US20230374770A1 - Modularized enclosed structures - Google Patents

Abstract

A pop-up enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame, a plurality of side panels, one or more side support edges, and a lower band extendable about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels. Each side panel of the plurality of side panels comprises a structural insulated panel, and each support edge of the one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application claims priority to U.S. Provisional Application No. 63/088,878 filed on Oct. 7, 2020 and entitled “Pop-Up Enclosed Structure,” and U.S. Provisional Application No. 63/237,940 filed on Aug. 27, 2021 and entitled “Modularized Enclosed Structures,” each of which is incorporated herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
• Not applicable.
BACKGROUND
• Various structures such as sheds can be used to provide an accommodation within a small space such as a yard. The structures are typically purpose built using raw materials including lumber, siding, and connectors. Each structure can be unique due to the extensive effort needed to construct the structure. Even when building kits are available, the kits typically contain the appropriate amount of raw materials that can then be assembled into a building structure using traditional construction techniques. Once constructed, the structure is essentially permanent and cannot be disassembled such that the structure could be rebuilt or constructed elsewhere and retain its structural stability.
SUMMARY
• In some embodiments, a pop-up enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame, a plurality of side panels, one or more side support edges, and a lower band extendable about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels. Each side panel of the plurality of side panels comprises a structural insulated panel, and each support edge of the one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels.
• In some embodiments, an enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame, a plurality of side panels, one or more side support edges, and a roof assembly comprising a plurality of roof panels. Each side panel of the plurality of side panels comprises a structural insulated panel, and each support edge of the one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels. At least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the plurality of side panels to align the roof panel with the first side panel and the corner panel.
• In some embodiments, an enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame, a plurality of side panels, and a roof assembly comprising a plurality of roof panels. The plurality of side panels form a first internal structure and a second internal structure, and the first internal structure and the second internal structure are formed on the floor assembly. At least a first roof panel of the plurality of roof panels is placed on the first internal structure, and a second roof panel of the plurality of roof panes is placed on the second internal structure. An alignment band is coupled to the plurality of roof panels and is configured to receive an upper end of the plurality of side panels to align the roof panel with the plurality of side panels, and the first roof panel abuts the second roof panel over the floor assembly to define a roof over the enclosed structure.
• In some embodiments, a method of forming an enclosed structure comprises providing a floor assembly comprising a support frame and a floor placeable upon the support frame, providing a plurality of side panels, and forming an enclosed structure using the floor assembly and the plurality of side panes. Each side panel of the plurality of side panels comprises a structural insulated panel, and each support edge of one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels. A lower band extends about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels.
• These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
• For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
• FIG.1 is a perspective view of a pop-up enclosed structure according to an embodiment of the disclosure.
• FIG.2 is an exploded view of a floor assembly of the enclosed structure ofFIG.1 according to an embodiment of the disclosure.
• FIG.3 is an exploded view of the enclosed structure ofFIG.1 according to an embodiment of the disclosure.
• FIG.4 is a perspective view of a corner panel of the enclosed structure ofFIG.1 according to an embodiment of the disclosure.
• FIGS.5-7 are exploded views of a roof assembly of the enclosed structure ofFIG.1 according to an embodiment of the disclosure.
• FIGS.8,9 are zoomed-in perspective view of the enclosed structure ofFIG.1 according to an embodiment of the disclosure.
• FIG.10 is a perspective view of another pop-up enclosed structure according to an embodiment of the disclosure.
• FIG.11 is a perspective view of another pop-up enclosed structure according to an embodiment of the disclosure.
• FIG.12 illustrates a perspective view of a structural insulation panel according to some embodiments.
• FIG.13 illustrates a cross sectional view of a SIP according to some embodiments.
• FIG.14 illustrates a cross-sectional view of an edge support according to an embodiment.
• FIG.15 illustrates a cross-sectional view of another edge support according to an embodiment.
• FIG.16 illustrates a perspective view of an elongated structure according to an embodiment.
• FIG.17 illustrates another perspective view of an elongated structure according to an embodiment.
• FIG.18 illustrates a plan view of a floor structure according to an embodiment.
• FIG.19 illustrates a perspective view of the walls within a structure according to an embodiment.
• FIG.20 illustrates a perspective view of a structure according to an embodiment.
• FIG.21 illustrates another perspective view of an elongated structure according to an embodiment.
DETAILED DESCRIPTION
• It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
• This disclosure pertains to pop-up enclosed structures which may be utilized for a variety of purposes upon completion of their construction. For example, pop-up enclosed structures may be utilized as a temporary office, a storage unit, an entertainment room, or for other purposes. Pop-up enclosed structures may include access to one or more utilities (e.g., electrical utilities) to grant a user of the structure access to said utilities while within the structure. Additionally, pop-up enclosed structures may be assembled at a variety of locations for only a limited period of time before disassembly and transport to another location.
• Pop-up enclosed structures may comprise temporary structures built for a variety of purposes. Pop-up enclosed structures may be assembled by someone other than a professional builder or contractor. For example, a pop-up enclosed structure may comprise a storage unit assembled by a homeowner in the backyard of the owner's home. Given that an amateur assembler of the pop-up enclosed structure, such as a homeowner, may not have access to specialized tooling or experienced personnel, it may be advantageous for the structure to be assemblable by the fewest people possible, in the shortest amount of time possible, and without requiring much or any specialized tooling to perform the assembly.
• Embodiments disclosed herein include pop-up enclosed structures that may be used for a variety of purposes such as an office, a storage unit, an entertainment room or unit, etc. The enclosed structures may include utilities, such as electrical outlets and an air conditioner to provide further utility to the structure. The enclosed structures described herein are configured to be assembled by only three to four people over a couple of hours and with a minimum amount of tooling, making the disclosed enclosed structures relatively easy to assemble by amateurs, such as a homeowner assembling a pop-up enclosed structure in their backyard.
• Additionally, embodiments of enclosed structures disclosed herein may comprise pre-fabricated, modular components allowing structures having a variety of dimensions and square footage to be assembled from said modular components while maintaining a minimum inventory for the manufacturer or supplier of the structures. For example, an enclosed structure having a size of 10 feet (ft) by 10 ft providing 100 square ft of space may comprise one or more components that may be used to assemble an enclosed structure having a size of, for example, 10 ft by 20 ft to provide a square footage of 200 ft. Given that the two differently sized enclosed structures may share common components, the inventory required to supply these two separate structures may be minimized. Additionally, a purchaser of an enclosed structure having a first square footage may be able to purchase one or more additional components to reconfigure the structure to have a second square footage without needing to purchase an entirely new enclosed structure.
• Turning now toFIG.1, a pop-up enclosedstructure100 is described. In an embodiment, the pop-upenclosed structure100 generally comprises afloor assembly102, a plurality offirst side panels120, asecond side panel140, a plurality ofside corner panels160A,160B, and aroof assembly200.Enclosed structure100 may comprise a kit to be assembled by a plurality of people or assemblers and thus may also be referred to herein as akit100 for assembling a pop-up enclosed structure.
• Referring toFIG.2, thefloor assembly102 ofenclosed structure100 may comprise a pair of support frames104A,104B, and afloor115. Eachsupport frame104A,104B may comprise an exterior rectangular or box-frame105 and a plurality ofelongate supports107 positioned in the box-frame105 and configured to provide support to therespective support frame104A,104B. In some embodiments, the box-frame105 of eachsupport frame104A,104B may comprise four elongate members or supports coupled together (e.g., welded, etc.) to form the box-frame105. In some embodiments, the box-frame105 and supports107 of eachsupport frame104A,104B may comprise a plurality of elongate steel beams; however, in other embodiments, the configuration of eachsupport frame104A,104B may vary.
• Eachsupport frame104A,104B may comprise a first orupper surface106 and a second orlower surface108 opposite theupper surface106. In an embodiment, eachsupport frame104A,104B offloor assembly102 may include a plurality of height adjustable feet or pedestals110 extending from thelower surface108 of the respective box-frame105. Particularly, afirst support frame104A offloor assembly102 may comprise fourfeet110 located at the four corners of the box-frame105 offirst support frame104A while asecond support frame104B offloor assembly102 may comprise only twofeet110 located at the outer corners of the box-frame105 ofsecond support frame104B.
• Rather than includingfeet110 at each corner of the box-frame105 ofsecond support frame104B, aninner edge112 of the box-frame105 ofsecond support frame104B may be configured to couple with a correspondinginner edge112 of the box-frame105 offirst support frame104A, via, for example, one or more releasable fasteners. In this manner, the twofeet110 positioned along theinner edge112 of the box-frame105 of thefirst support frame104A may support the center offloor assembly102. In other embodiments,support frame104B may comprise fourfeet110 positioned at the corners of box-frame105 and box-frames105 of support frames104A,104B may not be coupled together during the assembly offloor assembly102.
• Thefloor115 offloor assembly102 may be positionable on theupper surfaces106 of the box-frames104 of support frames104A,104B. Particularly,floor115 may have a dimension corresponding or equivalent to the combined dimensions of the box-frames105 of support frames104A,104B. For example, anouter perimeter119 offloor115 may equal or be slightly less than an outer perimeter of the box-frames105 of support frames104A,104B following the coupling of box frames105 during the assembly offloor assembly102. In some embodiments, thefloor115 offloor assembly102 may comprise a thin, light-weight laminate material.Floor115 may couple withsupport frames104A,104B via one or more releasable fasteners to securefloor115 to support frames114A,114B. In an embodiment,floor115 may comprise a plurality ofreceptacles117 each for receiving an electrical outlet.
• In an embodiment, thefloor115 may additionally comprise a lower band260 (e.g., as shown inFIG.9) which extends along a portion of the support frames104A,104B. Thelower band260 may extend in a direction extending upwards from the support frames104A,104B such that an upper edge of thelower band260 is disposed at a greater distance from the upper surface of support frames104A,104B than an upper surface of the support frames104A,104B themselves. In other words, thelower band260 may extend upwards from the support frames104A,104B, defining a recess within support frames104A,104B for receiving the outer walls. Thelower band260 can be coupled to the support frames104A,104B, for example, by being welded or fixedly coupled to the support frames104A,104B. Thelower band260 may generally comprise a metal band or plate. Further, thelower band260 can extend along a perimeter of each of the support frames104A,104B such that thelower band260 can be formed in multiple sections which can abut upon coupling of the support frames104A,104B together.
