Patent Abstract:
A collapsible portable shelter unit when in the collapsed mode is light and compact to make transport and storage convenient, but when opened provides an enclosed space that can be used for various purposes, which has an integrated high strength structured frame by the action of the interlocking extrusions which also provide resistance to water and wind infiltration. As needed, exterior windows and doors, air conditioning, electrical supply and other customization as required by the users&#39; needs.

Full Description:
RELATED APPLICATIONS 
     This application claims priority based upon U.S. Provisional Patent Application Ser. No. 61/510,564 filed Jul. 22, 2011. 
     FIELD OF THE INVENTION 
     This invention relates to a collapsible portable habitable shelter structure. More particularly, the present invention relates to a structure that collapses into a small, compact configuration that is light, easily stored, easily transported, and can be folded out to become a structurally habitable shelter. 
     BACKGROUND OF THE INVENTION 
     Emergency type housing units have been desired for numerous applications. Typically the units are nothing more than steel shipping containers which are modified for the usage desired. They tend to be heavy, difficult to transport, provide very limited functional space, and not desirable as a living area. Increasing of the functional space has been crudely addressed by cutting out portions of the container and affixing multiple containers together. The appearance of the units has remained to be that of a shipping container or trailer, usually with the need to perform extensive work on the interior to make the unit functional. Further, a single unit typically does not supply sufficient space to accomplish the needed function as the containers are so narrow in width that two or more containers must be placed together to get a functional space. When multiple units are assembled, the need to prevent water and wind infiltration causes considerable additional work to be done by skilled craftsmen, with specialty products to seal the units and properly connect them, which materials are not always available. 
     Since the steel units are bulky, heavy in weight, difficult to store and transport is typically handling one unit at a time, with a crane needed to move the units. These difficulties restrict the usage and desirability of container type units. 
     The challenge and need was for a unit that was light weight and compact when not in use so that it may be efficiently stored and transported, that supplies an attractive, functional space, that is strong, water and wind resistant, as well as adaptable to weather conditions, adaptable easily to special needs, and could be installed without special supplies or skilled labor in minimal time periods. 
     DISCLOSURE OF THE INVENTION 
     The present invention is a transformable collapsible structure or unit with a rigid center core structure with a top portion, a base portion, a first and second end section, affixed to a welded aluminum extrusion frame structure, to which is connected multiple sections, being a first and a second roof section, a first and a second floor section, a first and a second exterior wall section, and multiple side wall sections. The sections fold out to form an enclosed space adjoining the center core structure on side creating a useable and habitable interior space. The structure is unexpectedly strong and resistant to wind and water infiltration by use of metal extrusions caps at all folding joints which are continuous and interlocking, thereby stopping water or wind infiltration. The points of connection between wall sections where a rotating joint is not needed use a metal extrusion with tongue and groove configuration being tight fitting and which provides structural strength and resistance to both water and wind infiltration. 
     The structure or unit is stored in a folded configuration and can be put into use by first leveling the closed unit, placing floor support beams, rotating the roof sections upward to allow the floor and wall sections to be rotated downward, resting the floor section on the floor beams, rotating the exterior wall sections vertical and connecting the roof section to the exterior wall section. The side wall sections are then swung out to connect to the roof section and exterior wall sections. 
     When the roof section, floor section, exterior wall section and side wall section are rotated into position, the continuous extended metal caps lock the extrusions together providing structural strength and resistance to wind and water infiltration. 
     The connections between the wall sections where the sections do not have a rotation joint have a continuous extruded metal cap which is of a tongue and groove type connection, between mating edges providing structural strength and resistance to water and air infiltration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To further describe and obtain a fuller understanding of the nature and objectives of the invention, the accompanying drawings are provided in which like parts are given reference numerals. 
         FIG. 1  is a prespective of the collapsible portable shelter unit in a closed configuration for storage or transport. 
         FIG. 2  is a prespective showing the end of a collapsed unit without the end utility sections or cover in place. 
         FIG. 3  shows the frame structure of the center core section of the collapsible unit. 
         FIG. 4  shows the support and leveling unit at the corners of the center core section. 
         FIG. 5  is a prespective of the unit with the floor support beams being put into place. 
         FIG. 6  shows the motion of opening of the unit by rotating of the roof section. 
         FIG. 7  shows the floor section being rotated into place. 
