Patent Publication Number: US-7584763-B2

Title: Collapsible frame for portable shelter

Description:
BACKGROUND OF THE INVENTION 
   1. Field of Invention 
   This invention relates to the field of portable shelters, and more particularly, to a shelter frame that can be rapidly deployed and erected while providing superior strength and durability. 
   2. Description of Related Art 
   It is known to erect portable shelters during times of emergency for use as command shelters, decontamination stations, mobile hospitals and temporary housing. These shelters, commonly referred to as emergency portable shelters, desirably are easy and quick to deploy and take down. They also should be lightweight to permit easy transportation, yet be extremely durable because of their use in inclement weather including high wind and heavy rainfall. Ideally, these portable shelters are free-standing. One example of a shelter is illustrated in commonly assigned Korean Patent Application No. 10-2005-0113339. 
   Many governmental and rescue agencies and organizations provide such portable shelters in emergency situations and large event staging areas. However, most of the traditional shelter frames are so weak that the parts are easily broken and the shelter itself is eventually rendered useless after transport or use. Additionally, the shelters typically are complicated and inconvenient to use and require much time and man power to set up and take down. Most of conventional shelter frames require an added extra support poles or guy wires to be installed after set up. It would be desirable to have an improved lightweight, sturdy, free-standing, quickly erectable and strikable all-purpose utility structure. 
   SUMMARY OF THE INVENTION 
   This invention is for a shelter frame which, when combined with a fabric canopy, can be used outdoors or in large indoor areas and is designed to provide added stability and durability. By unfolding and spreading the frame components, this shelter frame can be deployed quickly with minimal personnel. One of the features of this invented shelter frame is its rapid deployment. Because the frame can be erected quickly and folded and taken down in a few minutes, it is properly suited to use under emergency conditions for command shelters, military shelters, decontamination shelters and temporary housing. 
   One aspect of the invention is directed to a portable shelter having a frame that is separately collapsible in a transverse direction and a longitudinal direction of the shelter to facilitate transportation and storage of the shelter. The frame includes a plurality of ribs, each rib having two support legs and a roof made of roof members forming a generally inverted U-shape when in an erect configuration. The support legs and the roof members are connected with foldable joints such that each rib may be collapsed in the transverse direction to a collapsed configuration wherein width of the rib is narrower in the collapsed configuration than when in the erect configuration. The frame also includes a wall support system connecting adjacent ribs. The wall support system is collapsible in the longitudinal direction to adjust the relative position between adjacent ribs. 
   In one embodiment, the wall support system is a dual X-connection system made of a plurality of crossing elongate connection members, wherein one end of each side of the X-connection system has a slide block with a runner that is slideably mounted in a guide in a support leg and the other end of each side of the X-connection system is fixed to the support leg such that one end of the X-connection system moves freely upward or downward relative the other end to permit expanding and narrowing of the X-connection system to adjust the relative position of adjacent ribs. 
   In one embodiment, each rib has two outer roof members that are of a length substantially equal to the length of the first leg portions and a third shorter middle roof member positioned in-between the two outer roof members. The rib may be collapsed such that the support legs are folded inward to be adjacent the outer roof members and the outer roof members are folded with respect to the inner roof member such that the support legs and roof members are adjacent each other and in a generally parallel condition. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The structure, operation, and advantages of the presently disclosed embodiment of the invention will become apparent when consideration of the following description taken in conjunction with the accompanying drawings wherein: 
       FIG. 1  illustrates a perspective view of a shelter according to one embodiment of the invention; 
       FIG. 2  illustrates a front view of a frame of the shelter of  FIG. 1  with the frame shown in a collapsed state in phantom; 
       FIG. 3  a section of a joint of the frame of  FIG. 2   
       FIG. 4  is the side view of the joint of  FIG. 3 ; 
       FIGS. 5A and 5B  are sectional views of the joint taken along line B-B of  FIG. 4  illustrating operation of the joint; 
       FIG. 6  shows a side view of the frame with the X-connection system; 
       FIG. 7  is a section view of the support leg and X-connection system of  FIG. 6 ; 
       FIG. 8  shows a side view of the roof cross frame poles and locking collar and swivel lock connection; and 
       FIG. 9  shows the swivel joint of the frame. 
