US20190078318A1

US20190078318A1 - Transportable Expanding Shelter With Upwardly Pivoting Roof

Info

Publication number: US20190078318A1
Application number: US16/130,558
Authority: US
Inventors: Meagan Jessica Strong
Original assignee: Expandwell Homes Inc
Current assignee: Expandwell Homes Inc
Priority date: 2017-09-14
Filing date: 2018-09-13
Publication date: 2019-03-14
Also published as: CA3017283A1

Abstract

A transportable structure having a roof section which is moveable between a collapsed configuration and an erected configuration is disclosed. In the collapsed configuration, panels of the roof section rest on the structure so as to bear down against at least one wall of the structure. In the erected configuration, panels of the roof section converge upwardly to form a gabled roof covering the structure. Method of transporting and erecting the structure at a site is also disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional Patent Application No. 62/558,683, filed Sep. 14, 2017 entitled “POP-UP HOUSE”, the entirety of which is incorporated herein by reference.

FIELD

Embodiments described herein relate to portable building structures, and more particularly, to portable building structures having foldable components.

BACKGROUND

Portable and expandable enclosures, shelters or building structures are known in the prior art. Such building structures have a compact and collapsed configuration that contributes to portability, and an erected and expanded configuration that provides the requisite living and headroom space. It is also known to increase the requisite living and headroom space by providing slide-outs within the building structures which can expand vertically or horizontally when the building structure is in an erected configuration. For example, building structures such as travel trailers with slide-outs (a secondary/auxiliary structure nested within the main/primary structure of the trailer and which slides out to enlarge the living or headroom space) are known in the art. Further, portable and expandable enclosures such as large containers with fold-down sides, collapsing wall panels, and lifting roofs are known.
Conventional portable and expandable building structures have a generally rectangular shaped primary structure and have a flat or level roof so that when the building structure is erected, it results in a “box-like” building structure. Typically a rectangular shaped primary structure is preferred as the rectangular shape provides maximum floor area while allowing the building structure to be transported on conventional road networks as per conventional transportation rules.
Flat or level roofs have multiple problems associated with it. A flat roof may allow water to pool thereby creating a risk of water ingress into the building structure. To guard against this, it is known to use a variety of seals and sealing systems. However, as one of skill in the art will understand, with time and environmental factors the seals may fail leading to leakage.
Additionally, a flat roof also results in the building structure having a “box-like” shape when erected and expanded into the living configuration. This “box-like” aesthetic of the building structure may not appeal to everyone. Although it is a matter of preference, existing portable and expandable building structures do not offer the same visual appeal as a more traditionally shaped building structure with a sloping or gabled roof line. Traditionally, building structures with gabled roofs are preferred.
Recreational vehicles (RVs) having slide-outs in a variety of shapes and sizes and that expand vertically or horizontally are well known in the art and are offered by most major brands on units ranging from truck campers to travel trailers and motorhomes. Again, these expandable RVs have generally flat or level roofs.
Further, rigid walled transportable shelters having pivotable components are known. For example, Applicant is aware of rigid walled transportable shelters marketed under the brand names HERCon™ by WeatherHaven Global Resources Ltd. and the Hom™ by Habitaflex Concept Inc. The shelters, referred to in this paragraph, include multiple pivoting components which pivot into place to form the roof, floor, and walls of the shelter when the shelter is being erected on-site. These rigid walled transportable shelters also have flat or level roofs. Because of the multiple moving parts, assembly may be cumbersome. Further, the multiple moving parts result in a plurality of seams, which especially on the roof surfaces may form potential points of water ingress, due to failure of seals or to faulty assembly on-site.
Applicant is also aware of vertically expanding shelters such as those sold by Jexcar, North America Trailer Co Ltd. These expanding shelters are commonly used as dressing rooms during motion picture productions. These shelters expand vertically by raising a rectangular auxiliary/secondary structure which sits over the main/primary structure. The secondary structure is slightly smaller than the main structure, such that in its collapsed position it nests snugly over the vehicle and conforms to conventional transportation rules. In a raised or vertically expanded position, the secondary structure forms an additional room above the main structure. The roof is level or flat and remains level in the expanded position and does not rotate or pivot as the secondary structure is being raised.
Another example of a vertically expanding rigid walled shelter is the Hi-Lo trailer sold by Hi-Lo Trailers Worldwide. As with the Jexcar shelter, an upper shell or structure nests over the bottom base shell and can be raised to increase interior living space.
Applicant is also aware of U.S. Pat. No. 7,488,030 which discloses a travel trailer having a travel configuration and a habitat configuration. The trailer includes a pivotable roof which is curved.
Applicant is also aware of U.S. Pat. No. 5,921,033 which discloses an expandable, retractable, portable structure having a stationary portion and a movable portion. The movable portion includes a hinged flat roof.