• Referring toFIG.3, each of thefirst side panels120 ofenclosed structure100 may generally include asupport frame122 positioned between an interior covering orfaçade124 and an outer or external covering orfaçade126. In some embodiments, a layer of insulation such as fiberglass insulation, foam panels, or injectable foam can be disposed between the interior covering orfaçade124 and an outer or external covering orfaçade126 in order to insulate the final structure. In an embodiment, thesupport frame122 of eachfirst side panel120 may comprise a plurality of elongate steel supports or beams. For example,support frame122 may share similarities with the support frames104A,104B shown inFIG.2. In an embodiment,coverings124,126 may each comprise a thin, light-weight material such as a laminate, pre-constructed shiplap, sheet rock, or other materials; however, in other embodiments, the configuration ofcoverings124,126 may vary. For example,coverings124,126 may comprise plywood in other embodiments. Additionally, a sealant and/or a decorative material may be applied tocoverings124,126.Coverings124,126 may provide cover to thesupport frame122. Additionally, a width of the interior covering124 may be greater than a width of the exterior covering126 of eachfirst side panel120 whereby the interior covering124 may form a pair ofextensions128 located at opposing ends of thefirst side panel120. Thus, the interior covering124 may define a maximum width of eachfirst side panel120.
• Thesecond side panel140 of the enclosed structure may also generally include asupport frame142 positioned between an interior covering orfaçade144 and an outer or external covering orfaçade146. Thesecond side panel140 may include afirst aperture148 and asecond aperture150, eachaperture148,150 extending entirely through thesupport frame142 andcoverings146,148. In an embodiment, thefirst aperture148 may comprise a doorframe in which a door may be positioned whilesecond aperture150 may comprise a window frame in which a window may be positioned.
• In an embodiment,support frame142 may comprise a plurality of beams, studs, or supports (e.g., formed of steel, wood, etc.) whilecoverings144,146 may each comprise a thin, light-weight material such as a laminate; however, in other embodiments, the configuration ofsupport frame142 andcoverings144,146 may vary. For example,coverings144,146 may comprise plywood in other embodiments. Additionally, a sealant and/or a decorative material may be applied tocoverings144,146. Further, unlike the configuration offirst side panels120 described above, the width ofinterior covering144 may be substantially equal to the width ofsupport frame142 and exterior covering146 wherebyinterior covering144 does not form a pair of extensions at the opposing ends ofsecond side panel140. However, in other embodiments, the width ofinterior covering144 may be greater than the widths ofsupport frame142 and exterior covering146 wherebyinterior covering144 may form extensions similar to theextensions128 formed by the interior covering124 of eachfirst side panel120. In an embodiment, at least one of thefirst side panels120 andsecond side panel140 may comprise an aperture to receive an electrical switch, such as a light switch for controlling one or more internal and/or external lights ofenclosed structure100.
• Referring toFIGS.3,4,enclosed structure100 may comprise fourcorner panels160A,160B positioned at the four corners ofenclosed structure100. Particularly,first corner panels160A may comprisefront corner panels160A positioned adjacentsecond side panel140 whilesecond corner panels160B may compriserear corner panels160B positioned distalsecond side panel140 at a rear ofenclosed structure100. Eachcorner panel160A,160B may generally include asupport frame162 positioned between an interior covering orfaçade164 and an outer or external covering orfaçade166. In an embodiment,support frame162 may comprise a plurality of beams, studs, or supports whilecoverings164,166 may each comprise a thin, light-weight material such as a laminate; however, in other embodiments, the configuration ofsupport frame162 andcoverings164,166 may vary. For example,coverings164,166 may comprise plywood in other embodiments.
• Unlike the first andsecond side panels120,140 described above, thesupport frame162,interior covering164, and exterior covering166 of eachcorner panel160A,160B may be angled. For example, thesupport frame162,interior covering164, and exterior covering166 may each extend along a ninety degree angle between a pair of opposing ends of thecorner panel160A,160B. Additionally, unlike the configuration offirst side panels120 andsecond side panel140 described above, the width of interior covering164 of eachcorner panel160A,160B may be less than the width ofsupport frame162 and exterior covering166 whereby arecess168 is formed at one or both of the opposing ends of thecorner panel160A,160B. Particularly, arecess168 is formed at only one of the opposing ends (the end distal second panel140) of eachfront corner panel160A while a pair ofrecesses168 are formed at the opposing ends of therear corner panels160B. Thus, at least a portion of thesupport frame162 may be exposed at one or both of the opposing ends of thecorner panels160A,160B.
• Referring toFIGS.5-7, theroof assembly200 ofenclosed structure100 may generally include a plurality ofroof panels202 each comprising asupport frame204, anupper panel220, and alower panel240. In the embodiment shown inFIGS.5-7 theroof assembly200 comprises a pair ofroof panels202; however, in other embodiments, the number ofroof panels202 comprisingroof assembly200. For example,roof assembly200 may comprise asingle roof panel202 or more than tworoof panels202. In an embodiment,support frame204 of eachroof panel202 may comprise a plurality of steel beams or supports whilepanels220,240 may each comprise a thin, light-weight material such as a laminate; however, in other embodiments, the configuration ofsupport frame204 andpanels220,240 may vary. For example,panels220,240 may comprise plywood in other embodiments.
• Thesupport frame204 of eachroof panel202 may comprise anexterior box frame206, a longitudinal beam orframe208, a pair of outerlateral frames210, and a plurality of inner lateral frames212. Thelongitudinal frame208 may extend longitudinally between opposing ends ofbox frame206 while outerlateral frames210 and inner lateral frames212 may each extend laterally between thebox frame206 and thelongitudinal frame208. In an embodiment,support frame204 may comprise a first or upper surface214 (shown inFIG.5) and a second or lower surface216 (shown inFIGS.6,7) opposite theupper surface214.
• In an embodiment, thesupport frame204 of eachroof panel202 may additionally comprise analignment band218 which extends along a portion of thelongitudinal frame208 and one of the outer lateral frames210.Alignment band218 may have an angled profile whereby the alignment band may extend at a ninety degree angle between opposing ends thereof. Thealignment band218 may extend in a direction extending away from theupper surface214 ofsupport frame204 such that a lower edge of thealignment band218 is disposed at a greater distance from theupper surface214 ofsupport frame204 thanlower surface216. In other words,alignment band218 may overhang thelower surface216 ofsupport frame204, defining arecess219 withinsupport frame204. Thealignment band218 can be coupled to thelongitudinal frame208 and one of the outer lateral frames210, for example, by being welded or fixedly coupled to thelongitudinal frame208 and one of the outer lateral frames210. Further, thealignment band218 can extend along a perimeter of each of thelongitudinal frame208 and one of the outer lateral frames210 such that thealignment band218 can be formed in multiple sections which can abut upon coupling of eachroof panel202 together.
• Theupper panel220 of eachroof panel202 may define an upper orroof surface222 ofenclosed structure100 and may have anouter perimeter224 that is substantially equal to an outer perimeter of thebox frame204 ofsupport frame204. Thus, during the assembly of each roof panel202 (e.g., prior to shipping the kit),upper panel220 may be overlaid upon theupper surface214 of thesupport frame204 ofroof panel202 such thatupper panel220 contactsupper surface214 and theperimeter224 ofupper panel220 is substantially flush with the perimeter of thebox frame206 ofsupport frame204. In an embodiment,upper panel220 may be secured to supportframe204 by mechanically connecting theupper panel220 to thesupport frame204 via, for example, one or more releasable fasteners.
• Thelower panel240 of eachroof panel202 may have anouter perimeter242 sized to fit within therecess219 defined byalignment band218 of thesupport frame204. Particularly, theperimeter242 oflower panel240 may be aligned withalignment band218 such that theperimeter242 oflower panel240 contacts or is disposed directlyadjacent alignment band218 with anupper surface244 oflower panel240 contacting thelower surface216 ofsupport frame204. In this configuration, theperimeter242 oflower panel240 may fit within or be substantially flush with each outerlateral frame210 ofsupport frame204, defining a pair of opposed lateral extensions oroverhangs246 and a longitudinal extension oroverhang248. Particularly, eachlateral extension246 may be located between one of the outer lateral frames210 and the box-frame206 whilelongitudinal extension248 is located betweenlongitudinal frame208 and box-frame206.
• Theupper panel220 of eachroof panel202 may have a longitudinal length and a lateral width that are each greater than a longitudinal length and a lateral width of thelower panel240 wherebyupper panel220 may cover theextensions246,248. Particularly, eachroof panel202 may be assembled by coupling theupper panel220 to theupper surface214 as discussed above whereby theperimeter224 ofupper panel220 is substantially flush with the perimeter of thebox frame206 ofsupport frame204,upper panel220 thereby coveringextensions246,248. Prior to or following the coupling ofupper panel220 withsupport frame204,lower panel240 may be positioned withinrecess219 and aligned with thealignment band218. Withlower panel240 positioned withinrecess219,lower panel240 may be secured to thelower surface216 ofsupport frame204. In an embodiment,lower panel240 may be secured to supportframe204 by mechanically connecting thelower panel240 to thesupport frame204 via, for example, one or more releasable fasteners. In an embodiment, theroof surface222 ofupper panel220 may be coated with a sealant, such as a spray-on sealant and/or paint to prevent moisture from penetrating or otherwise damaging theupper panel220 of eachroof panel202. When assembled, the joint or gap between adjacent panels can be sealed by a gasket, sealant (e.g., caulk, paint, etc.), or other water proof component to prevent leakage between the roof panels.
• Referring now toFIGS.1,3,enclosed structure100 may be assembled following the assembly offloor assembly102 and the pair ofroof panels202 ofroof assembly200. In an embodiment, the assembledfloor assembly102 ofenclosed structure100 may be positioned on a surface in a location (e.g., a homeowner's backyard, etc.) where it is desired by a user of theenclosed structure100 to assemble thestructure100. In an embodiment, one or more stabilizing pads or supports, such as concrete pads, stones, etc. may be positioned in the desired location and thefloor assembly102 may be landed on the stabilizing pads. Particularly, each of thefeet110 offloor assembly102 may be positioned on one of the stabilizing pads to thereby positionfloor assembly102 ofenclosed structure100 on a stable surface. The stabilizing pads may be utilized when the desired location comprises a soft surface (e.g., dirt, etc.). In this manner,enclosed structure100 may be assembled on uneven or soft terrain without the need of a foundation, such as a concrete foundation, to support thestructure100.
• In some embodiments, the support frames104 may be separately positioned on the stabilizing pads and subsequently coupled together following the placement of theframes104 on the stabilizing pads. This may be done to minimize the total amount of weight that must be carried by the assemblers ofenclosed structure100 during the positioning offloor assembly102 in the desired location. Following the placement of thefloor assembly102 on the stabilizing pads the height ofadjustable feet110 offloor assembly102 may be adjusted to ensure that thefloor115 offloor assembly102 is level prior to the completion of the assembly ofenclosed structure100. The use of the adjustable feet can allow thefloor assembly102 to be used on uneven terrain, thereby allowing for a quick assembly without the need for a permanent or pre-leveled foundation. In some embodiments, the floor assembly can be anchored to the ground or the pads using a coupling mechanism such as a metal band or anchor to anchor the final structure in place.
