Modular structure and method of creating modular structures

REFERENCE TO PRIOR APPLICATION

0001The present invention claims priority to previously filed Provisional Application, No. 61/578,886, filed 2012 Dec. 22.

BACKGROUND OF INVENTION

00021. Field of the Invention

0003The present invention addresses a new cover structure and design, that is useable for a variety of purposes, that is lightweight, that is easy to assemble and is shippable in compacted form. The present invention also addresses the method of creating these structures.

00042. Description of the Related Art

0005The present application has a variety of possible uses and the following are just a few. It should be noted that the invention is not limited to these specific examples but can be used for multiple purposes.

0006Conventional pickup truck and trailer covers, containers and structures are typically built out of heavy, rigid construction materials and are bulky, difficult to ship and if designed to be knocked down, generally have complicated assembly processes utilizing a multitude of parts and fasteners. The present invention permits a large cover, container or structure to be created with as few as three parts including one cover, two matching arched end walls, or end walls, and a connector or fastener. This extremely simple, elegant design allows for this assembly to be shipped in a highly compact form due to the unique folding and rolling ability of the material used in the invention and the limited number of parts required for construction.

0007Additionally, portable, modular structures are becoming popular as temporary or semi-permanent storage facilities. Often it is desirable to store equipment, vehicles or other items in places where no permanent storage is available. However, most of these temporary structures are complex and not easily set up.

0008Another area where compact shippable containers are needed is for additional cargo space needed with cars, SUV's, RV's and vehicles in general. The ability of an enclosed container to be knocked down and shipped in a highly compacted form provides great value by reducing the shipping cost to customers. The ability to use UPS® or FEDEX® package delivery or any other economical package delivery service for a product instead of using an LTL Freight carrier for delivery not only saves the customer money, but greatly reduces the risk of shipping damage.

0009There presently is a need for a modular structure that may be configured in many different shapes and sizes and for many different purposes that is lightweight, easy to assemble and that knocks down for shipping and storage. The present disclosure has been made with the view to such problems, and an object of the present invention is to provide a light-weight, versatile, multi-sizeable, multi-configurable and collapsible modular structure that is easily assembled.

SUMMARY OF THE INVENTION

0010To solve the above problems and to achieve the object noted above, the present disclosure is configured as follows.

0011The structure of the present invention utilizes a corrugated, semi-rigid sheet material having two outside surfaces connected by intermediate ribs. In its originally fabricated form this material is flat and non-pliable. However, with specific single surface and rib material removed and channels created the sheet is transformed into a flexible material that permits formation of complex radial geometries. These radial geometries cause the sheet to exhibit both compression forces on the cut side of the material surface and tension forces on the uncut surface when the sheet is formed into radial shapes. The gaps or channels resulting from the single surface material removal are closed by the hinging affect of the uncut side, causing the remaining blocks to occlude. The occlusion of the cut surface causes the uncut surface to be tensioned.

0012By removing material and allowing the formerly two dimensional sheet to be formed into three dimensional radial shapes, the sheet's resistance to deflection is increased due to the ability of the formerly semi-rigid sheet to have a “crown” shape. The radial shape is determined by the span and arc of the design and the amount of material removed from the desired arc. For a shallow arc the material removed is a thin strip, or thin channel. As more material is removed in wider strips, the sheet can be formed into shorter radius arcs.

0013Although numerous types of sheet can be used to create this novel mechanical property and its resulting designs, the description of the present invention will focus on the use of corrugated polypropylene sheet, as this material is readily available on the market and is used extensively for signs. This is not to narrowly define the material choices for the present invention, as many substitute materials can also be used to accomplish the novelty of the present invention. The invention's cross sectional appearance is for a material having two lateral surfaces joined by intermediate ribs/flutes/connecting the lateral orientation of the surface composition.

0014The choice of polypropylene (PP) as the substrate for the sheet is specific to several unique characteristics of PP, including but not limited to the following: thin, single wall sections of this material possessing a hinging ability without cracking or losing strength; the ability of the material to be colored; the ability of the material to accept adhesive stickers; the ability of the material to have insulate value due to trapped air between the two surfaces; the ability of the material to have its translucency varied; and the ability of the material to maintain its structure and competency in extreme temperatures, even when hinged numerous times.

0015The selection of the corrugated profile is important for the rigidity of the material, and for the ability to have wiring, lighting and heating elements placed or configured inside the cells that run along one dimension of the corrugated sheet.