SUMMARY

Embodiments described herein relate to a transportable structure having a roof section which is moveable between a collapsed configuration and an erected configuration.
Accordingly in one broad aspect, a transportable structure is provided. The structure has a body which provides a floor space having a first square footage. The first square footage is defined by at least one wall, a floor and a top. The structure comprises a roof section pivotally connected to the body and moveable between a collapsed configuration and an erected configuration. The roof section has first and second side panels connected together along a common ridge line and first and second end panels connected between and at opposite ends of the first and second side panels. In the collapsed configuration, the first and second side panels rest on the body over the top and, bear down against the at least one wall. In the erected configuration, the first and second side panels converge upwardly to meet along the common ridge line and vertically space the common ridge line from the top so as to form a roof covering at least the top.
Accordingly in another broad aspect, a method of transporting and erecting a structure at a site is provided. The structure has a body and a roof section. The body provides a floor space having a first square footage. The first square footage is defined by at least one wall, a floor and a top. The roof section has first and second rectangular side panels connected together along a common ridge line and first and second end panels connected between short edges of the first and second side panels. The method comprises pivotally connecting the roof section to the body at about the top. The method further comprises manipulating the roof section into a collapsed configuration wherein the first and second rectangular side panels of the roof section rest on the body over the top and bear down against the at least one wall. Further, the method comprises transporting the structure with the roof section in the collapsed configuration to the site. At the site, the roof section is manipulated into an erected configuration wherein the first and second side panels converge upwardly to meet along the common ridge line and vertically space the common ridge line from the top so as to form a roof covering at least the top.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an isometric view of the transportable structure in its collapsed configuration from a first direction;

FIG. 2 is an isometric view of the transportable structure of FIG. 1 from another direction;

FIG. 3 is an isometric view of the transportable structure of FIG. 1 in its erected configuration;

FIG. 4 is an isometric view of the transportable structure of FIG. 3 with a slide-out of the transportable structure in its extended position;

FIG. 5 is an isometric view of the transportable structure of FIG. 4 from another direction;

FIG. 6 is an isometric view of FIG. 4, with the slide-out in its extended position and a deck panel of the structure in its lowered position to form a horizontal deck surface extending from the structure; and

FIG. 7 is a top isometric view of the structure of FIG. 6 with the roof section removed and showing a loft formed above the body of the structure.

