INFLATABLE STRUCTURES AND METHODS OF MANUFACTURE AND USE

Abstract

An inflatable structure assembly, comprising: (a) a plurality of mechanically interconnected, Double Wall Fabric (DWF) inflatable wall panels; (b) a roof, constructed of DWF and removably attached to the plurality of wall panels; and, (c) a floor, removably attached to the plurality of wall panels on a side of the wall panels opposite the roof.

Description

RELATED APPLICATION

This application claims the benefit of priority under 35 USC §119(e) of U.S. Provisional Patent Application No. 63/745,831 filed January 16, 2025, the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention, in some embodiments thereof, relates to structures and, more particularly, but not exclusively, to a portable shelter.

BACKGROUND OF THE INVENTION

Inflatable shelters have been used in emergency situations by first responders as temporary, portable, quickly erected structure when traditional facilities have been unavailable. They have been used as Bunk Houses, Points of Distribution, Mobile Command Centers, Mobile Medical Clinics, and as Surge Capacity for hospital systems. Conventionally, an inflatable emergency tent uses an inflatable frame system with a PVC or Nylon fabric cover placed on the outside of the frame.

SUMMARY OF THE INVENTION

According to an aspect of some embodiments of the present invention there is provided an inflatable structure assembly, comprising: (a) a plurality of mechanically interconnected, Double Wall Fabric (DWF) inflatable wall panels; (b) a roof, constructed of DWF and removably attached to the plurality of wall panels; and, (c) a floor, removably attached to the plurality of wall panels on a side of the wall panels opposite the roof.

In an embodiment of the invention, at least one of the plurality of wall panels, roof and floor are pneumatically independent.

In an embodiment of the invention, at least one of the plurality of wall panels, roof and floor are pneumatically connected.

In an embodiment of the invention, the assembly further comprises at least one valve for at least one of inflating and deflating at least one the walls and the roof.

In an embodiment of the invention, the assembly further comprises an inflation bank cover to protect and hide from view the at least one valve.

In an embodiment of the invention, the assembly further comprises at least one air pump.

In an embodiment of the invention, at least one of the roof and the floor is attached to the plurality of the wall panels via a pin and anchor system.

In an embodiment of the invention, at least two of the plurality of wall panels, the roof and the floor are sealed with respect to each other using hook and loop fasteners.

In an embodiment of the invention, at least two of the wall panels, roof and floor are attached to each other by a waterproof seal.

In an embodiment of the invention, at least one of the plurality of wall panels, roof and floor are coated by at least one of polyvinyl chloride (PVC) or thermoplastic polyurethane (TPU).

In an embodiment of the invention, at least one of the walls and roof comprise at least one inflatable pneumatic tube for inflation to at least a semi-rigid state.

In an embodiment of the invention, the floor is attached to the walls through an internal and external hook mounted system.

In an embodiment of the invention, the assembly further comprises at least one over-inflation pressure relief valve.

In an embodiment of the invention, at least one of the wall panels includes at least one of a window and a door.

In an embodiment of the invention, the assembly further comprises at least one of a window covering assembly and a door covering assembly.

In an embodiment of the invention, at least one of the window covering assembly and the door covering assembly incorporates at least one of a privacy, clear and mesh screen.

In an embodiment of the invention, the assembly further comprises a sign attachment space.

According to an aspect of some embodiments of the present invention there is provided system of modular inflatable structures, comprising: (a) at least two inflatable structure assemblies; (b) at least one attachment mechanism to removably secure the at least two inflatable structure assemblies together.

In an embodiment of the invention, at least one of the inflatable structure assemblies is chosen from a group consisting of a bunk house, an infirmary, a surgical ward, a laboratory, a bathroom, a dining hall, a kitchen, a temperature controlled room, a meeting room, a theater, a storage space, a garage, a hangar, and a workshop.