0016One structural embodiment is an enclosed box without floor. This embodiment consists of a roof panel and two end walls, or end walls. The end walls are designed with a radial top surface and a straight bottom surface. The roof panel fits over the end walls with a tongue and groove connection created by the removal of the surface and center ribs of the formerly rigid sheet to provide a channel in the panel into which the end wall can lock. By removing strips of the surface skin from the inside of the panel, the formerly rigid panel is allowed to wrap itself around the upper edges of the end walls, lock itself onto the top of the end wall and self tension the resulting structure. The roof panel has material strips removed on the inside surface for the full length of the sheet. This allows the roof sheet to conform flexibly onto the end walls in a secure manner. The removal of periodic strips from only one surface of the roof panel creates defined channels and allows this embodiment of the roof panel to be rolled or folded to provide compact shipping and storage. Additionally the end walls can have material removed from one surface to provide this same folding or rolling ability for compact shipping and storage, yet assemble rigidly in conjunction with the roof or cover panel.

0017The four corners of this embodiment utilize secure mechanical connections or fasteners for the roof panel to the end walls by way of connection media including preferred embodiments such as hook and loop (velcro®), Pin & Barrel Nut hardware (Pin Nut™), as described in U.S. patent application Ser. No. 12/122,546, incorporated in its entirety by this reference, and self assembling spring buttons that allow for a no-tool setup and takedown. It should be noted that the connection means are not limited by this description and that any fastener or connection means may be utilized to connect the parts together.

0018This embodiment can also stand on its end, to provide, among other applications, a novel point of purchase display, shelving and cabinet functions. This embodiment can have a plurality of end walls that are distally separated in height through the creation of grooves or channels caused by material being removed from the inside of the cover so that additional shelving ledges may be provided. It should be noted that one key unique aspect of this design is that functionality is created by the removal of material from the cover, a unique process and technique that provides new value compared to other processes that require adding parts to accomplish these functions. Additionally, this stand up embodiment can have the cover sheet extended with material removed at decisive places for hinging so that the cover sheet also functions as a door or doors to fully enclose the structure, without adding parts. This embodiment is permitted by the inherent hinging ability of the thin PP wall that remains after removal of the opposite side skin and intervening flutes. This embodiment eliminates the cost and complexity of providing hinged doors using conventional methods.

0019Another preferred embodiment of the present invention is to have the structure include a floor that can be organically attached to the roof panel, or function as a part of the structure that attaches to the roof and end walls separately during assembly.

0020These two embodiments can be iterated in multiple applications and in many sizes to match with new product choices in widely disparate market niches including housing, storage, transportation, point of sale displays, agricultural and automotive products, examples of which can be seen in the attached art.

BRIEF DESCRIPTION OF THE DRAWINGS

0021<figref idref="DRAWINGS">FIG. 1</figref> is an elevated view of the cellular sheet used to create one of the many forms possible.

0022<figref idref="DRAWINGS">FIG. 2</figref> shows the cellular sheet for the cover of one of the forms possible with material removed to allow the sheet to fold and form radius shapes.

0023<figref idref="DRAWINGS">FIG. 3</figref> is an elevated view that shows the cover and end walls necessary to form the arch design.

0024<figref idref="DRAWINGS">FIG. 4</figref> is an exploded view of the arch design that shows the cover and end walls ready for assembly.

0025<figref idref="DRAWINGS">FIG. 5</figref> is another exploded view of the arch design that shows the process of assembly.

0026<figref idref="DRAWINGS">FIG. 6</figref> is an exploded view of a securing system used to secure the end walls to the cover to form the arch structure with an open floor.

0027<figref idref="DRAWINGS">FIG. 7</figref> is an elevated view of the cellular sheet laid flat with provision for an integrated floor.

0028<figref idref="DRAWINGS">FIG. 8</figref> is an elevated, exploded view of the arch design without floor

0029<figref idref="DRAWINGS">FIG. 9</figref> is an exploded view of arch design with floor.

0030<figref idref="DRAWINGS">FIG. 10</figref> shows a preferred method for securing the corners of arch structure.

0031<figref idref="DRAWINGS">FIG. 11</figref> is an elevated view of the arch design with floor and hinging door assembled.

0032<figref idref="DRAWINGS">FIG. 12</figref> is an rendered as a pickup or trailer cover in partial assembly.