• Withfloor115 level andfloor assembly102 fully assembled at the desired location, thefirst side panels120 may be positioned vertically on thefloor115 offloor assembly102. Particularly, each of the threefirst side panels120 may be positioned along theperimeter119 offloor115 where one of thefirst side panels120 is positioned at a rear (equidistantly between corners of the floor115) of theenclosed structure100 while the two remainingside panels120 may be positioned along opposing lateral sides (equidistantly between corners of the floor115) of theenclosed structure100. In an embodiment, eachfirst side panel120 may comprise twoseparate sub-panels125 separated along avertical seam127 which are separately positioned onfloor115, and once positioned, are mechanically coupled together (e.g., via one or more releasable fasteners) to secure the sub-panels125 together. In this manner, the total weight that needs to be moved at a single time by one or more assemblers ofenclosed structure100 when positioningfirst side panels100 onfloor115 may be minimized.
• With eachfirst side panel120 positioned along theperimeter119 offloor115, the fourcorner panels160A,160B ofenclosed structure100 may be positioned onfloor115 at the four corners thereof. Withcorner panels160A,160B positioned onfloor115, theextensions128 offirst side panels120 are received within therecesses168 ofcorner panels160A,160B to interlock thefirst side panels120 withcorner panels160A,160B. In an embodiment,first side panels120 may be mechanically coupled (e.g., via one or more releasable fasteners such as screws, etc.) withcorner panels160A,160B to provide stability tofirst side panels120 prior to the completion of the assembly ofenclosed structure100.
• In an embodiment, afirst sub-panel125 of afirst side panel120 and afirst sub-panel125 of another first side panel120 (positioned at a ninety degree angle from the first sub-panel125) may first be positioned onfloor115, followed by the positioning of one of therear corner panels160B therebetween the pair ofsub-panels125 whereby theextension128 of each sub-panel125 is received within one of therecesses168 of therear corner panel160B. The pair ofsub-panels125 may then be mechanically coupled to therear corner panel160B (e.g., via one or more releasable fasteners) to stabilize the pair ofsub-panels125 whereby they may not fall over onto an assembler of theenclosed structure100. Following the assembly of the first pair ofsub-panels125 andrear corner panel160B, a second pair ofsub-panels125 may similarly be positioned onfloor115 along with anotherrear corner panel160B and then mechanically coupled to therear corner panel160B. With the second pair ofsub-panels125 positioned onfloor115 the first pair ofsub-panels125 may be mechanically coupled (e.g., via one or more releasable fasteners, etc.) to the second pair of sub-panels125 (following the positioning of the sub-panels125 nearest the front ofenclosed structure100 onto the floor115) to form or complete the assembly of the threefirst side panels120. In this manner, the sub-panels125 may be vertically stabilized (via coupling with one of therear corner panels160B) as thefirst side panels120 are assembled onto thefloor115 ofenclosed structure100, minimizing the possibility of one of the first side panels120 (or one of thesub-panels125 thereof) falling over while positioned onfloor115. Additionally, in an embodiment, one or more of thefirst side panels120 and/orrear corner panels160B may be secured to thefloor115 via one or more releasable fasteners.
• Withfirst side panels120 andrear corner panels160B assembled onto thefloor115 ofenclosed structure100, thesecond side panel140 may be assembled onto thefloor115. In an embodiment,second side panel140 may comprise two separate sub-panels145A,145B separated along avertical seam147 which are separately positioned onfloor115, and once positioned, are mechanically coupled together (e.g., via one or more releasable fasteners) to secure the sub-panels145A,145B together.
• Particularly, first side panel145A (comprising second aperture150) may be positioned onfloor115 along with one of thefront corner panels160A whereby an end of the first side panel145A is directly adjacent or contacts an end of thefront corner panel160A while anextension128 of one of thefirst side panels120 is received in theextension168 of thefront corner panel160A. In this configuration, thefront corner panel160A may be mechanically coupled to thefirst side panel120 and/or first sub-panel145A ofsecond side panel140 via, for example, one or more releasable fasteners. In an embodiment, a window may be pre-installed (e.g., by a supplier or manufacturer of the components comprising enclosed structure100) in thesecond aperture150 of first side panel145A prior to the assembly of first side panel145A ontofloor115.
• Following the assembly of first side panel145A ontofloor115, second side panel145B (comprising first aperture148) may be positioned onfloor115 along with the otherfront corner panel160A whereby an end of the second side panel145B is directly adjacent or contacts an end of thefront corner panel160A while anextension128 of anotherfirst side panel120 is received in theextension168 of thefront corner panel160A. Thefront corner panel160A may then be mechanically coupled to thefirst side panel120 and/or second sub-panel145B ofsecond side panel140 via, for example, one or more releasable fasteners. In an embodiment, a door may be installed into thefirst aperture148 ofsecond side panel140 by an assembler ofenclosed structure100 following the assembly ofsecond side panel140 ontofloor115.
• Referring toFIGS.1,8, with each of theside panels120,140 andcorner panels160A,160B assembled onto thefloor115 ofenclosed structure100, theroof assembly200 may be installed ontoside panels120,140,160A, and160B. In an embodiment,roof panels202 ofroof assembly200 may be individually and sequentially assembled ontoside panels120,140,160A, and160B ofenclosed structure100 to minimize the total amount of weight that must be lifted by the one or more assemblies ofenclosed structure100 at a given time. For example, afirst roof panel202 may be lifted over the partially assembledenclosed structure100 whereby thealignment band218 of thefirst roof panel202 is substantially aligned with a perimeter or outer edge of a first pair of the first side panels120 (the first pair offirst side panels120 being positioned at a ninety degree angle relative each other) and one of therear corner panels160B positioned therebetween whereby an upper end of each of thepanels120,160B are at least partially received inrecess219 of thefirst roof panel202. The first pair offirst side panels120 may include thefirst side panel120 positioned at the rear of theenclosed structure100 and one of thefirst side panels120 positioned along a first side of theenclosed structure100.
• In this configuration, thelower surface216 of thesupport frame204 of thefirst roof panel202 may rest upon or contact an upper end of the first pair offirst side panels120 andrear corner panel160B. Additionally, thealignment band218 may be positioned directly adjacent or contact theexterior coverings126 of thefirst side panels120 and the exterior covering166 of therear corner panel160B as shown particularly inFIG.8. Thus,alignment band218 may allow for the alignment of theroof panel202 with thepanels120,160B on which theroof panel202 is to be positioned. Following the placement of thefirst roof panel202 onto the partially assembled enclosed structure100 (shown particularly inFIG.1), thefirst roof panel202 may be secured to one or more of the first pair offirst side panels120 and therear corner panel160B by mechanically coupling (e.g., via one or more releasable fasteners, etc.) thefirst roof panel202 to one or more of the first pair offirst side panels120 and therear corner panel160B.
• Following the assembly of thefirst roof panel202 with the partially assembledenclosed structure100, the other orsecond roof panel202 may be lifted over and onto theenclosed structure100 in a manner similar to the assembly of thefirst roof panel202 ontostructure100 described above. Particularly, thesecond roof panel202 may be lifted over the partially assembledenclosed structure100 whereby thealignment band218 of thesecond roof panel202 is substantially aligned with a perimeter or outer edge of a second pair of the first side panels120 (the second pair offirst side panels120 being positioned at a ninety degree angle relative each other) and one of therear corner panels160B positioned therebetween whereby an upper end of each of thepanels120,160B are at least partially received inrecess219 of thesecond roof panel202. The second pair offirst side panels120 may also include thefirst side panel120 positioned at the rear of theenclosed structure100 and the otherfirst side panel120 positioned along a second or opposing side of theenclosed structure100.
• In this configuration, thelower surface216 of thesupport frame204 of thesecond roof panel202 may rest upon or contact an upper end of the second pair offirst side panels120 and therear corner panel160B whereby thealignment band218 may be positioned directly adjacent or contact theexterior coverings126 of the second pair offirst side panels120 and the exterior covering166 of therear corner panel160B. Following the placement of thesecond roof panel202 onto the partially assembledenclosed structure100, thesecond roof panel202 may be secured to one or more of the second pair offirst side panels120 and therear corner panel160B by mechanically coupling (e.g., via one or more releasable fasteners, etc.) thesecond roof panel202 to one or more of the second pair offirst side panels120 and therear corner panel160B. In an embodiment, the pair ofroof panels202 may be mechanically coupled together via, for example, one or more releasable fasteners.
• Withsecond roof panel202 secured to thestructure100, thesecond roof panel202 may be located directly adjacent thefirst roof panel202 on top of theside panels120,140,160A, and160B ofenclosed structure100. In this configuration,extensions246,248 of the pair ofroof panels202 overhang each side (front, rear, and the pair of lateral sides) of theenclosed structure100, thereby providing additional protection from rain to users of theenclosed structure100. In an embodiment, a sealant may be applied (e.g., by the assemblers of enclosed structure100) to the interfaces between eachroof panel202 and between the pair ofroof panels202 and theside panels120,140,160A, and160B to thereby seal an enclosed space or room103 (shown inFIG.1) of theenclosed structure100 from moisture or rain landing uponroof assembly200.
• Referring toFIGS.1,9, the assembly ofroof assembly200 atop theenclosed structure100 can result in thealignment band218 being tightened about a perimeter of theside panels120,140,160A, and160B. Thealignment band218 can extend downwards along theside panels120,140,160A, and160B, and upon coupling theroof assembly200 together, eachalignment band218 on eachcorresponding roof panel202 can tighten about theside panels120,140,160A, and160B, thereby providing an inwards compression on theside panels120,140,160A, and160B. Similarly, the placement of theside panels120,140,160A, and160B within the floor assembly can place theside panels120,140,160A, and160B within thelower band260. Thelower band260 can then serve to provide an inward compression on theside panels120,140,160A, and160B.
• The completion of the structure may result in thealignment band218 and thelower support band260 being placed in tension (e.g., via the coupling of the floor assembly and roof assembly) whereby thealignment band218 and thelower support band260 may apply a compressive force against theexterior coverings126,146, and166 of theside panels120,140,160A, and160B, respectively. The compressive force applied by thealignment band218 and thelower support band260 may secure each of theside panels120,140,160A, and160B into position such that structural integrity is provided toside panels120,140,160A, and160B sufficient to resist external forces applied toenclosed structure100 during the operational life ofstructure100. Thus, while in some embodiments at least some ofside panels120,140,160A, and160B may also be mechanically coupled together to preventside panels120,140,160A, and160B from falling over during assembly ofenclosed structure100,support bands260 may be responsible for ensuringenclosed structure100 has sufficient structural integrity.
