Note: Descriptions are shown in the official language in which they were submitted.
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READY TO ASSEMBLE SHELTER
FIELD OF THE INVENTION
The present invention relates to structures such as shelters. More
specifically, the present invention relates to a ready to assemble shelter.
BACKGROUND OF THE INVENTION
Known in the art are conventional building structures and the like which are
used in various storage and housing applications. Also known in the art are
the various disadvantages associated with these types of conventional
building structures and the like, such as difficult assembly and lack of
variability and customisation.
Known to the Applicant are the following U.S. patents and patent
applications which describe different shelters and the like: US 2,897,668;
US 3,154,888; US 3,892,094; US 4,091,584; US 5,065,554; US 5,319,904;
US 5,444,946; US 5,598,668; US 6,266,932; US 6,324,791; US 6,584,732;
US 6,766,623; US 6,843,261; US 2002/0017068; US 2002/0100228; and
US 2004/0045227.
In addition, known to the Applicant are U.S. patents US 4,700,514; US
3,750,353; and US 3,187,852 which describe modular structures assembled
of curved elongate sections forming shelters.
However, a disadvantage with the three above-noted patents is that they
are difficult and cumbersome to assemble. Specifically, US 4,700,514 and
US 3,187,852 each provide arched structures made up of elongate sections
attached via lateral flanges extending therefrom which must be manually
aligned during assembly. A major drawback of these types of structures is
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that, in practice, they are difficult to assemble without a crane, boom lift,
or
ladder.
Hence, in light of the aforementioned, there is a need for a device or a
system which, by virtue of its design and components, would be able to
overcome some of the aforementioned prior art problems.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a ready to assemble shelter
which, by virtue of its design and components, satisfies some of the above-
mentioned needs and is thus an improvement over other related structures
known in the prior art.
Another object of the present invention is to provide a ready to assemble
shelter which is easy to assemble.
According to a first aspect of the invention, a ready to assemble shelter is
provided having first and second vertical faces made of fibre reinforced
composite material, a plurality of sections, and securing apparatus for
securing the sections side by side to form a structure, and for securing the
structure between the vertical faces to form the shelter. The sections each
include at least one elongate panel made of fibre reinforced composite
material, a first flange extending downwardly from a first lateral side of the
elongate panel; and a second L-shaped flange extending downwardly and
then outwardly from a second lateral side of the elongate panel that is
opposite to the first lateral side, the first flange being capable of
cooperating
with the second flange of an adjacent section.
According to a second aspect of the invention, a shelter kit is provided
having first and second vertical faces made of fibre reinforced composite
material, a plurality of sections, and securing apparatus for securing the
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sections side by side to form a structure, and for securing the structure
between the vertical faces to form the shelter. The sections each include at
least one elongate panel made of fibre reinforced composite material, a first
flange extending downwardly from a first lateral side of the elongate panel;
and a second L-shaped flange extending downwardly and then outwardly
from a second lateral side of the elongate panel that is opposite to the first
lateral side, the first flange being capable of cooperating with the second
flange of an adjacent section when assembled.
Preferably, in an embodiment of the present invention, each of the sections
has a primary curvature extending over its length. Still preferably, in
another embodiment of the present invention, each of the sections also has
a secondary curvature extending over its width.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood upon reading the following non-
restrictive description of the preferred embodiment thereof, made with
reference to the accompanying drawings in which:
Figure 1 is a perspective view a ready to assemble shelter in an assembled
state according to a first embodiment of the present invention.
Figures 2a to 2d are a top, side, front and back view, respectively, of a
ready to assemble shelter according to the first embodiment of the present
invention.
Figures 3a to 3c are perspective views of ready to assemble shelters
according to a second, third and fourth embodiments of the present
invention.
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Figure 3d is a partially exploded view a ready to assemble shelter according
to the fourth embodiment of the present invention
Figures 4a and 4b are a perspective and cross-sectional view taken along
line A-A, respectively, of a section of a ready to assemble shelter according
to the present invention.
Figure 4c is a cross-sectional view of two adjacent sections, each being
shown as in Figure 4b.
