CN117716093A

CN117716093A - Quick wall construction system and method

Info

Publication number: CN117716093A
Application number: CN202280049267.2A
Authority: CN
Inventors: 威廉·J·斯科菲尔德; 丹尼尔·斯科特·坎农; 杰勒德·J·克米塔; 杰里米·马瑟
Original assignee: Scofield Technology Co
Current assignee: Scofield Technology Co
Priority date: 2021-05-12
Filing date: 2022-05-12
Publication date: 2024-03-15

Abstract

A lightweight modular shelter and a method for assembling the shelter. The shelter includes first and second panels and first and second panel connectors. The board connector has a board edge channel operatively connected to one side of the first board and one side of the second board, and has a connector plug and a connector socket. The connector plug of the first board connector is inserted into the connector receptacle of the second board connector such that the first board and the second board are operatively connected. The shelter may further comprise a bottom rail, wherein the first plate, the second plate, the first plate connector, and the second plate connector mate with the bottom rail. The method includes attaching the plate and connectors to the bottom rail along with the corner connectors to form a freestanding structure. Roof panels and connectors and gable panels and connectors may be attached thereto.

Description

Quick wall construction system and method

Cross Reference to Related Applications

U.S. provisional application No. 63/208,949, filed on 6/9 at 2021; U.S. provisional application No. 63/187,438 filed on day 5 and 12 of 2021; U.S. provisional application No. 63/316,386 filed on 3/2022; U.S. application Ser. No. 29/834,548, filed on 4/12 at 2022; U.S. application Ser. No. 29/787,993, filed on 6/9 at 2021; U.S. application Ser. No. 29/787,996, filed on 6/9 at 2021; U.S. application Ser. No. 29/787,999, filed on 6/9 of 2021; U.S. provisional application No. 63/223,779, filed on 7.20 of 2021; united states provisional application No. 63/340,537 filed 5/11 at 2022; all of these applications are incorporated by reference in their entirety.

Technical Field

The present disclosure relates to a modular shelter structure and a method for constructing a modular shelter. More specifically, the present disclosure provides a lightweight modular, substantially rigid wall system for temporary shelter, storage units, property demarcations, emergency facilities, agricultural facilities, and the construction field of similar facilities for military, humanitarian purposes, industrial, recreational, and municipal uses.

Background

For example, existing shelter solutions (including tent structures) for practical purposes may be configured as short-term solutions that do not provide the durability, adaptability, safety, and protection required for practical purposes. Durable long-term shelter may be costly and/or require materials, tools, and/or skills that are not available in or readily transportable to the geographic area in which the shelter solution is desired. Furthermore, durable long-term shelters can be constructed such that they cannot be disassembled for reuse and/or repositioning, for example, from one geographic area to another.

Standard methods of shelter and storage of personnel and cargo are generally included in two main categories: (1) Soft wall structures (tents, etc.), and (2) rigid wall structures (shipping containers, framing walls, prefabricated structures, etc.). Each of these solutions solves one problem, but introduces many other problems during its use. Elements of tent and softside tarpaulins and canvas structures deteriorate, do not provide or provide limited structural capability, are substantially less thermally efficient, are typically ground-based (in direct contact with the ground), and must be replaced frequently to maintain minimum effectiveness in providing coverage for personnel, cargo and/or supplies.

Rigid structures can solve the problems of thermal efficiency and structural capacity, but are currently cumbersome to move and assemble, expensive, and more complex to assemble than tents. Furthermore, rigid structures are fixedly used-i.e., once in place, they remain in place-often requiring equipment and power to assemble and are not conducive to rapid deployment in areas where there is no accessibility, power, or skilled labor capable of lifting, maneuvering, and assembling these heavy rigid structures.

Disclosure of Invention

A lightweight modular shelter and a method for assembling a modular shelter are provided. The shelter includes a first panel and a first panel connector having a panel edge channel operatively connected to one side of the first panel and a connector plug and connector socket. The shelter includes a second panel and a second panel connector having a panel edge channel operatively connected to one side of the second panel and connector plugs and connector receptacles. The connector plug of the first board connector is inserted into the connector receptacle of the second board connector such that the first board and the second board are operatively connected. The lightweight modular shelter can also include a bottom rail. The first plate, the second plate, the first plate connector and the second plate connector mate with the bottom rail.

The method of assembling the shelter comprises: laying a plurality of bottom tracks on a substantially planar surface; connecting a plurality of wall panel connectors to a plurality of wall panels through panel edge channels in the wall panel connectors; a plurality of corner connectors are connected to the bottom rail. Connecting a wall panel connector and a plurality of wall panels to the bottom rail; connecting adjacent wall panel connectors by inserting connector plugs of one wall panel connector into connector receptacles of another wall panel connector; and connecting a wall panel connector to one of the corner connectors by inserting the connector plug of one wall panel connector into the connector receptacle of the other wall panel connector and inserting the connector plug of the corner connector into the connector receptacle of the other wall panel connector. Thus, the wall panels, wall panel connectors, corner connectors and bottom rail form a freestanding structure having at least four wall assemblies.

The rigid wall modular system disclosed herein may be referred to as a rapid wall construction system (RWBS) that uses RWBS components and methods to construct a lightweight modular shelter from reusable standardized components that are assembled together so that the shelter can be quickly erected and quickly disassembled for repositioning and/or redeployment when needed. These components are lightweight and sized for easy transport. No special tools or skills are required to assemble the shelter so that the shelter can be constructed, for example, by the person deploying and/or requiring use of the shelter, with minimal or no training required to the person.

The rapid wall construction systems and methods described herein may be used to construct a shelter for a wide range of practical purposes, including military deployment and use, wherein the term "shelter" as used herein is intended to be construed broadly to include structures configured to contain, store, protect and/or shelter living beings and/or non-living organisms (including, for example, humans, animals, equipment, vehicles and transportation equipment, medical equipment and supplies, communication equipment, artillery and ammunition, humanoid supplies including food and agricultural supplies, etc.).

As shown, the shelter components can be assembled into a variety of different shelter configurations. One or more of the shelter(s) have an initial configuration that is easily removable, and the removable components can be reassembled and reassembled into one or more of the shelter(s) having the same or a different configuration.

Advantages and benefits of RWBS systems and methods of constructing rigid wall structures are illustrated by the accompanying figures and description. As non-limiting examples, advantages and benefits include: fewer standardized components with simple, ergonomically advantageous standardized connections; doors, windows, barriers, etc. are easily integrated into panels and structures; due to the retractable and removable fasteners and limited tool use, significant time is saved during assembly and disassembly; less manpower is required for assembly of each structure than for traditional or permanent structures; and assembly without the need for measurement, cutting, power or heavy tools.

Additional advantages and benefits include, by way of non-limiting example: a lower weight material with high durability and sustainability; corrosion and water resistant materials; the method can be redeployed, adjusted and reconstructed aiming at the dynamically changed field requirements; an optimized hybrid cost solution between tent and traditional rigid structures; and greater versatility due to the modular lightweight, reconfigurable, standardized components that are suitable for a variety of changing environments.

The above features and advantages, and other features and advantages of the present teachings are readily apparent from the following detailed description of certain preferred and other embodiments of the present teachings taken in conjunction with the accompanying drawings.

Drawings

Figure 1 schematically illustrates an isometric view of an example shelter constructed using a rapid wall construction system (RWBS) with some or all of the components and methods described herein.

Figure 2 schematically illustrates a front view of the shelter of figure 1.

Figure 3 schematically shows a side view of the shelter of figure 1.

Figure 4 schematically illustrates an enlarged cross-sectional view of the shelter of figure 1 showing an interior view of the gable and wall assembly and a rear wall having two windows.

Figures 5A, 5B and 5C schematically collectively illustrate an example method of constructing or assembling a modular shelter using RWBS.

Fig. 6A schematically illustrates an isometric view of a wall plate bottom rail including receiving holes for connecting wall plate connectors to the bottom rail using retractable button connectors.

Fig. 6B schematically illustrates an end view of an alternative bottom rail having grooves.

Fig. 6C schematically shows an isometric view of an alternative bottom rail.

Fig. 7 schematically shows an end view of a plate connector for connecting plate members.

Fig. 8 schematically shows an isometric view of a shorter portion of the plate connector shown in fig. 7.

Fig. 9 schematically shows an exploded view of a plate assembly with a plate member and an opposing plate connector.

Fig. 10 schematically shows an end view of two plate assemblies connected by a plate connector and a retractable button connector.

Figure 11 schematically shows an end view of a corner connector for connecting panel members at corners of the shelter structure.

Figure 12 schematically shows an isometric view of a corner connector for connecting panel members at corners of the shelter structure.

Fig. 13 schematically illustrates an end view of an eave track for connecting a roof module to a wall module.

Fig. 14 schematically shows an isometric view of an eave rail.

Fig. 15 schematically illustrates an end view of an upper portion of a two-piece ridge rail assembly, which may be referred to as a ridge cap.

Fig. 16A schematically illustrates an end view of an alternative lower portion of a two-piece roof rail assembly, which may be referred to as a roof bracket.

Fig. 16B schematically illustrates an end view of an alternative lower portion of a two-piece roof rail assembly, which may be referred to as an alternative roof bracket.

Fig. 17 schematically illustrates a bottom isometric view of a two-piece ridge rail assembly and ridge splice for connecting to an adjacent ridge rail assembly.

Fig. 18 schematically illustrates an end view of a ridge assembly held together by a Locking Connector Assembly (LCA) and a cross beam, web member and two roof sheets.

Fig. 19 schematically shows an end view of an eave track connecting wall panels, roof panels and beams.

Fig. 20A schematically illustrates an isometric view of a gable track configured to mate the top of an end wall assembly with a gable element.