• As described above,enclosed structure100 may not require specialized tooling to assemble and may be assemblable by three to four people within a few hours. Following assembly of theroof assembly200 as described above, one or more electrical cords (e.g., extension cords, etc.) coupled to electrical outlets and/or light switches placed withinreceptacles125 offloor115 and/or receptacles formed withinside panels120,140 may be connected to an electrical outlet external theenclosed structure100 to provide enclosed structure with electrical power. In an embodiment, the electrical outlets/light switches may be coupled to the electrical cords and pre-assembled withfloor115 and/orside panels120,140 by the manufacturer or supplier of the components ofenclosed structure100. Alternatively, the electrical outlets/light switches may be coupled to thefloor115 and/orside panels120,140 by the assemblers ofenclosed structure100. In an embodiment, one of theside panels120,140 ofenclosed structure100 may comprise a receptacle for receiving an air conditioner (not shown inFIGS.1,9) to provide cooling and/or heating to the interior ofenclosed structure100. The air conditioner may also include an electrical cable which may be plugged into a receptacle along with the other electrical cables.
• Theenclosed structure100 described above may comprise a plurality of pre-fabricated, modular components which may be used, in addition to formingenclosed structure100, other enclosed structures having sizes and square footages which vary from the size and square footage provided byenclosed structure100. For example, support frames104 offloor assembly102, the sub-panels125,145 ofside panels120,140,corner panels160A,160B, and eachroof panel202 may be prefabricated or assembled by the manufacturer or supplier ofenclosed structure100 and thus need not be assembled by the user ofstructure100. In this manner, the user ofenclosed structure100 need only assemble floor assembly102 (e.g.,couple floor115 with support frames104,side panels120,140 (e.g., couple together sub-panels125,145, respectively), assembleside panels120,140,160A, and160B withfloor115, and assembleroof assembly200 withside panels120,140,160A, and160B to complete the assembly ofenclosed structure100.
• As described above,enclosed structure100 may comprise a first set of dimensions and may comprise a first square footage. For example,enclosed structure100 may have dimensions of 10 ft by 10 ft and providing room103 with approximately 100 square ft of space; however, in other embodiments, the dimensions and square footage ofenclosed structure100 may vary substantially. In an embodiment, at least some of the components of enclosed structure having dimensions and a square footage that varies from the first set of dimensions and the first square footage provided byenclosed structure100.
• For example, referring toFIG.10, another embodiment of a pop-upenclosed structure300 is shown. As withenclosed structure100 shown inFIGS.1-9,enclosed structure300 may be assembled by only three to four people without specialized tooling over a few hours. Additionally,enclosed structure300 may include features and components in common with theenclosed structure100 shown inFIGS.1-9, and shared features are labeled similarly. Particularly,enclosed structure300 may include afloor assembly302 comprising a plurality of support frames104 andfloors115, a plurality offirst side panels120, asecond side panel140, a plurality ofcorner panels160A,160B, and a pair ofspacer side panels340. Theenclosed structure300 may also comprise a roof assembly (not shown inFIG.10) that includes a plurality of roof panels similar in configuration asroof panels202 shown inFIGS.5-8.
• In an embodiment, the support frames104 offloor assembly302 may be coupled alonginner edges112 thereof with a pair offloors115 positioned atop toform floor assembly302. In an embodiment,side panels120 andrear corner panels160B may be assembled atopfloor assembly302 in a manner similar to the assembly offirst side panels120 ofenclosed structure100 described above. However, agap305 may be formed along a rear ofenclosed structure300 following the installation of thefirst side panels120 positioned along the rear and opposing lateral sides ofenclosed structure300. Thegap305 may be filled with one of thespacer side panels340 to enclose the rear of theenclosed structure300.
• In an embodiment, eachspacer side panel300 may generally comprise asupport frame342 positioned between an interior covering orfaçade344 and an outer or external covering orfaçade346.Support frame342 may comprise a plurality of steel beams or supports whilecoverings344,346 may each comprise a thin, light-weight material such as a laminate; however, in other embodiments, the configuration ofsupport frame342 andcoverings344,346 may vary. For example,coverings344,346 may comprise plywood in other embodiments. Additionally, a sealant and/or a decorative material may be applied tocoverings344,346. The width of interior covering344 of eachspacer panel340 may be less than the width ofsupport frame342 and exterior covering346 whereby arecess348 is formed at both of the opposing ends of thespacer panel340. Thus, at least a portion of thesupport frame342 may be exposed both of the opposing ends of thespacer panel340.
• A first orrear spacer panel340 ofenclosed structure300 therear spacer panel340 may then be positioned on thefloor assembly302 ofstructure300 between the pair offirst side panels120 positioned along the rear ofstructure300. In this configuration,extensions128 of the pair offirst side panels120 may be received within therecesses348 ofspacer panel340 whereby thefirst side panels120 may interlock with therear spacer panel340. In an embodiment, therear spacer panel340 may be mechanically coupled with one or both of the pair offirst side panels120 to secure therear spacer panel340 with the partially constructedenclosed structure300. Similarly, a second orfront spacer panel340 may be inserted between aside panel120 positioned along a front of theenclosed structure100 and thesecond side panel140. In an embodiment, thefront spacer panel340 may only have asingle recess348 to interlock with theextension128 of thefirst spacer panel120.
• As assembled, theenclosed structure300 may comprise asingle room307 and may comprise a second set of dimensions and a second square footage which differ from the first set of dimensions and the first square footage of theenclosed structure100 shown inFIGS.1-9. For example,enclosed structure300 may comprise dimensions of 10 feet (along each lateral side of structure300) by 20 ft (along the front and rear of structure300) providing a second square footage of approximately 200 square ft. Thus, support frames104,floors115, andside panels120,140,160A,160B may be utilized in assembling enclosed structures having a plurality of dimensions.
• The prefabricated, modular components described herein, such asside panels120,140,160A, and160B, may be utilize in assembling enclosed structures having two or more rooms separated by interior panels or walls. For example, referring toFIG.11, a multi-roomed pop-upenclosed structure400 is shown.Enclosed structure400 may be assembled by only three to four people without specialized tooling over a few hours. Additionally,enclosed structure400 may include features and components in common with theenclosed structure100 shown inFIGS.1-9 and theenclosed structure300 shown inFIG.10, and shared features are labeled similarly. Particularly,enclosed structure400 may include afloor assembly402 comprising a plurality of support frames104 andfloors115, a plurality offirst side panels120, asecond side panel140, a plurality ofcorner panels160A,160B, and athird side panel420, and pair ofspacer side panels440. Theenclosed structure400 may also comprise a roof assembly (not shown inFIG.11) that includes a plurality of roof panels similar in configuration asroof panels202 shown inFIGS.5-8.
• The support frames104 offloor assembly402 ofenclosed structure400 may be coupled alonginner edges112 thereof with a pair offloors115 positioned atop toform floor assembly402. Thethird side panel420 ofenclosed structure400 may be similar in configuration tosecond side panel140 except thatthird side panel420 may only includefirst aperture148, and thus may not includesecond aperture150. In an embodiment, eachspacer panel440 may generally include a T-shapedsupport frame442 and an exterior covering orfaçade444. Thus, unlikeside panels120,140,160A,160B,spacer panel440 may not include an interior covering or façade.Support frame442 may comprise a plurality of steel beams or supports while exterior covering444 may comprise a thin, light-weight material such as a laminate; however, in other embodiments, the configuration ofsupport frame442 andinterior covering444 may vary. For example,interior covering444 may comprise plywood in other embodiments. Additionally, a sealant and/or a decorative material may be applied toexterior covering444. Given thatspacer panel440 does not include an interior covering a recess446 is formed at opposing ends of thespacer panel440. Additionally, a third end of the T-shapedsupport frame442 which may extend into an interior of theenclosed structure400 may not include any covering
• In an embodiment, the pair offirst side panels120 andrear corner panels160B positioned along the rear ofenclosed structure400 may be assembled atopfloor assembly402 in a manner similar to the assembly offirst side panels120 ofenclosed structure100 described above. In this configuration, a gap (not shown inFIG.11) may remain between the rear pair offirst side panels120. Arear spacer panel440 may be disposed atop thefloor assembly402 and inserted into the gap wherebyextensions128 of the rear pair offirst side panels120 may be received within the recesses446 of therear spacer panel440 whereby the rear pair offirst side panels120 may interlock with therear spacer panel440. Additionally, as therear spacer panel440 is inserted into the gap, an interior end of thesupport frame442 of thespacer panel440 may be positioned adjacent anextension128 of the interiorfirst side panel120′, thereby interlocking therear spacer panel440 with the interiorfirst side panel120′. In an embodiment, therear spacer panel440 may be mechanically coupled with one or both of the rear pair offirst side panels120 and/or the interiorfirst side panel120′ to secure therear spacer panel440 with the partially constructedenclosed structure400.
• Similarly, following the assembly ofthird side panel420 andsecond side panel140 onto thefloor assembly402, afront spacer panel440 may be assembled ontofloor assembly402 whereby thefront spacer panel440 is inserted between the second andthird side panels140,420. As thefront spacer panel440 is inserted between second andthird side panels140,420, an end of the T-shapedsupport frame442 of thefront spacer panel440 may interlock with theother extension128 of the interiorfirst side panel120′ ofenclosed structure440, forming a first enclosed space or room405 and a second enclosed space or room407 that is separate and distinct from the first room405. The first room405 may be accessible via the first aperture148 (which may include a first door) ofsecond side panel140 while the second room407 may be accessible via the receptacle148 (which may include a second door) ofthird side panel420. In an embodiment, enclosed structure may comprise dimensions and an overall square footage similar to that ofenclosed structure300 shown inFIG.10.
• Additional structural techniques can be used to provide for the structures as described herein. In some aspects, one or more of the wall panels can use a structural insulation panel (SIP) as the entire wall element. The SIP can be used with or without additional structural members to support the walls and roof. In some aspects, the SIP has sufficient structural integrity to full support the wall structures and roof without the need for additional support members or beams. As described in more detail below, an edge support can be used with the SIP to couple the interior and exterior sheathing and provide a structural edge on the SIP, which may further enhance the structural integrity of the SIP when used in the pop up structure.
• As shown inFIGS.12 and13, aSIP500 can comprise acore material502 having aninterior sheathing504 on a first side of thecore material502 and anexterior sheathing506 on a second side of thecore material502. Thecore material502 can be formed from an insulating material. In some aspects, thecore material502 can be manufactured from a foam material (e.g., polyurethane foam, expanded polystyrene foam, XPS foam, or other rigid insulating materials) to provide insulation to individuals within the structure from environmental factors (e.g., heat, cold, precipitation, sound, humidity, aridity, etc.). In some aspects, thecore material502 can be fabricated from a rigid foam material so that thecore material502 is capable of providing some level of structural support, in addition to any insulative properties (including thermal, sound, etc.). In other aspects, thecore material502 can be fabricated from other conventional materials that can provide suitable insulation for the structure. Thecore material502 can have a selected width within theSIP500 that contributes to the overall width or thickness of theSIP500. For example, thecore material502 can have a width of between about 1 to 12 inches, or between about 2 to 8 inches.