Figure 5 is a detail of an exploded view of the ready to assemble shelter
according to the first embodiment of the present invention.
Figure 6 is a detail of an exploded view of a ready to assemble shelter
according to the second embodiment of the present invention.
Figures 7a and 7b are a partially exploded and an assembled view of a
ready to assemble shelter according to the first embodiment of the present
invention, additionally showing a base structure.
Figure 8 is a front view of a ready to assemble shelter in an assembled
state according to the present invention.
Figure 9 is a perspective view of a ready to assemble shelter according to
the first embodiment of the present invention, additionally showing
extension panels.
Figure 10 is partial plan view of the ready to assemble shelter according to
the first embodiment of the present invention.
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DETAILED DESCRIPTION OF THE INVENTION
Referring now to Figures 1 to 2e, there is shown a ready to assemble
5 shelter 10 according to the preferred embodiment of the present invention.
The shelter 10 comprises a first vertical face 12, a second face 14, and a
structure 19 extending therebetween. A plurality of sections 18 are formed
from at least one elongate panel 16 and are affixed side-by-side to form the
structure 19 and cover an interior space between the first and second
vertical faces 12 and 14. Preferably, each section 18 is formed of two
elongate panels 16 attached end-to-end along respective flanges 17,
however embodiments in which sections 18 comprises more or less
sections 18 are also well within the scope of the present invention.
A door 20, shown in an open position, is provided in the first vertical face
12
to allow access to the interior space enclosed by modular structure 10. As
seen best in Figures 2a to 2d, the first and second vertical faces 12 and 14
are of the same size and shape, with the exception of the presence of door
in the first face 12, although alternative configurations are also within the
20 scope of the present invention.
In the present embodiment, the first and second vertical faces 12 and 14
are semi-circular in shape and each have a straight bottom edge 22 and 24,
respectively, and a curved top edge 26 and 28, respectively. The bottom
edges 22 and 24 are in proximity with the ground or adjacent frame upon
which the shelter 10 is installed, while upper edges 26 and 28 engage the
structure 19, which forms the roof and sides of the construction. In addition,
each section 18 is provided with a first end flange 23 extending from a first
end 25, and a second end flange 27 extending from a second end 29. Both
sets of end flanges 23 and 27 are provided for mounting to an adjacent
frame. For example, as will be seen in Figures 7a and 7b, the shelter 10 is
mounted on a frame. However, the shelter 10 can also rest directly to the
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ground. Preferably, the end flanges 23 and 27 have horizontal surfaces for
connection and are equivalent to the vertical surfaces of flanges 17 used to
connect opposing elongate panels 16. Preferably still, the elongate panels
16 represent quarter-circular arcs, i.e. sweeps of 900, and the end flanges
23 and 27 and flanges 17 are interchangeable such that the elongate
panels 16 are symmetrical and have neither an "up" nor a "down". This
simplifies the assembly of the shelter 10, as well as manufacture and
storage of the panels 16, and aids the modularity of the design.
Each of the sections 18 has a primary curvature 30 extending over its
length which, in the present embodiment corresponds to the curvature off
upper edges 26 and 28. Each section 18 further includes a secondary
curvature 32 extending over its width. This primary curvature increases the
strength and rigidity of each section 18, and the structure 19 as a whole.
As illustrated in Figures 1 to 2d, each section 18 is formed by two quarter-
circular panels 16 affixed end-to-end to form a combined arc of 1800. The
plurality of sections 18 are then connected in parallel, side-by-side, to
extend the depth of the shelter 10. In the embodiment shown, the shelter
10 is six panels deep, although the depth of the structure is variable
according to the needs of a particular user by varying the number of
sections 18 employed.
In addition to the elongate panels 16, which form the curved sections 18
and which in turn form the structure 19, the first and second vertical faces
12 and 14 are each assembled from respective pluralities of straight
sections 13. Similarly to the sections 18, each straight section 13 is made
up of at least one elongate straight panel 15 and has a curvature 21
extending over its width, similar to the secondary curvature 32. Preferably,
two oppositely opening door panels 20 are formed from sets of two adjacent
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elongate straight panels 15, which are affixed side-by-side and pivotally
connected to respective ones of the remaining straight sections 13.