In an embodiment of the invention, at least two inflatable structure assemblies are connected by at least one of a counterpart door and window configuration.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings and images. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example, are not necessarily to scale and are for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings

FIG. 1 is a front view of an inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 2 is a side view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 3 is a rear view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 4 is a front perspective view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 5 is a top view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 6 is a close-up perspective view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 7 is a partially exploded side view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 8 is a partially exploded front perspective view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 9 is an exploded front perspective of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 10 is a close-up perspective view of an exterior corner of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 11 is bottom perspective view of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 12 is a close-up perspective view of a front right corner of the inflatable structure assembly, in accordance with an embodiment of the invention;

FIG. 13 is a close-up perspective view of the back left corner from the interior of the inflatable structure assembly, in accordance with an embodiment of the invention; and,

FIG. 14 is a close-up perspective view of a front left corner from an interior of the inflatable structure assembly, in accordance with an embodiment of the invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

The present invention, in some embodiments thereof, relates to structures and, more particularly, but not exclusively, to a portable shelter.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. While this invention as described herein encompasses use as sleeping quarters, other uses include portable office space, mobile command centers, field outposts, cooling/heating stations, remote operation centers, portable equipment storage, and communication centers. The adaptability and flexibility of the shelter allow it to facilitate a wide variety of applications.

As will be described herein, this invention relates to an inflatable structure intended to at least temporarily shelter one or more people, the design of which permits the structure to be easily erected, collapsed and/or stored while also exhibiting structural strength, insulation, and/or stability not found in traditional inflatable shelters. In an embodiment of the invention, the inflatable structure can be set up in minimal time by one or more people.

The invention as described herein incorporates the use of modular, Double Wall Fabric (DWF) panels, also commonly known as Drop Stitch, into a portable shelter. Through the use of pin and anchor attachments and hook and loop seals, the structure provides improved strength and protection from environmental conditions in comparison to common tents/temporary structures. DWF or Drop Stitch is a hollow, three dimensional textile fabric created by joining two coated panels with thousands of internal connecting threads. The external panels are traditionally coated with rubber, poly vinyl chloride (PVC), or thermoplastic polyurethane (TPU) although other coatings are available. Fire Retardants may be added to the coated materials to improve their safety performance. Internal connecting threads create the internal substrate from which the panels are coated.

Once pressurized and inflated, the DWF panels become stiff, rigid, and are able to support significant weight and pressure. The internal threads of the DWF hold the exterior panels in tension while internal pressure provides rigidity throughout the panel. Where traditional inflatable tents provide low pressure cylindrical frames, DWF material also allows for flat shapes, beveled edges, and higher internal pressures. This higher pressure yields higher strength and rigidity when compared to traditional inflatable structures.

The shape and stiffness of the DWF panels described herein, allow for vertical walls, greater deflection resistance, simpler attachments, part modularity, and/or improved structural load capacity over traditional inflatable structures.

In some embodiments, a plurality of inflatable DWF panels are used in a system of interchangeable and/or modular inflatable structures to meet specific mission needs. In other embodiments, a single, interconnected DWF structure is inflated to create the shelter. Due to the modularity of the DWF panels, individual parts can be added or removed as needed to best suit mission requirements.

The inherent three-dimensional structure of the DWF panels creates air gap insulation not found in traditional inflatable tents. This insulation allows for greater environmental performance and habitability through adverse weather conditions. and is safe, sturdy and weather resistant. Additional roof shades may be added to further increase insulation values.

Referring now to the drawings, FIG. 1 is a front view of an inflatable structure assembly 100, in accordance with an embodiment of the invention. Generally, inflatable structure assembly 100 is a portable shelter comprising two or more, optionally at least four, modular inflatable walls or partial walls. In some embodiments of the invention, one or more of the walls are DWF walls. In some embodiments of the invention, the modularity of the DWF walls allow for simultaneous, or independent, operation, removal, replacement, installation, inflation, or deflation. In some embodiments of the invention, the inflatable structure assembly 100 comprises inflatable pneumatic tubes for a semi-rigid DWF wall and/or roof system greatly improving stability, security, strength, insulation, and safety for the occupants.

The thickness of the DWF walls and roof provide improved insulation from the outdoor environment in comparison to tents constructed from a single layer of fabric over a frame. Once inflated to an internal stabilizing pressure, the walls harden and stiffen allowing shape, structure, and rigidity not previously obtained in traditional camping or inflatable tents.

In some embodiments of the invention, one or more of the walls of the inflatable structure assembly 100 are pneumatically independent from each other. In an alternative embodiment of the invention, all walls of the inflatable structure assembly 100 are in pneumatic communication, for example, for inflating all the walls from a single source, where the plurality of walls are connected in fluid communication end to end in a continuous relationship defining the shape of the structure.