DETAILED DESCRIPTION

The present disclosure relates to a transportable structure 10 having a roof section which may be a gabled roof. The roof section is moveable between a collapsed configuration of FIGS. 1 and 2 and an erected configuration of FIGS. 3 and 4.
In one embodiment, the structure 10 includes a frame or body 12 providing a floor space having a first square footage. The first square footage is defined by at least one wall, a floor and a top which may be a top opening. In the embodiments illustrated in FIGS. 1 to 7, the floor space having a first square footage is defined by a floor 14, a top opening 16, opposing first and second sidewalls 18 and interconnecting opposing first and second end walls 20. The top opening 16 is defined by uppermost edges 22 of the sidewalls 18 and end walls 20. The area of the top opening 16 is preferably substantially the same as the first square footage.
The structure 10 further includes a roof section 24. As stated above, the roof section 24 is moveable, preferably by pivoting, between a raised or erected and collapsed configuration. The roof section 24 is in the collapsed configuration when the structure 10 is being transported and positioned for use. When the roof section is in the raised or erected configuration, the structure 10 may be used as a shelter.
In one embodiment and with reference to FIGS. 1 to 6, the roof section 24 includes first and second rectangular side panels 26 and 26′, respectively. Each rectangular side panel has opposing upper and lower edges such as long edges 26 a and opposing end edges such as short edges 26 b and share a common ridge line 26 c. The first and second side panels are connected together along common ridge line 26 c. In one embodiment, the first and second side panels are connected to each other in a substantially perpendicular relationship. The roof section further comprises first and second triangular end panels 28 connected between short edges 26 b of the first and second side panels 26 and 26′. Side panels 26 and 26′ do not need to be rectangular as they may, for example, be square. Also, end panels 28 do not need to be triangular.
In one embodiment, long edge 26 a of the first panel 26, opposite the common ridge line 26 c, is pivotally connected to the first or second sidewall 18 at about its uppermost edge 22 via a hinging mechanism 30.
Hinging mechanism 30 may for example be one long continuous hinge or multiple hinges at discrete points along edge 22 of one of sidewalls 18.
In the collapsed configuration of the roof section 24, the first and second side panels 26 and 26′ rest on the body 12 so at to completely cover the top opening 16 and bear down against the sidewalls 18 and/or end walls 20.
In one embodiment and with reference to FIGS. 1 to 6, in the collapsed configuration, the first side panel 26 rests on the top opening with its short edges 26 b resting on uppermost edges 22 of the opposing end walls 20 and its long edges 26 a resting on uppermost edges 22 of the opposing sidewalls 18 so as to cover the top opening 16. The second side panel 26′ rests against the first or second sidewall 18 with its long edge 26 a, opposite the common ridge line 26 c, located at about the level of floor 14. Typically, the structure 10 is transported to a desired site and positioned for use when in this configuration.
In order to move the roof section 24 into the raised or erected configuration so as to use the structure 10, for example as a living space, the roof section 24 is raised or pivoted upwardly in direction A about hinging mechanism 30 until the lower edges of the end panels 28 are horizontal and long edge of panel 26′, opposite the common ridge line, is level with the hinging mechanism or uppermost edges of the sidewalls and/or end walls. Once raised, the first and second side panels and the end panels form a roof 32 covering at least the top opening. In the raised configuration, since the common ridge line is vertically spaced from the top opening, the first and second side panels and the end panels create a loft space such as a second storey between the top opening and the vertically spaced common ridge line. The roof section 24 is rotated about the hinging mechanism 30 so that the first and side panels 26, 26′ are lifted from their resting position on the body 12, as seen in FIG. 1, to provide equally sloping sides of the raised roof 32, sloping downwardly from the common ridge line 26 c.
Advantageously, roof 32 is a gabled roof. There are several known advantages associated with a gabled roof. For example, a gabled roof is considered to be aesthetically more pleasing as compared to a flat or level roof. Further, a gabled roof facilitates water drainage from the roof because of its sloping surfaces, whereas flat roofs, such as found on typical recreational vehicles and trailers, tend to pool water and may be prone to leakage.
In one embodiment, the structure 10 may include doors or windows 34 which may be formed in the sidewalls or end walls of the structure 10. In the collapsed configuration, the second side panel 26′ rests flush against the first or second sidewall and the end panels 28 pivot downwardly (during the lowering of the roof section 24) so as to slide snugly past the end walls 20, to rest against the end walls 20. Doors or windows in the side or end walls are, therefore, at least partially covered by the second side panel and/or the end panels and thus are at least partially protected from damage by road debris such as flying rocks during transportation. In the raised position, the end panels may be secured in place, for example, by being pinned to the uppermost edges of the end walls 20.