Preferably, the vertical faces 12 and 14, and the plurality of sections 18 are
made of a fibre-reinforced composite material, such as fibreglass, carbon-
epoxy, or aramid fibre composites. Achieving an arched design comprising
both primary and secondary curvatures 30 and 32 is much easier with
moulded materials such as composites and the like. In addition, the
curvature 21 of the straight sections 13 serves to further enhance the
strength and stability of the shelter 10.
For its low cost, fibreglass is preferred for commercial applications.
However, for special cases in which a shelter 10 is required with a lighter
weight and greater strength, carbon-epoxy or aramid fibre composites are
preferable. Such special cases include, for example, a temporary military
barracks.
The shelter 10 has a number of different applications. When made of
transparent fibreglass, it can serve readily as a greenhouse, for creating a
micro-climate suitable for growing non-native plants, or simply enabling
plant growth beyond the regular growing season. Indeed, by properly
moulding the elongate panels 15 and 16, a focusing lens effect can be
obtained to increase the incident light received within the structure. For
example, the secondary curvature 32 of the elongate panels 15 and 16 can
be controlled to heat the interior of the structure.
If an opaque composite is used, the shelter 10 can serve as a shed, garage
or storage space.
With reference now to Figure 3a, a second embodiment of the present
invention is illustrated. The ready to assemble shelter 1 0a comprises much
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the same elements as shown in Figures 1 to 2d, with the addition of
openable louvers 34 for allowing, for example, ventilation. Whereas the
elongate panels 16 are connected end-to-end to form an arched section of
1800, the louvered section replaces one of the 90 panels 16 with the
louver 34 and a louver base 36. In the example illustrated herein, the
louver 34 and louver base 36 are of equal sizes, each being half of a
regular elongate panel 16. It is to be understood however that other
configurations are well within the scope of the present invention, for
example, but in no way limited to, a 60/40 split or an 80/20 split.
Figure 3b illustrates a third embodiment of the present invention dubbed the
"hybrid" design. This hybrid design comprises two openable roof portions
38, similar in structure to the louvered embodiment illustrated in Figure 3a.
The roof portions 38 are made from transparent composite, such as
fibreglass, while the remainder of hybrid modular structure 10b is made
from an opaque composite. This design is well suited for housing an
outdoor hot tub, which would allow users to open the roof for ventilation, or
simply gaze through the transparent roof created by the transparent
portions 38. The hybrid structure 10b can also be equipped with a mosquito
screen.
In use, both the louvers 34 of Figure 3a and the openable roof portions 38
of Figure 3b can be opened and closed manually, or by pneumatic or
electro-mechanical actuators. Such methods are commonly known in the
art and will therefore not be discussed further here.
Figures 3c and 3d illustrate a fourth embodiment of the present invention
meant for installation adjacent to an existing structure (not shown). In this
embodiment, the ready to assemble shelter 10c includes first end flanges
23 extending from a first end 25 of each elongate panel 16 for providing a
horizontal surface for connection, and a second end flange 27 extending
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from a second end 29 of each elongate panel 16 for providing a vertical
surface for connection. As described above, the horizontal first end flanges
23 are operable to mount to an adjacent frame, or simply connect with the
ground. With the open side 40 of the shelter 10c, the vertical second
flanges 27 are operable to mount to an adjacent pre-existing wall.
With specific reference to Figure 3d, the fourth embodiment of the present
invention, shelter 10c, is shown in a partially exploded state. The first
vertical face 12 is shown exploded into the straight sections 13 made of the
straight elongate panels 15. Additionally identified are the straight elongate
panels 15a which form the door panel 20. As illustrated, two such straight
elongate panels 15a compose the door panel 20. As such, these two are
affixed to one another while one of the two is hingedly connected to an
adjacent panel 15. Above each of the straight elongate panels 15a is a
smaller straight elongate panel 15b. When the door 20 is closed, as seen
in Figure 3c, these two straight elongate panels 15 and 15a form a straight
section 13. As will be apparent to one of ordinary skill in the art, this door
construction is equally applicable to the other embodiments of the present
invention disclosed herein.