Fig. 20B schematically illustrates an end view of an alternative gable track.

Fig. 20C schematically illustrates an isometric view of an alternative gable track.

Detailed Description

Provided herein are modular, real shelter 100 produced with a rapid wall construction system (RWBS) comprising wall assemblies 200 and roof assemblies 300, which shelter 100 may also be referred to as modular shelter 100 or shelter 100. Additionally, provided herein is a method 500 for assembling a modular real shelter 100, as described in the specification and included schematic representations and as shown in the accompanying drawings. RWBS components may be used to form lightweight modular shelter 100.

Figures 1-3 respectively illustrate isometric, front and side views of one exemplary structure of a modular shelter 100 constructed using the components and methods of the RWBS described herein. Figure 4 shows a cross-sectional view taken at the midpoint of the sides, showing the interior components and rear wall of shelter 100. Note that the example modular shelter 100 shown in the figures is a very small and basic representation of the RWBS system capabilities.

In the drawings, wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts, and the elements shown in the drawings are not necessarily to scale or proportion. Accordingly, the particular dimensions and applications provided in the drawings presented herein should not be considered limiting. The reference numerals may be presented out of order.

The term "substantially" as used herein refers to an ideal perfect or complete relationship, but manufacturing reality prevents absolute perfection. Thus, basically represents a typical difference from perfect. For example, if height a is substantially equal to height B, it may be preferable that the two heights be 100.0% equal, but manufacturing reality may result in a gap from such perfection. The skilled artisan will recognize acceptable amounts of variance. For example, but not limited to, coverage, area, or distance may typically be within 10% of substantially equivalent perfection. Similarly, relative alignment (e.g., parallel or perpendicular) may be generally considered to be within 5%.

As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any one" should be understood to include any possible combination of the referenced items, including "any one" of the referenced items.

An advantage of the RWBS and modular shelter 100 constructed therefrom is that it includes a minimum number of standardized components that can be attached to one another by mere manual force or use of a mallet, hammer, or similar striking tool capable of providing a striking or hammering force. Thus, modular shelter 100 can be assembled at any location by a person with minimal and/or no construction experience or skill, without requiring training and without requiring power or tools other than tapping tools. Notably, because the modular shelter 100 can be assembled without the use of power tools, the modular shelter 100 can be assembled where there is no power, generator, battery, etc.

The various shelter components are lightweight, portable, and are connected to one another by removable means, including but not limited to a plurality of retractable connectors 64 or ergonomically advantageous T-bolt fasteners, for quick assembly and disassembly. Thus, modular shelter 100 can be used repeatedly with components in different combinations and configurations and can be quickly disassembled and repositioned. Modular shelter 100 can be moved or altered, for example, in response to changes in the installation environment, including climate changes or in response to military and/or government operations, availability of food and water, or other humane needs or conditions.

A non-limiting example method 500 of assembling (e.g., by constructing or erecting) the modular shelter 100 is illustrated by fig. 5A-5C of the drawings. The illustrative examples provided herein and in relation to the figures are non-limiting, and it should be understood that there are a variety of alternative configurations of shelter 100 within the scope of the description to assemble a plurality of differently shaped wall assemblies containing the various modular components described, as well as other similar components.

The RWBS modular shelter 100 is formed from a plurality of standardized components including, but not limited to: a plurality of wall panels 10, a plurality of roof panels 12, and a plurality of gable panels 14. In addition, a plurality of plate connectors 20 and a plurality of corner connectors 60 may be used to tie or connect each of the different plates together.

Note that the wall panels 10 and roof panels 12 may be very similar in particular so that each may be used for other purposes and/or may be cut into gable panels 14. Further, the panel connector 20 may be used as the panel connector 20, the roof panel connector 20, or the gable panel connector 20.

Multiple tracks, including wall panel bottom track 50 (or simply bottom track 50), eave track 70, and gable track 80, may be used to assemble a plurality of differently shaped shelters 100, as desired for a particular application and/or intended use. Other constructions of the roof assembly 300 may be used with the wall assembly 200, with the wall assembly 200 including, for example, conventional and/or known roof structures, tarpaulins, including roof coverings constructed of materials including natural materials available at and/or harvested from an installation site. It should also be appreciated that the shelter 100 and/or components comprising the shelter 100 can be tailored to fit electrical systems, plumbing systems, lighting systems, heating systems, ventilation systems, air conditioning systems, solar systems, and communication systems, as desired for a particular application and/or intended use.

An advantage of the shelter 100 described herein is its flexibility as a temporary shelter, for example, the ability to assemble the shelter 100 in a minimum amount of time, including less than a day. Furthermore, the shelter 100 can be disassembled, as desired, in a minimum amount of time (including less than a day) for repositioning and reassembly, and/or reassembly into a different configuration of the shelter 100. Repositioning and reassembly may be performed by reconfiguration of components and/or by combination or exchange of disassembled components with additional components.

The example of a temporary shelter is non-limiting in that the durability of the shelter 100 and its various components allows the shelter 100 to be installed in a semi-permanent and/or permanent configuration, which may include installing the shelter 100 on a foundation provided for making the shelter 100 more permanent. In addition, shelter 100 can be lifted off the ground, for example, in areas where flooding is likely to occur. Although not shown, modular shelter 100 can include a floor attached to bottom rail 50 or laid on the ground. Examples of structures that may be replaced by the various configurations of shelter 100 may include, but are not limited to: l-shape, T-shape, U-shape and multi-layer structures. Note that the corner connectors 60 may be rotated relative to their positions (fig. 1-3) such that they act as interior corners.

The rapid wall construction system (RWBS) described herein includes standardized components that can be assembled into various configurations to construct the modular shelter 100. As shown and described in further detail herein, RWBS standardized components may be combined in various numbers of various components to construct various shelter 100, shelter 100 comprising at least one wall panel 10 and at least one panel connector 20.

The retractable connector 64 may be used to connect other elements or components together. The retractable connector 64 includes a retractable button 66, the retractable button 66 being spring loaded such that they are selectively extendable from the retractable connector 64. For example, the retractable connector 64 may be used to connect the bottom rail 50 to the plate connector 20 or the corner connector 60. Fig. 10 schematically illustrates the use of a retractable connector 64 to tie two plate connectors 20 to a bottom rail 50, schematically shown in phantom. Similarly, retractable connectors 64 may be used to connect panel connectors 20 to eave rail 70 or gable rail 80. Note that alternative spring-based connector elements may be used, including but not limited to hairpin spring connectors having buttons that interface with holes formed in the connected components. The hairpin spring connection can also be used during transport and then replaced by a retractable connection 64 or reused within the shelter 100.

All or some of the components referred to herein may be collectively referred to as RWBS components, each of which may be referred to herein as RWBS components. As shown in the exemplary figures, the different panel members may be provided in different shapes, heights, lengths, and widths to form a plurality of wall panel 10 members, roof panel members 12, and gable 14 members for use in constructing the various configurations of the modular shelter 100.

Figures 5A-5C illustrate an exemplary method 500 for constructing a shelter using the RWBS components shown in more detail in the remaining figures. The discussion of fig. 5A-5C also incorporates additional components that are shown in the additional figures, including fig. 1-4 and 6-20.

The description may move between method 500 and the various components and figures illustrating the components. Note that additional steps or fewer steps may be included with respect to the method 500 shown in the figures. The RWBS shelter 100 created with the method 500 and RWBS components described and illustrated herein may have a lifetime of over twenty years.

Step 510: preparing a foundation. In the example method 500 shown in figures 5A-5C for constructing a modular shelter 100 using RWBS components, the method 500 begins at step 510, where a foundation for the shelter 100 is prepared at step 510. The skilled artisan will recognize that the foundation may be comprised of one or more of, for example, but not limited to, concrete, brick, block, wood, polymer-based structural members, decking, columns, compacted earth, gravel, stacked rock, or similar foundation materials and constructions.

In a non-limiting example, the shelter 100 can be attached to the foundation, such as by fasteners, adhesives, cements, and/or other mounting members configured for this purpose, to mount the bottom rail 50 to the foundation. The examples of foundations given herein are non-limiting, for example, it should be understood that shelter 100 may be constructed on any surface suitable for supporting a wall panel bottom rail in a desired configuration (e.g., square or rectangular arrangement) for receiving wall assembly 200 and corner connectors 60 and supporting shelter 100 thereon. In a non-limiting example, shelter 100 can be constructed without foundations by placing bottom rail 50 directly on the ground, on gravel, asphalt, or concrete paved surfaces (e.g., roads or runways), or on other structures (e.g., roofs of buildings, decks of ships, etc.). The skilled artisan will recognize a variety of options for the foundation upon which the modular shelter 100 may be placed.

Step 512: the bottom rail is positioned. At step 512, the wall panel bottom track 50 is positioned in the configuration of the shelter 100 to be constructed, and in the example shown in fig. 1-4, the shelter 100 is rectangular in shape. The arrangement or positioning of the bottom track 50 generally defines the outline or footprint of the modular shelter 100 to be constructed. The rectangular example is non-limiting, and it will be appreciated by those of ordinary skill in the art that various combinations of RWBS components can be used to construct other shapes of the shelter 100, including many additional shapes and sizes. The shelter 100 can be a single layer, for example, comprised of a first wall assembly 200, or can be multiple layers, comprised of two or more wall assemblies 200 stacked upon one another.

