Abstract:
Disclosed is a foldable transportable structure with a three dimensional rectangular shed roof shape having improved component and structural properties, and improved shipping and deployment capabilities. The integrated unique geometric folding pattern means provides enhanced folding accuracy and correct placement of interactive panels during collapse or assembly of the structure, and also greatly increases the flexibility for multiple unit combinations and component materials selection. The folding transportable structure provides a strong, safe, insulated weatherproof structure with a quick setup time, and requires NO tools or separate loose components for assembly.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a foldable transportable structure that when deployed provides a truly collapsible, transportable, insulated and lightweight structure that is safe, reliable and internationally compliant. Its designed flexibility provides maximum convenience for the following: quick deployment to nearly any geographic location; use of varying component materials and sizes; and interconnectability of single units for multiple unit combinations. The ability of the structure to be air-dropped also allows service to the most remote locations where shelter or facility use is needed. 
     2. Description of the Prior Art 
     Typically, supplied conventional structures offer only one or a few of a complete set of required properties that include: an easily erectable configuration for fast field installation; a requirement of NO tools or separate parts and pieces for assembly; a capability for remote deployment; a specific insulation value if needed; structural integrity; long-term durability; a design that allows for flexible use of materials choice and the potential to combine together multiple units. 
     U.S. Pat. No. 5,493,818 describes a “collapsible” structure having improved storage and shipping properties which are achieved by specific designing of the size, shape and hingeable connection positions whereas said structure is erectable and collapsible within minutes utilizing a minimal amount of tools and effort. 
     Geometric and dimensional limitations will not allow this structure to physically collapse into a stackable configuration as claimed. The roof panels will not be able to completely stretch out to lay flat when the roof panels are of a long enough dimension to form a gabled configuration, as their combined length when laying flat is much longer than the available length that the wall panels provide when they are in their folded flat configuration. An attempt to collapse the roof panels into a fully folded flat position will cause the wall panels below to hinge-bind dramatically resulting in neither of the roof or wall panels being able to lay completely flat. Alternately, when the wall panels are in a completely folded flat position the gable roof panels will not be allowed to fully stretch out and lay flat. In summary, the designed geometry will not allow full complete collapse of the stacked panels. All Sections and Claims within U.S. Pat. No. 5,493,818 refer to the invention as being a fully collapsible structure, which it will not be able to accomplish. This may be why it has not been adopted for large scale use. 
     U.S. Pat. No. 4,779,514 describes a “modular portable building unit” susceptible to air transport, and includes a roof, foldable side walls and foldable end walls having the same width as the height of the side walls. Three of the modular building units can be interfitted (sic) to form a building having four times as much floor space as the single modular building unit. The inclusion of a floor in the modular building is optional, and the inclusion of a separate pitched roof assembly for positive roof drainage is optional. Additional object of the invention is to provide a modular building unit that when folded down will allow transport by air or truck, and to allow combinations of multiple units together. 
     This method is limited by the gable end panels being separate components, and the separate fastening components and systems required to erect and/or collapse the unit. Redeployment and transport of this structure can be accomplished only after a very time consuming and tedious removal of many parts and pieces has been done. The lack of provisions for a passage opening, door, or other means shown for ingress or egress between the connected units is detrimental to the function and internal occupant flow of the connected units. Therefore no added value to the user from connecting the units together is recognized, and this may be why this system has not been adopted for large scale use. 
     U.S. Pat. No. 4,166,343 describes a hollow, generally rectilinear structure having a top, a bottom, sides and ends that can be constructed so as to be capable of being manipulated between a “normal” or unfolded type configuration and a collapsed or folded configuration in which the ends extend generally parallel to and beneath the top and in which the sides are folded so as to be located next to the ends generally between the bottom and the top. Such a structure includes hinges connecting the ends to the top so that they can be pivoted so as to lie generally parallel to the top. Such a structure is disclosed as having utility as a playhouse or storage shed but can be utilized for other purposes such as a container. 
