Abstract:
The disclosure describes a portable garage with a ballast-containing base. The garage is assembled at a site without physical attachment thereto and disassembled for erection at another site. Each elongated base segment extending along the sidewall of the garage has a cavity therein for receiving ballast which stabilizes the structure. The bases have extensions which interlock and overlie connector portions. Apertures through the connectors have a metal sleeve housing support columns and, upon the sidewall being assembled, these columns are vertically disposed. Between support members a prefabricated roof is attached. The ballast-container is a lightweight, molded plastic construct of high-impact, UV resistant material. The base is equipped with suitable inlet and outlet ports for the addition and removal of ballast.

Description:
REFERENCE TO RELATED APPLICATION  
       [0001]    This application is continuation-in-part of pending application Ser. No. 09/745,128, filed Dec. 21, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    This invention relates to a garage, and, more particularly, to a garage which is readily erected and disassembled and is secured in place by adding ballast, such as water, to cavities at the base of the walls. The structure is designed to be disposed atop a flat surface such as a blacktop driveway or a concrete slab without physical attachment thereto.  
           [0004]    2. Description of the Prior Art  
           [0005]    In the past, the automobile has been cared for in innumerable creative ways. The romance with the automobile has led to devices and structures ranging from cloth covers tailored, like raincoats to fit the make and model of the automobile, to detached three- and four-car garages, some replete with living quarters for the chauffeur and his spouse. All of these have sought to protect the automobile from the elements—both natural and corrosive—including, of course, sun, precipitation and acid rain, salt air and industrial pollution.  
           [0006]    Also, garage construction has usually been dominated by conventional construction methods involving footings or foundations and has paid little attention to the ability of being knocked down and re-erected at another site.  
           [0007]    As will be seen in the patent discussion which follows, “Jersey-type” barriers have not been widely adapted to structures. In the solid form, the Jersey barrier has been used for a multilevel roadway structure. In 1987 the ballast-containing form of the Jersey barrier was introduced and the adaptive use thereof includes a highway sign support device.  
           [0008]    In preparing for the parent application, several United States patents became known to the inventor hereof. The familiarity resulted from a review of several subclasses of Classes 52, 135, and 404, which review produced the following patents:  
                                                           U.S. Pat. No.   Inventor   O.C.   Issue Date                           5,846,020   McKeown   404/1    Dec. 8, 1998           5,815,991   de Ridder   52/88   Oct. 6, 1998           5,414,966   Montoya   52/66   May 16, 1995           5,295,335   Collier   52/86   Mar. 22, 1994           5,208,585   Sprague     340/908.1   May 4, 1993           4,856,228   Robinson   47/29   Aug. 15, 1989           4,627,205   Hitchins    52/294   Dec. 9, 1986           3,492,767   Pincus   52/79   Feb. 3, 1970           2,928,405   Lawson   135/5    Mar. 15, 1960           1,540,988   Hensel   49/5    Jun. 9, 1925                      
 
           [0009]    McKeown—U.S. Pat. No. 5,846,020  
           [0010]    The patent discloses a pre-fabricated reinforced concrete multi-level roadway structure. The structure is erected so as to cover an existing lane on a roadway and is assembled from modules that are cast, transported, and moved, as needed. The cover of the lower roadway forms the roadway-of the upper lane with the bottom section thereof consisting of two “Jersey-type” barriers.  
           [0011]    Robinson—U.S. Pat. No. 4,856,228 and de Ridder—U.S. Pat. No. 5,815,991  
           [0012]    These patents disclose the use of water ballasted, inflatable tunnel systems for pressurized tunnel-type greenhouses. The tunnels are generally semicircular in cross section.  
           [0013]    Sprague—U.S. Pat. No. 5,208,585  
           [0014]    This patent discloses a portable “Jersey-type” highway barrier constructed of light weight material and has an interior cavity which can be filled with a fluid ballast. The barrier includes vertical slots which support a highway sign.  
           [0015]    Pincus—U.S. Pat. No. 3,492,767  
           [0016]    This patent discloses a prefabricated building construction including a prefabricated utility core which contains the entire power supply for a building.  
           [0017]    Hitchins—U.S. Pat. No. 4,627,205  
           [0018]    This patent discloses the associating of a conventional form for in-situ casting of concrete foundations with a pair of sacrificial adjuncts, including reinforcement pins, rods, and hook-bolts.  
           [0019]    Hensel—U.S. Pat. No. 1,540,988  
           [0020]    This 1923 patent discloses a portable shelter adapted to minimize the effectiveness of aerial bomb attacks. A netting or protective structure is stretched across and arranged to overlie the object to be protected, which netting is supported so as to yield at the moment of impact.  
           [0021]    Lawson—U.S. Pat. No. 2,928,405  
           [0022]    This patent discloses a lightweight, portable shelter which can be compactly folded up when not in use, and is erectable in various configurations to provide different types of canopies or shades.  
           [0023]    Collier—U.S. Pat. No. 5,295,335  
           [0024]    This patent discloses a prefabricated shelter which consists of an arched framework having open opposite ends, an anchoring structure for securing the footing of the framework to the ground, and a roof assembly mounted to the top of the arched framework.  
           [0025]    Montoya—U.S. Pat. No. 5,414,966  
           [0026]    This patent discloses a vehicle enclosure for storing and protecting a vehicle. The enclosure has a base plate and a shell-like cover disposed thereover which, in turn, is hinged to the base plate. A retractable dolly is coupled to the cover with the dolly positionable in a retracted mode for placing the vehicle enclosure in a stowed configuration and in an extended mode for placing the vehicle enclosure in a transportable configuration.  
           [0027]    The citing of the above patents is not intended as an admission that any such patent constitutes prior art against the claims of the present application. Applicant does not waive any right to take any action that would be appropriate to antedate or otherwise remove any listed document as a competent reference against the claims of the present application.  