Referring to fig. 6A, the wall panel bottom rail 50 in the example construction may be formed of a metal-based material, including but not limited to aluminum or steel, to provide a lightweight and relatively low cost component. In one example, the bottom rail 50 may be formed as an extrusion that is cut to a desired length and/or angle. Extrusion is not limiting and other forming methods (including, for example, but not limited to, bending and stamping) may be used to form the metal base track 50. The metal base track 50 may be surface treated to prevent corrosion, such as by anodic oxidation, electroplating, painting, galvanization, plating, or other suitable means for inhibiting and/or preventing corrosion or environmental attack on the base track 50. One preferred material may be glass filled nylon, which has high strength and stiffness and excellent melt strength, making it well suited for extrusion and blow molding. Such materials can be molded but are also beneficial when extruded. The glass filled nylon bottom rail 50 may be lighter in weight than metal-based materials and may also have reduced costs.

Further, without limitation, the bottom rail 50 may be formed from a polymer-based material, a polymer composite material, or a carbon fiber reinforced material (e.g., a nylon-based material, a PVC-based material, or a high strength polymer), such as by extrusion or molding. As shown in fig. 6A, the bottom rail 50 defines a rail channel 54 for receiving a wall assembly, which may be formed from one or more wall panels 10, one or more panel connectors 20, and/or one or more corner connectors 60.

The bottom rail 50 includes a plurality of receiving holes or apertures 58 positioned to align with the retractable buttons 66 of the retractable connector 64 of the plate connector 20. Thus, when the panel assembly is inserted into the bottom rail 50, the retractable connector 64 engages the receiving aperture 58 to retain the wall panel assembly to the bottom rail 50. The bottom rail 50 may include steps, which are lowered portions of the bottom rail 50 and are best shown in fig. 2, configured to provide a threshold (as shown in fig. 1 and 2) for a door 112 mounted in a wall assembly 200, for example, to reduce the crossing height through a doorway.

In one example, the bottom rail 50 may include one or more drain holes 59 formed through one or more walls of the bottom rail 50 and distributed along the length of the bottom rail 50, which may also be referred to herein as drain holes, to provide drainage of fluid from the rail channels 54 of the bottom rail 50, including drainage of rain water or other runoff from the roof assembly 300 or wall plate 10, which may collect in the rail channels 54, for example. The bottom rail 50 may include one or more seals, such as spherical seals, along the length of the bottom rail 50, particularly within the rail channel 54. The seal may limit the intrusion of water or other liquids into the bottom rail 50 so that less water is drained through the drain holes 59.

Fig. 6B schematically shows an end view of an alternative bottom rail 51 and fig. 6C schematically shows an isometric view of an alternative bottom rail 51. The alternative bottom rail 51 is similar to the bottom rail 50 and includes a rail channel 55, but with some additional features. The alternative bottom rail 51 has an offset or raised portion that forms a channel 56 alongside the offset portion. A drain hole 59 may be formed in the groove 56 to allow water to drain therefrom.

Step 514: and connecting the corner connectors. At step 514 of method 500, corner connectors 60 are inserted into bottom rail 50 at one or more corresponding corners of shelter 100 and connected to bottom rail 50. Similar to the plate connector 20, the corner connector 60 includes a retractable connector 64 in the connector portion 26, the connector portion 26 extending orthogonally from the corner channel 62 of the corner connector 60, as shown in fig. 11. Thus, the corner connectors 60 connect the ends of adjacent, substantially vertical bottom rails 50 by engaging the retractable buttons 66 of the retractable connectors 64 into the receiving holes 58 of the bottom rails 50 to form the corners of the shelter 100. Fig. 11 also shows corner connectors 60 and adjacent board connectors 20, with the adjacent board connectors 20 shown in phantom to demonstrate the connection therebetween.

As shown in fig. 11 and 12, in a non-limiting example, the corner connectors 60 may be formed from a metal-based material (e.g., aluminum or steel) to provide lightweight and relatively low cost components. In one example, the corner connector 60 may be formed as an extrusion that is then cut to the desired length. This example is not limiting and other forming methods (including, for example, bending and stamping) may be used to form the corner connectors 60. The metal-based corner connector 60 may be surface treated to prevent corrosion, such as by anodic oxidation, electroplating, painting, galvanization, plating, or other suitable means for inhibiting and/or preventing corrosion of the corner connector 60 by environmental attack.

Alternatively, and without limitation, the corner connectors 60 may be formed from a polymer-based material, a polymer composite, or a carbon fiber reinforced material (e.g., a nylon-based material, a PVC-based material, or a high strength polymer), such as by extrusion or molding. One preferred material may be glass filled nylon, which has high strength and stiffness and excellent melt strength, making it well suited for extrusion and blow molding. Such materials can be molded but are also beneficial when extruded. The glass-filled nylon corner connector 60 may be lighter in weight than metal-based materials and may also have reduced costs.

As shown in fig. 11 and 12, the corner connector 60 includes a pair of connector portions 26 extending from the corner channel 62 such that when the bottom rail 50 is connected to the connector portions 26, the corners of the shelter 100 are formed. In the example shown, the connector portions 26 are substantially orthogonal to each other to define a 90 degree corner angle between the bottom rail 50 and the wall panel 10 connected to the corner connector 60. This example is non-limiting, and the skilled artisan will appreciate that the corner connector 60 may have non-orthogonal connector portions 26, for example, for assembling the modular shelter 100 having a non-rectangular shape.

For example, and without limitation, corner connector 60 may have connector portions 26 extending from corner channels 62 to define a 108 degree angle therebetween, which may be used to assemble pentagonal wall assembly 200; or the corner connectors may have connector portions 26 defining 120 degree angles therebetween, which may be used to assemble hexagonal wall assembly 200, and so forth. In addition, combinations of corner connectors 60 having different included angles may be used to connect the bottom rail 50 to assemble a wall assembly 200 having an irregular polygonal perimeter.

Advantageously, as described herein, the RWBS including the standard components (including the board connectors 20 and corner connectors 60) is configured to assemble wall assemblies 200 having various perimeter shapes and perimeter dimensions, and can be disassembled and reassembled to form wall assemblies 200 of other perimeter shapes and perimeter dimensions. In this way, the wall assembly 200 provides flexibility and reusability of RWBS components when needed to change, reposition or reconfigure the shelter 100, or a combination thereof.

Referring again to the corner connector 60 shown in fig. 11 and 12, the connector portion 26 is connected to the corner channel 62 by the bridge portion 24, the bridge portion 24 including the connector slot 28 defined by the outer surface of the corner connector 60. Similarly, the panel connector 20 shown in fig. 7-10 also includes a similar connector portion 26, the connector portion 26 being connected to the panel edge channel 22 by a bridge portion 24, the bridge portion 24 including opposed connector slots 28 defined by opposed surfaces of the panel connector 20. In the example shown, the connector slot 28 is a generally T-shaped slot such that the connector slot 28 is configured to receive a fastener, such as, but not limited to, a T-bolt, for attaching an object to the corner connector 60 through the connector slot 28.

As shown, each of the plate connector 20 shown in fig. 7-10 and the corner connector 60 shown in fig. 11 and 12 includes at least one connector slot 28. Note that the panel connector 20 may be used to connect both the wall panels 10 and the roof panels 12.

In the installed position, connector slots 28 may be located on the outward surface of panel connector 20 or corner connector 60 (on the outside of shelter 100 when installed) for attaching various external components to shelter 100. The type and configuration of external components that may be connected to the exterior of the shelter 100 wall assembly 200, gable, roof assembly 300, or a combination thereof using the connector slots 28 is not limited. External components include, but are not limited to: brackets, hangers, shelves, storage containers, canopies, electrical and/or plumbing conduits, lighting fixtures, communications equipment, other utility components, water sumps, solar panels, perimeter rails, wall extensions, and other external components recognizable to the skilled artisan.

In the installed position, connector slots 28 may be located on the inward surface of panel connector 20 or corner connector 60 (inside shelter 100 when installed) for attaching internal components to shelter 100. The type and configuration of the internal components that may be connected to the interior of the wall assembly 200, gable and/or roof assembly 300 of shelter 100 using connector slots 28 included in the connectors is not limited. Internal components include, but are not limited to: brackets, hangers, shelves, storage containers, electrical and/or plumbing conduits, equipment, lighting fixtures, communications equipment, other utility components, work tables or desks, sanitary ware, beds, canvases, bunkers, storage shelves, containers, interior walls and/or wall extensions, and other interior components recognizable to the skilled artisan.

As shown, the connector slots 28 extend the entire length of the corner connectors 60 and the entire length of the board connectors 20 so that they can be attached to the connector slots 28 at any location along the length of the board connectors 20 or corner connectors 60. This may allow for flexibility of use and/or easy repositioning of the component or both. The connector slots 28 may be formed during extrusion and/or molding of the plate connector 20 or corner connector 60, minimizing the manufacturing costs of the connector slots 28.

This example is not limiting and other means for forming the connector slots may be used, including machining, stamping, and the like. In the non-limiting example shown, the connector slot 28 has a generally T-shaped cross section such that the T-bolt end of the fastener can be inserted at any location along the slot length and rotated to maintain the T-bolt end within the connector slot 28. This example is non-limiting such that it is contemplated within the scope of the present disclosure that other slot shapes and/or configurations may be formed in the panel connector 20 or the corner connector 60 to provide attachment means for attaching the inner and outer components and/or wall extensions to the panel connector 20 or the corner connector 60.

Referring again to the corner connector 60 shown in fig. 11 and 12 and to the board connector 20 shown in fig. 7-10, the connector portion 26 includes connector pins 30 and connector sockets 40 that are configured such that the connector portions 26 of adjacent board connectors 20 or corner connectors 60 may be connected-i.e., assembled to each other as shown in fig. 10-by inserting the connector pins 30 of one board connector 20 or corner connector 60 into the connector sockets 40 of an adjacent board connector 20 or corner connector 60. The interface between the connector plug 30 and the connector receptacle 40 may be sealed to reduce the flow of air or liquid therebetween.

