperture created in the wall assembly, such as a hole cut into an element of the perimeter frame.

FIGS. 8A-8E are, respectively, front (exterior) perspective and rear (interior), side and top views of a wall assembly 3000 of a conversion system for an intermodal shipping container, or other suitable structure such as those described elsewhere herein, according to a particular embodiment. As may be understood from FIG. 8A, which depicts a front (exterior) view of the wall assembly 3000E, the wall assembly 3000E may include, for example, (1) a door (e.g., a security door) 3010E having a door handle (e.g., a standard rotatable door handle) 3015E for allowing a user to selectively open/close the door 3010E; (2) a substantially rectangular opening 3020E; and (3) a substantially rectangular, substantially horizontal support portion 3030E disposed adjacent a bottom portion of the substantially rectangular opening 3020E. The wall assembly 3000E may be adapted to support a heating/air-conditioning unit, which may be installed adjacent the rectangular opening 3020E and supported by the support 3030E. The wall assembly 3000E may also be powered (e.g., by a suitable power source 3040E) and comprise one or more electrical outlets 3054E and/or one or more lights 3060E installed, for example, on a rear (interior) surface of the wall assembly 3000E. The wall assembly 3000E may also include one or more light switches 3052E for selectively activating the one or more lights 3060E.

The wall assembly 3000E may be a self-contained add-on to a standard (or non-standard) shipping container (e.g., an ISO intermodal shipping container) for use in converting the shipping container into a temporary (or non-temporary) workspace or shelter. To this end, as noted above, in various embodiments, the wall assembly 3000E may include one or more (e.g., substantially planar) attachment members 3070E (e.g., substantially planar tabs) that extend (e.g., intermittently along the top and/or sides of the wall assembly 3000E). These attachment members 3070E may be used to attach the wall assembly 3000E adjacent (e.g., into, partially into, or just outside of) the open end of a shipping container (e.g., with one or more suitable fasteners) so that the wall assembly 3000E at least substantially blocks access to the interior of the container when the wall assembly's door is closed. As noted above, the wall assembly 3000E may include a gasket assembly (not shown) that extends at least partially around the perimeter of the wall assembly 3000E (e.g., at least about 70%, about 80%, about 90%, or about 100% around the perimeter of the wall assembly 3000E) for use in sealing the perimeter of the wall assembly 3000E as it is installed adjacent the container (e.g., so that air doesn't leak substantially between the wall assembly 3000E and the container).

After the wall assembly 3000E is installed adjacent a suitable container, users may access the interior of the container by opening the wall assembly's door 3010E. Once inside the container, a user may then close the door 3010E for protection from the elements. The AC/Heating unit may then be used to control the air temperature (and/or other environmental conditions) within the container and the light 3060E may selectively provide light within the container. A user may power electronic devices by plugging the devices into the wall assembly's power outlet(s) 3054E. The wall assembly 3000E may be powered by any suitable source of electricity including, for example, a generator, one or more batteries, solar power, and/or a suitable connection to an external power source.

FIGS. 9A-9E depict a wall assembly 3000F according to an alternative embodiment. It should be understood that this wall assembly 3000F is structurally similar to the wall assembly 3000E discussed above except that it includes a bolt-lock handle/lock configuration 3015F and sliding-bolt attachment mechanisms 3080F.

FIGS. 10A-10D show example sliding bolt attachment mechanisms 3080F in greater detail. As may be understood from these figures, an example the attachment mechanism 3080F includes a sliding bolt 3090F that is slideably supported by a bolt support 3084F and base 3087F. The bolt 3090F is adapted to slide laterally within a substantially cylindrical opening defined by the bolt support 3084F when a user moves a handle 3082F either toward or away from the sliding bolt 3090F. One or more mechanical link systems 3086F may be used to facilitate a defined rotational path of the handle about a particular axis of rotation as the user moves the handle 3082F radially between various positions. This may, for example, allow a user to selectively extend the bolt 3090F by moving the handle 3082F fully away from the bolt 3090F (as shown in FIG. 10A), and to retract the bolt 3090F by rotating the handle 3082F toward the bolt 3090F.

