Note: Descriptions are shown in the official language in which they were submitted.
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ROLL-OUT STRUCTURE WITH SELF-TIGHTENING FEATURE
BACKGROUND
[0001] This disclosure relates to the field of building materials and more
particularly to a
universal modular roll-out building material with self-tightening features.
[0002] There is a long recognized need for modular construction material, for
example,
roofing, flooring, roadways and the like, which can be delivered from a remote
location,
rapidly assembled and deployed, and easily removed when it is no longer
required.
[0003] Traditionally, the modular construction material includes a series of
panels which
can be linked or jointed to form a roofing or roadway having a flat surface.
The panels
are laid according to a predetermined pattern (for example, side by side) and,
subsequently, assembled with each other by using connectors, including straps,
cords,
adhesives, metal fasteners and the like.
[0004] The known construction material has several drawbacks. For example,
assembly
and disassembly of the panels are complex and require significant amount labor
and time.
Furthermore, the extra connectors, required in addition to the panels, incur
additional
costs on material and transportation. In addition, secured coupling of the
panels cannot
be ensured, because of the potential breakage, abrasion, erosion or otherwise
damage of
the connectors; accordingly, deformation can occur to the deployed roofing or
roadway.
SUMMARY OF THE DISCLOSURE
[0005] Therefore, in order to address these and other deficiencies in the
prior art,
provided according to an aspect of the present invention is a slat for use in
a roll-out
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structure of construction material. The slat includes an elongated body
extending
longitudinally; a projection disposed at a first lateral end of the body; a
socket disposed at
a second lateral end of the body opposite to the first lateral end; and a
wedge associated
with the projection. The projection and the socket are structurally
complementary to each
other.
[0006] Preferably, the slat further includes a ledge disposed at the first
lateral end of the
body and a shelf disposed at the second lateral end of the body. The bottom
surface of
the ledge and the top surface of the shelf are substantially vertically
aligned with each
other.
[0007] Preferably, the slat further includes a first beveled edge disposed at
the first lateral
end of the body and a second beveled edge disposed at the second lateral end
of the body.
[0008] Preferably, both the projection and the socket are substantially
cylindrical and
have a circular lateral cross section.
[0009] Preferably, the wedge is integrally formed with the projection and the
circumferential span of the wedge with respect to the center of the circular
lateral cross
section of the projection is within the range of 50-300. More preferably, the
circumferential span of the wedge is 150
[0010] Preferably, the slat further includes at least one hole formed in the
body.
[0011] Preferably, the slat further includes at least one opening formed in
the body,
which opening is exposed to a bottom surface of the body.
[0012] Preferably, the projection includes a groove and the socket includes an
elevation.
The groove and the elevation are structurally complementary to each other.
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[0013] A roll-out structure of construction material is provided according to
another
aspect of the present invention. The roll-out structure includes at least a
first slat and a
second slat which are structurally the same. Each slat includes an elongated
body
extending longitudinally; a projection disposed at a lateral end of the body
and a socket
disposed at an opposite lateral end of the body; and a wedge associated with
the
projection. The projection and the socket are structurally complementary to
each other.
The projection of the first slat is insertable into the socket of the second
slat to connect
the first slat to the second slat, and a gap is provided between the
projection of the first
slat and the socket of the second slat to allow rotation of the projection in
the socket. The
wedge of the first slat engages the socket of the second slat to lock the
first slat and the
second slat, upon rotation of the projection of the first slat in the socket
of the second slat.
[0014] Preferably, each slat further includes a ledge disposed at the lateral
end of the
body and a shelf disposed at the opposite lateral end of the body. The bottom
surface of
the ledge and the top surface of the shelf are substantially vertically
aligned with each
other.
[0015] Preferably, each slat further includes a first beveled edge disposed at
the lateral
end of the body and a second beveled edge disposed at the opposite lateral end
of the
body.
[0016] Preferably, both the projection and the socket are substantially
cylindrical and
have a circular lateral cross section.
[0017] Preferably, the wedge is integrally formed with the projection and the
circumferential span of the wedge with respect to the center of the circular
lateral cross
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section of the projection is within the range of 50-300. More preferably, the
circumferential span of the wedge is 150
[0018] Preferably, each slat further includes at least one hole formed in the
body.
[0019] Preferably, each slat further includes at least one opening formed in
the body,
which opening is exposed to a bottom surface of the body.
[0020] Preferably, the projection includes a groove and the socket includes an
elevation.