In one embodiment and with reference to FIGS. 4 and 5, the structure 10 may include a slide out structure 36 to provide a second square footage in addition to the first square footage. In the collapsed configuration, the slide-out is nested within the first square footage (best seen in FIG. 3). In the erected configuration, the slide-out structure 36 is extended from the first square footage to provide the additional living space (best seen in FIG. 4). As seen in FIG. 4, in the erected configuration, the gabled roof 32 overhangs the top opening 16 of the body 12 and a top 36 a of the slide-out structure so as to cover both the body 12 and the slide-out structure 26. As shown in FIG. 4, outer wall 36 b of the slide-out structure is the same height as the end wall 20 of the transportable structure 10, allowing it to meet the gabled roof 32.
In one embodiment and with reference to FIG. 6, the transportable structure 10 may include a deck section including a panel 38. The panel 38 is pivotally connected to a sidewall 18 at about the floor 14. In the collapsed configuration, the panel 38 is held against the sidewall 18 using fasteners (not shown) and in the expanded configuration, the panel 38 is pivoted away from the sidewall 18 so as to form a horizontal deck surface 38 a extending from the body 12.
In the collapsed configuration, while the structure is being transported, since the panel 38 is held against the sidewall 18, it protects any windows or doors 34 formed on the sidewall from flying debris such as gravel, and also acts as a barrier to unwanted entry into the structure 10.
In one embodiment and with reference to FIG. 7, depending on the size and purpose of the structure 10, an upper floor or loft 40 may be formed over all, or a portion of the top opening 16, thus creating a second storey/floor (third square footage) of living-space. As one of skill in the art will understand, in an embodiment where the loft is formed over all of the top opening 16, the loft functions as a ceiling. This is possible because in the erected configuration, the common ridge line 26 c is separated from the top opening by a vertical distance thereby enabling formation of a third square footage between the top opening and the vertically spaced common long ledge. Depending on the size of the structure 10, the loft 40 may need to be supported at one or at several points within the structure 10 by one or more vertical support posts 42. If structure includes a slide-out structure, the one or more vertical support posts 42 should be positioned such that they do not interfere with the travel of the slide-out structure. If there are two support posts 42, one possible solution may be to locate the slide-out structure 36 between the two support posts 42.
Another possible solution and best seen in FIG. 7, may be to include a support post 42 within, and integral to, the slide-out structure 36 itself at a point which would be in-line with an unsupported edge of the loft 40. The support post 42 may be joined at the ceiling height of the slide-out structure to a first beam 44 that runs the length of the slide-out structure and to another beam 46, placed perpendicularly to the first beam 44 and which runs the breadth of the slide-out structure. This of course is just one contemplated embodiment and many configurations of support posts may be possible, including an embodiment having no support posts at all.
In one embodiment, the transportable structure 10 may be partially or completely manufactured from a composite material such as composite material panels, also known as sandwich panels. Such panels generally include a low-density core bonded on each side to a thin outer layer having low elasticity and high tensile strength. In one embodiment, the panel cores may be structural foam or honeycomb core, however, as would be appreciated by a person skilled in the art, other materials or combinations thereof may be possible. Composite panels are known to offer strength, rigidity, and low weight needed to withstand the jostling of transportation and yet, for certain uses and embodiments, remain lightweight enough to be towed by a passenger vehicle. The insulative properties of foam core composite panels are also beneficial in creating an energy efficient living space. In other embodiments a variety of other materials could be used to manufacture the transportable structure 10.
Several embodiments have been contemplated for pivotal movement of the roof section 24 or deck panel 38 and extension of the slide-out structure 36 from the body 12. In one embodiment, the roof section 24 or deck panel 28 may be pivoted manually. In another embodiment, for larger structures 10 that are placed at a site using heavy equipment such as a crane, the crane that is used to place the structure 10 at the site may be used to rotate the roof section 24, or lower the deck panel 38 or extend the slide-out structure 36.
In another embodiment, the roof section 24 may be rotated by at least one actuator (not shown) integral to the transportable structure 10. The at least one actuator may include motorized or manually operated systems. The actuator may include one or more linear actuators, either connected to and acting directly on the roof section 24, or connected to the roof section 24 via one or more mechanical linkages. The linear actuators may be mechanical, hydraulic, pneumatic, electro-mechanical, or linkages driven by motors, (not shown). If more than one mechanism is used to rotate the roof section 24, the mechanisms may be synchronized mechanically, electrically, hydraulically or pneumatically to ensure that the roof section 24 is raised into the erected configuration smoothly and evenly and along its length