In an embodiment of the invention, the inflatable structure assembly 100 comprises at least five independently inflated surfaces. For example, four walls and independent removable roof are inflated independently from one another. In other embodiments, all interconnected walls are inflated simultaneously. The walls and roof are optionally connected through a pin and anchor system, described in more detail below and mounted on the wall and roof surfaces. The floor is optionally attached to the walls through an internal and external hook mounted system, also described below.

Component 1 represents the Double Wall Fabric Roof Assembly. Attached to the 1 DWF Roof Assembly is the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. Component 1 attaches to 2, 3, 4, and 5 through multiple component 18 Pin and Anchor Systems and 22 Roof Seal Hook and Loop. Two 19 Inflation Ports and one 20 Overinflation Relief Valve are located on the 1 Roof Assembly.

In an embodiment of the invention, two inflation valves are located on the DWF roof for introducing air allowing them to be rigid, pitched, and self-supporting when inflated and define a closed volume. In other embodiments of the invention, the DWF roof may be optionally attached and placed in a horizontal or flat position.

An overpressure valve is located adjacent to the inflation valves and prevents users from overinflating the roof assembly. Once filled with air, the roof system becomes rigid and easily allows for water runoff. In an embodiment of the invention, a second inflating valve is located on the DWF roof system allowing it to inflate over the DWF wall system

In an embodiment of the invention, a first inflating valve is located on the DWF wall system for introducing air to the plurality of wall members, allowing them to be rigid and self-supporting when inflated and define a closed volume.

Wall and roof seals wrapping around the exterior and the interior of the structure use a hook and loop system to ensure protection from the external environment. For example, a PVC seal system is utilized on the interior and exterior of the connected wall assembly to ensure protection from external environmental conditions. This seal uses a hook and loop closure system to hold the seal to the wall assembly.

Component 2 is the Front Wall. Component 2 attaches to 1 Roof Assembly, 3 Left Side Wall, and 4 Right Side Wall through multiple 18 Pin and Anchor Systems, 21 Wall Seal Hook and Loop, and 22 Roof Seal Hook and Loop. Component 2 attaches to 6 Floor Assembly through hook and loop. Two 19 Inflation Ports and one 20 Overinflation Relief Valve are located on the lower left outer edge of 2 Front Wall. Two 8 Upper D-Rings are located on opposite upper exterior corners of 1 Roof Assembly. A sign attachment space 9, optionally Hook and Loop, is located on the exterior of the 2 Front Wall. Two 11 Windows are positioned outward of the central 23 Front Door. 12 Window Covering Assembly allows for occupants of the structure to function 11 Windows in privacy, mesh, or clear modes. Two each, 12 total 7 PVC Retaining clips hold four 12 Window Covering Assemblies and two 13 Door Covering Assembly in the open position.

In an embodiment of the invention, two inflation valves are located on each DWF wall for introducing air allowing them to be rigid and self-supporting when inflated and define a closed volume. An overpressure valve is located adjacent to the inflation valves and prevents users from overinflating the walls.

In an embodiment of the invention, at least one window incorporates privacy, clear, and/or mesh screens that may be used independently of each other upon inflation of the DWF wall assembly. A roll up strap with nylon push lock assists in holding the screen material in the open position. Exterior hook and loop is positioned along the exterior frame of the window to allow for closure. An independent, interior-mounted privacy screen ensures occupants remain out of view if in the down or closed position. Component 7 is the PVC Retaining Clip. Two 7 PVC Retaining Clips are used for each 12 Window Covering Assembly. Two 7 PVC Retaining Clips are used for 13 Door Covering Assembly. Six total 7 PVC Retaining Clips on the exterior, six on the interior.

Component 8 is the Upper D-Ring. Used to secure the tent to the ground, two are in each upper corner of the 2 Front Wall and 5 Back Wall.

Component 9 is the Sign Hook and Loop. This is positioned on the exterior lower left of 2 Front Wall.

Component 10 is the Inflation Bank Cover. This cover is located on 1 Roof Assembly, 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. This cover is used to protect and hide from view each 19 Inflation Port and 20 Overinflation Relief Valve.

Component 11 is the Window. Two 11 Windows are located within the 2 Front Wall.

Component 12 is the Window Covering Assembly. Each 11 Window has two 12 Window Covering Assemblies. One for the interior of the structure and one for the exterior. These are rolled up and down vertically and utilized to maintain privacy, ventilation, or visibility within the structure. When in the closed position, the assembly utilizes hook and loop along the exterior perimeter to hold it in place.