The groove and the elevation are structurally complementary to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] These and other features, benefits and advantages of the present
invention will be
made apparent with reference to the following detailed description and
accompanying
figures, where like reference numerals refer to like structures across the
several views,
and wherein:
[0022] Fig. 1 is a schematic perspective view of a roll-out structure
according to an
exemplary embodiment of the present invention;
[0023] Fig. 2 is a schematic perspective view of a single slat of the roll-out
structure
shown in Fig. 1;
[0024] Fig. 3 is a sectional view along lines 3-3 of Fig. 2, showing the
detailed structure
of the slat;
[0025] Fig. 4 is a sectional view of two adjacent slats showing the insertion
of one slat
into the other;
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[0026] Fig. 5 is a schematic perspective view of the two adjacent slats
showing the slats
locked with each other;
[0027] Fig. 6 is a front view of a roll-out structure according to another
exemplary
embodiment of the present invention;
[0028] Fig. 7 is a front view of two adjacent slats according to Fig. 6,
showing the
insertion of one slat into the other; and
[0029] Fig. 8 is a front view of the two adjacent slats showing the slats
locked with each
other.
DETAILED DESCRIPTION OF DISCLOSURE
[0030] Fig. 1 illustrates a roll-out structure 10. which can be in the form of
a rollable
sheet, according to an exemplary embodiment of the present invention. The roll-
out
structure 10 includes a plurality of slats 100, which are structurally the
same or similar.
Any two adjacent slats of the roll-out structure 10 are connected to each
other to permit
the roll-out structure 10 to be deployed in a rollable manner.
[0031] As shown in Fig. 1, a three-dimensional coordinate system is defined.
In this
coordinate system, each slat extends longitudinally along the X-axis; the
jointed slats
extend laterally in a rollable manner along the Y-axis; and each slat extends
vertically in
its thickness along the Z-axis. Preferably, the slats 100 have identical
longitudinal,
lateral, and/or vertical dimensions, to ensure interchangeability of the
slats.
[0032] Fig. 2 is a schematic perspective view showing the structure of a slat
100. The
slat 100 is substantially fiat and elongated, extending in the longitudinal
direction. For
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example, the length of the slat in the longitudinal direction is substantially
larger than the
width in the lateral direction and the thickness in the vertical direction.
[0033] Fig. 3 is a sectional view of the slat 100 along lines 3-3 in Fig. 2.
The slat 100 has
an elongated body 101, which has a top surface 102 and a bottom surface 104.
The top
surface 102 and the bottom surface 104 are substantially flat and parallel
with each other,
to define the thickness T of the slat 100. Alternatively, part or all of the
surfaces 102 and
104 can be concave or convex, or angled with respect to teach other, which
allows the
roll-out structure 10 to be other than flat when deployed. In this and other
figures,
clearances are exaggerated to show the parts of the embodiments, and the
figures should
not be interpreted as being to scale.
[0034] As shown in Fig. 3, the slat 100 includes a ledge 106 and a projection
108
provided at a first lateral end of the slat 100, which in combination serve as
a male
component for joining the slat with an adjacent slat. The slat 100 further
includes a
socket 110 and a shelf 112 provided at an opposite second lateral end of the
slat 100,
which in combination serve as a female component for joining the slat with an
adjacent
slat.
[0035] For example, the projection 108 is structurally complementary to the
socket 110,
which permits adjacent slats 100 to be rotatably assembled with each other to
form the
roll-out structure 10. In the shown embodiment, the projection 108 is
substantially
cylindrical in the longitudinal direction. The projection 108 has a
substantially circular
lateral cross section, which is substantially consistent along the length of
the slat 100.
The socket 110 defines a complementary space S for operatively receiving the
projection
108. The space S is also substantially cylindrical in the longitudinal
direction, and
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properly dimensioned to permit insertion of the projection 108 with force into
the space S
and rotation of the projection 108 within the space S.
[0036] Other complementary configurations of the projection and the socket are
within
the scope of the present invention. For example, the socket can be a rounded
"bull-nose"
notch, and on the opposite lateral side, the projection can be a "bull-nose"
tab
dimensioned to snugly mate with the notch.
[0037] The ledge 106 and the shelf 112 are preferably structurally
complementary to
permit the ledge to sit on the shelf of an adjacent slat, which enhances the
integrity and
strength of the roll-out structure 10. In the shown embodiment, the ledge 106
has a flat
bottom surface 114 and the shelf 112 has a flat top surface 116. The bottom
surface 114
and the top surface 116 are substantially aligned vertically, yet spaced from
each other
laterally, such that when two adjacent slats are rotated with each other to
deploy the roll-
out structure, the ledge of one slat sits on the shelf of the other slat.