In another embodiment, a roof raising system which is integral to the transportable structure 10 may include one or more electric motors connected to one or more gearboxes suitably configured to rotate the roof section through its range of movement, for example in direction A (best seen in FIG. 1). The gearboxes may also be driven by external means, such as hand cranks, or external motors such as electric drills.
In another contemplated embodiment of, the roof section 24 may be raised by the action of a motorized or manually operated winch system, whereby a cable or line would be fixed at one or more points on the roof section 24 and would be driven by one or more winches placed on or within the transportable structure 10, and with the cable or line passing through a pulley or series of pulleys (or other method of changing the direction of movement of the cable or line) at or near uppermost points in the body of the structure 10 in order to translate the action of the winch or winches into angular lift of the roof section 24 into the erected configuration. If more than one winch is used, the mechanisms may be synchronized to ensure that the roof section is raised into the erected configuration evenly.
In an embodiment wherein the structure 10 includes a slide-out structure 36, the extension or retraction of the slide out structure may operate independently of the raising of the roof section 24. Alternatively, the system employed for extending and retracting the slide-out structure 36 may be synchronized with, and possibly driven by, the system employed for raising the roof section 24. The slide-out structure 36 may be extended from the body 12 as the roof section 24 is being pivoted into the erected configuration, or after the roof section 24 is in the erected configuration, or at a suitable time during the roof raising process.
In one embodiment, the transportable structure 10 may be built onto a wheeled chassis so as to be towable. In another embodiment, the transportable structure 10 may be built on a container base so as to be intermodal compatible and be transported as would a container. As will be appreciated by a person skilled in the art, other bases or transport methods may be used.
The transportable structure 10 described herein may be sold as an upscale recreational vehicle which appears in the expanded configuration of the roof section, as an attractive cabin, complete with sleeping loft and vaulted ceiling, large windows, and glass doors opening to a fold-down deck. As with conventional RVs, all the moving parts may be made to move at the push of a button for the convenience of the user. Alternatively, the transportable structure 10 described herein may be used as a temporary housing in a remote location or as a temporary sales office or workspace. It may also be useful for government or humanitarian organizations needing to respond with disaster relief in situations where instant housing is needed to replace something that has been destroyed.
The transportable structure 10 may also be useful as a seasonal cabin on a recreational property, offering the benefits of speed of installation as well as the ability to close up securely or remove the unit from the location in the off-season.
As is clear from the foregoing paragraphs, structure 10 disclosed herein expands a shelter in a way that changes its form from that of a “box shape”, to that of a dwelling with a steeply sloped gabled roof. This change in shape is achieved by rotating the roof section 24 from its collapsed configuration to the erected configuration.
In one embodiment and with reference to FIGS. 1 to 6, in the closed configuration, the roof section 24 nests over the body 12 and the overall shape of the unit is rectangular. In its erected configuration, the roof section forms a gabled roof, that is, one that slopes downward in two parts at an angle from a central ridge, so as to create a triangular gable at each end. In this erected configuration, a long edge 26 a of the roof section (long edge of panel 26′ opposite common ridge line) which was formerly level with the floor of the body now rests level with the hinging mechanism 30. Further, in the erected configuration, the common long edge 26 c of the roof section sits at a distance from the top opening of the body thereby introducing an opportunity to further expand the living space.
As discussed above, the steeply sloped or gabled roof 32 is able to efficiently shed water, and thus does not rely on seals to keep pooling water from entering the living-space, as is common in RV slide-outs. In this design all seals are sheltered from the elements by the gabled roof 32 which overhangs the top opening. This is the case in both the collapsed and erected configurations.
Furthermore, since the roof section 24 remains as one intact unit throughout the collapsing and erecting process, reliance on on-site workmanship during the set-up process is largely eliminated. The structure disclosed herein offers a relative simplicity of design and set-up when compared to many other rigid-walled, expanding structures.
As stated above, when the roof section is in the erected configuration, the structure is aesthetically appealing. With its appealing roofline, vaulted ceiling and expansive windows, this structure will appeal to those who need or want a more traditional look.