   

   Corresponding reference characters indicate corresponding parts throughout the views of the drawings. 
   DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
   The invention will now be described in the following detailed description with reference to the drawings, wherein preferred embodiments are described in detail to enable practice of the invention. Although the invention is described with reference to these specific preferred embodiments, it will be understood that the invention is not limited to these preferred embodiments. But to the contrary, the invention includes numerous alternatives, modifications and equivalents as will become apparent from consideration of the following detailed description. 
   Referring now to the drawings,  FIG. 1  shows a lightweight yet sturdy free-standing portable shelter, indicated generally by numeral  10 , according to one embodiment of the invention. The shelter  10  comprises a rigid frame  12  that supports a shelter canopy  14 . The frame  12  is desirably made from aluminum and/or plastic injection molding. The canopy  14  is desirably made of nylon, polyester, or other suitable material. In one desirable embodiment, the canopy  14  is made from 200 denier nylon coated with polyurethane and has vinyl windows. 
   The frame  12  has a number of ribs  16  spaced along the length of the erect shelter  10 . As best seen in  FIG. 2 , each rib  16  has a pair of support legs  18  connected by a roof portion  20  such that the rib  16  has a generally inverted U-shape. The support leg  18  desirably comprises a first leg portion  22  having a first diameter and a second leg portion  24  having a smaller diameter such that the second leg portion  24  may be received into and extended from the first leg portion in a telescoping manner when collapsing or erecting the shelter as shown by arrow A in  FIG. 2 . The first and second portions  22 ,  24  of the support leg  18  are locked in the extended position with a conventional locking mechanism (not shown). The locking mechanism may use locking pin, locking collar and the like known to one skilled in the art and selected using sound engineering judgment. 
   In the illustrated embodiment, the roof portion  20  of each rib  16  comprises two outer roof members  20 A that are of a length substantially equal to the length of the first leg portions  22  and a third shorter middle roof member  20 B positioned in-between the two outer roof members  20 A. An apex of the canopy  14  is connected, such as with a strap or loop  26  (seen in  FIG. 1 ), to the middle roof member  20 B and similar loops or straps placed at suitable intervals connect the canopy to the outer roof members  20 A and support legs  18 . The support legs  18  are connected to the outer roof members  20 A and the outer roof members  20 A are connected to the inner roof member  20 B with foldable joints  30  such that the rib  16  may be folded to a collapsed configuration as shown in phantom in  FIG. 2  to facilitate transportation and storage of the shelter  10 . When the shelter  10  is in the erected or raised condition, the support legs  18  and roof members  20 A,  20 B are connected such that each joint  30  forms a greater than 90 degree angle. These joints  30  help form the designed shape of the roof portion  20  of the shelter  10  and enable smooth folding and unfolding. 
   In the illustrated embodiment, each rib  16  has four joints  30  where folding is desired at the junctures of the support legs  18  and roof members  20 A,  20 B. There are two joints  30  where the respective outer roof members  20 A meet the inner roof member  20 B along the top of the rib  16 . These two joints  30  and the length of the inner roof member  20 B are designed to allow each rib  16  to be folded such that the support legs  18  are folded inward to be adjacent the outer roof members  20 A as shown by the arrow B in  FIG. 2  and the outer roof members  20 A are folded with respect to the inner roof member  20 B as shown by arrow C such that the support legs  18  and roof members  20 A are adjacent each other and in a generally parallel condition as shown in phantom in  FIG. 2 . 
   Referring now to  FIGS. 3-5 , a description of one embodiment of the joint  30  will be given. The joint  30  comprises two skeleton frames  32 A,  32 B attached to the connected components of the rib  16  (i.e., support legs  18 , outer roof members  20 A, and inner roof member  20 B) and a hinge  34 . It is desirable that all the joints  30  in the frame  12  be substantially similar such that the only difference in the joints  30  is in the angle formed between adjacent components connected by the joint  30  in the rib  16  when in the erected condition. 