In view of FIG. 9C, it should be understood that the various attachment mechanisms 3080F can be used to attach the wall assembly 3000F adjacent the opening of an ISO intermodal container, or other container. More specifically, before installation, a user may retract the respective bolts 3090F of the attachment mechanisms 3080F. The user may then coordinate positioning the wall assembly 3000F adjacent the access opening of the ISO intermodal container so that the perimeter of the wall assembly 3000F substantially aligns and/or mates with the perimeter of the access opening and so that the respective bolts 3090F of the attachment mechanisms 3080F align with one or more fastening recesses defined adjacent or by the container. Such fastening recesses may include, for example, recesses defined respectively by a female fastening portion that is bolted to the container. Alternatively, the fastening recesses may be recesses defined respectively by a portion of the container itself. The user may then use the respective attachment mechanism handles 3082F to extend the respective bolts 3090F into the respective fastening recesses (or simply against the interior surface—or other surface—of the container, where the surface is not necessarily recessed) to thereby fixedly maintain the wall assembly 3000F in place adjacent the opening of the container. To remove the wall assembly 3000F, the user may simply reverse the steps of the process described above.

CONCLUSION

Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, as will be understood by one skilled in the relevant field in light of this disclosure, the embodiments may take form in a variety of different mechanical and operational configurations. As a particular example, it should be understood that, in various embodiments, the door assemblies and related methods described herein could be used with non-intermodal containers, such as non-intermodal containers having a width and height that are about the same as those of intermodal containers (e.g., standard or high-cube intermodal containers). Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed herein, and that the modifications and other embodiments are intended to be included within the scope of the appended exemplary concepts. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation.

Claims

1. A method of converting an intermodal container into a workspace or shelter, the method comprising:

providing the intermodal container, the intermodal container comprising: a substantially planar container bottom; a substantially planar container top spaced apart from and co-facing the planar container bottom; a first, substantially planar side wall extending between respective first lateral sides of the container top and container bottom; a second, substantially planar side wall extending between respective second lateral sides of the container top and container bottom; a substantially planar rear wall extending between respective first end sides of the container top, container bottom, first side wall, and second side wall, wherein: said container top, container bottom, first side wall, second side wall, and rear wall define an enclosure substantially in the shape of a rectangular prism, the enclosure defining an interior and a front opening; and said intermodal container further comprises one or more doors that are mounted adjacent the container so that the one or more doors are moveable between: (1) a closed position in which the one or more doors substantially cover the intermodal container's front opening; and (2) an open position in which the one or more doors do not substantially cover the intermodal container's front opening,

providing a temporary wall that is adapted to be temporarily attached adjacent the container's front opening to selectively prevent individuals from entering the container via the front opening, the temporary wall defining a door opening and comprising a door that is positioned adjacent the door opening and that is adapted to be selectively moved between: (1) a first, closed position in which the door is positioned within the door opening so that the door prevents passage of individuals through the door opening and into the interior of the container; and (2) a second, open position in which the door is positioned to allow passage of individuals through the door opening and into the interior of the container; and

attaching the temporary wall adjacent the container's front opening so that the door may be used to selectively prevent individuals from entering the container.

2. The method of claim 1, wherein the temporary wall has a width of about 8 feet and a height of about 8.5 feet.

3. The method of claim 1, wherein the temporary wall has width of about 8 feet and a height of about 9.5 feet.

4. The method of claim 1, wherein the temporary wall comprises at least one attachment mechanism that is adapted for use in temporarily attaching the temporary wall adjacent the container's front opening.

5. The method of claim 4, wherein the at least one attachment mechanism comprises a plurality of attachment mechanism, each of the attachment mechanisms extending from a different position along an outer perimeter of the temporary wall.

6. The method of claim 5, wherein the plurality of attachment mechanism comprises a first attachment mechanism that is disposed on a first lateral side of the temporary wall and a second attachment mechanism that is disposed on a second lateral side of the temporary wall.

7. The method of claim 5, wherein each of the plurality of attachment mechanisms comprises a selectively extendable fastener that is adapted to extend into a corresponding recess within the container and to thereby facilitate holding the temporary wall in place adjacent the container.

8. The method of claim 1, wherein the temporary wall includes at least one power receptacle for use in providing power to one or more powered accessories disposed adjacent the temporary wall.

9. The method of claim 8, wherein at least one of the one or more powered accessories is an environmental control unit that is configured to regulate a temperature of air within the interior of the container.