Claims

What is claimed is:

1. A transportable structure having a body providing a floor space having a first square footage which is defined by at least one wall, a floor and a top, the structure comprising:

a roof section pivotally connected to the body and moveable between a collapsed configuration and an erected configuration, the roof section having first and second side panels connected together along a common ridge line and first and second end panels connected between and at opposite ends of the first and second side panels; and

wherein, in the collapsed configuration, the first and second side panels rest on the body over the top and, so as to bear down against the at least one wall, and in the erected configuration, the first and second side panels converge upwardly to meet along the common ridge line and vertically space the common ridge line from the top so as to form a roof covering at least the top.

2. The structure of claim 1, wherein the body is a rectangular parallelepiped and the at least one wall includes first and second opposing sidewalls connected by first and second opposing end walls, and wherein the top is defined by uppermost edges of the sidewalls and the end walls.

3. The structure of claim 2, wherein the first side panel is pivotally connected to the first or second sidewall at about its uppermost edge via a hinging mechanism for pivotal movement of the roof section between the collapsed configuration and the erected configuration.

4. The structure of claim 2, wherein each of the first and second side panels have opposite upper and lower edges connected by opposite end edges, and in the collapsed configuration, the first panel rests on the top with its end edges resting on the uppermost edges of the first and second end walls and its upper and lower edges resting on the uppermost edges of the first and second sidewalls so as to cover the top, and the second side panel rests against the first or second sidewall with its lower edge, opposite the common ridge line, located at about the floor.

5. The structure of claim 1 further comprising a slide-out structure slidably nested in the body to provide a second square footage in addition to the first square footage of the floor space, and wherein in the collapsed configuration, the slide-out structure is nested within the first square footage of the floor space, and in the erected configuration, the slide-out is extended from the first square footage of the floor space to be located substantially outside of the first square footage.

6. The structure of claim 5, wherein in the erected configuration, the roof section covers both the top of the body and a top of the slide-out structure, so as to cover both the body and the slide-out structure.

7. The structure of claim 2, wherein in the erected configuration, a third square footage is formed as a second storey between the vertically spaced common ridge line and the top.

8. The structure of claim 7, wherein the third square footage is a loft.

9. The structure of claim 1 further comprising a deck section including a panel, the panel being pivotally connected to the at least wall at about the floor, and wherein in the collapsed configuration, the panel is held against the at least one wall and in the expanded configuration, the panel is pivoted away from the at one wall so as to form a horizontal deck surface extending from the body.

10. The structure of claim 1, wherein the structure is partially or completely formed of a composite material.

11. The structure of claim 7, wherein the roof section or the deck section are manually pivotable.

12. The structure of claim 7 further comprising at least one actuator for pivoting the roof section or the deck section.

13. A method of transporting and erecting a structure at a site, the structure having a body and a roof section, the body providing a floor space having a first square footage which is defined by at least one wall, a floor and a top, and the roof section having first and second rectangular side panels connected together along a common ridge line and first and second end panels connected between short edges of the first and second side panels, the method comprising:

pivotally connecting the roof section to the body at about the top;

manipulating the roof section into a collapsed configuration wherein the first and second rectangular side panels of the roof section rest on the body over the top and, so as to bear down against the at least one wall;

transporting the structure with the roof section in the collapsed configuration to the site and at the site, manipulating the roof section into an erected configuration wherein the first and second side panels converge upwardly to meet along the common ridge line and vertically space the common ridge line from the top so as to form a roof covering at least the top.

14. The method of claim 11, where in the manipulation step at the site further comprises rotating the roof section about a hinging mechanism connected between the first side panel and an uppermost edge of the at least one wall.