   One skeleton  32 A has a male hook part  36  with a hook point  38 . The male hook part  36  is desirably attached to the skeleton with screws  39  or other suitable fastener or glue. The other skeleton  32 B has a female hook body  40  attached thereto with screws  39  or other suitable fasteners or glue. The female hook body  40  receives a slide  42  having an inclined front face  43  and a spring  44  that pushes against the slide  42  such that the front face  43  protrudes past the front of the female hook body  40 . An unlocking member  50  that is used to unlock the joint  30  is received through openings  51 ,  52  in the sides of the female hook body  40  and the slide  42  respectively. The unlocking member  50  has a substantially flat push button  53  with an actuation arm  54  extending from the rear surface thereof. As best seen in  FIG. 5 , the actuation arm  54  has a flat front face  56  and a sloping contact zone  57  in its rear face  58  such that a distal end  60  is narrower than a proximal end  62  of the arm with the sloping contact zone  57  intermediate the distal and proximal ends  60 ,  62 . 
   When the unlocking member  50  is in a first or locked position, the narrower distal end  60  of the actuation arm is adjacent the slide  42  and the rear face  58  contacts a rear portion  63  of the slide. The biasing force of the spring  44  presses the slide  42  up against the rear face  58  such that the inclined front face  43  of the slide  42  extends past the front of the female hook body  40 . Because the actuation arm  54  is narrower at the distal end  60 , the slide  42  is able to travel forward a distance sufficient to permit the front face  43  to extend out of the female hook body  40 . In this position, the inclined face  43  of the slide  42  mates with the hook point  38  of the male hook part  36  in a locked condition as shown in  FIGS. 3 and 5A . 
   When moving the joint  30  to the locked position while setting up the shelter  10 , the components of the rib  16  are positioned to the erect position. As the joint  30  is moved to this position, the male hook part  36  on skeleton frame  32 A moves toward the female hook body  40  such that the hook point  38  contacts and presses against the inclined face  43  of the slide  42 . As the male hook part  36  moves downward over the inclined face  43  of the slide  42 , the slide  42  is pushed rearward against the biasing force of the spring  44  with respect to the female hook body  40  until the hook point  38  clears the inclined face  43 . When this happens, the spring  44  forces the slide  42  back against the inner face of the male hook part  36  such that the hook point  38  catches the slide  42  in the locked condition such that the skeleton frames  32 A,  32 B are prevented from pivoting about the hinge  34 . As can be seen, the joint  30  automatically locks itself when it is moved into the locked condition simply by moving the skeleton frames  32 A,  32 B into position. 
   When the shelter  10  needs to be folded, the joint  30  is released and opened by pressing on the push button  53  to reposition the actuating arm  54 . As the actuation arm  54  is repositioned, the intermediate sloped portion  57  of the actuation arm  54  begins to press on the rear portion  63  of the slide  42  and forces the slide rearward against the biasing force of the spring  44 . When the push button  53  is pressed fully, the wider proximal end  62  of the actuation arm  54  forces the slide  42  back against the spring  44  a sufficient distance so that the inclined face  43  moves clear of the hook point  38 , allowing the male hook part  36  to disengage from the slide  42 . The skeleton frames  32 A,  32 B can then be freely rotated about the hinge  34  to fold the rib  16 . 
   As the skeleton frames  32 A,  32 B are rotated, a tip  62  of the actuation arm  54  contacts a curved return pad  64  on the skeleton frame  32 A. The return pad  64  is configured to force the actuation arm  54  to move back to the position where the narrower distal end  60  of the arm is adjacent the slide  42  so that it is in position to automatically lock the next time the joint  30  is operated. Desirably, the return pad  64  causes the actuation arm  54  to move such that the slide  42  contacts the actuation arm  54  in the sloped contact zone  57  at which time force from the spring  44  takes over and causes the actuation arm  54  to continue moving. 
   As mentioned above, this joint  30  helps the lock of frame  12  of shelter  10  in the erect condition and prevents inadvertent unlocking. Desirably, when the frame  12  of shelter  10  is spread, the joints  30  automatically lock. When the frame  12  of shelter  10  is folded, the joints  30  are unlocked by pressing the push button  50  thereby allowing the ribs  16  of the frame  12  to be folded. It can be seen that the frame  12  of the shelter  10  may therefore be erected and taken down without the use of any additional tools. One skilled in the art will recognize however that other locking joints may be used in the frame  12  using sound engineering judgment. 