     This structure is limited in that the gable end panels are separate panels that are hinged to the roof panel. The erection of the unit will not be manageable by the roof having to carry the added weight of the gable panels during erection of the side walls and roof panels at the same time. This will be completely unmanageable in the field. The structure also does not have means for combination of multiple units, or optional door placement locations, or a window to provide ventilation. This may be why this structure has not been adopted for field use, and is not a presently being manufactured. 
     U.S. Pat. No. 3,906,671 describes an adjustable door frame having frame portions formed by first and second frame sections cooperatively arrangeable (sic) on a wall of an opening. 
     This method provides adjustability only to the door frame for installation to variable wall thicknesses, and can only provide one of four possible door swing functions or configurations when installed. The mitered head jamb and casing pieces directly attach to the mitered hinge and strike jambs. This static configuration does not allow for the potential inversion of the hinge and strike jambs that would be required so that the entire door and frame assembly could be installed in either a right or left hand, or inside or outside, door swing configuration. In order for a door frame assembly to be completely and fully adjustable both of the hinge and strike jamb components must have the ability to be inverted and attachable to either the head or sill components so that the entire frame and door assembly can be installed in any of the 4 each possible swing configurations. This may be why this invention has not been adapted for field structures use. 
     U.S. Pat. No. 4,395,855 describes a pre-fabricated door frame assembly, the components which are adjustable and such that the assembly can be used for either right or left handed doors and can fit a wide variety of widths and heights of door openings through walls of varying thicknesses. 
     This method is designed to attach to standard constructed building walls that are normally much wider than the thinner wall panels typically used for flat-pack shelter units, and requires separate fasteners and tools for attachment to the wall system. This invention also does not include an integrated threshold or weather strip component for exterior wall use, which would be necessary for shelter units that would be deployed in hot or cold climates. This invention has limited use in that is does not offer diversity and the flexibility to be used in both interior and/or exterior applications, and it is not easily reversible or re-installable in the field without the use of tools or separate fasteners that may or may not be available. 
     U.S. Pat. No. 3,420,003 describes an adjustable door frame that adjusts to varying wall thicknesses, and can be installed quickly and easily with screws that go directly into the wall system. It consists of several longitudinal trim and jamb components that overlap and stay in place by ratchet teeth and backing plates that when the installation screw component is installed the separate pieces become locked into place. 
     This method is designed to attach to standard constructed building walls, and requires separate fasteners and tools for attachment to the wall system. This invention also does not include an integrated threshold or weather strip component for exterior wall use, which would be necessary for shelter units that would be deployed in hot or cold climates. This invention has limited use in that is does not offer diversity and the flexibility to be used in both interior and/or exterior applications, and it is not easily reversible or re-installable in the field without the use of tools or separate fasteners that may or may not be available. 
     U.S. Pat. No. 5,448,799 describes a hinge assembly for pivotally adjoining two panels together such as a shower door and its enclosure. A pair of continuous channel members are provided which are provided with an axial aligned rod and tubular channel for rotatably (sic) receiving the rod. 
     This method includes a weather strip component that protrudes beyond the profile of the wall panel extrusions. This component could not be utilized in a foldable structure as the protrusion will not allow adjacent and connected together wall panels to lay flat against each other when the structure is in a collapsed position. 
     SUMMARY OF THE INVENTION 
     The present invention is a folding transportable shelter with improved properties of: accurate folding hinge geometry, advanced interactive and integrated components that are designed to allow for either transportable or assembled structure configurations; advanced component materials for increased insulation; structural integrity; long-term dependability; built-in flexibility for optional placements of doors, windows or clear openings; and built-in flexibility for choice and use of varying materials and sizes for integrated components. 
     It is therefore a primary objective of the present invention to provide a foldable transportable structure that will significantly enhance the quality, functionality, stackable transportability, flexibility and affordability of moveable shelter structures. 
     It is another object of the present invention to include in the design a sophisticated geometric folding pattern means that significantly improves the allowance for integration and use of varying component materials, and also significantly improves the interactive complimentary relationships of folding accuracy, necessary clearances, and continual structural contact between adjacent components during the collapse and assembly functions of the unit. 