As shown in fig. 7 and 11, the connector plug 30 includes a plug end that may be tapered in some configurations to facilitate insertion of the connector plug 30 into the connector receptacle 40. However, the plug end shown in the figures has substantially no taper. The plug end is disposed in a receptacle channel defined at least in part by receptacle flange 36. In the non-limiting example shown, the plug end is recessed to interface with the socket flange 36, which may facilitate sealing of the joint formed between the adjoining plate connectors 20 or corner connectors 60 to prevent fluid (air, water) from flowing (intrusion, leakage) through the joint at the outer surface of the adjoining connector portion 26.

As shown in fig. 10, the non-linear and/or multi-directional joint interface defined by the surfaces of the interconnected plug 30 and socket 40 of the adjoining connector portions 26 further seals the joint to prevent fluid flow through the joint. In some constructions, the plate connector 20 or corner connector 60 may include one or more plug seals located in or along the length of the receptacle channel to additionally seal the joint between the adjoining connector portions 26. In one example, the plug seal may be made of a compressible elastomer, polymer, or rubber-like material such that the plug seal is compressed during insertion of the plug end into the receptacle channel to seal the joint.

Non-limiting example configurations of plug seals include ball seals, D-seals, O-seals, and the like. In one example, the plate connector 20 or the corner connector 60 is provided with a plug seal that is pre-applied to the receptacle channel. In another example, the plate connector 20 or corner connector 60 and the plug seal are provided as separate components, and the plug seal is attached to the socket channel during assembly of the shelter 100. In a non-limiting example, the plug seal may be adhered to the receptacle channel by an adhesive or other fastening means, and/or the plug seal may include an adhesive strip for adhering the plug seal to the receptacle channel.

Referring again to the corner connector 60 shown in fig. 11 and 12 and to the board connector 20 shown in fig. 7-10, the connector plug 30 of the connector portion 26 includes a connector housing for receiving the retractable connector 64 within each end of the connector portion 26. In the example shown in the figures, the retractable connector 64 is configured with a spring loaded retractable button 66, which may also be referred to herein as button 66, protruding through holes 58 formed in the connector housing of the plate connector 20 and the corner connector 60.

As shown, the connector portion 26 has a retractable connector 64 including a retractable button 66 inserted into each end of the plate connector 20. Thus, in the installed position, the connector portion 26 of the board connector 20 and the corner connector 60 are attached to the bottom rail 50 at a first end (the lower end when installed) by engaging the retractable button 66 of the retractable connector 64 in the receiving aperture 58 of the bottom rail 50 to form the wall assembly 200 of the shelter 100 shown in fig. 1 and described in the method shown in fig. 5A-5C. Note that the corner connector 60 and the aperture 58 of the plate connector 20 may be considered to pass through the aperture.

As shown in fig. 4 and 19, the second ends (upper ends when installed) of the corner connectors 60 and the panel connectors 20 are attached to a second rail, either an eave rail 70 (best seen in fig. 13 and 14) or a gable rail 80 (best seen in fig. 20A). Engagement with the receiving holes 58 formed in the eave rail 70 and gable rail 80 typically occurs at the second ends of the corner connectors 60 and the panel connectors 20 by the retractable buttons 66 of the retractable connectors 64 to form the upper edge of the wall assembly 200, as seen in fig. 1-4.

Referring to fig. 7-10, in a non-limiting example, the plate connector 20 may be formed of a metal-based material (e.g., aluminum or steel) to provide a lightweight and relatively low cost component. Although this discussion focuses on the board connectors 20, the skilled artisan will recognize that similar construction methods, materials and processes may be used for the corner connectors 60, eave rails 70, gable rails 80 and gable end rails 120 (best seen in fig. 1 and 2) or other components of the RWBS system. In one example, the panel connector 20 may be formed as an extrusion that is then cut to a desired length and/or miter angle, for example, to form the wall panel connector 20, the roof panel connector 20, or the gable panel connector 20.

The extrusion example is not limiting and other forming methods including bending and stamping may be used to form the plate connector 20. The metal substrate connector 20 may also be surface treated to prevent corrosion, such as by anodic oxidation, electroplating, painting, galvanization, plating, or other suitable means for inhibiting and/or preventing corrosion of the board connector 20 by environmental attack, among other components. In non-limiting examples, the board connector 20 may be formed from a polymer-based material, a polymer composite material, or a carbon fiber reinforced material (e.g., a nylon-based material, a PVC-based material, or a high strength polymer), such as by extrusion or molding.

One preferred material may be glass filled nylon, which has high strength and stiffness and excellent melt strength, making it well suited for extrusion and blow molding. Such materials can be molded but are also beneficial when extruded. The glass-filled nylon sheet connection 20 may be lighter in weight than metal-based materials and may also have reduced costs. In one example, the wall, roof and gable connectors 20 are formed of the same material, which in a preferred example is extruded and/or molded into a continuous length, which can then be cut into the desired length for each of the respective wall, roof and gable connectors 20.

Alternatively, the wall panel connector 20 may be made of a different material than the roof panel connector 20 or gable panel connector 20, depending on the requirements of the use of the shelter 100 including these components. For example, the panel connector 20 may be made of a metal-based material depending on the stiffness or column strength requirements of the wall assembly 200, and the roof panel connector 20 may be made of a lighter non-metal or polymer-based material sufficient to support roof loading requirements to provide a lighter weight roof panel 12 to facilitate lifting and placement during assembly of the roof assembly 300. These examples are non-limiting and other combinations may be used.

As shown in fig. 7-10, the board connector 20 includes a connector portion 26, the connector portion 26 being connected to the board edge channel 22 by a bridge portion 24, the bridge portion 24 including opposed connector slots 28 defined on opposite sides of the board connector 20. Advantageously, the connector portion 26, including the connector plug 30 and the connector receptacle 40, is configured such that the panel connector 20 can be mounted to either side edge of the wall panel 10, as shown in fig. 9 and 10, thereby eliminating the need for left and right panel connectors 20. This simplifies inventory management and simplifies assembly by eliminating the need to provide different left and right connectors, thereby eliminating assembly errors that may occur when different configurations of left and right connectors are required. In addition, the panel assembly, which typically includes one wall panel 10 and two panel connectors 20, can be rotated about its transverse and/or longitudinal axes during installation to align the corresponding plugs 30 and sockets 40 of adjacent panels so that the same configuration of panel assembly can be used throughout the wall assembly 200, thereby simplifying the inventory management and assembly process.

Furthermore, in the preferred example shown, the wall panel connectors 20, roof panel connectors 20 and gable connectors 20 have the same cross-sectional shape and dimensions so that all panel connectors 20 can be cut into standardized lengths of extruded or molded blanks, thereby reducing manufacturing and tooling costs. Standardization of the cross-sectional shape of the extruded or molded blank may also be beneficial, for example, in situations requiring field repair and/or to simplify spare part supply and management. For example, the longest board connector 20 may be provided as a standard repair part that may be shortened to the length required for the board connector 20 to be replaced in the field when needed, thereby minimizing spare part inventory and complexity. The panel connector 20 may also be cut at an angle, such as when used as a gable panel connector 20.

Optional step 516: and installing a door. At optional step 516 and as shown in the non-limiting example shown in fig. 1 and 2, at least one wall panel 10 may be provided as a wall panel member including a door assembly or door 112, which door assembly or door 112 may also be connected to panel connector 20 to form a wall door panel having door 112. In some constructions, the entire wall panel 10 may be replaced with the door 112.

Optional step 518: the window(s) are installed. Similarly, at optional step 518, and as shown in the non-limiting example shown in fig. 1-4, at least one wall panel 10 may be provided as a wall panel member including a window assembly or window 114 and connected to the panel connector 20 to form a wall window panel member. In many constructions, one or more particular wall panels 10 will have a window 114 pre-assembled therein, such that the window wall panels 10 are installed as simply as any other wall panel 10.

These examples are illustrative and not limiting, and it should be understood that other configurations of wall panels 10 may be included in shelter 100. Alternate wall panels 10 include, but are not limited to, those having a panel frame and panel inserts. The plate frame may be configured to be received into the rail channel 54 of the bottom rail 50. The plate inserts may have various configurations depending on the use requirements of shelter 100. For example, but not limited to, the plate insert may be configured for monitoring and be composed of reinforced, colored, and/or ballistic resistant materials. Additional example panel inserts may be made of a barrier or mesh material for ventilation of shelter 100. Additional panels, including roof panels 12 and gable panels 14, may include panels with panel frames and/or panel inserts.

In the illustrative example, one or more roof panels 12 include a panel insert configured as a window panel or skylight for receiving light into shelter 100. Other configurations are also possible, for example, installing windows and/or barrier inserts into gable panels for lighting and/or ventilation. In a non-limiting example, steps 516 and/or 518 are completed prior to transporting wall panels 10 or roof panels 12 to the location where shelter 100 is to be constructed. In a non-limiting example, steps 516 and/or 518 and/or assembly of the panel frame and panel insert may be performed at the location where shelter 100 is to be assembled. In addition, the door 112, window 114, and/or materials for the panel frame and inserts may be locally available, for example, disposed near the assembled location of the shelter 100, and mounted to the panel.

Step 520: and assembling the wall body plate. At step 520, the panel connector 20 may be assembled, attached, or otherwise coupled to the wall panel 10. Note that this may be regarded as an optional step. In many cases, the wall panels 10 will be provided with panel connectors 20 that are pre-attached, for example, from a factory or assembly facility, which may simplify the construction of the shelter 100 at the installation site.

The wall panels 10, roof panels 12 and gable 14, which may be collectively referred to as panel members, are manufactured as lightweight panels that are easy to transport and easy to handle during assembly of shelter 100. In a non-limiting example, the plate members have opposed plate faces defining a plate thickness PT therebetween, opposed plate side edges defining a plate width PW, and upper and lower edges defining a plate height PH. The upper and lower edges of the plate members may be defined relative to the mounting positions of the respective plate members, but note that in many configurations, the upper and lower edges may be exchangeable.