• The interior andexterior sheathing504,506, respectively, can be coupled to thecore material502 using any suitable processes such as using an adhesive, thermal bonding, or direct coupling during thecore material502 formation process. Thesheathing504,506 can be formed of any suitable materials such as DUROCK®, Forticrete®, fiber cement, STRUCTO-CRETE®, carbon fiber, poly-aramid fibers (e.g., Kevlar®), Plycem®, corrugated metal, metal cladding, fiberglass mesh, or other conventional materials that are capable of providing insulation and structural support. In some aspects, thesheathing504,506 can comprise a carbon fiber material that is bonded to thecore material502 during the manufacturing process. Thesheathing504,506 may also provide suitable compressive and tensile strength such that finishing elements within the structure (e.g., cabinets, shelving, awnings, etc.) can be affixed to the interior orexterior sheaths504,506. Thesheathing504,506 may also be formed such that thesheathing504,506 can be painted or otherwise finished (e.g., covered with stucco).
• In order to provide additional structural support to theSIP500, anedge support508 can be coupled to an edge of theSIP500 as shown inFIG.13. Theedge support508 may serve to couple theinterior sheathing504 to theexterior sheathing506 at the edge. Theedge support508 can serve to transfer a load on theSIP500 evenly between the interior andexterior sheathing504,506. Theedge support508 can also help to prevent any environmental effects from contacting or entering thecore material502. As shown inFIG.13, theedge support508 can form a U-shaped channel around the edge of theSIP500 and extend down along theinterior sheathing504 and theexterior sheathing506 to allow for theedge support508 to be coupled and/or bonded to theinterior sheathing504 and theexterior sheathing506. In some aspects, theedge support508 may not be bonded to thecore material502 at the edge of the SIP, but may form a layer over thecore material502.
• As shown inFIG.13, theedge support508 may be in the form of a U-shaped channel formed of any suitable material such as plastic, metal, carbon fiber, or the like. In some aspects, theedge support508 may be formed from a polymeric material or plastic that can be easily formed and coupled to thesheathing504,506. In order to form a complete support, the edge support may be bonded to thesheathing504,506 using a material such as an adhesive, caulk, epoxy, or the like placed between theedge support508 and an exterior surface of theinterior sheathing504 and theexterior sheathing506. The bonding material may be applied to form a complete seal along the length of theedge support508 and thesheathing504,506 to keep environmental factors such as water from contacting the insulating material. In some aspects, a retainingmember510 such as a screw, nail, bolt, or other attachment mechanism may be used after the bonding material is applied and theedge support508 positioned about theSIP500 in order to retain theedge support508 in position while the bonding material cures or otherwise forms a bond between theedge support508 and thesheathing504,506. Once cured, the retaining member(s)510 can be removed or left in place, though the retaining member(s)510 may not contribute significantly to the overall structural integrity of the SIP (as opposed to theedge support508 that may contribute to the structural integrity of the SIP500).
• Theedge support508 as illustrated inFIG.13 may serve as theedge support508 to the top and bottom edges of theSIP500 that may not be coupled toother SIPs500. In order to connectadjacent SIPs500 forming the walls of the overall structure, different edge supports512,514 as illustrated inFIGS.14 and15 may be used. As shown inFIG.14, anedge support512 may comprise two mirrored U-channels for accepting twoadjacent SIPs500. As illustrated, a first SIP would inserted into a first side of theedge support512, and a second SIP would be inserted into the second side of theedge support512. The bonding material and any retaining member(s)510 could be used to couple the edges support512 to the first and second SIPs as described above. In some aspects, theedge support512 could be used to connect two adjacent SIPs along a vertical edge to thereby form a portion or all of a wall. Additional edge supports512 can be used to couple as many SIPs as necessary to form a wall of a desired length. In some aspects, theedge support512 can be used on a top or bottom edge to couple two SIPs in a vertical direction, thereby forming a taller wall or potentially a second floor of a structure.
• In order to form a corner, an edge support such asedge support514 shown inFIG.15 can be used. As shown, the U-channels in theedge support514 may be positioned at right angles to allow a first SIP to be inserted into one channel, and a second SIP to be positioned in the second channel at a right angle to the first SIP. This can allow theedge support514 to be coupled to two SIPs and form a corner of the structure. In some aspects, theedge support514 may be used on a top surface of a SIP to allow an upper floor or top SIP to be coupled to a wall. WhileFIGS.14 and15 show straight and corner edge supports512,514, the edge supports can be configured to allow for the connection of any two adjacent panels at any angles.
• In use within a structure, the SIPs as described herein can be used to replace the wall panels in any of the structures described with respect toFIGS.1-11. The floor and roof structures as described herein with respect toFIGS.1-11 can be the same and can be coupled to the SIPs as described herein and/or as described below. For example, the SIPs can be formed as prefabricated components as used as side panels within the structure. When pre-fabricated, the edge supports can be coupled to one or more SIPs as pre-fabricated components, and the additional SIPs used in the coupling edge supports can be assembled on site to allow for transportation of the panels to the construction location as separate pieces. As an example of a resulting structure, reference is made toFIG.11 where the SIPs can be used in place of the side panels (e.g.,120,140,160A, and160B), and the SIPs may be utilized in assembling enclosed structures having two or more rooms separated by interior panels or walls. For example, theenclosed structure400 may include afloor assembly402 comprising a plurality of support frames104 andfloors115, a plurality of side panels formed using the SIPs as described herein. Theenclosed structure400 may also comprise a roof assembly (not shown inFIG.11) that includes a plurality of roof panels similar in configuration asroof panels202 shown inFIGS.5-8.
• As shown inFIG.11, the side panels such asside panel120 may be formed from a SIP as described herein. Rather than having acorner assembly160B, the edge support (e.g., edge support514) may be used to couple to SIPs at the corner, and anedge support512 may be used to couple first and second SIPs to form a side wall. A plurality of SIPs may be coupled in order in order to form the front and back walls of the structure. The floor and roof may be the same as those described herein. The doors and windows can be formed directly within the SIP panels by cutting and removing the corresponding shapes to form spaces. Frames such as traditional door and window frames can be used to couple the doors and windows and/or edge supports such as the U-channels can be used to form a frame for the doors and windows.
• The interior walls can be connected using an edge support having three U-channels for coupling the interior SIP panels to the exterior SIP panels. The resulting structure can then be similar to the structure shown and described with respect toFIG.11 only with SIPs forming the exterior and/or interior walls rather than the panels described with respect toFIG.11.
• As described herein, a lower band may be used to place the panels used for forming the walls in compression and/or retain the walls in position in the final structure based on retaining the wall panels against other wall panels. The lower band therefore functions to prevent any outward movement of the panels in the final structure. Similarly, the alignment band on the roof panels contains a band configured to place the panels used for forming the walls in compression and/or retain the walls in position in the final structure based on retaining the wall panels against other wall panels. The alignment band then similarly prevents any outward movement of the panels in the final structure. As described herein, the lower band and the alignment band may comprise metal or other bands of material coupled to the floor panels and/or roof panels, and/or bands used at or near the roof and/or floor panels.
• In some aspects, the lower band can be formed from a retaining band coupled to each floor support frame such that when the floor support frames are coupled together, an entire band of retaining material is formed around the outside of the structure. This configuration is similar in structure and function to the alignment band on the roof panels as described herein. As an example, reference can be made toFIG.2. As shown inFIG.2, thefloor assembly102 ofenclosed structure100 may comprise a pair of support frames104A,104B, and afloor115. In order to form the lower band, a portion of the band may be formed on eachsupport frame104A,104B. As an example, the lower band can be formed partially on thefirst support frame104A by coupling a metallic band or lip onto the three sides of thefirst support frame104A that form exterior edges of the floor (e.g., the three sides not between theframes104A and104B). The band or lip can extend upwards from the support frame edges. Similarly, a second portion of the lower band can be formed partially on thesecond support frame104B by coupling a metallic band or lip onto the three sides of thefirst support frame104B that form exterior edges of the floor (e.g., the three sides not between theframes104A and104B). The band or lip can extend upwards from thesupport frame104B edges. Separately, the first portion of the band and the second portion of the band form C-shaped lips on theseparate support frames104A and104B. In the final structure, the support frames104A,104B are coupled together, using for example, bolts or other attachments between the support frames104A,104B to couple the two support frames together. Once the support frames are coupled together, the separate first and second portions of the lower band can become coupled together mechanically through the support frames104A,104B. The individual lower band on thefirst support frame104A and the individual lower band on thesecond support frame104B may not end up being directly coupled, and a gap can exist between the two portions. However, the two portions are mechanically coupled based on the rigid connections between the portions of the lower band and the support frame, and the rigid connection between the support frames104A,104B. As a result, the lower band can be formed in segments that may not directly connect but still serve to retain the wall panels together to provide structural support to theenclosed structure100 in the same way that thealignment band218 is used to hold and/or compress the side panels upon assembly of the roof, as described in more detail herein.
• In some aspects, larger structures can be formed using the structures and structural components as described herein. An embodiment of a larger structure is shown inFIGS.16 and17. As illustrated, the structures are elongated structures having a plurality of individual units that can comprise wall elements including any of the panels described herein with respect toFIGS.1-11 or any of the SIPs described with respect toFIGS.12-15. The wall elements can be joined to form a structure elongated in one direction with corresponding front and back walls. Side walls can be used to form the rectilinear building shape. The floor and roof panels can comprise any of those described herein. Adjacent floor panels can be coupled as described herein, and the roof panels can similarly be joined. The gaps between the roof panels can be sealed using a seal, sealant, or joinery piece between each adjacent segment. In some aspects, a waterproof material can be coated over the joined roof panels after the structure is complete to waterproof the overall roof structure. One or more interior walls can be formed using wall panels and/or SIPs as described herein. This can allow the overall structure to form a plurality of individual rooms, connecting rooms, and/or one or more open spaces.
• As shown inFIGS.16 and17, the structure can be formed as a multiroom structure having individual access doors and windows for each unit. The structure can serve as a shelter or accommodation in some aspects. For example, the units can individually serve as a shelter or living unit.
• Structurally, theelongated structure600 can comprise the same or similar components to those described herein, including the same or similar walls, floor and roof. In some aspects, the interior and/or exterior walls can comprise SIP panels having the connections and support edges as described herein.