Component 13 is the Door Covering Assembly. Two 13 Door Covering Assemblies are used for the 23 Front Door. One is located on the interior of the structure and one for the exterior. These are rolled up and down vertically and utilized to maintain privacy, ventilation, or visibility within the structure. When in the closed position, the assembly utilizes a combination of hook and loop along the perimeter and zippers along the side to hold it in place.

Component 23 is the Front Door. The 23 Front Door is located within the 2 Front Wall. Slightly elevated off the ground, it serves as the entrance to the interior of the structure. Atop of the 23 Front Door and located on the interior and the exterior of the structure is the 13 Door Covering Assembly. This assembly rolls up and down and allows the door to be in the open or closed position. In an embodiment, the entry door is positioned at the midpoint of the front DWF wall assembly when inflated. An optional privacy and mesh screen allows for independent use and is joined using an exterior zipper. An optional interior mounted privacy door ensures occupants remain out of view and provides additional security if in the down and closed position.

In some embodiments, a separate overpressure valve is incorporated into at least one of the walls and roof to ensure integrity and protection from over-pressurization. In an embodiment of the invention, the roof is peaked along the centerline of the structure to allow for water and snow runoff. In other embodiments, a roof is positioned horizontally across wall panel members allowing a flat configuration. In an embodiment of the invention, the removable floor prevents water intrusion under damp conditions and/or is integrated with at least one wall. In some embodiments, Upper and Lower Tie Downs are used to connect the structure to the ground.

In an embodiment of the invention, air is introduced to the independent DWF Walls and DWF Roof through inflation valves from an external blower and inflate the structure. Upon attainment of a desired internal pressure, the inflated, interconnected walls and roof form the perimeter of the structure while the independent and/or removable floor is stretched into position. Optional overinflation valves on the walls and roof ensure the structure does not over pressurize. Occupants can now utilize the inflatable structure. In an embodiment of the invention, a single inflation tube is used to connect all DWF wall and DWF roof inflation valves in unison. Under such conditions, a single external air blower may be used to inflate the walls and roof simultaneously.

For structure deflation and/or to reduce pressure, air can be removed or vacuumed through the inflation valves located on the roof and walls. When fully deflated, the DWF walls can be folded and rolled back into the storage container. All deflated walls, the roof, and floor optionally remain connected while in storage. In an embodiment of the invention, a single deflation tube may be used to connect all DWF walls and DWF roof valves. Under such conditions, a single external air blower may be used to vacuum the internal air from the wall sections.

In some embodiments of the invention, the inflatable structure assembly is constructed from separate components that are inflated independently and then connected. The first component comprises a fabric floor connected on each of four sides to four inflatable walls. The second component or the walls are interconnected and configured so that, with the addition of air, the walls expand into the shape of the shelter. The inflated walls cooperatively support the shelter in an upright position. The third component is the roof section which may be inflated and installed separately or in conjunction with the walls. When deflated the structure can be rolled and compacted for easy transport. In some embodiments, a separate but connected DWF roof system is attached to the rectangular structure through Nylon straps and metal D-Rings. This roof system may be inflated or deflated independently of the wall system.

FIG. 2 is a side view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. In an embodiment of the invention, Component 3 is the Left Side Wall. Component 3 attaches to 1 Roof Assembly, 2 Front Wall, and 5 Back Wall through multiple 18 Pin and Anchor Systems, 21 Wall Seal Hook and Loop, and 22 Roof Seal Hook and Loop. Component 3 attaches to 6 Floor Assembly through hook and loop. Two 19 Inflation Ports and one 20 Overinflation Relief Valve are located on the lower left corner of 3 Left Side Wall. Two 15 Lower D-Rings are located in opposite lower corners of 3 Left Side Wall. One 14 Side Vent is located along the centerline and approximate to the apex of the vertical wall. 24 Side Vent Cover allows for 14 Side vent to be in the open or closed position. An added mesh screen can be added to prevent insect intrusion. These side vents allow for fresh air ventilation and heat removal during high external temperature operations.