In the example shown in the figures, the wall panels 10 and roof panels 12 are generally rectangular in shape. The plate members may be formed or manufactured, such as by trimming or cutting, into other shapes as desired for assembly of shelter 100. For example, gable panels may be formed in a triangular shape. In an illustrative example, the panel member includes a core member and has a panel face made of a sheathing material attached to opposite sides of the core member to form a composite or laminate member. For example, and without limitation, the panel members are formed from one or more materials selected to render the panel members lightweight and portable while providing an R-value of at least 2 such that shelter 100 formed therefrom has better insulating properties than tent structures. In one example, the panel member is characterized by an R value in the range of about 4 to 10, and in another example, the panel member is characterized by an R value of 9 or greater to provide thermal efficiency to the shelter 100 formed thereby.

For example, and without limitation, the core may be formed from a rigid foam material such as a polystyrene-based material. In one example, the rigid foam is graphene-infused polystyrene to provide an insulating core member having an R value of 9 or greater, and in a preferred example, an insulating core member having an R value of at least 10 to provide thermal efficiency while maintaining the lightweight characteristics of the plate member. One or both of the core member and the sheath material on the face are preferably formed of a waterproof, water-repellent and/or hydrophobic material to form a modular shelter 100 that is resistant to ingress of water. For example, and without limitation, the panel is made of a sheathing material attached to opposite sides of the core member, such as by an adhesive, wherein the sheathing material forming the panel is made of a polymeric material such as Fiberglass Reinforced Polymer (FRP), polyvinyl, high Density Polyethylene Elastomer (HDPE), polyamide, vinyl material, or nylon-based polymeric material to provide additional rigidity, strength, and water resistance to the panel member.

In a non-limiting example, the panel member may be formed by laminating a jacket material to the formed core, including applying an adhesive (e.g., cold glue or spray adhesive) to one or both of the core member and the jacket material, followed by laminating the layers together to form the panel member. Alternatively, heat may be applied to bond or laminate the sheath members to the core member, or an expanded foam core may be placed between the sheath members such that the expanded foam adheres directly to the sheath members. In a non-limiting example, the foam core structure of the wall panel 10 provides the advantage of being easily modified to install the door 112, window 114, etc. with minimal manual tools (e.g., a hand saw, knife, or other manual cutting tool), e.g., without the use of special tools or power tools.

One or more of the plate height PH, the plate width PW, the plate thickness PT, and/or the shape of the plate members may be varied to meet the operational requirements of the shelter 100 assembled from the respective plate members. Various configurations and combinations of core and/or one or more panels may be used to construct the panel member as desired to meet the operational requirements of shelter 100 formed from the panel member and/or to provide the panel member with selective features or properties.

For example, and without limitation, the panel member may be configured for intrusion and/or ballistic, fire and/or smoke protection, water resistance, wind resistance, thermal insulation or other thermal properties, electrical properties, appearance characteristics-including camouflage, light reflection, light absorption, or decorative appearance characteristics, and the like. The combination of sheath and core materials may vary, for example, to provide various configurations of the plate member. In one example, the face and core members may be formed as a unitary, homogenous structure defining the plate members. In another example, the core member may be formed of multiple layers to provide desired characteristics, such as the core member including ballistic resistant inserts, reinforcements, or rigid inserts, such as for windbreak and/or load dissipation, etc.

In a non-limiting example, the plate member may include opposing plate faces made of different materials and/or configured to provide different characteristics to the plate member. In a non-limiting illustrative example, the panel member may include an exterior (as installed) panel having weather resistance, camouflage properties, and/or ballistic resistance properties, and an interior (as installed) panel having thermal insulation and/or decorative properties. All of these examples are illustrative and non-limiting, and it is understood that other combinations of panel members, including materials and build-up layers, are possible within the scope of this description.

In one non-limiting example, an adhesive may be applied to the channel inner surface of the board edge channel 22, and/or to the board side edges and/or to portions of the board surface inserted into the board edge channel 22 to adhere the board members to the channel inner surface to attach the board connectors 20 to the board members to form the wall panel 10. In one example, the adhesive may be configured as a sealant and distributed and/or applied to the plate member and/or channel inner surface to seal the joint between the plate member and the plate edge channel 22, thereby preventing and/or inhibiting fluid (water, liquid, air, etc.) from flowing through the joint.

Step 522: the plate is connected to the rail. Referring again to the method shown in fig. 5A-5C, at step 522, the wall panels 10 assembled at step 520 or pre-assembled prior to the installation site are installed to the respective bottom tracks 50. As referred to herein, a combination of one plate member and one or more connector members may be considered a plate assembly.

At step 522, the panel assemblies are connected to each other and to the corner connectors 60 (as shown in fig. 1-4) and inserted into the wall panel bottom rail 50 and connected to the wall panel bottom rail 50. The panel assembly is connected to the bottom rail 50 by engaging the retractable connectors 64 of the panel connector 20 and the corner connector 60 to the receiving holes 58 of the bottom rail 50 to form the wall assembly 200.

As previously described, the panel connectors 20 and corner connectors 60 include connector portions 26 for connection to adjacent panel connectors 20 and corner connectors 60 by inserting connector plugs 30 into connector receptacles 40 to provide a sealed connection between each panel assembly and adjacent panel assemblies or corner connectors 60 when assembling the wall assembly 200. In one example, a plug seal, which may be a ball seal, may be installed along the socket channel and compressed by inserting the connector plug 30 into the socket channel to provide additional sealing of the joint between the wall panel assemblies and further to prevent air flow through the joint for purposes of insulation and sealing. Any of the components of the RWBS shelter 100 described herein can include a sealing element to, for example, but not limited to, minimize intrusion of water, allow removal of water via a specific path, or minimize airflow through the components.

Each panel connector 20 includes at least one retractable connector 64 (shown in fig. 10) positioned in the panel connector 20 such that the wall panel connector 20 is connected to the bottom rail 50 by engaging the retractable button 66 in the receiving aperture 58 of the bottom rail 50 to form the wall assembly 200 of the shelter 100. As shown in fig. 1-4, the wall assembly 200, including the bottom rail 50, corner connectors 60, and wall panel assemblies (including panel connectors 20 and wall panels 10), forms a rigid freestanding structure that can be used in this configuration without further modification.

For example, the freestanding wall assembly 200 may be used as an open-top structure for housing livestock or storage products. In one example, a roof covering such as tarpaulin, mesh, or the like, or a covering made of a non-RWBS roof material, such as a locally-obtained material including thatch, bamboo, wood, or the like, may be used to cover the freestanding wall assembly 200. In one example, the roof covering may be attached by ties or ropes connected to the wall assembly 200 via the connector slots 28. In a non-limiting example, conventional roofs (e.g., wooden trusses and shingle roofs) may be mounted to the wall assemblies 200 to form a complete shelter. In the example shown in fig. 1-4, the roof assembly 300 is mounted to the wall assembly 200 using the steps of the example method 500 shown in fig. 5A-5C.

Step 524: connecting gable tracks. At step 524, gable track 80 is attached to upper ends of panel connector 20 and corner connector 60 of wall assembly 200. As shown in fig. 20A, each gable track 80 includes a first plate channel 92 or wall plate channel for receiving an upper edge of a plate assembly (e.g., a wall plate assembly) and a second plate channel 94 or gable plate channel for receiving a lower edge of a plate assembly (e.g., a gable plate assembly).

Each of the first and second plate passages 92, 94 includes a receiving aperture 58 formed therethrough and positioned to receive and engage the retractable button 66 of the retractable connector 64 of the plate connector 20 and the corner connector 60 inserted into these passages. One or more seals (e.g., spherical seals) may be incorporated into any of the channels of gable track 80. In particular, the second plate channel 94 may have a seal such that liquid is prevented from entering the second plate channel 94.

In some constructions, the skilled artisan will recognize that the modular shelter 100 can have more than one floor, such that the gable track 80 can be used to assemble the upper wall assembly 200 to the lower wall assembly 200. The gable rail 80 is mounted to the upper edges of the wall panels 10 and corner connectors 60 forming the lower wall assembly 200, and the second panel channel 94 of the gable rail 80 serves as a bottom rail channel to receive and connect to the corner connectors 60 and panel connectors 20 of the upper wall assembly 200 and to receive and connect to the lower edges of the wall panels 10 forming the upper wall assembly 200.

As shown in fig. 20B and 20C, an alternative gable track 81 includes a first plate channel 93 and a second plate channel 95. Furthermore, the alternative gable track 81 includes an additional channel 96 that may be used to connect multiple additional elements. The additional channels 96 may be used, for example, but not limited to, support members connecting the floors in the two-layer shelter 100, or for attachment of additional components/elements of the shelter 100. The alternative gable track 81 also includes offset and grooved sections that are similar in character to the alternative bottom track 51.

Gable track 80 or gable track 81 may include a plurality of drain holes 59 extending through any wall of gable track 80 or between first plate channel 92 and second plate channel 94 to provide drainage of fluid (including rain water) that may flow from upper wall assembly 200 and collect in second plate channel 94, which functions as previously described for drain holes 59 of bottom track 50. Thus, if water enters gable track 80 or gable track 81, such as by passing through an optional seal, water is allowed to drain therefrom. Gable track 80 may be formed from, or by a similar method of manufacture as, without limitation, base track 50, panel connector 20, or corner connector 60.

