Expeditionary pod construction

Abstract

A modular pod assembly capable of being readily assembled and disassembled for transportation includes a plurality of modular panels and a plurality of connectors. Each said modular panel includes a rigid and substantially planar structure delimited along one or more edges by respective coupling portions, each coupling portion formed to define a plurality of preconfigured access points for receiving respective connectors. Multiple connectors are provided to securely fasten a coupling portion of a given modular panel to a coupling portion of another adjacent modular panel at a selected access point. The plurality of modular panels may be provided in an assembled state to include at least one top panel, bottom panel, and a plurality of respective side walls, all securely fastened together at respective coupling portions with the plurality of connectors to form an integrated enclosure.

1 . A modular pod assembly capable of being assembled and disassembled for transportation, comprising:
 a plurality of modular panels, each said modular panel comprising a rigid and substantially planar structure delimited along one or more edges by respective coupling portions, each coupling portion formed to define a plurality of preconfigured access points for receiving respective connectors;   a plurality of connectors, each connector provided to securely fasten a coupling portion of a given modular panel to a coupling portion of another adjacent modular panel at a selected access point, wherein multiple connectors are used to securely fasten each coupling portion of a modular panel to a coupling portion of an adjacent modular panel;   wherein the plurality of modular panels when provided in an assembled state include at least one modular panel forming a top panel for the modular pod assembly, at least one modular panel forming a bottom panel, and a plurality of modular panels forming respective side walls, all modular panels securely fastened together at respective coupling portions via said plurality of connectors to form an integrated enclosure;   wherein the plurality of modular panels when provided in a disassembled state and stacked one on top of another are characterized by a total height of less than about 96 inches.   
     
     
         2 . The modular pod assembly of  claim 1 , wherein each said modular panel comprises:
 first and second rigid and substantially planar support layers;   an adhesive insulating layer in between said first and second rigid and substantially planar support layers; and   a protective sealant provided on outer surfaces of the first and second rigid and substantially planar support layers.   
     
     
         3 . The modular pod assembly of  claim 1 , wherein each connector comprises an angle iron and plurality of carriage bolts, each said access point in each said coupling portion configured to receive at least one of said plurality of carriage bolts. 
     
     
         4 . The modular pod assembly of  claim 1 , wherein each connector is a cam lock connector comprising an engaging connector portion and a receiving connector portion, some of said access points within some of said coupling portions in the plurality of modular panels including respective engaging connector portions and some of said access points within some of said coupling portions in the plurality of modular panels including respective receiving connector portions such that each adjacent access point in the modular pod assembly where a given modular panel is connected to an adjacent modular panel comprises one engaging connector portion and one receiving connector portion. 
     
     
         5 . The modular assembly of  claim 4 , wherein each said engaging connector portion comprises a cylinder for receiving a locking tool capable of actuating the engaging connector portion between a locked and an unlocked state. 
     
     
         6 . The modular pod assembly of  claim 1 , further comprising one or more adapter posts having additional coupling portions, each coupling portion of each adapter post formed to define a plurality of preconfigured access points for receiving respective connectors, each adapter post provided as an interface between two or more of said plurality of modular panels. 
     
     
         7 . The modular pod assembly of  claim 1 , further comprising a plurality of wheels mounted to a plurality of outer locations on said bottom panel. 
     
     
         8 . The modular pod assembly of  claim 1 , wherein said integrated enclosure formed when six of said modular panels are provided in an assembled state is characterized by respective length, width and height dimensions of between about 80 and 100 inches. 
     
     
         9 . The modular pod assembly of  claim 1 , wherein the plurality of modular panels when provided in a disassembled state and stacked one on top of another are characterized by a total height of between about 30 inches and about 48 inches. 
     
     
         10 . The modular pod assembly of  claim 1 , wherein the plurality of modular panels when provided in a disassembled state and stacked one on top of another are characterized by a total weight of less than about 1500 pounds. 
     
     
         11 . A modular pod assembly, comprising:
 a plurality of rigid and substantially planar modular panels, each said modular panel comprising first and second support layers and an insulating layer in between said first and second support layers, each said modular panel further comprising respective coupling portions along selected edges, each coupling portion formed to define a plurality of preconfigured access points for receiving respective connectors;   a plurality of connectors, each connector capable of transitioning between a locked and an unlocked state and provided to securely fasten a coupling portion of a given modular panel to a coupling portion of another adjacent modular panel at a selected access point, wherein multiple connectors are used to securely fasten each coupling portion of a modular panel to a coupling portion of an adjacent modular panel;   wherein the plurality of modular panels are securely attached to one another at said coupling portions via said plurality of connectors to form an integrated enclosure with at least one modular panel forming a top panel for the modular pod assembly, at least one modular panel forming a bottom panel, and a plurality of modular panels forming respective side walls.   
     
     
         12 . The modular pod assembly of  claim 11 , wherein each said rigid and substantially planar modular panel comprises:
 first and second planar support layers;   an adhesive insulating layer in between said first and second planar support layers; and   a polyurethane protective coating provided on outer surfaces of the first and second rigid and substantially planar support layers.   
     