In an embodiment of the invention, Component 4 is the Right Side Wall. Component 4 attaches to 1 Roof Assembly, 2 Front Wall, and 5 Back Wall through multiple 18 Pin and Anchor Systems, 21 Wall Seal Hook and Loop, and 22 Roof Seal Hook and Loop. Component 4 attaches to 6 Floor Assembly through hook and loop. Two 19 Inflation Ports and one 20 Overinflation Relief Valve are located on the lower right corner of 4 Right Side Wall. Two 15 Lower D-Rings are located in opposite lower corners of 4 Right Side Wall. One 14 Side Vent is located along the centerline and approximate to the apex of the vertical wall. 24 Side Vent Cover allows for 14 Side vent to be in the open or closed position.

In an embodiment of the invention, Component 14 is the Side Vent. One each 14 Side Vent is located on 3 Left Side Wall and 4 Right Side Wall along the respective centerlines. A 24 Side Vent Cover is positioned at the top of the 14 Side Vent and allows for the vent to be in the open or closed position.

In an embodiment of the invention, Component 15 is the Lower D-Ring. Two each D-Rings are positioned in the opposite lower corners of the 3 Left Side Wall, and 4 Right Side Wall. A retaining clip holds the 15 Lower D-Rings in the up position when not in use. These 15 Lower D-Rings are utilized to hold the structure to the ground.

In an embodiment of the invention, Component 21 is the Wall Seal Hook and Loop. The 21 is utilized to cover interior and exterior gaps between the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. Positioned along the interior and exterior of the structure this system separates the internal and external environments.

In an embodiment of the invention, Component 22 is the Roof Seal Hook and Loop. The 22 Roof Seal Hook and Loop is utilized to cover interior and exterior gaps between the 1 Roof Assembly and the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. Positioned along the interior and exterior of the structure this system separates the internal and external environments.

FIG. 3 is a rear view of the inflatable structure assembly 100, in accordance with an embodiment of the invention.

In an embodiment of the invention, Component 5 is the Back Wall. Component 5 attaches to 1 Roof Assembly, 3 Left Side Wall, and 4 Right Side Wall through multiple 18 Pin and Anchor Systems, 21 Wall Seal Hook and Loop, and 22 Roof Seal Hook and Loop. Component 5 attaches to 6 Floor Assembly through hook and loop. Two 19 Inflation Ports and one 20 Overinflation Relief Valve are located on the lower right outer edge of 5 Back Wall. Two 8 Upper D-Rings are located in opposite upper corners of the 5 Back Wall. One 17 Utility Vent is located along the vertical centerline of the 5 Back wall. A 25 Utility Vent cover allows for the 17 Utility Vent to be in the open or closed position. Two 16 HVAC vents are distanced from the vertical centerline of 5 Back Wall. 26 HVAC Cover allows for the vents to be in the open or closed position. These vents allow for air exchange and circulation through interior or exterior mounted HVAC units. These ducts may be interchanged and represent outlets for HVAC supply and return ducts. HVAC vents may be positioned in the open or closed utilizing exterior hook and loop. An added mesh screen is present to prevent insect intrusion and allow for fresh air ventilation.

In an embodiment of the invention, Component 16 is the HVAC Vent. Two 16 HVAC vents are located within the 5 Back Wall. A 26 HVAC cover is positioned on the exterior of 5 Back Wall and is utilized to position the 16 HVAC Vent in the open or closed position.

In an embodiment of the invention, Component 17 is the Utility Vent. The 17 Utility vent is located within the 5 Back Wall. A 25 Utility Vent Cover is positioned on the exterior of 5 Back Wall and is utilized to position the 17 Utility Vent in the open or closed position. Utility vents may be positioned in the open or closed using an exterior mounted hook and loop closure. An added mesh screen is present to allow for fresh air ventilation.

In an embodiment of the invention, Component 25 is the Utility Vent Cover. The 25 Utility Vent Cover is located along the 5 Back Wall. The 25 Utility Vent Cover sits atop the 17 Utility Vent and allows the vent to be in the open or closed position using hook and loop to adjust the position of the cover.

In an embodiment of the invention, Component 26 is the HVAC Cover. Two 26 HVAC Covers are located along the 5 Back Wall. The 26 HVAC Cover sits atop the 16 HVAC Vent and allows the vent to be in the open or closed position using hook and loop to adjust the position of the cover.

FIG. 4 is a front perspective view of the inflatable structure assembly 100, in accordance with an embodiment of the invention.

