Abstract:
A modular structure and method of creating a modular structure where the structure has a cover made from a corrugated, lightweight material, at least one end wall and at least one corner connection means where the cover has at least one channel cut therein and where the end wall is inserted into the channel so that the cover wraps around the end wall to form a structure, and where at least one corner connection means connects and secures the cover to the end wall.

Description:
REFERENCE TO PRIOR APPLICATION 
     The present invention claims priority to previously filed Provisional Application No. 61/578,886, filed 2012 Dec. 22. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of the Invention 
     The 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. 
     2. Description of the Related Art 
     The 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. 
     Conventional 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. 
     Additionally, 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. 
     Another area where compact shippable containers are needed is for additional cargo space needed with cars, SUV&#39;s, RV&#39;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. 
     There 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 
     To solve the above problems and to achieve the object noted above, the present disclosure is configured as follows. 
     The 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. 
     By removing material and allowing the formerly two dimensional sheet to be formed into three dimensional radial shapes, the sheet&#39;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. 
     Although 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&#39;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. 
     The 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. 
     The 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. 
     One 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. 
     The 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 &amp; 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. 
     This 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. 
     Another 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. 
     These 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 
         FIG. 1  is an elevated view of the cellular sheet used to create one of the many forms possible. 
         FIG. 2  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. 
         FIG. 3  is an elevated view that shows the cover and end walls necessary to form the arch design. 
         FIG. 4  is an exploded view of the arch design that shows the cover and end walls ready for assembly. 
         FIG. 5  is another exploded view of the arch design that shows the process of assembly. 
         FIG. 6  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. 
         FIG. 7  is an elevated view of the cellular sheet laid flat with provision for an integrated floor. 
         FIG. 8  is an elevated, exploded view of the arch design without floor 
         FIG. 9  is an exploded view of arch design with floor. 
         FIG. 10  shows a preferred method for securing the corners of arch structure. 
         FIG. 11  is an elevated view of the arch design with floor and hinging door assembled. 
         FIG. 12  is an rendered as a pickup or trailer cover in partial assembly. 
         FIG. 13  is a side view of the pickup cover assembled with end wall/cover retaining bands installed. 
         FIG. 14  is a perspective view of one preferred method for tensioning the cover bands. 
         FIG. 15  is a perspective view of another preferred method for tensioning the cover bands. 
         FIG. 16  is a perspective view of one preferred method to compactly ship and store the cover of the invention. 
         FIG. 17  is a frontal view of the structure used as a point of sale display with additional end walls fitted for shelving. 
         FIG. 18  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. 
         FIG. 19  is an elevated side view of the structure used as a cargo box that opens from either side. 
         FIG. 20  is a perspective view of the large format version of the arch design knocked down for shipping. 
         FIG. 21  is a perspective view of the large format arch design partially assembled. 
         FIG. 22  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 
     Referring now to the structure in more detail, in  FIG. 1  there is shown a blank of the raw material used to create an arch structure showing the cellular structure  10  of the sheet. 
     In  FIG. 2  the sheet is shown with the material removed  12  and creating channels  11  to allow the formerly rigid sheet to roll and the material removed  11  to create an engagement point for the end walls to fit. 
       FIG. 3  shows the invention complete and ready to assemble with the cover  13  and the end walls  14  in perspective view. 
       FIG. 4  shows the preferred assembly method where by the cover  13  is ready to have the end walls  14  inserted into the channel  11  at each end of the cover. 
       FIG. 5  shows the preferred enclosure partially assembled with the cover  13  adopting the shape of the end wall  14  by way of the end wall  14  fitting into the cover channel  11 . In  FIG. 6  an example of the corner connection is shown whereby the end wall  14  and cover  13  have a metal channel cap  16  so that when the end wall  14  inserts into the cover channel  11 , a pin or spring button  17  engages through both the bulk head  16  and cover channel hole  15  to positively lock the corner together to form the radial shape. 