     It is another object of the present invention to include in the design same said sophisticated geometric folding pattern means that remains static, while allowing complete flexibility for: choice of overall structure size; use of any chosen dimension for panel thicknesses and relative connector widths; ability to combine together floor, wall and roof panels that are comprised of different individual thicknesses to obtain varying insulation values; without any of the above impacting the folding and assembly accuracy, or overall capabilities of the structure. 
     It is a further object of the present invention to provide specific designed continuous pivot hinge-to-panel connectors, an adjustable door assembly, a leveling foot assembly, a strap conveyance and tie-down assembly, and a flexible fillable bladder bag component to further improve the function, flexibility and use of the structure. 
     It is a further object of the present invention to provide a foldable transportable structure that has flexible integral components that are interchangeable during the manufacturing process for making structures that provide specific solutions for use in variable field conditions that include climatic, structural, deployment and usage considerations. 
     It is still another object of the present invention to provide a foldable transportable structure that contains the flexibility to be interconnected with additional like units of varying wall thicknesses to make larger structures, and includes removable wall panel sections for in-the-field-flexibility to interchange doors, windows or clear openings to create various configurations for maximum internal occupant flow and use. 
     These, and other objects of the present invention, will become apparent to those skilled in the art upon reading the accompanying description, drawings, and claims set forth herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the erected foldable transportable structure according to the present invention. 
         FIG. 2  is a cross sectional view of the collapsed foldable transportable structure according to the present invention. 
         FIG. 3  is a cross sectional view of the geometric folding pattern included in the foldable transportable structure according to the present invention. 
         FIG. 4  is a detail cross sectional view of the roof eave-to-wall connector component according to the present invention. 
         FIG. 5  is a detail cross sectional view of the roof ridge-to-wall connector component, and connection to the separate adjacent continuous pivot hinge wall-to-roof connector component (as shown in  FIG. 6 ), and the related hinging motion according to the present invention. 
         FIG. 6  is a detail cross sectional view of the continuous pivot hinge wall-to-roof connector component according to the present invention. 
         FIG. 7  is a detail cross sectional view of the continuous pivot hinge wall-to-wall connector component (as shown in  FIG. 8 ), and connection between adjacent lower and upper wall panels, and the related hinging motion according to the present invention. 
         FIG. 8  is a cross sectional view of the continuous pivot hinge wall-to-wall connector component according to the present invention. 
         FIG. 9  is a detail cross sectional view of the floor-to-curb panel connector component according to the present invention. 
         FIG. 10  is a detail cross sectional view of the floor-to-curb panel connector component, and connection to the floor panel and adjacent lower wall panel, and the related hinging motion according to the present invention. 
         FIG. 11  is perspective view showing the architectural horizontal grid pattern that provides specific layout locations for removable and interchangeable wall panels, door and window components according to the present invention. 
         FIG. 12  is a detail cross sectional view of the removable wall panel interlocking edge trim component according to the present invention. 
         FIG. 13  is a perspective view showing a removable panel assembly according to the present invention. 
         FIG. 14  is a perspective view of the reversible and invertible door frame assembly according to the present invention. 
         FIG. 15  is a detail cross sectional view of the FlexFrame door components according to the present invention. 
         FIG. 16  is a perspective cutaway elevation view of the various door frame components showing their locking and invertible functions and capabilities according to the present invention. 
         FIG. 17  is a perspective cut-away view of the collapsed structure showing the adjustable strap conveyance and tie-down assembly, the adjustable leveling foot assembly, the spiral ground stake component, and the fillable bladder bag component according to the present invention. 
         FIG. 18  is a section and elevation view of the valance draw latch. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a perspective view of the best mode contemplated by the inventor of the erected foldable transportable structure  10  according to the concepts of the present invention. As seen by the drawings the foldable transportable structure  10  consist of a series of structural panels and continuous pivot hinge components connected together in a way that allows for either a folding up of the structure into a fully erected configuration as seen in  FIG. 1 , or a folding down of the structure into a flat fully collapsed configuration for transportable methods as seen in  FIG. 2  and  FIG. 17 . 