In an embodiment of the invention, Component 24 is the Side Vent Cover. The 24 Side Vent Covers are located along the centerline and near the apex of the 3 Left Side Wall and 4 Right Side Wall. The 24 Side Vent Cover sits atop the 14 Side Vent and allows the vent to be in the open or closed position using hook and loop to adjust the position of the cover.

FIG. 5 is a top view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. The pitched roof is inflated independently and attaches to the four walls using a pin and anchor system. In addition, Roof seals on the exterior and interior of the structure hold the roof securely down onto the walls while ensuring the interior is protected from the external environment. The seals are held in place by a hook and loop system. The pitch of the roof allows for adequate rain and or snow runoff during adverse weather conditions.

The DWF wall assembly and DWF roof assembly extend substantially when inflated and unconstrained. The DWF wall and roof assemblies are collapsible without inflating fluid at a minimum pressure.

In an embodiment of the invention, a second, independently inflated DWF pitched roof assembly system is connected to the DWF wall assembly through a pin and anchor system. A PVC seal system is utilized on the interior and exterior of the connected roof and wall assembly to ensure protection from external environmental conditions. This seal uses a hook and loop closure system to hold the seal to the wall assembly. The DWF roof system is positioned along the centerline of the DWF wall structure and is peaked to allow for water or snow runoff.

FIG. 6 is a close-up perspective view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. PVC wall and roof seals have been hidden from view to allow visibility of the pin and anchor systems connecting the roof and walls. In an embodiment of the invention, Component 18 is the Pin and Anchor System. Multiple 18 Pin and Anchor Systems are utilized to attach the 1 Roof Assembly to the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. Multiple 18 Pin and Anchor Systems are also used to attach the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. Anchors are welded to the appropriate wall and removable pin is utilized to connect the two.

FIG. 7 is a partially exploded side view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. The roof has been disconnected from this perspective, allowing the roof and wall pin and anchor system to be visible.

FIG. 8 is a partially exploded front perspective view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. The flooring assembly has been disconnected from the wall assembly allowing view of the interior and exterior PVC seal accomplished through hook and loop. In an embodiment of the invention, the protective film floor is mounted on the interior and exterior of the walls through a hook and loop closure system. This connection ensures the system remains watertight and is protected from the exterior elements.

In an embodiment of the invention, Component 6 is the Floor Assembly. Component 6 attaches to the 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall through hook and loop. 6 is connected on the interior and exterior of 2, 3, 4, and 5, by wrapping underneath 2, 3, 4, and 5. In an embodiment of the invention, the floor prevents water intrusion under damp conditions and/or is integrated with at least one wall.

FIG. 9 is an exploded front perspective of the inflatable structure assembly 100, in accordance with an embodiment of the invention. In FIG. 9 the four walls, the roof assembly, and the floor assembly have been disconnected. The interior and exterior PVC wall seal system has been removed to allow visibility of the pin and anchor system used between the walls and roof.

FIG. 10 is a close-up perspective view of an exterior corner of the inflatable structure assembly 100, in accordance with an embodiment of the invention.

The exterior PVC wall seal has been removed in the photo to allow visibility of the pin and anchor system. A cover for the inflation valves has been rolled back to allow visibility of the inflation valves and overpressure valves. When all four walls and the roof are deflated, the structure can be folded, rolled and compacted for easy transport.

In an embodiment of the invention, Component 19 is the Inflation Port. Two each 19 Inflation Ports are located within the 1 Roof Assembly, 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. A separate air blower is used to inflate or deflate the walls through these ports.

In an embodiment of the invention, Component 20 is the Overinflation Relief Valve. One each 20 Overinflation Relief Valves are located within the 1 Roof Assembly, 2 Front Wall, 3 Left Side Wall, 4 Right Side Wall, and 5 Back Wall. These valves allow air to be released in the event the wall or roof assemblies are over pressurized through internal or external conditions.

FIG. 11 is bottom perspective view of the inflatable structure assembly 100, in accordance with an embodiment of the invention. Looking from below the roof, the PVC Roof Seal is visible.

FIG. 12 is a close-up perspective view of a front right corner of the inflatable structure assembly 100, in accordance with an embodiment of the invention. FIG. 12 shows the PVC Roof Seal system utilizing hook and loop.

FIG. 13 is a close-up perspective view of the back left corner from the interior of the inflatable structure assembly 100, in accordance with an embodiment of the invention. The Wall and Roof Seal systems are shown utilizing hook and loop.