       FIG. 7  shows a version of the structure dissembled with the cover  13  and floor  19  having a common recess  20 ,  11  into which the end walls  14  engage. By removing intermediate strips of material from the inside surface of the cover  12 , the formerly rigid flat sheet  10  can now form itself to the radius of the end walls  14  and lock in place. Further, this embodiment shows a hinged door  30  in the end wall  14  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  30 , thereby allowing the door  30  to hinge on the outside material surface. The cover  13  in this embodiment has angle  18  attached to the longitudinal edge of the cover.  FIG. 8  shows the cover  13  with angle  18  about to wrap around the end walls  14  on an enclosure without floor. 
       FIG. 9  shows the structure shown in  FIG. 8  with the addition of the floor  19 . The channel  16  at the bottom of the end wall  14  fits in the floor groove  20  and the cover groove  11  so that when assembled threaded fasteners can fit though the angle  18  in holes  21  in each of the four corners to securely lock the assembly together with the floor  19  fits between the angle  18  and the bottom of the cover wrap  13  and cover angle  18 . 
       FIG. 10  shows the corner connection in detail with the end wall  14  channel  16  having a fastener, and specifically a Pin Nut™  22 , that is engaged by a fastener  23  threading through the cover angle  18  and thereby drawing the cover  11  securely onto the end wall  14  with the end wall channel  16  fitting on top of the cover angle  18 . A Pin Nut™ is a connector as disclosed in U.S. patent application Ser. No. 12/122,543. Specifically, it is a fastener assembly for securing two components to one another, where the fastener assembly has a pin for insertion into a hole formed in a first component; a reduced diametrical portion on one end of the pin forming a shoulder on the pin where the shoulder engages with an outer wall of said first component and where another end of said pin engages with another outer wall of said first component; a radially extending threaded hole formed in said pin; an elongated fastener having a head portion and a threaded portion where the fastener is inserted through at least one hole in the second component and where the threaded portion is inserted and threadedly received into the radially extending threaded hole in the pin to engage and secure the first component to the second component such that when the fastener is tightened into the threaded portion of the pin, the reduced diametrical portion contacts with the outer wall and the another end of the pin contacts with the another outer wall causing the pin to be seated in a slightly cocked position resulting in thread lock between the fastener and the threaded portion of the pin. Pin Nut™ vis-à-vis HexWerx™ is a corner connector that threadably engages the cover wrap and the end wall in a secure connection. 
       FIG. 11  shows one embodiment of the invention assembled with the hinged door  30  integrated into the end wall  14  as one continuous piece. The construction details of the invention as shown in  FIG. 10  and  FIG. 11  are such that the flexible cover as wrapped around the end walls and floor transforms the previously flexible cover and components  19 ,  14  and  13  into a rigid structure that is more resistant to deformation than the individual parts, is lightweight and is exceedingly easy to assemble and disassemble. 
     Referring now to  FIG. 12 , a pickup topper embodiment is shown partially assembled.  FIG. 13  shows the cover fully assembled with compression bands  31  commonly attached to the corner fasteners  23  and further secured in the center of the lid by either a mechanical connection  25 , as shown in  FIG. 14 , or with an elastomeric connection as shown in  FIG. 15 . The compression bands  31  ensure that the cover has a weather proof connection to the end walls at highways speeds. 
     Referring now to  FIG. 16 , the cover as shown in  FIG. 15  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. 
     Referring to  FIG. 17 , this shows how the structure can be rendered as a novel display and/or shelving unit with multiple shelf locations. 
     Referring to  FIG. 18 , this shows a roof top version of the cover with the end walls  14  defining the aerodynamic shape of the cover  13 , with the end walls  14  profiled in a longitudinal orientation. 
       FIG. 19  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. 
       FIG. 20  show a large format version of the invention in knock down view with three cover sections  13  rolled into shipping profile and two end walls  14  folded into shipping profile.  FIG. 21  shows the large format structure partially assembled with one of the three cover  13  panels in place and both end walls  14  locked into the covers  13  groove  11 . The end walls  14  have places where material has been removed  12  that allow the large format end walls to be folded for storage and shipping. 
       FIG. 21  shows the large format structure fully assembled with the three roof panels  13  connected using common hardware and locked onto the end walls  14  with one end wall providing a hinged door created by removing material  29  from three sides of the panel along the door perimeter. 
     The 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. 
     The 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. 
     In broad embodiment, the present invention includes a structure and the method of creating that structure. 
     While 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.