     The foldable transportable structure  10  consists of a single floor panel  11  of which each of its long axis edges are connected to a floor-to-curb panel connector  19 , as seen in  FIG. 9  and  FIG. 10 . A continuous pivot hinge wall-to-wall connector  20  is attached between one of the floor-to-curb panel connectors  19  and the short side wall panel  13  as seen in  FIG. 10 . A continuous pivot hinge wall-to-wall connector  20  is attached between the remaining floor-to-curb panel connector  19  and the tall side wall panel  17  as seen in  FIG. 10 . A continuous hinge wall-to-wall connector  20  is attached between the short side wall panels  13  and  14  as seen in  FIG. 7 . A continuous hinge wall-to-wall connector  20  is attached between the tall side wall panels  16  and  17  as seen in  FIG. 7 . A continuous hinge wall-to-roof connector  21  is connected between the short side wall panel  14  as seen in  FIG. 5 , and the roof eave-to-wall component  22  as seen in  FIG. 4 . A continuous hinge wall-to-roof connector  21  is connected between the tall side wall panel  16  and the roof ridge-to-wall component  23  as seen in  FIG. 5 . The single roof panel  15  is connected between the roof eave-to-wall connector  21  and the roof ridge-to-wall connector  23  as seen in  FIG. 1 ,  FIG. 4 , and  FIG. 5 . A continuous pivot hinge wall-to-wall connector  20  as seen in  FIG. 8  is connected between the bottom of each of the gable end wall panels  12  and  18  and the floor panel  11  as seen in  FIG. 1 . The exposed ends of the wall panels  13 ,  14 ,  16  and  17 , and the exposed edges of the roof panel  15  are capped off with a trim piece that includes a weather strip lip to provide a sealed positive stop for each of the gable panels  12  and  18  when erected. 
       FIG. 2  shows a cross section of the collapsed structure in its folded flat transportable configuration. For further reference  FIG. 17  also shows a more detailed view of the individual panels when they are arranged in the folded flat configuration. When the structure  10  is in its fully erected configuration each individual wall panel is secured to its adjacent panel by a series of structural recessed draw latches  26 , as seen in  FIG. 1  and  FIG. 18 , that are located on the interior of the structure and must be disengaged in order to allow each individual wall panel to be folded down. To collapse the structure the following procedure is followed: gable end wall panels  12  and  18  are folded inward to lay flat on top of the single floor panel  11 ; the short side walls  13  and  14  are folded inward to lay flat on top of the gabled wall panels  12  and  18 ; the tall side walls  16  and  17  are folded inward to lay flat on top of the gabled wall panels  12  and  18 ; the single roof panel  15  follows the folding path of each side wall  14  and  16 , as each are folded down into their relative position, to then lay flat on top of walls  14  and  16 . To secure the panels together in the folded flat configuration for transportation a series of adjustable strap tie-down assemblies made up of components  46 ,  47  and  48  are attached to the roof eave-to-wall connector  22 , and roof ridge-to-wall connector  23  as seen in  FIG. 17 . To erect the structure simply reverse the process as described above. 
       FIG. 3  shows the vertical layout for the geometric folding pattern that formulates the static hinge-to-hinge centering relationships between the structure&#39;s individual panels, and establishes a guide for the finished panel widths or height dimensions for the floor panel  11 , the wall panels  13 ,  14 ,  16  and  17 , the roof panel  15 , the gabled wall panels  12  and  18 , and the vertical short and long points for the gabled wall panels  12  and  18 . The relative dimensions are defined using the following pattern formulation: a floor panel expressed as ‘A’ with an arbitrarily chosen width dimension being designated as ‘X’; a bottom short wall panel expressed as ‘B’ being of a height that is relative to 41.27617% of ‘X’; an upper short wall panel expressed as ‘C’ being of a height that is relative to 43.27018% of ‘X’; a bottom tall wall panel expressed as ‘D’ being of a height that is relative to 55.63310% of ‘X’; an upper tall wall panel expressed as ‘E’ being of a height that is relative to 57.76271% of ‘X’; a roof panel expressed as ‘F’ that is of a width that is relative to 103.98803% of ‘X’; a pair of gable panels expressed as ‘G’ that are of a width that is relative to 99.70089% of ‘X’; a pair of gable panels expressed as ‘G’ with a short point height that is of a length that is relative to 84.24725% of ‘X’ plus the chosen thickness width of the wall panels; a pair of gable panels expressed as ‘G’ with a long point height that is of a length that is relative to 112.96111% of ‘X’ plus the chosen thickness width of the wall panels. 