• The structure can be formed using a lower band and alignment band as described herein. In some aspects, the lower band can extend around the exterior perimeter of the elongated structure. For example, the lower band may not extend between individual units. In this embodiment, the lower band can be directly coupled to the wall segments and/or the lower band can be coupled to the floor segments and coupled together based on the coupling of the floor segments. For example, the floor segments on theends602A,602B of thestructure600 can have lower bands forming a C-shape around the lower end of the wall segments. The floor segments between theends602A,602B can have the lower band positioned on the front and back of thestructure600. The adjacent lower bands can be directly coupled together or coupled to the floor segments and mechanically coupled based on the connection through the floor segments as described herein. The resulting structure can have a lower band positioned around the perimeter of the lower edge of the wall segments, where the lower band retains the wall segments and prevents any outward movement of the lower portion of the wall segments.
• In some aspects, the alignment band can extend around the exterior perimeter of the elongated structure. For example, the alignment band may not extend between individual units. In this embodiment, the alignment band can be directly coupled to the wall segments and/or the alignment band can be coupled to the roof panels and coupled together based on the coupling of the roof panels. For example, the roof panels on theends602A,602B of thestructure600 can have alignment bands forming a C-shape around and retaining the upper end of the wall segments. The roof panels between theends602A,602B can have the alignment band positioned on the front and back of thestructure600. The adjacent alignment bands can be directly coupled together or coupled to the roof panels and mechanically coupled based on the connection through the roof panels as described herein. The resulting structure can have an alignment band positioned around the perimeter of the upper edge of the wall segments, where the alignment band retains the wall segments and prevents any outward movement of the upper portion of the wall segments. When used with the lower bands, the wall segments or panels can be retained within the structure, and in some aspects, tensioned inward and/or against the other wall segments to provide structural support for thestructure600.
• FIGS.16 and17 illustrate some aspects of theelongated structure600.
• In some aspects, a larger structure can be constructed using the components as described herein and the techniques described herein. As shown inFIGS.18-20, alarger structure700 can be formed by forming and coupling two elongated structures together. Thestructure700 can have a floor structure using the components as described herein. In an embodiment, thestructure700 generally comprises afloor assembly750, a plurality ofpanels720, and a roof assembly760. Referring toFIG.18, thefloor assembly750 can comprise a plurality of floor panels having support frames104, and a floor that can be placed upon thesupport frame104 as described with respect toFIG.2. Eachsupport frame104 may comprise an exterior rectangular or box-frame and a plurality ofelongate supports107 positioned in the box-frame105 and configured to provide support to therespective support frame104. In some embodiments, the box-frame105 of eachsupport frame104 may comprise four elongate members or supports coupled together (e.g., welded, etc.) to form the box-frame105. In some embodiments, the box-frame105 and supports107 of eachsupport frame104 may comprise a plurality of elongate steel beams; however, in other embodiments, the configuration of eachsupport frame104 may vary. In an embodiment, eachsupport frame104 offloor assembly750 may include a plurality of height adjustable feet or pedestals110 extending from thelower surface108 of the respective box-frame105. Particularly, afirst support frame104A offloor assembly102 may comprise fourfeet110 located at the four corners of the box-frame105.
• Thefloor assembly750 can comprise a plurality of box-frames105 coupled together to form anoverall floor assembly750 have the desired dimensions of the overall structure. As shown inFIG.18, thefloor assembly750 can comprise the box-frames105 arranged in a pattern suitable to for forming the desired dimensions of the floor. As an example, thefloor assembly750 can comprise six box-frames105 arranged in a first direction and coupled together, with an adjacent three box-frames1-5 turned ninety degrees and coupled to the six box-frames105. This pattern can be repeated to form the desired overall building footprint. While shown as a6x3 pattern, and suitable number of box-frames105 can be used to form the final footprint for thestructure750.
• The structure can also comprise a plurality of panels720 (e.g., as shown inFIG.19) arranged to form thestructure750. Thepanels720 can comprise any of the panels described with respect toFIGS.1-11 or any of the SIPs described with respect toFIGS.12-15, each with the associated arrangements and coupling mechanisms. As shown inFIG.19, the panels can be arranged to formexterior walls722, endwalls724,interior hallway panels726, and a resultinghallway728 disposed between theinterior hallway panels726. In an aspect, the panels can comprise SIPs, and the panels can be coupled using the edge supports as described herein. The end panels can connect to the other adjacent panels, but may not be structural in the finaloverall structure700.
• In order to retain the walls and panels in place, thefloor assembly750 may additionally comprise alower band752, which can be similar to or the same as lower band260 (e.g., as shown inFIG.9) which extends along a portion of the support frames104. Thelower band260 may extend in a direction extending upwards from the support frames104 such that an upper edge of thelower band752 is disposed at a greater distance from the upper surface of support frames104 than an upper surface of the support frames104 themselves. In other words, thelower band752 may extend upwards from the support frames104, defining a recess within support frames104 for receiving the outer walls. Thelower band752 can be coupled to the support frames104 for example, by being welded or fixedly coupled to the support frames104. Thelower band752 may generally comprise a metal band or plate. Further, thelower band752 can extend along a perimeter of the support frames104 such that thelower band752 can be formed in multiple sections which can abut upon coupling of the support frames104 together.
• As shown inFIG.18, thelower band752 may be configured to extend around theinner wall panels726, theouter panels720 forming theouter wall722, and theend panels724. In this configuration, a lower band can extend along thehallway728 and retain the rooms formed by the panels on one side in place. WhileFIG.18 shows only a singlelower band752 to allow the elements of the support frames104 to be seen, another lower band can also be formed along the panels defining the rooms on the opposite side of thehallway728. This results in at least two perimeterlower bands752 formed within thestructure700. Thelower bands752 can serve the same purpose within thestructure700 as in an individual structure.
• In some aspects, a partiallower band754 can also be coupled to thefloor assembly750 at the ends of thehallway728. Thelower band segments754 can serve to retain the hallway wall panels within the structure, and the resulting partial lower bands754 (e.g., on both ends of the building) can result in a full perimeter of thestructure700 having a lower band (e.g.,lower band752 and partial lower bands754) disposed thereabout.
• Thestructure700 can comprise a plurality of roof panels coupled together to form aroof assembly780. Referring toFIGS.20-21, theroof assembly780 of thestructure700 may generally include a plurality ofroof panels782, which can be the same as the roof panels described with respect toFIGS.5-7. Theroof assembly780 can comprises any suitable number ofroof panels782 sufficient to cover thestructure700. As described herein, the roof panels can be supported on the exterior and hallway wall panels and can be cantilevered over the hallway without any structural support over the hallway. In this embodiment, the room structures serve as self-supporting structures with the wall panels and roof panels, and the roof can simply extend over the hallway to meet with the opposing roof structure. For example, eachroof panel782 can be disposed on and coupled to theexterior wall720 and theinterior wall panels726 to form a roof structure as described herein. The coupling of the roof panels to the exterior and interior walls can provide the full structural support to eachroof panel782 to support the roof without additional structural elements. As also described herein, the plurality ofroof panels782 can be coupled to each other and sealed to form aroof780 having a desired length.
• Eachroof panel782 may have an alignment band to retain the wall panels in position. The alignment band can be the same or similar to thealignment band218 described herein. The alignment band can be coupled directly to the wall panels and/or coupled to theroof panels782 and then coupled to the wall panels. As with thelower band752, the alignment band can form a perimeter around the rooms defined by the exterior wall and the hallway to encircle the first set of rooms (e.g., matching the pattern of the lower band752). The alignment band can be tightened as the roof panels are coupled to thereby place the outer walls in compression to retain them in position. As with the lower band,partial alignment bands786A,786B can be present on the cantilevered portions of theroof panels782A,782B as shown inFIG.21 in order to retain the upper portion of the end panel788 in position. Theseparate alignment bands786A,786B can be coupled to each other and/or to theroof panels782A,782B. This can result in the entire upper perimeter of the outer walls having an alignment band disposed thereabout as well as an interior parameter about the rooms on each side. For the end panel788, it can be noted that the end panel788 may be used to seal the hallway, but may not be required from a structural perspective to support theroof panels782A,782B. Rather, theroof panels782A,782B may be supported by the other panels in the structure, and the end panels788 may be present primarily to provide a weather seal for the building.
• As described herein, theroof panels782A,782B can each be coupled to the corresponding wall segments and be cantilevered over the hallway. As shown inFIG.21, the roof panels on each separate segment can contact over the center of the hallway. In some aspects, theroof panels782A,782B can touch or be coupled in order to provide a waterproof layer, though the coupling is not necessary from a structural perspective. Various types of connections such as direct coupling, using C-channel or H-channel type connectors, or other connection types can be used to couple theroof panels782A,782B together. Once coupled, the resultinggap784 between theroof panels782A,782B can have a seal, sealant, and/or a waterproofing material can be added to seal the roof panels.
• Once assembled, theoverall structure700 can serve as a multi-room building for various uses. In some aspects, the building can serve as a care unit for medical care of patients. Various utilities such as water, electrical, data, and medical grade gases can be supplied to the individual rooms from an exterior of thestructure700. For medical uses, a negative pressure system can be connected to each room through an air vent726 (e.g., as shown inFIG.19) that can draw air out of thestructure700, thereby avoiding recirculation of air in each room. Similar vents can be used in other portions of thestructure700 to allow the air to be removed and cleaned. Additional structures can be added to provide for support and staffing. The additional structures can be also be constructed in a similar manner and connected by hallways to thestructures700.Additional structures700 can be added to accommodate additional rooms to build a facility having a desired room count and meet spacing requirements. This can allow for medical facilities to be quickly constructed and used in the event of an emergency of the need for additional medical space at an established medical facility.
• FIGS.18-21 illustrate some aspects of thestructure700.
• Having described various systems and methods, various aspect can include, but are not limited to:
• In a first aspect, a kit for assembling a pop-up enclosed structure comprises: a floor assembly comprising a support frame and a floor placeable upon the support frame; a first side panel comprising a support frame, an exterior covering, and an interior covering, wherein a width of the interior covering is greater than a width of both the support frame and the exterior covering of the first side panel whereby an end of the interior covering forms an extension; and a corner panel comprising a support frame, an exterior covering, and an interior covering, wherein a width of the interior covering of the corner panel is less than a width of both the support frame and the exterior covering of the corner panel whereby an end of the corner panel forms a recess configured to receive the extension of the first side panel.