In Figures 4a and 4b, a section 18 is illustrated in perspective and in cross-
section, respectively. In this embodiment, the section 18 includes a single
elongate panel 16 which spans a full 180 as opposed to the two elongate
panels 16 joined along their flanges 17 discussed hereinabove. It is to be
noted, however, that the following description of the section 18 applies
equally to the above-described two-panel embodiment.
Extending downwardly from a first lateral side 41 of the elongate panel 16 is
a first flange 43. A second flange 46 extends downwardly and then
outwardly, thereby forming an L-shape, from a second lateral side 45 of the
elongate panel 16 that is opposite the first lateral side. While the L-shape
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of the second flange 46 is not visible in every Figure, it is to be noted that
the preferred embodiment is illustrated in the Figures 4a to 4c.
With specific reference to Figure 4c, it can be seen that, during assembly,
5 the first and second flanges 43 and 46 of adjacent sections 18 are operable
to cooperate. A first section 18a is shown adjacent to a second section 18b
and each of the sections 18a and 18b have first flanges 43a and 43b and
second flanges 46a and 46b extending from respective panels 16a and
16b. As shown, the first flange 43a of the first section 18a sits atop the
10 outwardly extending portion of the L-shaped second flange 46b of the
second section 18b. This cooperation advantageously aids in the aligning
and fixing of the sections, discussed in further detail hereinbelow.
Furthermore, the L-shaped second flanges advantageously provide
additional surfaces within the shelter 10 for hanging or otherwise attaching
objects, as well as for routing wiring.
With reference now to Figure 5, there is shown in detail the engagement of
a straight section 13 with a section 18 at the corner of the shelter 10. A
gasket 42 is sandwiched between a side flange 44 extending outwardly
from the straight section 13, and the first flange 43 of the section 18.
Additional gaskets 42 can be provided between any of adjacent sections 18,
sandwiched between connected first and second flanges 43 and 46.
The gaskets 42 are made of a resilient elastomeric material, such as
rubber, and operable to account for physical changes in the structure due
to, for example, changes in temperature or shifting of the ground upon
which the shelter 10 is installed. The gaskets 42 are further operable to aid
in sealing the inside of the shelter 10 against wind and rain.
In addition, to securing the sections 18 side-by-side to one another to form
the structure 19, the securing means 48 are utilised to secure the structure
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19 between the vertical faces 12 and 14 to form the shelter 10. More
specifically and with reference to the corner of the shelter 10, the securing
means 48 preferably includes pluralities of holes 49 extending through the
flanges 43, 44 and 46, as well as nuts and bolts 50 for passing through the
corresponding holes 49 and securing the sections 18 side-by-side to both
form the structure 19, and connect the structure 19 to the vertical faces 12
and 14 to form the shelter 10. It will be apparent to one of ordinary skill in
the art that the securing means 48 could alternatively, or additionally,
include any of rivets, screws, clips, grommets, pins, snap and any other
mechanical fastener, as well as chemical or thermal bonds, without
departing from the scope of the present invention.
As with the curved sections 18, the straight sections 13 further include first
and second lateral flanges 57 extending from opposing lateral sides 51 of
each elongate straight panel 15. The first and second lateral flanges 57 of
adjacent straight sections 13 are capable of cooperating in order to enable
attachment via the straight section securing means 53, which is further
included in the securing means 48. As above, the straight section securing
means 53 includes pluralities of holes 49 in the lateral flanges 57, as well
as
nuts and bolts 50 for passing through corresponding holes 49 and securing
the straight sections 13 side-by-side.