Optional step 526: and installing the wall body assembly. At step 526, the corner connectors 60, the panel connectors 20, and the wall panels 10 of the upper wall assembly 200 are installed onto the second panel channels 94 of the gable track 80. This may include installing a panel with a door 112 and/or window 114. The wall structure comprising the lower wall assembly 200 and the upper wall assembly 200 forms a rigid freestanding structure of increased height that can be used, for example, to store items and/or equipment that exceed the height of the lower wall assembly 200. As previously described, a freestanding structure comprising an upper wall assembly and a lower wall assembly 200 may be used as the open-top structure. Alternatively, any of the roof structures previously discussed may be mounted to the upper wall assembly 200.

Optional step 528: a floor or floor assembly is installed. Referring again to method 500, at step 528, floor joists and floors may be installed onto the example shelter 100 to separate the upper wall assembly and the lower wall assembly 200 and provide a second level of interior space within the shelter 100. In a non-limiting example, the floor joists may be configured as cross beams attached to gable tracks 80 by brackets. The term "floor joist" is not limiting, and it should be understood that many cross beams may also be used, for example, to install and/or attach a ceiling above the first floor of shelter 100.

Note that the example method 500 is non-limiting, such that it should be appreciated that the steps may be repeated to assemble a plurality of wall assemblies 200 stacked and connected via gable tracks 80 to construct an additional height and/or multi-layer shelter 100.

Optional step 530: and installing an upper channel. At step 530, some sort of channel to the upper layer may be installed. For example, without limitation, an opening in a staircase, ladder or interior floor may be installed to allow access to the upper floors. The skilled artisan will recognize a variety of configurations leading to the upper layers.

Step 532: and connecting with eave rails. At step 532, the RWBS roof assembly 300 is initially installed onto the wall assembly 200. Referring to method 500, one or more eave rails 70 are attached to the upper ends of the eave-side panel connector 20 and corner connector 60 of the wall assembly 200. The term "eave side" is used to refer to the side of the wall assembly 200 that is joined to the lower edge of the roof deck 12. Eave rail 70 is shown in fig. 13 and 14, and the connections between wall panels 10, roof panels 12 and eave rail 70 are shown in fig. 4 and 19.

Fig. 19 shows an end view of the roof deck 12 inserted into the eave rail 70, the eave rail 70 being connected to the wall panels 10 on the eave side of the wall assembly 200. Construction of eave rails 70 as shown in fig. 13 and 14, each eave rail 70 is attached by engagement of the retractable buttons 66 of the panel connector 20 and the corner connector 60 of the wall assembly 200 in the receiving holes 58 formed in the eave rail 70, as best seen in fig. 14. As shown in fig. 13 and 14, each eave rail 70 includes a wall-panel channel 72 for receiving an upper edge of the wall panel 10 and a roof-panel channel 74 for receiving a lower edge of the roof panel 12. The wall plate channel 72 includes a receiving hole 58 formed therethrough and is positioned to receive and engage the retractable button 66 of the retractable connector 64 of the plate connector 20 and the corner connector 60 of the wall plate 10 inserted into the wall plate channel 72.

The roof deck channel 74 of the eave rail 70 includes offset cornice legs (fascia legs) 82 and two soffit legs 84 that cooperate to receive the lower end of the roof deck 12. As shown in fig. 19, the cornice legs 82 and soffit legs 84 respectively interface with the roof deck 12 to define the tilt angle PA of the roof deck 12. The cornice legs 82 may also be referred to herein as roof tilt reference legs or tilt reference legs. Soffit legs 84 may also be referred to herein as roof deck legs or support legs.

Eave rail 70 can include additional fastener holes formed in soffit legs 84 and distributed along the length of eave rail 70. These faster holes may be positioned in alignment with the connector slots 28 of the roof deck connectors 20. During assembly of the roof assembly 300 to the wall assembly 200, as shown in the non-limiting examples described herein, the T-bolts may be positioned in the connector slots 28 of the roof deck connectors 20 such that the threaded ends of the T-bolts are received by and extend through the fastener holes of the lower soffit legs 84 of the eave rail 70. The knob of the T-bolt fastener may be threaded onto the threaded end of the T-bolt and tightened to attach the panel connector 20 and/or roof panel 12 to the eave rail 70. The knob may also be referred to herein as a T-bolt handle.

As shown in fig. 19 and 20, the lower edge of the roof deck 12 abuts the angled cornice legs 82 between the soffit legs 84 and interfaces with the angled cornice legs 82. The eave rail 70 may have a plurality of drain holes formed therein, the function of which is as previously described for the drain holes of the bottom rail 50, particularly at the lowermost portion of the eave plate recess 86, so that water, such as rain water, flowing into the eave rail 70 from the roof assembly 300 is drained through the eave plate recess 86. Eave rail 70 may be formed from, or by a similar method of manufacture as, but not limited to, base rail 50, panel connector 20, corner connector 60, or gable rail 80.

In addition, some configurations of roof assembly 300 may include an eave seal (not shown) that is likely to be positioned on lower soffit 84 along the length of eave rail 70, in contact with the inner panel face of roof panel 12. Other eave seals may be included. In one example, the eave seal is made of a compressible elastomer, polymer, or rubber-based material such that during assembly of the roof deck 12 to the eave rail 70, the eave seal is compressed, creating a continuous seal between the surface of the soffit legs 84 and the inner plate surface along the length of the eave rail 70. If water collects in the roof deck channel 74 at a rate or amount that cannot drain through the drain Kong Chongli, the eave seal can seal the flange to the roof deck interface and prevent water from entering the interior of the shelter 100 along the lower soffit legs 84.

If a sufficient amount of water is present, the eave seal may pressurize the collected water to force the water out of the roof deck channel 74 via the drain holes. Non-limiting example configurations of eave seals include ball seals, D-seals, O-ring seals, etc. to provide a seal to the joint between adjoining connector portions 26. In one example, the eave rail 70 can be provided with eave seals that are pre-applied to the lower soffit legs 84. In another example, eave rail 70 and eave seal are provided as separate components, and the eave seal is attached to lower soffit leg 84 during assembly of shelter 100. In a non-limiting example, the eave seal can be adhered to the lower soffit leg 84 by an adhesive or other fastening means, and/or the eave seal can include an adhesive strip for adhering the eave seal to the lower soffit leg 84.

Step 534: and assembling the gable. At step 534, the RWBS roof assembly 300 assembles the gable portion from at least the gable 14 and the gable connectors 20. Gable track 80 may have been attached to wall plate 10 and wall plate connector 20 and corner connector 60 along the gable sides of wall assembly 200, with gable track 80 attached by engagement of retractable buttons 66 in receiving holes 58 of gable track 80.

At step 534, the gable panel connector 20 is attached to the gable panel 14 to form a gable panel assembly, as shown in fig. 1, 2, and 4, similar to the description of the assembly of the wall panel 10 at step 520. In a non-limiting example, the gable 14, shown as two triangular plates in the figures, may alternatively be provided as an integral gable 14, for example, where the gable is smaller in size so that the gable 14 may be manufactured and transported as an integral component. Further, without limitation, gable 14 may include one or more windows 114, panel frames, and/or panel inserts, such as transparent panels or barriers, for providing light and/or ventilation to shelter 100.

Gable panels 14 may be inserted into the second panel channels 94 (upper channels) of gable tracks 80 to form gable assemblies, in the example shown in figures 1 and 2, at each gable end of shelter 100. The gable panel 14 including the panel connector 20 is connected by engagement of the retractable button 66 with the receiving aperture 58 in the gable track 80. The gable connection 20 is substantially identical to the wall connection 20, but may be shorter and may have an angle cut into the upper portion.

Note that alternative gable constructions may be used. For example, without limitation, roof assembly 300 may have a single span along a single tilt angle PA such that gable 14 is substantially a right triangle, which may be a single solid panel. It may also include one side with an upper (possibly shorter) wall assembly 200 attached to an additional gable track 80.

Step 536: and assembling the roof plate. At step 536, the roof panel connectors 20 are attached to the roof panels 12 to form the roof assembly 300, as shown in fig. 1 and 3. The view of fig. 1 may be considered as one roof assembly 300 or two roof assemblies 300. The connection and assembly process may be similar to the assembly process of the wall panel 10 to the panel connector 20 previously described at step 520. The panel connectors 20 are attached to the roof panel 12 and then connected similar to the view shown in fig. 10, but without the bottom rail 50 and possibly without the retractable connectors 64, so that the roof assembly 300 is held together by the gable end rail 120 as required by the roof assembly 300.

Step 538: the gable ends are closed. At step 538, the gable end rail 120 is attached to the gable 14 (which may also be referred to herein as gable closure) by inserting the upper edge of the gable 14 into the gable channel of the gable end rail 120. Gable end rail 120 generally includes two access channels, a gable channel and a roof channel, that are substantially at right angles to each other.

Gable end rail 120 (which is best seen in fig. 1-3) surrounds the upper edge of gable 14 and receives one or more roof panels 12. Gable end rail 120 may be formed from, or by a similar method of manufacture as, but not limited to, base rail 50, panel connector 20, corner connector 60, gable rail 80, or eave rail 70.

Step 540: and connecting the cross beams. In step 540, one or more beams 130 may be connected to the eave rail 70 to provide additional rigidity to the wall assembly 200, truss support to the roof assembly 300, or both. The cross beam 130 and the elements attached thereto are best seen in fig. 4 and 18. Note that in some configurations, modular shelter 100 can be configured without cross beams 130, such that step 540 can be optional, but many configurations will include some trusses or lateral supports.

In a non-limiting example, the eave rail 70 includes a transverse channel 76, the transverse channel 76 having a receiving aperture 58 defined therein, as best seen in fig. 14. Thus, the transverse channel 76 receives the cross beam 130 via, for example, the retractable button 66 of the retractable connector 64 engaged with the receiving bore 58.