       FIG. 11  shows a perspective view of the grid layout system for the removable wall panel  24  locations to allow the creation of a door opening (as can also be seen in  FIG. 1  Detail  28 ), or a window opening (as can also be seen in  FIG. 1  Detail  27 ), or clear openings (as can also be seen in  FIG. 1  Detail  24 ) in any one of variable locations within the tall or gable walls of the structure. The finished dimension width of the removable wall panel  24  and its respective rough opening is a result of two (2) times an Arbitrary Dimension expressed as ‘A’.  FIG. 12  shows a detail cross sectional view of the interlocking edge trim  25  that is installed around the perimeter of each of the removable wall panel  24  components as seen in  FIG. 13 .  FIG. 13  shows a perspective elevation of the removable wall panel  24 , and the locations of the interlocking edge trims  25  and the continuous pivot hinge wall-to-wall connector locations. 
       FIG. 14  is a perspective elevation view of the overall configured door frame assembly  28  which includes a series of separate adjustable interlocking jamb components  29  and  30 , and a series of hinge components  31 . 
       FIG. 15  shows a detail cross section of the jamb components to include the following: an L′ shaped jamb component  29  that is used for the side jambs, header and sill components; an L′ shaped jamb component  30  that is used for the side jambs and header components only, and installs behind side jamb and header components  29 ; a thru-bolt and compression nut assembly  36  for securing jamb components  29  and  30  together; and a hinge component  31  for attachment of the door  42  and door panel trim  43  to the side jamb component  29 . 
       FIG. 16  shows a perspective cut-away elevation of the various door frame components to illustrate more specifically individual component relationships, details, and the reversible and invertible function of the door assembly. Jamb component  29  and separate hinge components  31  each include a round hollow profile  32  on their respective outside edges that allow insertion of a continuous hinge securing rod  33  to attach the two components together. The single hinge-side jamb component  29  includes a series of cut-out sections to allow insertion of hinge components  31  and corresponding vertical alignment of their respective round hollow profiles  32 . Side jamb, header and sill components  29  each include an extruded open slot to receive a continuous weatherstrip component  34 . Side jamb and header components  29  include a series of holes  35  where a finger-turn locking assembly  36 , comprised of a thru-bolt and a non-removable compression nut, is installed. Corresponding side jamb and header components  30  include a series of open-ended slots  37  that align with the series of thru-bolts  36  installed on jamb components  29 . Together components  36  and  37  allow for a sliding back and forth motion between jamb components  29  and  30  for adjustability to variable adjacent wall panel thicknesses. Jamb components  29  include a series of protruding ‘v’ shapes  38  that rest into a corresponding series of reverse retention ‘v’ shapes  39  that are integral to jamb components  30 . Jamb components  29  and  30  are then prevented from sliding apart when tightened together with the bolt and compression nut assembly  36 . The two each side jamb components  29  each include on their ends a pair of male tabs  40  that fit into a corresponding pair of female slots  41  that are punched into the top surfaces of the header and sill components  29 . The series of tabs  40  and slots  41  prevent potential horizontal movement between the two each side jamb components  29  and the header and sill components  29 . The series of tabs  40  and slots  41  also allow the hinge-side jamb component  29  and attached door components  42  and  43  to be inverted between the header and sill components  29  in order to change the door to either a right or left handed swing function. The entire door assembly  28  is also installable on either the exterior or interior of the wall to additionally provide for any of the 4 each possible swing functions required. A structural insulated door panel  42  as seen in  FIG. 15  is wrapped on all 4 sides with a ‘U’ shaped trim cap component  43 , and is attached with a series of fasteners  44  to a series of symmetrically centered surface mounted hinge components  31 . A commercially available flush mounted latching and locking mechanism is installed in the door panel component  42  to complete the door assembly. Each of the door assembly components can be made from any variety or combination of metals, plastics, composites, fiber reinforced polymers, fiberglass or other types of material. 