         FIG. 8  shows the exterior wall section being rotated into an upright position. 
         FIG. 9  shows the motion of the side walls being rotated outward to interlock with the roof and exterior wall sections. 
         FIG. 10  shows a prespective of the unit with one side opened and locked into place. 
         FIG. 11  shows a prespective of the unit with both sides opened. 
         FIG. 12   a  shows a detail of the interconnection for a rotating joint. 
         FIG. 12   b  shows a detail of the edge interlock. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referencing  FIG. 1  is a transformable rectangular collapsible portable unit in the collapsed state being one embodiment of the present invention, which forms a modular unit  10  which is approximately 30 inches in width at edge  16  with a length of approximately 18 feet at edge  19 , with height approximately 8 feet at edge  14  allowing three units to be placed side by side in a typical shipping container or tractor trailer. Different dimensions can be used to meet the intended need for the unit. 
     The modular unit  10  has a rigid central core frame  19 , composed of aluminum extrusions. The frame,  FIG. 3 , has horizontal  56  and vertical  27  extrusions welded together to form a rectangle and two such rectangles are welded together with cross beam  28  extrusions. The result is a box beam frame that has greater strength than expected. With the attachment of base portion  26 , roof portion  25 , and the end sections  20 ,  13 , the core provides support for the roof sections  25 , floor sections  22 , exterior wall sections  21 , and side wall sections  24 , that are adhered to the core and fold out to form an interior space. At the end of the core,  FIG. 1 , attached is an air conditioning unit  17 , which can provide both cooled or heated air to the interior space. An electrical storage cabinet  18  is also provided for any needed electrical equipment for power distribution. At the other end of the core, in other configurations a storage cabinet can be affixed. In this closed configuration,  FIG. 1 , the unit  10  can be easily transported by a lift or wheeled with installation of wheels at each corner of the base portion. 
       FIG. 2  shows the exposed end of the modular unit. The central core end portion  20  is shown and adjacent to it, on each side, are multiple panels which fold out to transform the modular unit into an expanded useable shelter. The most exterior panel  23  is the extending roof sections, followed by the floor sections  22 , and then the exterior wall sections  21 . The inner most section is the side wall sections  24 . The roof  23 , floor  22 , exterior wall  21  and side wall  24  sections can rotate out to locking positions to create an interior space. The roof, floor, exterior wall and side wall sections are composite panels. 
     The preferred center core section  FIG. 3  is a rigid frame of extruded aluminum vertical beams  27  welded together with horizontal extruded aluminum beams  28 , to create a box beam structure which provides high strength but is light in weight. However, the rigid frame can be configured in various shapes known in the art to provide rigid structures. 
       FIG. 1  shows supports  15  at each of the corners of the modular unit  10 .  FIG. 4  shows the configuration of the support  15 , in detail. It consists of a base plate  29  a supporting leg  30 , supporting plates  32  and  31  to hold the core structure with a wrench  34  that can be inserted into the socket  33  to allow ratcheting or cranking of the supporting leg  30  to allow height and leveling adjustment of the modular unit both quickly and easily. Although this is the preferred embodiment numerous other known mechanisms can be used such as a multi-holed support through which a bolt is passed through to set heights at various discrete settings, or plates with threaded rods connected thereto which can be adjusted by rotating the threaded rod to adjust height. 
     When it is desired to employ the modular unit, the unit  10  is placed in a cleared area. This can be on stabilized ground, or any reinforced base such as gravel, concrete or asphalt, and the unit  10  is leveled using the supports  15 , to set the correct height and all corners are leveled. Support beams  37  are inserted as shown in  FIG. 5  in receptacles  36  located along the base portion of the modular unit. At the other end of the beams  37  are plates with welded threaded rods which thread into the end of the beam  37 . The plate  40  is rotated until all the beams  37  are level and thereby perpendicular with the exterior wall surface  12  of the unit  10 . 
       FIG. 6  shows the modular unit  10  being opened. The exterior roof panel section  23  is rotated out approximately 90 degrees, away from the unit body. Two spring-loaded dampers  41  as shown in  FIG. 6  assist in providing support to the roof section  23 . The exterior portion of the top of the core section  11  and the exterior surface  12  of the roof section  23  are preferably covered with a roofing material or other material, depending upon the use of the unit. 