0033<figref idref="DRAWINGS">FIG. 13</figref> is a side view of the pickup cover assembled with end wall/cover retaining bands installed.

0034<figref idref="DRAWINGS">FIG. 14</figref> is a perspective view of one preferred method for tensioning the cover bands.

0035<figref idref="DRAWINGS">FIG. 15</figref> is a perspective view of another preferred method for tensioning the cover bands.

0036<figref idref="DRAWINGS">FIG. 16</figref> is a perspective view of one preferred method to compactly ship and store the cover of the invention.

0037<figref idref="DRAWINGS">FIG. 17</figref> is a frontal view of the structure used as a point of sale display with additional end walls fitted for shelving.

0038<figref idref="DRAWINGS">FIG. 18</figref> is a side view of the structure when rendered as a car top enclosure with the end walls cut in an aerodynamic shape for the cover to conform too.

0039<figref idref="DRAWINGS">FIG. 19</figref> is an elevated side view of the structure used as a cargo box that opens from either side.

0040<figref idref="DRAWINGS">FIG. 20</figref> is a perspective view of the large format version of the arch design knocked down for shipping.

0041<figref idref="DRAWINGS">FIG. 21</figref> is a perspective view of the large format arch design partially assembled.

0042<figref idref="DRAWINGS">FIG. 22</figref> is a side view of the large format version of the arch design for use with a utility trailer, fully assembled into a shelter with integrated hinging door.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

0043Referring now to the structure in more detail, in <figref idref="DRAWINGS">FIG. 1</figref> there is shown a blank of the raw material used to create an arch structure showing the cellular structure <b>10</b> of the sheet.

0044In <figref idref="DRAWINGS">FIG. 2</figref> the sheet is shown with the material removed <b>12</b> and creating channels <b>11</b> to allow the formerly rigid sheet to roll and the material removed <b>11</b> to create an engagement point for the end walls to fit.

0045<figref idref="DRAWINGS">FIG. 3</figref> shows the invention complete and ready to assemble with the cover <b>13</b> and the end walls <b>14</b> in perspective view.

0046<figref idref="DRAWINGS">FIG. 4</figref> shows the preferred assembly method where by the cover <b>13</b> is ready to have the end walls <b>14</b> inserted into the channel <b>11</b> at each end of the cover.

0047<figref idref="DRAWINGS">FIG. 5</figref> shows the preferred enclosure partially assembled with the cover <b>13</b> adopting the shape of the end wall <b>14</b> by way of the end wall <b>14</b> fitting into the cover channel <b>11</b>. In <figref idref="DRAWINGS">FIG. 6</figref> an example of the corner connection is shown whereby the end wall <b>14</b> and cover <b>13</b> have a metal channel cap <b>16</b> so that when the end wall <b>14</b> inserts into the cover channel <b>11</b>, a pin or spring button <b>17</b> engages through both the bulk head <b>16</b> and cover channel hole <b>15</b> to positively lock the corner together to form the radial shape.

0048<figref idref="DRAWINGS">FIG. 7</figref> shows a version of the structure dissembled with the cover <b>13</b> and floor <b>19</b> having a common recess <b>20</b>, <b>11</b> into which the end walls <b>14</b> engage. By removing intermediate strips of material from the inside surface of the cover <b>12</b>, the formerly rigid flat sheet <b>10</b> can now form itself to the radius of the end walls <b>14</b> and lock in place. Further, this embodiment shows a hinged door <b>30</b> in the end wall <b>14</b> that is created by completely removing material on the bottom and two sides of the door, but only removing the inside surface and center ribs from the material at the top of the door <b>30</b>, thereby allowing the door <b>30</b> to hinge on the outside material surface. The cover <b>13</b> in this embodiment has angle <b>18</b> attached to the longitudinal edge of the cover. <figref idref="DRAWINGS">FIG. 8</figref> shows the cover <b>13</b> with angle <b>18</b> about to wrap around the end walls <b>14</b> on an enclosure without floor.

0049<figref idref="DRAWINGS">FIG. 9</figref> shows the structure shown in <figref idref="DRAWINGS">FIG. 8</figref> with the addition of the floor <b>19</b>. The channel <b>16</b> at the bottom of the end wall <b>14</b> fits in the floor groove <b>20</b> and the cover groove <b>11</b> so that when assembled threaded fasteners can fit though the angle <b>18</b> in holes <b>21</b> in each of the four corners to securely lock the assembly together with the floor <b>19</b> fits between the angle <b>18</b> and the bottom of the cover wrap <b>13</b> and cover angle <b>18</b>.