Extending outwardly from the lower longitudinal side of each straight section
13 is a straight section end flange 52. The series of straight section end
flanges 52 of each vertical face 12 and 14 form the straight bottom edges
22 and 24, respectively. Extending upwardly from the opposing longitudinal
side of each straight section 13 is the afore-mentioned side flange 44 for
engaging a section 18. Because the upper edges 26 and 28 correspond
substantially to the primary curvature 30 of the structure 19, the side
flanges
44 of the straight sections 13 also follow that curvature 30. As such, the
corner-piece straight section 13 illustrated in Figure 5 is an exception in
that
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it does not include a second lateral flange 54 but rather a side flange 44
which cuts across where the second side flange 54 would be.
Figure 6 illustrates in detail an exploded view of the top on the shelter 10
including the louvered construction of the second embodiment of the
present invention. As illustrated in Figures 1 to 2d, the sections 18 are
formed from first and second elongate panels 16 attached end-to-end along
flanges 17. Preferably, the securing means 48 further includes panel
securing means 55 for securing opposing pairs of elongate panels 16 to
form the sections 18. As before, the panel securing means 55 preferably
also includes pluralities of holes 49 in the flanges 17, as well as nuts and
bolts 50 for passing through corresponding holes 49 and securing the
opposing panels 16 end-to-end.
At each louvered section, the louver 34 hingedly attaches to the opposite
elongated panel 16 via its flange 17 and a hinge 54, or hinges. The hinge
54 is preferably a stainless steel piano hinge. A similar hinge is used to
attach the door panels 20 to the first vertical face 12.
Additionally, utility holes 56 are provided in each of the first and second
flanges 43 and 46 of the sections 18. The utility holes 56 are not meant for
assembly purposes but rather to provide attachment points within the
shelter 10 from which to hang plants, for example. Similar utility holes may
also be provided along the outwardly extending portion of the L-shaped
flange 40.
With reference now to Figures 7a and 7b, base 59 is shown in an exploded
and unexploded state, respectively. Beams 58 are stacked in pairs such
that at one end, a portion of a first beam 58 overlaps a second beam 58. At
the other end, a portion of the second beam 58 overlaps the first beam 58.
When assembled, four such pairs are positioned around the bottom edges
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of the shelter 10 in order to engage the first and second end flanges 23 and
25, and the lower flanges 52. Preferably, pegs 60 are passed through the
overlapping portions of adjacent pairs, and into the ground. The beams 58
are preferably a bio-treated wood.
Figure 8 illustrates a front view of a specific example of the present
invention including an alternate, single-piece door panel 20 and the addition
of a fan 62 installed in an upper area of the first vertical face 12.
With reference to Figure 9, the sections 18 are further provided with straight
extension panels 64. While the primary curvature 30 of the sections 18 is
structurally beneficial, the utilisation of an enclosed space with curved
walls
can be enhanced by raising the curved shelter 10 with the straight extension
panels 64. The extension panels 64 are secured to the bottom edges of
each section 13 and 18. More specifically, the extension panels are
secured to the first and second end flanges 23 and 27, and the lower
flanges 52. The door panel, or panels, 20 can be provided with extension
panels 64, or as illustrated can simply be extended to accommodate the
new height of vertical faces 12 and 14. Alternatively, the extension panels
64 are operable to enable use of a conventional garage door.
With reference to Figure 10, a double and triple glazed panel 66 and 68 are
shown, made up of individual layers 70. Manufactured in the same manner
as the elongate panels 16, the double and triple glazed panels 66 and 68
can be used to improve the thermal insulation of the modular structure. In
addition, a gas can be inserted between the layers 70 to filter incoming
light,
or, again, improve thermal insulation.
In conjunction with the modularity and ease of assembly of the present
invention, it is preferred that users purchase ready to assemble shelter
online from a website that allows them to customise a shelter according to
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their specific needs (size, type, colour, material, additional features,
etc.).
Upon completion of the order, an unassembled modular structure is sent to
the purchaser as a kit where it is to be assemble by the purchaser himself
or herself. As noted, the presence of the L-shaped second flange 46 (see
Figures 4a and 4b) advantageously enables the user to assemble and
install the ready to assemble shelter themselves with minimal aid.
Additionally, the beams 58 (see Figure 7a) are preferably part of the
packaging in which the un-assembled structure is shipped. In this way,
packaging waste is reduced.