FIG. 14 is a close-up perspective view of a front left corner from an interior of the inflatable structure assembly 100, in accordance with an embodiment of the invention. The structure’s door, interior door covering assembly, window, interior window covering assembly, and associated retaining clips are shown in this figure.

While hook and loop fasteners are described throughout, it should be understood that alternatively, additionally and/or optionally, radio frequency, hot air, or hot wedge welding could be used.

In an alternative embodiment of the invention, attached to the DWF Roof Assembly is a PVC Roof Flap, a Nylon Strap and D-Ring Assembly, an Overpressure Valve and/or an Inflation valve.

DWF Wall Assembly and comprises a plurality of Double Wall Fabric (DWF) inflatable wall members in an inflated state and rectangular in shape DWF Roof Assembly attaches to DWF Wall Assembly through PVC Roof Flap and Nylon Strap and D Ring assembly..

One or more windows are incorporated onto the structure. Each window contains a privacy layer, a clear vinyl layer and mesh screen layer. These layers attach to DWF Roof Assembly via hook and loop fasteners. They may be placed and held in the open position.

The structure includes an entry door. The entry door incorporates a PVC liner and mesh screen. These are attached to DWF Wall Assembly via zipper. In an embodiment of the invention, the door may be inflated and fill the space as a plug allowing for greater insulation.

An inflation port flap is provided to the DWF Wall Assembly. Inside the inflation port flap is the inflation port and over pressurization valve for the Wall unit. This valve prevents users from inadvertently applying too much internal pressure.

A Tie Down is attached to DWF Wall Assembly by RF welded PVC film. There are 4 component 6’s located in all 4 upper corners. They are used to anchor the structure during environmental wind loads.

In some embodiments, 2 lines of Hook and Loop fasteners are designed to hold exterior signage.

The structure is optionally provided with at least one side wall air vent. This vent includes a PVC cover and inner mesh lining that will allow fresh air to enter the structure if required.

The structure is provided with at least one utility vent, optionally located in the rear of the structure. Additional passages through at least one wall, the floor and/or the roof are optionally provided, for example to permit the passage of wiring, tubing, venting and the like, for the provision of power, communications, hot/cold water/plumbing, HVAC, etc.

The PVC Roof Flap is attached to DWF Roof Assembly by RF welding. On the interior side of the PVC roof flap is a roof of hook and loop that allows it to attach to DWF Wall Assembly. This flap prevents water intrusion during rain or snow events. There are 2 flaps total one on either side of the structure.

In an embodiment of the invention, a Nylon Strap and D Ring assembly allows occupants to secure DWF Roof Assembly and DWF Wall Assembly together. By pulling Nylon Strap and D Ring assembly, the DWF roof is tightened onto DWF walls. Loosening all members of Nylon Strap and D Ring assembly allow for the removal and separation of DWF Roof Assembly and DWF Wall Assembly. Alternative methods of attachment are the pin and anchor system and/or hook and loop attachments.

In an embodiment of the invention, the DWF Roof Assembly is provided with an over pressurization valve. This valve releases excess internal air pressure at approximately 5 pounds per square inch, in some embodiments of the invention. Optionally, the internal air pressure level is above or below 5 lbs/in².

The structure is provided with a DWF Roof Assembly Inflation Valve. This valve is used to inflate and pressurize DWF Roof Assembly.

A floor is also provided. In an embodiment of the invention, this floor is attached to the structure by radio frequency welding and ensures water remains outside of the structure. Alternative methods of attachment include hook and loop.

Additionally, it should be understood that a plurality of inflatable structures could be connected or used together to provide an expanded protected space and/or to enhance functionality of the structure(s). In an embodiment of the invention, a system of interchangeable and/or modular inflatable structures is provided which are optionally configured on a case-by-case basis to suit the needs of the user(s). For example, the inflatable structures described herein can be configured as “bunk houses” to provide living/sleeping space for occupants. Optionally, multiple structures are used to provide an expanded living/sleeping space for multiple occupants (i.e., more than could fit into a single structure). Other examples of inflatable structure configurations include infirmary/medical/therapeutic/surgical, bathroom/restroom, dining, food preparation, cooling/heating (owing at least in part to the choice to use DWF construction, where DWF is a passable insulator), meeting/conference/presentation, recreation, theater/auditorium, storage, garage/hangar, workshop, and the like. Two or more inflatables of one, some or all of these exemplary configurations could be attached together, or at least used in conjunction with one another, to form an inflatable structure “city” which supplies structures which fulfill multiple different needs of the user(s) depending on the use case.

