Ready to assemble shelter

Abstract

The ready to assemble shelter includes 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. A shelter kit is also provided.

Description

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: U.S. Pat. No. 2,897,668; U.S. Pat. No. 3,154,888; U.S. Pat. No. 3,892,094; U.S. Pat. No. 4,091,584; U.S. Pat. No. 5,065,554; U.S. Pat. No. 5,319,904; U.S. Pat. No. 5,444,946; U.S. Pat. No. 5,598,668; U.S. Pat. No. 6,266,932; U.S. Pat. No. 6,324,791; U.S. Pat. No. 6,584,732; U.S. Pat. No. 6,766,623; U.S. Pat. No. 6,843,261; US 2002/0017068; US 2002/0100228; and US 2004/0045227.

In addition, known to the Applicant are U.S. patents U.S. Pat. No. 4,700,514; U.S. Pat. No. 3,750,353; and U.S. Pat. No. 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, U.S. Pat. No. 4,700,514 and U.S. Pat. No. 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 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 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:

FIG. 1 is a perspective view a ready to assemble shelter in an assembled state according to a first embodiment of the present invention.

FIGS. 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

FIGS. 3a to 3c are perspective views of ready to assemble shelters according to a second, third and fourth embodiments of the present invention.

FIG. 3d is a partially exploded view a ready to assemble shelter according to the fourth embodiment of the present invention

FIGS. 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.

FIG. 4c is a cross-sectional view of two adjacent sections, each being shown as in FIG. 4b.

FIG. 5 is a detail of an exploded view of the ready to assemble shelter according to the first embodiment of the present invention.

FIG. 6 is a detail of an exploded view of a ready to assemble shelter according to the second embodiment of the present invention.

FIGS. 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.

FIG. 8 is a front view of a ready to assemble shelter in an assembled state according to the present invention.

FIG. 9 is a perspective view of a ready to assemble shelter according to the first embodiment of the present invention, additionally showing extension panels.

FIG. 10 is partial plan view of the ready to assemble shelter according to the first embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1 to 2e, there is shown a ready to assemble 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 FIGS. 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 20 in the first face 12, although alternative configurations are also within the 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 FIGS. 7a and 7b, the shelter 10 is mounted on a frame. However, the shelter 10 can also rest directly to the 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 90°, 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 FIGS. 1 to 2d, each section 18 is formed by two quarter-circular panels 16 affixed end-to-end to form a combined arc of 180°. 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 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 FIG. 3a, a second embodiment of the present invention is illustrated. The ready to assemble shelter 10a comprises much the same elements as shown in FIGS. 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 180°, 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.

FIG. 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 FIG. 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 FIG. 3a and the openable roof portions 38 of FIG. 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.

FIGS. 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 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 FIG. 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 FIG. 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 FIGS. 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 of the second flange 46 is not visible in every Figure, it is to be noted that the preferred embodiment is illustrated in the FIGS. 4a to 4c.

With specific reference to FIG. 4c, it can be seen that, during assembly, 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 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 FIG. 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 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 FIG. 5 is an exception in that 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.

FIG. 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 FIGS. 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 FIGS. 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 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.

FIG. 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 FIG. 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 FIG. 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 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 FIGS. 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 FIG. 7a) are preferably part of the packaging in which the un-assembled structure is shipped. In this way, packaging waste is reduced.

Claims

1. A ready to assemble shelter comprising:

a first vertical face made of fibre reinforced composite material;

a second vertical face made of fibre reinforced composite material;

a plurality of sections, each section comprising: 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; and

securing means for securing the sections side by side to form a structure, and for securing the structure between the vertical faces to form the shelter.

2. The ready to assemble shelter of claim 1, wherein the securing means are characterized in that each of the first and second flanges is provided with corresponding holes therethrough, the securing means also comprise a plurality of bolts and nuts for securing the sections side by side via the holes.

3. The ready to assemble shelter of claim 1, wherein each of the sections comprises a primary curvature extending over the length thereof.

4. The ready to assemble shelter of claim 3, wherein each of the sections comprises a secondary curvature extending over the width thereof.

5. The ready to assemble shelter of claim 4, wherein each of the sections comprises first and second ends provided respectively with first and second end flanges, the first and second end flanges being for mounting the shelter on an adjacent frame.

6. The ready to assemble shelter of claim 5, wherein the first end flanges have horizontal surfaces for connection and the second end flanges have vertical surfaces for connection.

7. The ready to assemble shelter of claim 5, wherein the first and second end flanges have horizontal surfaces for connection.

8. The ready to assemble shelter of claim 5, wherein the at least one elongate panel of each section comprises first and second elongate panels, and the securing means comprise panel securing means for securing end to end the first and second elongate panels of each section.

9. The ready to assemble shelter of claim 8, wherein the panel securing means are characterized in that each of the first end flanges is provided with a plurality of holes therethrough, the panel securing means also comprise a plurality of bolts and nuts for securing the panels end to end via the holes.

10. The ready to assemble shelter of claim 4, wherein the first and second vertical faces each comprise an upper edge aligned with the primary curvature of the elongate section panels.

11. The ready to assemble shelter of claim 10, wherein:

each of the vertical faces comprises a plurality of straight sections, each straight section comprising: an elongate straight panel; and first and second lateral flanges extending from opposing lateral sides of the elongate straight panel, the first lateral flange being capable of cooperating with the second lateral flange of an adjacent section; and

the securing means further comprise straight section securing means for securing the straight sections side by side to form each of the vertical faces.

12. The ready to assemble shelter of claim 11, wherein the straight section securing means are characterized in that each of the lateral flanges is provided with a plurality of holes therethrough, the straight section securing means also comprise a plurality of bolts and nuts for securing the straight sections side by side via the holes.

13. The ready to assemble shelter of claim 12, wherein each of the straight sections comprises a curvature extending over the width thereof.

14. The ready to assemble shelter of claim 13, wherein at least two of the elongate straight panels are connected together to form a door panel, the door panel being pivotally connected to one of the remaining straight sections of the first vertical face.

15. The ready to assemble shelter of claim 1, wherein each of the plurality of sections further comprises a straight extension panel secured to a bottom edge of the corresponding elongate panel.

16. The ready to assemble shelter of claim 1, wherein the securing means further comprise gaskets mounted between the panels of the shelter that are adjacent.

17. The ready to assemble shelter of claim 1, wherein each elongate panel is double walled.

18. The ready to assemble shelter of claim 1, further comprising a wooden base, the structure and first and second vertical faces being mounted thereto.

19. A shelter kit comprising:

a first vertical face made of fibre reinforced composite material;

a second vertical face made of fibre reinforced composite material;

a plurality of sections, each section comprising: 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; and

securing means for securing the sections side by side to form a structure, and for securing the structure between the vertical faces to form the shelter.