• A second aspect can include the kit of the first aspect, wherein the support frame of the first side panel comprises a plurality of steel supports, and at least one of the interior covering and the exterior covering comprises a laminate material.
• A third aspect can include the kit of the first or second aspect, further comprising a second side panel comprising a first aperture configured to receive a door and a second aperture configured to receive a window.
• A fourth aspect can include the kit of any one of the first to third aspects, further comprising a spacer panel comprising a support frame and an exterior covering, wherein the support frame of the spacer panel defines a recess configured to receive the extension of the first side panel.
• A fifth aspect can include the kit of the fourth aspect, wherein the support frame of the spacer panel is T-shaped.
• A sixth aspect can include the kit of any one of the first to fifth aspects, further comprising a lower band coupled to the support frame, wherein the lower band extends about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the first side panel and the corner panel
• A seventh aspect can include the kit of any one of the first to sixth aspects, further comprising a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the first side panel and the corner panel to align the roof panel with the first side panel and the corner panel
• In an eighth aspect, a kit for assembling a pop-up enclosed structure comprises: a floor assembly comprising a support frame and a floor placeable upon the support frame; a first side panel comprising a support frame, an exterior covering, and an interior covering; a corner panel comprising a support frame, an exterior covering, and an interior covering; and a lower band extendable about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the first side panel and the corner panel.
• A ninth aspect can include the kit of the eighth aspect, wherein the lower band comprises a steel material and is coupled to the floor assembly.
• A tenth aspect can include the kit of the eighth or ninth aspect, wherein the kit further comprises an alignment band coupled to a roof assembly, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the first side panel and the corner panel, and wherein the alignment band is configured to be positioned at an upper end of the first side panel and the corner panel.
• An eleventh aspect can include the kit of any one of the eighth to tenth aspects, wherein a width of the interior covering is greater than a width of both the support frame and the exterior covering of the first side panel whereby an end of the interior covering forms an extension; and wherein a width of the interior covering of the corner panel is less than a width of both the support frame and the exterior covering of the corner panel whereby an end of the corner panel forms a recess configured to receive the extension of the first side panel.
• A twelfth aspect can include the kit of any one of the eighth to eleventh aspects, wherein the support frame of the first side panel comprises a plurality of steel supports, and at least one of the interior covering and the exterior covering comprises a laminate material.
• A thirteenth aspect can include the kit of any one of the eighth to twelfth aspects, further comprising a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the first side panel and the corner panel to align the roof panel with the first side panel and the corner panel.
• A fourteenth aspect can include the kit of any one of the eighth to thirteenth aspects, wherein the at least one of the roof panels is configured to overhang the first side panel and the corner panel when the first side panel and the corner panel are received in the recess in the roof panel.
• In a fifteenth aspect, a kit for assembling a pop-up enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame; a first side panel comprising a support frame, an exterior covering, and an interior covering; a corner panel comprising a support frame, an exterior covering, and an interior covering; and a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the first side panel and the corner panel to align the roof panel with the first side panel and the corner panel.
• A sixteenth aspect can include the kit of the fifteenth aspect, wherein the at least one of the roof panels is configured to overhang the first side panel and the corner panel when the first side panel and the corner panel are received in the recess in the roof panel.
• A seventeenth aspect can include the kit of the fifteenth or sixteenth aspect, wherein the alignment band is configured to contact the exterior coverings of the first side panel and the corner panel when the first side panel and the corner panel are received in the recess.
• An eighteenth aspect can include the kit of any one of the fifteenth to seventeenth aspects, wherein a width of the interior covering is greater than a width of both the support frame and the exterior covering of the first side panel whereby an end of the interior covering forms an extension; and wherein a width of the interior covering of the corner panel is less than a width of both the support frame and the exterior covering of the corner panel whereby an end of the corner panel forms a recess configured to receive the extension of the first side panel.
• A nineteenth aspect can include the kit of any one of the fifteenth to eighteenth aspects, wherein the support frame of the first side panel comprises a plurality of steel supports, and at least one of the interior covering and the exterior covering comprises a laminate material.
• A twentieth aspect can include the kit of any one of the fifteenth to nineteenth aspects, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the first side panel and the corner panel.
• In a twenty first aspect, a pop-up enclosed structure comprises a floor assembly comprising a support frame and a floor placeable upon the support frame; a plurality of side panels, wherein each side panel of the plurality of side panels comprises a structural insulated panel; one or more side support edges, wherein each support edge of the one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels; and a lower band extendable about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels.
• A twenty second aspect can include the structure of the twenty first aspect, wherein each structural insulated panel comprises: a core material comprising an insulation; an exterior sheath coupled to the core material on a first side of the core material; and an interior sheath coupled to the core material on a second side of the core material, wherein the first side is on an opposite side of the core material from the second side.
• A twenty third aspect can include the structure of the twenty first or twenty second aspect, wherein each side panel comprises a top support edge and a bottom support edge.
• A twenty fourth aspect can include the structure of the twenty third aspect, wherein the top support edge and the bottom support edge is bonded to the exterior sheath and the interior sheath.
• A twenty fifth aspect can include the structure of any one of the twenty first to twenty fourth aspects, wherein the lower band comprises a steel material and is coupled to the floor assembly.
• A twenty sixth aspect can include the structure of any one of the twenty first to twenty fifth aspects, further comprising: an alignment band coupled to a roof assembly, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of side panels at an upper edge of the plurality of side panels.
• A twenty seventh aspect can include the structure of any one of the twenty first to twenty fifth aspects, further comprising: a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the first side panel and the corner panel to align the roof panel with the first side panel and the corner panel.
• A twenty eighth aspect can include the structure of the twenty seventh aspect, wherein the at least one of the roof panels is configured to overhang the first side panel and the corner panel when the first side panel and the corner panel are received in the recess in the roof panel.
• In a twenty ninth aspect, an enclosed structure comprises: a floor assembly comprising a support frame and a floor placeable upon the support frame; a plurality of side panels, wherein each side panel of the plurality of side panels comprises a structural insulated panel; one or more side support edges, wherein each support edge of the one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels; and a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the plurality of side panels to align the roof panel with the first side panel and the corner panel.
• A thirtieth aspect can include the structure of the twenty ninth aspect, wherein the at least one of the roof panels is configured to overhang the plurality of side panels when the plurality of side panels are received in the recess in the roof panel.
• A thirty first aspect can include the structure of the twenty ninth or thirtieth aspect, wherein the alignment band is configured to contact the exterior coverings of the plurality of side panels when the plurality of side panels are received in the recess.
• A thirty second aspect can include the structure of any one of the twenty ninth to thirty first aspects, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of panels.
• In a thirty third aspect, an enclosed structure comprises: a floor assembly comprising a support frame and a floor placeable upon the support frame; a plurality of side panels, wherein the plurality of side panels form a first internal structure and a second internal structure, wherein the first internal structure and the second internal structure are formed on the floor assembly; a roof assembly comprising a plurality of roof panels, wherein at least a first roof panel of the plurality of roof panels is placed on the first internal structure, and wherein a second roof panel of the plurality of roof panes is placed on the second internal structure, and wherein an alignment band is coupled to the plurality of roof panels and is configured to receive an upper end of the plurality of side panels to align the roof panel with the plurality of side panels, and wherein the first roof panel abuts the second roof panel over the floor assembly to define a roof over the enclosed structure.
• A thirty fourth aspect can include the structure of the thirty third aspect, wherein a hallway is defined between the first internal structure and the second internal structure.
• A thirty fifth aspect can include the structure of the thirty third or thirty fourth aspect, wherein the at least one of the roof panels is configured to overhang the plurality of side panels when the plurality of side panels are received in the recess in the roof panel.
• A thirty sixth aspect can include the structure of any one of the thirty third to thirty fifth aspects, wherein the alignment band is configured to contact the exterior coverings of the plurality of side panels when the plurality of side panels are received in the recess.
• A thirty seventh aspect can include the structure of any one of the thirty third to thirty sixth aspects, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of panels.
• A thirty eighth aspect can include the structure of any one of the thirty third to thirty seventh aspects, wherein the alignment band extends about the first internal structure, and where the alignment band extends about the second internal structure.
• A thirty ninth aspect can include the structure of any one of the thirty third to thirty eighth aspects, further comprising a lower band coupled to the floor assembly and configured to receive a lower end of the plurality of side panels to align the floor assembly with the plurality of side panels.
• A fortieth aspect can include the structure of the thirty ninth aspect, wherein the lower band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of side panels.
• A forty first aspect can include the structure of the thirty ninth or fortieth aspect, wherein the lower band extends about the first internal structure, and where the lower band extends about the second internal structure.
• In a forty second aspect, a method of forming an enclosed structure comprises: providing a floor assembly comprising a support frame and a floor placeable upon the support frame; providing a plurality of side panels, wherein each side panel of the plurality of side panels comprises a structural insulated panel, wherein each support edge of one or more support edges comprises a plurality of channels configured to receive at least one edge of a side panel of the plurality of side panels; and forming an enclosed structure using the floor assembly and the plurality of side panes, wherein a lower band extends about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels.
• While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.
• Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims (21)