       FIG. 7  shows the continued opening of the roof section  23  which allows the combined floor  22  and exterior wall  21  sections to be rotated outward to a resting position upon the supporting floor beams  37 . With the floor section  22  put into place the exterior wall section  21  is rotated vertically and the upper edge  61  interlocks with the exterior edge  62  of the roof section  23 . The detail of the interconnection of edges  61  and  62  is seen in  FIG. 12   b . Additional interlocking can be accomplished with conventional locking mechanisms located along the exterior wall edge. With the roof edge  62  affixed to the exterior wall edge  61 , the side walls  24  can be folded out as shown in  FIG. 9 , the edges  46  and  47  of which connect with the roof edge  48  and exterior wall edge  49 . 
       FIG. 10  shows the expanded configuration of one side of the modular unit  10 , and in  FIG. 11  the modular unit has been completely opened. The roof, exterior wall and side wall sections are insulated composite panels comprised of an exterior panel, being a lightweight rust free material, a center core of a thermal resistant material, and an interior panel, all adhered together. In the preferred configuration the interior and exterior panels are aluminum with an interior core of expanded polystyrene foam or a polyurethane foam. The use of insulated panels provides temperature stability and the center core section, with the air conditioning/ventilation unit  17  provide both cooling and heating directly into the habitable interior space. The edges of the panels are capped with metal extrusions which provide the connecting functions between panel edges, either a rotating hinged connection as seen at connections  64  between base portion and floor section, or top portion and roof section  63 , or floor and exterior wall section  65  as shown in  FIG. 8 , or an interlocking between roof section edge  62  and exterior wall section edge  61  as seen in  FIG. 8 . 
       FIG. 12   a  shows typical rotating connection wherein a top roof portion cross-section  25  and roof section cross-section  23  are connected by an extrusion intersection with cross-section of the components. The two metal extrusion caps A, B interlock by rotating about each other in a circular mating of a portion of the extrusion  71  of the roof top cap with a portion of the extrusion  72  of the roof section cap, locking the extrusions together creating a seal between extrusions. As shown in  FIG. 12   a , top roof portion extrusion  71  is C-shaped interface with an upwardly disposed open C-mouth and roof section extrusion  72  is a complementary C-shaped interface with a downwardly disposed C-mouth. Both extrusions mate and interlock with downward C-shaped extrusion  72  overlaid into the upward C-shaped extrusion  71  when the roof portion and roof section are generally aligned together (after rotation of the section with respect to the portion; see  FIG. 6 ). The result is a locking of the extrusions and panels to create a structure stronger than expected. Further, the connection stops water and wind infiltration through the joint. 
     In other configurations, at the tongue and groove connection, a sealant may be placed at the exterior of the connection to prevent water or wind infiltration. Preferably if sealant is used it should be placed after the connection between the sections are made to allow easier removal of the sealant when dissembling the unit. 
       FIG. 12   b  shows the interlock connection used between the roof section  25  outer edge  62  and the upper edge  61  of the exterior wall  21 , which may also be used by the side wall section connecting with the exterior wall section or with the roof section edge. This tongue  74  and groove  73  connection interlock is a substantially continuous contact that provides a structural integrity for the frame of the opened structure that is stronger than expected. Further, the tongue and groove connection prevents water and air infiltration. 
     In the configuration shown in  FIGS. 8 ,  10  and  11 , one or more windows  44  or doors  45  can be provided in the exterior walls section or side walls sections, as well as pre-wiring the walls and interior core for electric, data, and plumbing services. In other configurations, the modular unit may have interior partitions installed at a later time, to be adjusted as the use of the unit requires. Kitchenette modules and bathroom modules can be added to the unit if those functions are desired. 
     Since the modular unit contains all needed components pre-installed, a minimally trained crew of two men can level and fully expand a modular unit, having it operational in 15 to 30 minutes, depending on the skill and experience of the crew. 
     In other configurations, the modular units have wheels located at each end of the rigid central core section which allows the units to be conveniently wheeled to and from storage to truck loading dock without special equipment or moved at the desired location prior to opening. While various exemplary aspects and embodiments have been shown or discussed herein, other modifications that may be employed are within the scope of the invention. Accordingly, the present invention is not limited to the configuration shown, and is intended to embrace all such attention modifications or variations that fall within the spirit and scope of the appended claims. 
     Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a traditional word in a claim.

Technology Classification (CPC): 4