The cross beam 130 may include a web member 132 that is operatively connected with the cross beam 130 and that serves as a truss element to support the roof rail 110 or a portion of the roof rail assembly 110 (shown in fig. 15-18) in which the upper edge of the roof deck 12 is received at a height corresponding to the roof tilt angle. The web members 132 may be fixedly attached to the cross beam 130, such as by welding, brackets, or other fixed fastening methods, such that the roof rail assembly 110 rests on, e.g., is supported by, the uppermost end of the web members 132.

As shown in fig. 4 and 18, web member 132 may be hingedly attached to beam 130 such that web member 132 may be rotated from a folded or stowed position of web member 132 adjacent beam 130 via hinge bracket 134. The web member 132 may then be rotated to an upright or deployed position, as shown in fig. 4 and 18.

For packaging and shipping efficiency, web members 132 may be positioned in a folded position adjacent to cross-beams 130 such that with web members 132 in the folded position, cross-beams 130 may nest more tightly with one another during shipping. The upper end of web member 132 includes one or more retractable connectors 64 and retractable buttons 66, with retractable connectors 64 and retractable buttons 66 being engageable with receiving holes 58 of ridge rail assembly 110 to connect web member 132 to ridge rail assembly 110 in a truss configuration, as shown in fig. 4 and 18.

Step 542: assembling the ridge rail sections. At step 542 of method 500, portions of roof rail assembly 110 are assembled. As shown in fig. 15-18, the roof rail assembly 110 includes two rail sections, an upper rail 116 and a lower rail 118, held together by a spring-loaded Lock Connector Assembly (LCA) 138. Fig. 15 shows a side view of the upper rail 116, the upper rail 116 may be referred to as a ridge cap; fig. 16A shows a side view of lower track 118, lower track 118 may be referred to as a roof truss; fig. 16B shows a side view of an alternative lower track 119, which alternative lower track 119 may be referred to as an alternative roof bracket; FIG. 17 shows an isometric view of the assembled roof rail assembly 110; fig. 18 shows the assembled roof rail assembly 110 with the cover plate of LCA 138 removed to show the internal springs.

The assembly of the roof rail assembly 110 may be performed in a variety of sequences, and the sequence suggested herein is only one example, as are the remaining steps of the method 500. After mounting the cross beam 130 and rotating the web member 132 upward, the lower track 118 may be attached to the web member 132 by the retractable connector 64 and retractable button 66 engaging the receiving hole 58 in the web channel of the lower track 118. The elements of ridge rail assembly 110, including upper rail 116 and lower rail 118, may be formed from similar materials or by similar manufacturing methods as bottom rail 50, panel connector 20, corner connector 60, gable rail 80 or eave rail 70, and other components of shelter 100, without limitation. In some constructions, there may be a seal, such as a ball seal, between the upper rail 116 and the roof deck 12.

In some constructions, the plurality of lower rails 118 will be aligned and connected by at least one ridge splice 90, as shown in fig. 17. The ridge splice 90 may be stored within the web channel of the lower track 118 and then rotated outwardly to slot in and attach to the web channel of an adjacent lower track 118. Ridge splice 90 may be attached to lower track 118 by retractable connector 64 and retractable button 66 engaging receiving hole 58 formed in the web channel.

Additional fasteners may be used for shipping, assembling, or both, any of the components of modular shelter 100. For example, and without limitation, the ridge splice 90 may pivot about a bolt or pivot pin, which may then be removed, or may be retained within the assembled shelter 100.

Fig. 16B shows an alternative lower track 119 or alternative roof truss. The alternative lower track 119 includes a brace or support element for reinforcing the alternative lower track 119.

Step 544: and (5) installing a roof. At step 544 of method 500, one or more roof panels 12 having panel connectors 20 connected to one or more edges may be placed onto the assembled portion of the roof rail assembly 110. The installed lower track 118, supported by the web members 132, provides a base upon which the roof deck 12 and roof deck connections 20 may be placed during installation. Note that in step 536, the roof panel 12 is assembled to the roof panel connection 20. However, the installing step 544 may also include assembling the roof deck.

The shingle 12 may also be inserted into a shingle channel of the gable end rail 120. In addition, roof panels may be inserted into the roof panel channels of the eave rail 70. This allows the roof panel 12 and roof panel connectors 20 (i.e., portions of the roof assembly 300) to be installed on top of a freestanding structure prior to installing the rails 116 with the LCAs 138.

Step 546: and finishing the ridge rail. At step 546 of method 500, the remainder of ridge rail assembly 110 is assembled. As best seen in fig. 16-18, the lower track 118 includes a bracket cutout 122 or locking notch formed adjacent to a bracket slot 124 or handle aperture. These elements are configured to mate with the pull 140 of the LCA 138. The lower channel of the lower track 118 may be referred to as a bracket channel. The alternative lower track 119 also includes a similar bracket cutout 122.

To attach the upper rail 116 to the lower rail 118, the LCA 138 is attached to the upper rail 116, for example, with bolts or retractable connectors 64. The handle 140, which is rotated substantially 90 degrees relative to the orientation shown in the figures, is then pulled through the bracket slot 124 in the lower track 118. After pulling through the bracket slot 124, the pull handle 140 is rotated 90 degrees to the orientation shown in the figures and released such that the internal spring of the LCA 138 pulls the pull handle 140 into engagement with the bracket cut 122.

The bracket cutout 122 may be difficult to see in fig. 17, however, the splice 90 includes a splice cutout 126 that is similarly shaped to allow the handle 140 to lock when rotated. Similarly, bracket slot 124 may be difficult to see in fig. 17, but splice 90 includes a splice slot 128 that is similarly shaped to allow handle 140 to be pulled through prior to rotation.

The upper rail 116 and the lower rail 118 are pressed by the LCA 138 onto the sides of the roof deck 12 between them, as best seen in fig. 18. In addition, the springs of LCA 138 maintain ridge splice 90 connected to other portions of ridge track assembly 110. In the example modular shelter 100 shown in fig. 1, there are two ridge tracks 110 connected by one ridge splice 90 (not visible in fig. 1). Note that multiple LCAs 138 and handles 140 may be used. In the view of figure 17, there are three LCAs 138, such that for the modular shelter 100 shown in figure 1, there can be up to six LCAs 138 for connecting elements of two roof rails 110.

Optional step 550: connecting the inner wall body part. Optional steps 550-556 are provided to install or connect components including, but not limited to, interior components, exterior components, utilities, wall components, or combinations thereof. At step 550, the inner wall portion may be attached to the connector slot 28 of the board connector 20, for example. Alternatively, any additional components may be attached by other mechanisms or devices including, but not limited to, brackets attached to wall panels 10, roof panels 12, gable panels 14, panel connectors 20, or corner connectors 60.

Other components may be mounted to shelter 100, including but not limited to floors, ceiling components, lighting, communication equipment, toilets, plumbing, kitchen equipment, and other components recognizable to one of ordinary skill in the art. Note that these components may not be shown in the figures, but the skilled artisan will appreciate these components.

Optional step 552: and installing a utility. At step 552, one or more utilities may be installed on the shelter 100. Possible utilities include, but are not limited to, lighting devices, electrical wiring and/or outlets, HVAC and plumbing.

Optional step 554: connecting the internal components. At step 554, one or more internal components may be installed or connected to the shelter 100. Possible interior components include, but are not limited to, floors, ceiling components, shelves, and hooks.

Optional step 556: the external components are connected. At step 556, one or more external components may be mounted or attached to shelter 100. Possible external components include, but are not limited to, air conditioning units, solar units, and communication systems. Method 500 may end after optional step 556, or additional steps may be provided to further customize or better prepare modular shelter 100 for the particular needs of a particular installation.

The RWBS components described herein with reference to method 500 and other figures may be constructed, combined, and assembled into a variety of different configurations of modular shelter 100 for a variety of uses, including recreational, real, humanoid, military, and other uses identifiable to those of ordinary skill in the art. The various RWBS components described herein, including wall panels 10, roof panels 12, panel connectors 20, corner connectors 60, bottom rails 50, eave rails 70, gable rails 80, ridge rails 110, and the like, may be adjusted and/or modified within the scope of the present disclosure to assemble shelter 100 for various uses.

As a non-limiting example, various RWBS components may be modified according to the intended use of the shelter 100, including modifications for providing desired appearance or functional characteristics, including, but not limited to: camouflage, decorative treatments, light reflection characteristics, ballistic characteristics, surface texture and embossing, decorative finishing, decal applications, and the like, as appropriate for the intended use and/or location of the modular shelter 100.

Examples of retractable connectors 64 are illustrative and not limiting, and it is understood that the use of other types of reusable connectors (including spring loaded or spring type connectors or conventional removable and reusable connectors, such as bolts and nuts, etc.) are contemplated as falling within the scope of the present disclosure. For permanent installation of the modular shelter 100, RWBS components having disposable and/or non-reusable connectors (e.g., rivets) can be provided and are contemplated to be within the scope of the present disclosure.

A further advantage of the rapid wall construction system (RWBS) described herein is logistical efficiency due to the ability to compactly package and transport standardized components, many or all of which can be nested within one another to significantly reduce empty transport space. In combination with the lightweight nature of the RWBS components, the transportation costs and energy savings are significantly lower relative to the transportation costs of conventional materials of similarly sized modular shelter 100.

The detailed description and drawings or figures are supporting and descriptive of the present teachings, but the scope of the present teachings is limited only by the claims. While certain of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings as defined in the appended claims.

Claims

1. A lightweight modular shelter, comprising:

a first plate;

a first plate connector having a plate edge channel operatively connected to one side of the first plate and a connector plug and connector socket;

a second plate;

a second plate connector having a plate edge channel operatively connected to one side of the second plate and a connector plug and connector socket; and is also provided with

Wherein the connector plug of the first board connector is inserted into the connector receptacle of the second board connector such that the first board and the second board are operatively connected.