1. A pop-up enclosed structure, comprising:

a floor assembly comprising a support frame and a floor placeable upon the support frame;

a plurality of side panels, wherein each side panel of the plurality of side panels comprises a structural insulated panel; and

a lower band extendable about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels.

2. The structure ofclaim 1, wherein each structural insulated panel comprises:

a core material comprising an insulation;

an exterior sheath coupled to the core material on a first side of the core material; and

an interior sheath coupled to the core material on a second side of the core material, wherein the first side is on an opposite side of the core material from the second side.

3. The structure ofclaim 1, wherein each side panel comprises a top support edge and a bottom support edge.

4. The structure of3, wherein the top support edge and the bottom support edge is bonded to the exterior sheath and the interior sheath.

5. The structure ofclaim 1, wherein the lower band comprises a steel material and is coupled to the floor assembly.

6. The structure ofclaim 1, further comprising: an alignment band coupled to a roof assembly, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of side panels at an upper edge of the plurality of side panels.

7.-8. (canceled)

9. The structure ofclaim 1, further comprising:

a roof assembly comprising a plurality of roof panels, wherein at least one of the roof panels comprises a support frame, an upper panel, and a lower panel, and wherein the support frame of the roof assembly comprises an alignment band that forms a recess configured to receive an upper end of the plurality of side panels to align the roof panel with the first side panel and a corner panel.

10. The structure ofclaim 9, wherein the at least one of the roof panels is configured to overhang the plurality of side panels when the plurality of side panels are received in the recess in the roof panel.

11. The structure ofclaim 9, wherein the alignment band is configured to contact the exterior coverings of the plurality of side panels when the plurality of side panels are received in the recess.

12. The structure ofclaim 9, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of panels.

13. An enclosed structure comprising:

a floor assembly comprising a support frame and a floor placeable upon the support frame;

a plurality of side panels, wherein the plurality of side panels form a first internal structure and a second internal structure, wherein the first internal structure and the second internal structure are formed on the floor assembly;

a roof assembly comprising a plurality of roof panels, wherein at least a first roof panel of the plurality of roof panels is placed on the first internal structure, and wherein a second roof panel of the plurality of roof panes is placed on the second internal structure, and wherein an alignment band is coupled to the plurality of roof panels and is configured to receive an upper end of the plurality of side panels to align the roof panel with the plurality of side panels, and wherein the first roof panel abuts the second roof panel over the floor assembly to define a roof over the enclosed structure.

14. The structure ofclaim 13, wherein a hallway is defined between the first internal structure and the second internal structure.

15. The structure ofclaim 13, wherein the at least one of the roof panels is configured to overhang the plurality of side panels when the plurality of side panels are received in the recess in the roof panel.

16. The structure ofclaim 13, wherein the alignment band is configured to contact the exterior coverings of the plurality of side panels when the plurality of side panels are received in the recess.

17. The structure ofclaim 13, wherein the alignment band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of panels.

18. The structure ofclaim 13, wherein the alignment band extends about the first internal structure, and where the alignment band extends about the second internal structure.

19. The structure ofclaim 13, further comprising a lower band coupled to the floor assembly and configured to receive a lower end of the plurality of side panels to align the floor assembly with the plurality of side panels.

20. The structure ofclaim 19, wherein the lower band extends about a perimeter of the enclosed structure whereby the alignment band is configured to apply a compressive force against the plurality of side panels.

21. The structure ofclaim 19, wherein the lower band extends about the first internal structure, and where the lower band extends about the second internal structure.

22. A method of forming an enclosed structure, the method comprising:

providing a floor assembly comprising a support frame and a floor placeable upon the support frame;

providing a plurality of side panels, wherein each side panel of the plurality of side panels comprises a structural insulated panel; and

forming an enclosed structure using the floor assembly and the plurality of side panes, wherein a lower band extends about a lower perimeter of the enclosed structure whereby the lower band is configured to apply a compressive force against the plurality of side panels.

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