   Turning now to  FIG. 6 , support legs  18  of adjacent ribs  16  are connected with a wall support  60  extending along the length of the shelter  10  that can be spread to erect the shelter  10  and collapsed to take down the shelter  10 . In one embodiment, the wall support  60  is a dual X-connection system made of a plurality of crossing connection members  62 . Turning also now to  FIG. 7 , the figures show how the support leg  18  and X-connection system  60  works. The support leg  18  has a guide  64 . In one embodiment, the guide  64  is a groove formed in the support leg  18 . One end of the X-connection system  60  has a slide block  66  with a runner  68  that is slideably mounted in this guide  64 . The other end of the X-connection system  60  is fixed to the support leg  18 . Therefore one end of the X-connection system  60  moves freely upward or downward during folding and spreading of the X-connection system  60  to position the adjacent ribs  16 . Intersections of the connection members  62  are connected at cross points  69  which connects the outside and inside connection members  62  to permit a durable support yet allow for smooth movement. 
   When the space between adjacent ribs  16  needs to be reduced, such as when collapsing the shelter  10 , the slide block  66  moves upward through the guide  64  and then, connection members  62  come close to a vertical angle (90 degrees). When the distance between adjacent ribs  16  needs to be widened, such as when erecting the shelter  10 , the slide block  66  moves downward through the guide  64  so that the connection members  62  come close to a horizontal angle (180 degree). Therefore, moving adjacent ribs  16  closer together causes the slide block  66  to move in the guide  64  in one direction causing the connection members  62  of the X-connection system  60  to be positioned in a substantially vertical condition and moving adjacent ribs further apart causes the slide block  66  to move in the guide  64  in an opposite direction causing the connection members  62  of the X-connection system  60  to be positioned in a more horizontal condition. 
   Referring now to  FIG. 8 , there are two cross frame poles  70  connecting the outer roof members  20 A of adjacent ribs  16 . These poles  70  telescope open upon deployment to provide support on each side of the roof frame. Each cross frame pole  70  comprises two members  72  and a locking collar  74  that is tightened when the frame is extended. These poles  70  attach at one end to the frame  12  with a swivel mechanism  76  as seen in  FIG. 9 . 
   After understanding these components, it becomes apparent how to erect and to fold and pack the shelter  10 . In order to fold the shelter, the height of shelter  10  is reduced by positioning the lower portion  24  of each leg  18  inside the upper portion  22 . The shelter  10  is collapsed in the length or longitudinal direction or the shelter  10  by collapsing the X-connection system  60  to bring adjacent ribs  16  into close proximity. Then, the individual ribs  16  are collapsed in the width or transverse direction of the shelter  10  by unlocking the joints  30  and moving the legs  18  and roof members  20 A to the collapsed position illustrated in phantom in  FIG. 2 . 
   To set up the shelter  10 , the individual ribs  16  are expanded in the width or transverse direction by moving the legs  18  and roof members  20 A to the erected position illustrated in  FIG. 2  and locking the joints  30 . The shelter  10  is then expanded in the length or longitudinal direction by expanding the X-connection system  60  to spread adjacent ribs  16 . The frame  12  is raised by pulling the lower portion  24  of each leg  18  from the upper portion  22 . The canopy  14  can be installed inside or outside of the frame  12  as desired. 
   With the explanation above, it is evident that this system is not complicated, but provides a much more durable and stable shelter  10 , based on the following: 
   1. The shelter  10  is pre-assembled and all parts are connected in the frame  12 . This one piece frame  12  can then be folded. 
   2. There is a reinforced dual X-connection system  60  which gives extra strength lengthwise where the most pressure is directed. It provides strength and durability against lateral forces such as high winds or rain. 
   Therefore, this shelter  10  can be used anywhere rescue operations are required, such as irregular surfaces or terrain. It can be used during inclement weather conditions for outdoor shelter, rescue shelter, and event shelter. With minimal personnel, training and in a short time period, this shelter  10  can be deployed and/or taken down. 
   While this invention has been described in conjunction with the specific embodiments described above, it is evident that many alternatives, combinations, modifications and variations are apparent to those skilled in the art. Accordingly, the preferred embodiments of this invention, as set forth above are intended to be illustrative only, and not in a limiting sense. Various changes can be made without departing from the spirit and scope of this invention.