2. The lightweight modular shelter of claim 1, further comprising:

a bottom rail; and is also provided with

Wherein the first plate, the second plate, the first plate connector and the second plate connector mate with the bottom rail.

3. The lightweight modular shelter of claim 2,

wherein the mating of the first plate, the second plate, the first plate connector and the second plate connector with the bottom rail is performed by engagement of a retractable connector with a receiving hole formed in the bottom rail.

4. The lightweight modular shelter of claim 3, further comprising:

a third plate;

a third plate connector having a plate edge channel operatively connected to one side of the third plate and a connector plug and connector socket;

a fourth plate;

a fourth plate connector having a plate edge channel operatively connected to one side of the fourth plate and a connector plug and connector socket;

The eave rail is provided with a wall plate channel and a roof plate channel which is arranged at a certain angle with the wall plate channel;

wherein the first and second panels are wall panels and the third and fourth panels are roof panels;

wherein the wall panel channel of the eave rail mates with the top of the connected first and second panels;

wherein the connector plug of the third board connector is inserted into the connector receptacle of the fourth board connector such that the third board and the fourth board are operatively connected; and is also provided with

Wherein the roof deck channel of the eave rail mates with the bottoms of the connected third and fourth panels such that the third and fourth panels are at an angle to the first and second panels.

5. The lightweight modular shelter of claim 4,

wherein the mating of the first plate, the second plate, the first plate connector and the second plate connector with the eave rail is performed by the retractable connector engaging with a receiving hole formed in the eave rail.

6. The lightweight modular shelter of claim 5, further comprising:

Ridge cap;

roof rack;

a spring loaded locking connector assembly configured to selectively join the ridge cap to the ridge bracket; and is also provided with

Wherein the third plate and the fourth plate are disposed between the ridge cap and the ridge bracket when joined by the spring loaded locking connector assembly.

7. The lightweight modular shelter of claim 6, further comprising:

a cross beam;

wherein the eave track comprises a transverse channel substantially orthogonal to the wall-panel channel; and is also provided with

Wherein the cross beam mates with the transverse channel.

8. The lightweight modular shelter of claim 7, further comprising:

a web member hingedly connected with the beam and movable between a stowed position substantially adjacent to the beam and a deployed position substantially orthogonal to the beam; and is also provided with

Wherein the web member mates with the roof bracket.

9. The lightweight modular shelter of claim 8,

wherein the web member mates with the roof bracket by a retractable connector engaging a receiving aperture formed in the roof bracket.

10. The lightweight modular shelter of claim 9, further comprising:

A plurality of corner connectors, each corner connector having two connector plugs and two connector receptacles;

wherein the two connector plugs are substantially orthogonal to each other;

wherein the two connector receptacles are substantially orthogonal to each other;

wherein the connector plug and connector socket of the corner connector are capable of mating with the connector plug and connector socket of the first and second plates; and is also provided with

Wherein the corner connector mates with the bottom rail.

11. The lightweight modular shelter of claim 10, further comprising:

a fifth plate;

a fifth plate connector having a plate edge channel operatively connected to one side of the fifth plate and a connector plug and connector socket;

a sixth plate;

a sixth plate connector having a plate edge channel operatively connected to one side of the sixth plate and a connector plug and connector socket;

a gable track having a wall panel channel and a gable panel channel;

two gable panels;

two gable connectors, each having a panel edge channel operatively connected to one side of the two gable panels and a connector plug and connector socket;

Wherein the connector plug of one of the two gable panel connectors is inserted into the connector receptacle of the other of the two gable panel connectors such that the two gable panels are operably connected;

wherein the connector plug of the fifth plate connector is inserted into the connector receptacle of the sixth plate connector such that the fifth plate and the sixth plate are operatively connected;

wherein the wall panel channel of the gable track mates with the top of the fifth and sixth panels connected; and is also provided with

Wherein the gable channel of the gable track mates with the bottom of two gable connected.

12. A lightweight modular shelter, comprising:

a plurality of wall panels;

a plurality of wall panel connectors having panel edge channels operatively connected to one side of the wall panel and connector plugs and connector receptacles opposite the panel edge channels;

a plurality of corner connectors, each corner connector having two connector plugs and two connector receptacles, wherein the connector plugs and the connector receptacles are substantially orthogonal to each other;

A plurality of bottom rails;

the connector plug of one of the wall panel connectors is inserted into the connector socket of the other wall panel connector so that adjacent wall panels are operatively connected;

a connector plug of one of the corner connectors is inserted into a connector socket of an adjacent wall panel connector such that the wall panel is operatively connected to the corner connector; and is also provided with

Wherein the connected wall panels and corner connectors mate with the bottom rail and the connected wall panels mate with the bottom rail to form a freestanding structure.

13. The lightweight modular shelter of claim 12, further comprising:

a plurality of roof panels;

a plurality of roof deck connections having a deck edge channel operatively connected to one side of the roof deck and a connector plug and connector receptacle opposite the deck edge channel;

a plurality of eave tracks having wall-panel channels and roof-panel channels disposed at an angle to the wall-panel channels;

wherein the wall panel channel of the eave rail is mated with the top of the wall panel, the wall panel connector and the corner connector opposite the bottom rail;

A connector plug of one of the roof panel connectors is inserted into a connector socket of another of the roof panel connectors such that adjacent roof panels are operatively connected;

wherein the roof deck channel of the eave track mates with the roof deck connector and the bottom of the roof deck such that the roof deck is at an angle to the wall panel.

14. The lightweight modular shelter of claim 13,

wherein the mating of the wall panel connectors and the corner connectors with the bottom rail is by engagement of a retractable connector with a receiving hole formed in the bottom rail; and is also provided with

Wherein the mating of the wall panel connectors and the corner connectors with the eave rail is performed by the retractable connectors engaging receiving holes formed in the eave rail.

15. The lightweight modular shelter of claim 14, further comprising:

a plurality of gable panels;

a plurality of gable panel connectors having a panel edge channel operatively connected to one side of the gable panel and connector plugs and connector receptacles opposite the panel edge channel;

A plurality of gable tracks having wall plate channels and gable plate channels substantially aligned on opposite sides of the gable tracks;

wherein a wall panel channel of a gable track cooperates with a top of the wall panel, the wall panel connector and the corner connector opposite the bottom track;

the connector plug of one of the gable panel connectors is inserted into the connector receptacle of the other gable panel connector such that adjacent gable panels are operatively connected; and is also provided with

Wherein the gable channel of the gable track mates with a bottom of the gable and the gable connector such that the gable is substantially aligned with the wall panel.

16. The lightweight modular shelter of claim 15,

wherein mating of the gable connection with the gable track is by engagement of a retractable connection with a receiving hole formed in the gable track.

17. The lightweight modular shelter of claim 16, further comprising:

a plurality of cross beams;

a plurality of web members hingedly connected to the cross beam and movable between a stowed position substantially adjacent to the cross beam and a deployed position substantially orthogonal to the cross beam; and is also provided with

Wherein the cross beam mates with the transverse channel of the eave rail.

18. The lightweight modular shelter of claim 17, further comprising:

at least one ridge cap;

at least one roof rack;

a plurality of spring loaded locking connector assemblies configured to selectively join the ridge cap to the ridge bracket;

wherein an upper edge of the roof panel is disposed between the ridge cap and the ridge bracket when the ridge cap and the ridge bracket are joined by the spring-loaded locking connector assembly; and is also provided with

19. The lightweight modular shelter of claim 18, further comprising:

a splice, wherein the splice is configured to connect one roof bracket to another roof bracket.

20. The lightweight modular shelter of claim 19,

wherein one of the wall panels comprises a door; and is also provided with

Wherein one of the wall panels comprises a window.

21. A method of assembling a modular shelter, comprising:

laying a plurality of bottom tracks on a substantially planar surface;

connecting a plurality of wall panel connectors to a plurality of wall panels through panel edge channels in the wall panel connectors;

connecting a plurality of corner connectors to the bottom rail;

connecting the wall panel connectors and the plurality of wall panels to the bottom rail;

connecting adjacent wall panel connectors by inserting connector plugs of one wall panel connector into connector receptacles of another wall panel connector;

connecting a wall panel connector to a corner connector by inserting a connector plug of one wall panel connector into a connector socket of the corner connector and inserting a connector plug of the corner connector into a connector socket of another wall panel connector;

such that the wall panels, wall panel connectors, corner connectors, and bottom rail form a freestanding structure having at least four wall assemblies.

22. The method of assembling a modular shelter of claim 21, further comprising:

Connecting a plurality of eave tracks to the top edges of two wall assemblies; and

a plurality of roof panels are connected to the eave rail at an angle to the wall assembly.

23. The method of assembling a modular shelter of claim 22, further comprising:

connecting a plurality of gable tracks to top edges of two wall assemblies; and

a plurality of gable panels are connected to the other side of the gable track.

24. The method of assembling a modular shelter of claim 23, further comprising:

supporting a top edge of the roof deck with one or more ridge brackets;

one or more ridge caps are tied to the ridge brackets with a plurality of spring-loaded locking connector assemblies such that the ridge caps are partially between the ridge caps and the ridge brackets.

25. The method of assembling a modular shelter of claim 24, further comprising:

connecting a plurality of cross beams to the eave rail;

a plurality of web members hingedly attached to the beam; and

the web member is connected to the roof bracket.

26. The method of assembling a modular shelter of claim 25, further comprising:

Wherein the connection of the corner connectors and the wall panel connectors to the bottom rail is made by engagement of retractable connectors with receiving holes formed in the bottom rail; and is also provided with

Wherein the connection of the corner connectors and the wall panel connectors to the eave rail is made by engagement of retractable connectors with receiving holes formed in the eave rail.