0050<figref idref="DRAWINGS">FIG. 10</figref> shows the corner connection in detail with the end wall <b>14</b> channel <b>16</b> having a fastener, and specifically a Pin Nut™ <b>22</b>, that is engaged by a fastener <b>23</b> threading through the cover angle <b>18</b> and thereby drawing the cover <b>11</b> securely onto the end wall <b>14</b> with the end wall channel <b>16</b> fitting on top of the cover angle <b>18</b>. Pin Nut™ visa vi HexWerx™ is a corner connector that theadably engages the cover wrap and the end wall in a secure connection.

0051<figref idref="DRAWINGS">FIG. 11</figref> shows one embodiment of the invention assembled with the hinged door <b>30</b> integrated into the end wall <b>14</b> as one continuous piece. The construction details of the invention as shown in <figref idref="DRAWINGS">FIG. 10</figref> and <figref idref="DRAWINGS">FIG. 11</figref> are such that the flexible cover as wrapped around the end walls and floor transforms the previously flexible cover and components <b>19</b>, <b>14</b> and <b>13</b> into a rigid structure that is more resistant to deformation than the individual parts, is lightweight and is exceedingly easy to assemble and disassemble.

0052Referring now to <figref idref="DRAWINGS">FIG. 12</figref>, a pickup topper embodiment is shown partially assembled. <figref idref="DRAWINGS">FIG. 13</figref> shows the cover fully assembled with compression bands commonly attached to the corner fasteners <b>23</b> and further secured in the center of the lid by either a mechanical connection as shown in <figref idref="DRAWINGS">FIG. 14</figref> or with an elastomeric connection as shown in <figref idref="DRAWINGS">FIG. 15</figref>. The bands ensure that the cover has a weather proof connection to the end walls at highways speeds.

0053Referring now to <figref idref="DRAWINGS">FIG. 16</figref>, the cover as shown in <figref idref="DRAWINGS">FIG. 15</figref> is shown in a knocked down or collapsed profile. This makes the product design highly advantageous for shipping or storing and also demonstrates how the structure cover can be rolled into a compact shape.

0054Referring to <figref idref="DRAWINGS">FIG. 17</figref>, this shows how the structure can be rendered as a novel display and/or shelving unit with multiple shelf locations.

0055Referring to <figref idref="DRAWINGS">FIG. 18</figref>, this shows a roof top version of the cover with the end walls <b>14</b> defining the aerodynamic shape of the cover <b>13</b>, with the end walls <b>14</b> profiled in a longitudinal orientation.

0056<figref idref="DRAWINGS">FIG. 19</figref> shows a version of the invention with access available from either side of the box because of the unique folding and rolling ability of the invention.

0057<figref idref="DRAWINGS">FIG. 20</figref> show a large format version of the invention in knock down view with three cover sections <b>13</b> rolled into shipping profile and two end walls <b>14</b> folded into shipping profile. <figref idref="DRAWINGS">FIG. 21</figref> shows the large format structure partially assembled with one of the three cover <b>13</b> panels in place and both end walls <b>14</b> locked into the covers <b>13</b> groove <b>11</b>. The end walls <b>14</b> have places where material has been removed <b>12</b> that allow the large format end walls to be folded for storage and shipping.

0058<figref idref="DRAWINGS">FIG. 21</figref> shows the large format structure fully assembled with the three roof panels <b>13</b> connected using common hardware and locked onto the end walls <b>14</b> with one end wall providing a hinged door created by removing material <b>29</b> from three sides of the panel along the door perimeter.

0059The advantages of the structure include, without limitation, that it is portable and exceedingly easy to transport. That the structure has unique folding and rolling abilities that greatly reduce the cubic space necessary to ship or store the structure. That among these folding advantages is the ability to create hinged openings in the cover or end walls of the structures through the process of removing material from the rigid sheet. It is easy to move these structures when assembled because they are relatively lightweight and rigid. The present structure has unique mechanical and aerodynamic characteristics that make it robust in windy conditions or under heavy weighting from snow loads.

0060The method of creating the structure is unique to the structural design. The creation of channels in the semi-rigid material to make the material flexible yet strong when incorporated with the end panels, or end walls, is new and creative.

0061In broad embodiment, the present invention includes a structure and the method of creating that structure.

0062While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.