In some embodiments of the invention, the inflatable structures described above are provided with more than one counterpart door and/or vent and/or window and/or other opening configuration (e.g., where doors on two connected structures match up) for use with this system, to facilitate passage of people and things between the various structures which are connected together. In some embodiments of the invention, at least one of the structures used in a combination of multiple structures is provided with additional attachment mechanisms, for example using hook and loop fasteners and/or pin and anchor, to provide secure connection between inflatable structures.

Exemplary features which are added into the modular inflatable structures optionally include at least one surface to sit and/or lie down and/or hold items and/or to work on, shapes and/or vessels for holding liquids, at least one compartment (optionally, also to hold things in a cooler or warmer temperature than ambient), at least one toilet, at least one showers, at least one bath. In some embodiments of the invention, any or all the above are also inflatable and/or are incorporated into the inflatable structure such that are inflated in conjunction with and/or separately from the walls, floor and/or roof.

The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to".

The term “consisting of” means “including and limited to”.

The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

The term “plurality” means “two or more”.

As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise. For example, the term "a compound" or "at least one compound" may include a plurality of compounds, including mixtures thereof.

Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” “downward”, and the like merely describe the configuration shown in the FIGS. from a particular point of view Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.

Claims

1. An inflatable structure assembly, comprising:

(a) a plurality of mechanically interconnected, Double Wall Fabric (DWF) inflatable wall panels;

(b) a roof, constructed of DWF and removably attached to the plurality of wall panels; and,

(c) a floor, removably attached to the plurality of wall panels on a side of the wall panels opposite the roof.

2. The assembly according to claim 1, wherein at least one of the plurality of wall panels, roof and floor are pneumatically independent.

3. The assembly according to claim 1, wherein at least one of the plurality of wall panels, roof and floor are pneumatically connected.

4. The assembly according to claim 1, further comprising at least one valve for at least one of inflating and deflating at least one the walls and the roof.

5. The assembly according to claim 4, further comprising an inflation bank cover to protect and hide from view the at least one valve.

6. The assembly according to claim 1, further comprising at least one air pump.

7. The assembly according to claim 1, wherein at least one of the roof and the floor is attached to the plurality of the wall panels via a pin and anchor system.

8. The assembly according to claim 1, wherein at least two of the plurality of wall panels, the roof and the floor are sealed with respect to each other using hook and loop fasteners.

9. The assembly according to claim 1, wherein at least two of the wall panels, roof and floor are attached to each other by a waterproof seal.

10. The assembly according to claim 1, wherein at least one of the plurality of wall panels, roof and floor are coated by at least one of polyvinyl chloride (PVC) or thermoplastic polyurethane (TPU).

11. The assembly according to claim 1, wherein at least one of the walls and roof comprise at least one inflatable pneumatic tube for inflation to at least a semi-rigid state.

12. The assembly according to claim 1, wherein the floor is attached to the walls through an internal and external hook mounted system.

13. The assembly according to claim 1, further comprising at least one over-inflation pressure relief valve.

14. The assembly according to claim 1, wherein at least one of the wall panels includes at least one of a window and a door.

15. The assembly according to claim 14, further comprising at least one of a window covering assembly and a door covering assembly.

16. The assembly according to claim 15, wherein at least one of the window covering assembly and the door covering assembly incorporates at least one of a privacy, clear and mesh screen.

17. The assembly according to claim 1, further comprising a sign attachment space.

18. A system of modular inflatable structures, comprising:

(a) at least two inflatable structure assemblies according to claim 1;

(b) at least one attachment mechanism to removably secure the at least two inflatable structure assemblies together.

19. The system according to claim 18, wherein at least one of the inflatable structure assemblies is chosen from a group consisting of a bunk house, an infirmary, a surgical ward, a laboratory, a bathroom, a dining hall, a kitchen, a temperature controlled room, a meeting room, a theater, a storage space, a garage, a hangar, and a workshop.

20. The system according to claim 18, wherein the at least two inflatable structure assemblies are connected by at least one of a counterpart door and window configuration.