However, the
complementary bottom surface of the ledge and top surface of the shelf can be
curved or
otherwise non-flat. The top suiface of the ledge 106 forms a part of the top
surface 102
of the elongated body 101, or is continuous with the top stuface 102. The
bottom surface
of shelf 112 forms a part of the bottom surface 104 of the elongated body 101,
or is
continuous with the bottom surface 104.
[0038] As shown in Fig. 3, the slat 100 includes a first beveled edge 120
extending
between the top surface 102 and the outer circumferential surface 122 of the
projection
108. The first beveled edge 120 and the top surface 102 define an angle a in
the range of
90 -180 , preferably in the range of 120 -150 . The beveled edge 120 allows
the slats to
have a greater degree of rotation upwardly.
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[0039] Alternatively or additionally, the slat 100 includes a second beveled
edge 124
provided at the opposite lateral side of the first beveled edge 120. The
second beveled
edge 124 extends between the top surface 102 and the inner circumferential
surface 126
of the socket 110. The second beveled edge 124 is inclined oppositely with
respect to the
first beveled edge 120. The second beveled edge 124 and the top surface 102
define an
angle (3 in the range of 90 -180 , preferably in the range of 120 -150 . The
beveled edges
120 and 124 are dimensioned to beneficially reduce storage size required for
the roll-out
sheet.
[0040] Fig. 4 is a sectional view showing an alternative configuration of two
adjacent
slats 200 and 300. In this configuration, the slats 200 and 300 are jointed
with each other;
the slats 200 and 300 are ready to lock with each other, to prevent potential
movement of
the slats with respect to each other along the longitudinal direction.
[0041] The slats 200 and 300 have the same structure as the slat 100.
Initially, the
projection 108 of the slat 300 is inserted into the socket 110 of the slat
200, while the
bottom surfaces of the slats 200 and 300 define an angle u. The angle u can be
in the
range of 150-750, preferably, about 45 .
[0042] When the projection 108 is inserted into the socket 110, the socket 110
temporarily deforms and expands to allow the projection 108 to be positively
and snugly
received within the socket 110, because of the resilience of the material for
forming the
slats. Certain tolerance is provided between the jointed projection and the
socket, i.e.,
between the outer circumferential surface 122 of the projection 108 and the
inner
circumferential surface 126 of the socket, to allow the slat 300 to rotate
with respect to
the slat 200. For example, after the projection 108 of the slat 300 is
inserted into the
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socket 110 of the slat 200, a gap G (shown in Fig.. 5) of about 0.003 inches
is provided
between the projection and the socket.
[0043] Each slat 200 or 300 includes a self-tightening mechanism for
implementing or
enhancing locking of the two slats. As shown in Fig. 4, the self-tightening
mechanism
includes a wedge 130 associated with the outer circumferential surface 122 of
the
projection 108. The wedge 130 is preferably formed with the projection 108
through a
material extrusion process. For example, the wedge 130 can be a single piece
of material,
extending along the entire length of the projection 108; alternatively, the
wedge 130 can
be disposed discretely at certain predetermined location(s) along the length
of the
projection 108.
[0044] The wedge 130 is properly dimensioned, such that when the slat 300 is
rotated
clockwise (or the slat 200 is rotated counterclockwise) from the insertion
position, the
wedge 130 progressively engages the inner circumferential surface 126 of the
socket 110
to create a cam type lock between the slat 200 and the slat 300. When the slat
300 is
rolled to align vertically with the slat 200, the cam type lock prevents the
slats 200 and
300 from moving longitudinally with respect to each other, as shown in Fig. 5.
As a
result, the final product will not become loose. According to another aspect
of the
invention, the slats can be pre-connected and packaged in a compact manner in
a roll.
During the deployment of the slats for forming a roofing (for example), the
adjacent slats
can be simply rolled to form a flat surface of the roofing; at the same time,
the slats are
locked consequently, as the slats are rolled, to achieve a self-tightened
roofing.
[0045] In addition, the cam type lock created by the wedge 130 will eliminate
the gap G
between the projection 108 and the socket 110, when the slats 200 and 300 are
vertically
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aligned. Without the gap, any potential lateral movement between the adjacent
slats is
prevented, which in turn further enhances the integrity, stability and
torsional strength of
the roll-out structure. Alternatively or additionally, stop pins can be
provided to achieve
or enhance the locking result.