10. The method of claim 9, wherein at least one of the one or more powered accessories is a light that is disposed adjacent a side of the temporary wall that is positioned facing the interior of the enclosure when the temporary wall is attached adjacent the container's front opening.

11. The method of claim 1, wherein the temporary wall comprises at least one escape hatch for facilitating an emergency departure of a human from the interior of the container.

12. The method of claim 1, wherein the container has dimensions corresponding to a type 1AA, 1BB, 1CC, 1A, 1B, 1C, or 1D container specified in ISO 668.

13. The method of claim 1, wherein the temporary wall comprises a gasket disposed adjacent a perimeter of the temporary wall for creating a substantially weatherproof seal between the temporary wall and the container adjacent the container's front opening.

14. The method of claim 1, wherein the gasket extends around at least about 80% of the entire perimeter of the temporary wall.

15. A temporary wall system for use in temporarily converting a shipping container into a living space or workspace, the shipping container having a substantially rectangular access opening having a perimeter, wherein the wall system comprises:

a wall having exterior dimensions suitable to allow the perimeter of the wall to at least substantially mate with the perimeter of the container's access opening, wherein: the wall defines an access opening that is sized to allow an adult human to pass from one side of the wall to the other through the access opening, and the wall comprises a door that is mounted so that the door can be selectively moved between: (1) a first position in which the door obstructs the access opening to prevent passage of individuals through the access opening; and (2) a second position in which the door does not sufficiently obstruct the access opening to prevent passage of individuals through the access opening; and

a power hookup for powering one or more accessories supported by the wall.

16. The temporary wall system of claim 15, wherein the wall has a width of about 8 feet and a height of about 8.5 feet.

17. The temporary wall system of claim 15, wherein the wall has a width and a height that is between about 95% and about 100% of the width and height of a standard intermodal shipping container.

18. The temporary wall system of claim 15, wherein the wall has a width and height that is between about 95% and about 100% of the width and height of a high-cube intermodal shipping container.

19. The temporary wall system of claim 15, wherein the power hookup is attached adjacent the wall.

20. The temporary wall system of claim 15, wherein:

the wall defines an environmental control opening that is dimensioned for receiving a heating/air-conditioning unit; and

the wall comprises a shelf disposed adjacent a bottom portion of the opening and that is configured for supporting the heating/air-conditioning unit so that an output portion of the heating/air-conditioning unit is at least substantially aligned with the environmental control opening.

21. The temporary wall system of claim 15, wherein:

the wall comprises a light that is mounted adjacent the wall, the light being adapted to be powered by power supplied by the power hookup.

22. The temporary wall system of claim 15, wherein:

the wall comprises a power outlet that is mounted adjacent the wall, the power outlet being adapted to be powered by power from the power hookup.

23. The temporary wall system of claim 15, wherein the door comprises an escape hatch.

23. The temporary wall system of claim 15, wherein the wall is dimensioned to allow the wall to be operatively positioned within the shipping container while one or more exterior doors associated with the shipping container are closed to prevent access to the wall from outside the shipping container.

24. The temporary wall system of claim 15, wherein the shipping container has length selected from a group consisting of: (1) about 10 feet; (2) about 20 feet; and (3) about 40 feet.

26. A method of converting a shipping container into a temporary living space or temporary workspace, the method comprising:

providing a temporary wall system for use in temporarily converting an intermodal container into a temporary living space or workspace, the container having a substantially rectangular access opening having a perimeter, wherein the wall system comprises: a wall having exterior dimensions suitable to allow the perimeter of the wall to at least substantially mate with the perimeter of the container's access opening, wherein: the wall defines an access opening that is sized to allow an adult human to pass from one side of the wall to the other through the access opening, and the wall comprises a door that is mounted so that the door can be selectively moved between: (1) a first position in which the door obstructs the access opening to prevent passage of individuals through the access opening; and (2) a second position in which the door does not sufficiently obstruct the access opening to prevent passage of individuals through the access opening; and a power hookup disposed adjacent the wall for powering one or more accessories supported by the wall;

positioning the temporary wall system adjacent the container's access opening so that the perimeter of the wall substantially mates with the perimeter of the container's access opening;

connecting the power hookup to a power source; and

using power from the power hookup to power an environmental control unit adjacent the wall, the environmental control unit being adapted for selectively providing heated or cooled air to an interior of the container.

27. The method of claim 26, wherein the shipping container is an ISO intermodal container.