       FIG. 17  shows a perspective cut-away view of the collapsed structure to illustrate details for the conveyance and tie-down strap and hook assembly, the dual-function pad leveler and stacking guide assembly, and the bladder bag assembly. A series of load compliant looped strap carrying handles  45  are attached to the floor curb component  19  for conveyance of the transportable structure  10 . Two separate continuing sections of the tie-down strap  46  are interconnected with a commercially available load compliant ratchet-tight buckle  48 . The remaining end of the tie-down strap  46  is attached to a commercially available load compliant flat hook  47 . Hook  47  connects to the roof-to-wall connector curb  23  for securing the structure  10  while it is in a flat collapsed transportable configuration, or alternately hooks onto either the eyelet  54  that is integral to bladder bag  53 , or onto a spiral ground stake  55 , for securing the fully erected structure  10  to the ground. The bladder bag  53  is filled with water, earth, sand, gravel, or other material to add hold-down ballast weight to the fully erected structure  10 . A series of adjustable leveling pad assemblies are installed inside of the floor-to-wall connector component  19 . A load compliant square tube  49  is securely installed in component  19 . A load compliant leveling tube adapter  50  is inserted into component  49 . A load compliant fast-turn threaded rod  51  of sufficient length is welded to a load compliant leveling foot  52 , and is then inserted into the receiving threads of the leveling tube adapter  50 . When the structure  10  is in its collapsed transportable configuration the leveling foot pad  52  is in a completely retracted position and alternately provides stacking guidance and transportation containment by sliding into and resting on the top track and curb of a lower structure&#39;s roof component  23 . 
     The problems addressed by the foldable transportable shelter  10  are many as can be easily seen by those skilled in this art. The foldable transportable structure  10  greatly enhances the ability and proficiency to deploy moveable structures and reduce transportation costs, by including a well-arranged series of structural panels, hinges and other components, which are connected together in a certain way that allows the structure to be folded down into a collapsed configuration to provide a very compact transportable structure. The foldable transportable structure  10  supports easy and complete assembly in the field, especially in more remote locations, by not requiring the use of power, separate hand tools, or separate loose connectors and fasteners that can be misplaced or lost. The foldable transportable structure  10  saves field time and labor costs by requiring only three to four unskilled persons less than fifteen minutes to fully erect it, and it can also be as easily collapsed and re-deployed to a different location in as little time. The foldable transportable structure  10  is environmentally responsible as all individual components are designed to provide more than just one integrated function, thus substantially reducing raw material quantities, environmental impact and production costs. The flexible design of the foldable transportable structure  10  allows for choice of varying raw materials to meet fluctuating market conditions or any user required specifications. The design of the foldable transportable structure  10  includes a geometric folding pattern, as seen in  FIG. 3  that provides folding ability of the structure, and also establishes or allows for: combination of varying panel thicknesses for the floor, wall and roof panels; the guided folding motion and cohesive interaction of each individual structure component; maintaining minimal clearances and continual structural support between all adjacent components during the folding process or transportable configuration. The foldable transportable structure  10  provides additional value to the end user as units can be optionally equipped with an integrated removable wall panel system, as amply seen in  FIGS. 11 through 13  to allow for the in-the-field switching of the door or window locations, or to create other clear opening locations for flexible flow-through configurations within multiple combined units. The reversible door assembly, as amply seen in  FIGS. 14 through 16  saves raw materials and costs by providing a one-size-fits-all assembly. The foldable transportable structure  10  will find wide use anywhere disaster relief, military, and other civil types of operations are required. Private industry would be employed to manufacture the many units required. 
     Thus it will be appreciated by those skilled in the art that the present invention is not restricted to the particular preferred embodiments described with reference to the drawings, and that variations may be made therein without departing from the scope of the present invention as defined in the appended claims and equivalents thereof.