[0046] The wedge 130 can have a variety of shapes and profiles. For example,
the wedge
can be crescent-shaped to permit easy progressive engagement between the wedge
and
the socket. Furthermore, the position of the wedge 130 on the projection 108
and the
circumferential span of the wedge 130 with respect to the center of the
projection 108 are
properly determined, such that when the projection 108 is inserted into the
socket 110, no
obstruction occurs. As shown in Fig. 4, the wedge 130 has a circumferential
span defined
by it, which is between 50 and 30 , preferably 15 .
[0047] The slats 100, 200 and 300 can be of solid cross-section, for example
if
manufactured of plastic, wood or metal. Alternately, the slats can have
hole(s) and/or
opening(s) disposed longitudinally through the slats. Referring to Fig. 1, a
plurality of
holes 152 and a plurality of openings 154, exposed to the bottom surface 104,
are
provided to the slat 100. The provision of these holes and openings can
effectively
reduce the weight of the roll-out structure, while maintaining the strength of
the structure
at a satisfactory level. The holes and openings can be formed through
extrusion of plastic
or metal materials. In addition, these holes and openings can be
advantageously filled
with other material, for example one or more of foam or fiberglass, as
insulation against
transfer of heat and/or sound, for example.
[0048] Figs. 6-8 illustrate a slat 400 according to another exemplary
embodiment of the
present invention. The slat 400 includes an elongated body 402, which is
similar to the
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elongated body 101 of the slat 100. Certain parts of the elongated body 402
can be
selectively hollowed to reduce the weight and material of the slat 400,
without comprising
the structural strength of the slat 400. The slat 400 also includes a
projection 404, which
is provided at an end of the body 402, and a socket 406, which is provided at
the opposite
end of the body 402. The projection 404 and the socket 406 have profiles
complementary
to each other, such that the projection 404 of a slat can be inserted into the
socket 406 of
an adjacent slat to join the two slats together, as shown in Fig. 7.
[0049] The projection 404 has a curved, preferably rounded, profile. In this
embodiment,
the projection 404 further includes a groove 408, which is recessed from the
outer
circumference of the projection 404. The socket 406 has a C-shaped profile,
which
defines a space to admit the projection 404. The socket 406 is properly
dimensioned to
allow the projection 404 to enter the space of the socket 406 and form a snug-
fit with the
socket 406. The socket 406 includes an elevation 410 extending toward the
space, which
is located at the edge of the C-shaped socket. The elevation 410 is configured
to be
substantially structurally complementary to the groove 408. In operation,
after the
projection 404 of a slat has been inserted into the socket 406 of an adjacent
slat (as shown
in Fig. 7), the slats are rotated with respect to each other to allow the
elevation 410
associated with the socket 406 to positively engage the groove 408 associated
with the
projection 404. The engagement between the elevation 410 and the groove 408
locks the
two adjacent slats, as shown in Fig. 8. The projection 404 of the slat 400 can
also have a
wedge as described in the previous embodiment.
[0050] The roll-out sheathing and the slat as described above with respect to
Figs. 1-5 are
designed to be customizablely joined with any number of slats with a minimum
of effort
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and, generally, without the need for tools. Thus, the roll-out sheathing can
be provided as
individual slats, which are later joined on-site by a contractor or homeowner.
[0051] In an alternative arrangement, a predefined number of slats may be
provided
prepackaged, and pre-joined. However, the modular design of the slats allows
the user to
easily remove unneeded slats from the roll-out sheathing or, when necessary,
add
additional slats to the ends of the roll-out sheathing.
[0052] The roll-out sheathing described herein has many uses in a variety of
fields,
including but not limited to roofing, flooring, housing, roadways and the
like. The
present invention is well suited for deployment as a temporary repair of
damaged roofing
and for temporary protection for windows, glass doors and other easily damaged
structures of a residential or commercial structure in areas prone to
hurricanes and other
damaging conditions. Additionally, the present invention can be utilized as
permanent
building material for roofing and flooring. Moreover, the present invention
can be
utilized as a temporary road surface at construction and mining sites, where
permanent
cement or asphalt road surfaces are impractical. When intended as a surface
for use by
heavy vehicles, the slats of the present invention can be constructed of steel
or aluminum
and may be solid throughout.
[0053] The present invention has been described herein with reference to
certain
exemplary and/or preferred embodiments. These embodiments are offered as
merely
illustrative, and not limiting, on the scope of the invention. Certain other
alterations and
modifications may be apparent to those skilled in the art in light of the
present disclosure,
without departing from the spirit or scope of the present invention, which is
defined
solely with reference to the following appended claims.
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