     
         13 . The modular pod assembly of  claim 11 , wherein each connector is a cam lock connector comprising an engaging connector portion and a receiving connector portion, some of said access points within some of said coupling portions in the plurality of modular panels including respective engaging connector portions and some of said access points within some of said coupling portions in the plurality of modular panels including respective receiving connector portions such that each adjacent access point in the modular pod assembly where a given modular panel is connected to an adjacent modular panel comprises one engaging connector portion and one receiving connector portion. 
     
     
         14 . The modular assembly of  claim 13 , wherein each said engaging connector portion comprises a rotatable latch and a cylinder for receiving a locking tool capable of actuating the rotatable latch into engagement with an adjacent receiving connector portion. 
     
     
         15 . The modular pod assembly of  claim 11 , further comprising one or more adapter posts having additional coupling portions, each coupling portion of each adapter post formed to define a plurality of preconfigured access points for receiving respective connectors, each adapter post provided as an interface between two or more of said plurality of modular panels. 
     
     
         16 . The modular pod assembly of  claim 11 , wherein at least one of said plurality of side walls corresponds to a front wall that is formed to define an opening therethrough, and wherein said modular pod assembly further comprises a door positioned within the opening defined in said front wall and securely attached to said front wall. 
     
     
         17 . The modular pod assembly of  claim 11 , wherein at least one of said plurality of rigid modular panels is formed to define at least first and second access points for respectively interfacing with an input air duct and an output air duct of an HVAC unit. 
     
     
         18 . The modular pod assembly of  claim 17 , further comprising:
 an electrical panel coupled to an exterior location of one of said plurality of rigid modular panels; and   an HVAC unit comprising at least first and second air ducts coupled to said at least first and second access points formed within at least one of said plurality of rigid modular panels, said HVAC unit being electrically connected to said electrical panel.   
     
     
         19 . The modular pod assembly of  claim 11 , further comprising an acrylic-reinforced polyurethane protective coating applied over selected interior and exterior surfaces of said plurality of rigid modular panels. 
     
     
         20 . A modular pod assembly, comprising:
 a plurality of rigid modular panels each characterized by four perimeter portions;   a plurality of connectors securely fastening each said perimeter portion of each said modular panel to another perimeter portion of another one of said plurality of rigid modular panels to form an integrated enclosure having at least one top panel, at least one bottom panel and a plurality of respective side walls, the integrated enclosure having respective interior and exterior surfaces of each rigid modular panel;   wherein at least one of said plurality of side walls corresponds to a front wall that is formed to define an opening therethrough, and wherein said modular pod assembly further comprises a door positioned within the opening defined in said front wall and securely attached to said front wall;   wherein at least one of said plurality of rigid modular panels is formed to define at least first and second access points;   an electrical panel coupled to an exterior location of one of said plurality of rigid modular panels and adapted to provide an electrical interface for a power supply; and   an HVAC unit comprising at least first and second air ducts coupled to said at least first and second access points formed within at least one of said plurality of rigid modular panels, said HVAC unit being electrically connected to said electrical panel.   
     
     
         21 . The modular pod assembly of  claim 20 , further comprising an acrylic-reinforced polyurethane protective coating applied over selected interior and exterior surfaces of said plurality of rigid modular panels. 
     
     
         22 . The modular pod assembly of  claim 20 , further comprising an integrated hygiene unit mounted to an interior surface of one of said side walls, said integrated hygiene unit comprising a sink and a toilet. 
     
     
         23 . The modular pod assembly of  claim 20 , wherein an interior surface of said top panel is formed to define at least one opening therein, and wherein said modular pod assembly further comprises at least one light source mounted in the opening formed within the interior surface of said top panel. 
     
     
         24 . The modular pod assembly of  claim 23 , further comprising a transparent thermoplastic covering over said at least one light source. 
     
     
         25 . The modular pod assembly of  claim 20 , wherein said door comprises a view opening covered with at least one fixed layer of rigid transparent thermoplastic material. 
     
     
         26 . The modular assembly of  claim 20 , wherein said door comprises an access opening and access door securely mounted to said door and capable of being alternately provided between an open position to allow limited exchange through the access opening and a closed position secured with at least one latch mechanism. 
     
     
         27 . The modular assembly of  claim 20 , wherein said bottom panel is formed to define at least one opening therein, and wherein said modular pod assembly further comprises a drain affixed within the at least one opening formed in said bottom panel. 
     
     
         28 . The modular pod assembly of  claim 20 , wherein each said rigid modular panel further comprises:
 first and second planar support layers;   an adhesive insulating layer in between said first and second planar support layers; and   a polyurethane protective coating provided on outer surfaces of the first and second rigid and substantially planar support layers.   
     
     
         29 . The modular pod assembly of  claim 20 , wherein selected connectors of said plurality of connectors is a cam lock connector comprising an engaging connector portion and a receiving connector portion, some of said access points within some of said coupling portions in the plurality of rigid modular panels including respective engaging connector portions and some of said access points within some of said coupling portions in the plurality of rigid modular panels including respective receiving connector portions such that each adjacent access point in the modular pod assembly where a given rigid modular panel is connected to an adjacent modular panel comprises one engaging connector portion and one receiving connector portion. 
     
     
         30 . The modular pod assembly of  claim 20 , further comprising one or more adapter posts having additional coupling portions, each coupling portion of each adapter post formed to define a plurality of preconfigured access points for receiving respective connectors, each adapter post provided as an interface between two or more of said plurality of rigid modular panels.