           [0028]    Many technical problems relating to surface-mounted portable structures are overcome or resolved by the invention disclosed herein. In contradistinction to the parent case, the method of manufacturing the major components hereof, namely, the vertical-support-holding base connector and the cavity-containing wall base are substantially improved. In the base connector, for example, an open-ended metal sleeve forms the inner part of the base connector mold, and, during manufacture, the sleeve is molded into the base connector. In this application, while the structure described is a portable garage, the same construction techniques are applicable to smaller structures, such as tool sheds and shopping cart corrals. The innovative approach and other improvements over the parent case become apparent in the description which follows.  
         SUMMARY OF THE INVENTION  
         [0029]    The present invention is directed to a portable garage with ballast-containing base. The garage is readily assembled at a chosen site without physical attachment thereto and disassembled for erection at another site. Base segments or portions, which are elongated and extend along the sidewalls of the garage, are configured with a cavity therein. The cavity for receiving ballast is, after the erection of the portable garage, filled with water, sand or gravel. The weight of the ballast stabilizes the structure. The elongated wall bases have extensions or tabs which interlock with a base connector. An aperture through the connector houses a support or column member and, upon the sidewall being assembled and set up, the columns are substantially, vertically disposed. The interposing of the two base portions—one onto the other—is such that the weight of the ballast-containing base is exerted upon the column-receiving base portions. Between the support members a roof is attached. The roof is either prefabricated attaching directly to the support members or is assembled from discrete components mounted on roof beams or trusses which are mounted to the support members.  
           [0030]    The ballast-container or wall base has a cavity for receiving ballast and is a lightweight, molded plastic construct of high-impact, UV resistant material. A typical base unit weighs 6 to 7 lbs per linear foot and, typically upon loading with ballast, 80 to 120 lbs. per linear foot. The base is equipped with suitable inlet ports and outlet ports for the addition and removal of ballast, namely, water, sand or gravel. The column base connectors which interlock with the ballast-container wall base are further provided with a metal sleeve or tube insert. In the present embodiment this is a square aluminum tube. Each tube forms the inner portion of the mold used in the manufacture of the base connector. The base connectors, which are manufactured from thermoplastic material, are molded around the sleeves. The sleeves have retainer grooves which, upon the thermoplastic material reaching a molten state, receive the molten material therein. After curing, the sleeves are retained by the base connector. Each base connector is made in a stepped configuration which is overlapped by the upper portion of the wall base.  
           [0031]    The upper portion of the base connector has a fixed spline which interlocks with the keyway of the upper portion of the wall base. On the sides adjacent to the fixed spline and on the side opposite the fixed spline, lands are formed permitting the attachment of mountable spline(s) and thereby adapting the connector to a 90°, 180° or T-configuration. The sleeves are designed to accept vertical support members in a telescopic relation therewith. Jacking screws are attached to the lower face of the base connector for levelling purposes, and, upon levelling bring the support members into vertical alignment.  
           [0032]    After erecting the portable garage, the ballast containers are filled through the inlet port with a ballast material of choice. Upon disassembly for relocating the structure, the ballast material is removed through the drain port. For ease of handling, the ballast containers nest for compact storage and transport.  
         OBJECT AND FEATURES OF THE INVENTION  
         [0033]    It is an object of the present invention to provide a shelter which is a readily erected and readily disassembled structure.  
           [0034]    It is a further object of the present invention to provide a sturdy, free-standing structure that is erectable on a concrete or blacktop surface.  
           [0035]    It is yet another object of the present invention to provide a garage structure with ballast-containing walls.  
           [0036]    It is still yet another object of the present invention to provide a structure which is erected and disassembled using simple tools, and, upon disassembly, can be readily relocated.  
           [0037]    It is a feature of the present invention that the weight of the ballast is sufficient to securely mount the garage structure to the floor.  
           [0038]    It is another feature of the present invention to have the ballast-containing wall portions interlockingly engage the column bases so as to provide support and stabilization therefor.  
           [0039]    Other objects and features of the invention will become apparent upon review of the drawings and the detailed description which follow. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0040]    In the following drawings, the same parts in the various views are afforded the same reference designators.  
         [0041]    [0041]FIG. 1 is a perspective view of the garage with ballast-containing walls of the present invention;  
         [0042]    [0042]FIG. 2 is a perspective view of one section of the wall base of FIG. 1 partially cut away to show the connecting keyways which overlie the base connectors;  
         [0043]    [0043]FIG. 3 is a cutaway view of one section of the wall base of FIG. 2 taken line 3-3 of FIG. 2 and showing the ballast chamber with the inlet and outlet ports therefor;  
         [0044]    [0044]FIG. 4 is a perspective view of the base connector shown with the open-ended sleeve and the vertical support member therewithin and shown with a mountable spline exploded therefrom;  
         [0045]    [0045]FIG. 5 is a cutaway view of the base connector and vertical support member taken along line 5-5 of FIG. 4 and shows the stepped configuration of the wall base and the base connector;  
         [0046]    [0046]FIG. 6 is a perspective view of three wall bases as in FIG. 2 assembled to four base connectors as in FIGS. 4 and 5;  
         [0047]    [0047]FIG. 7 is a partially exploded view showing the upper framework and the roof support of the invention; and  
         [0048]    [0048]FIG. 8 is a sectional view of the extrusions for the upper wall and roof support structure of this invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0049]    In the description which follows, while the structure described is a portable garage, the same construction technique is applicable to other shelters, such as tool sheds and shopping cart corrals. Referring now to FIGS. 1 through 3, the portable garage with ballast-containing walls is shown and is referred to generally by reference numeral  10 . The elongated wall bases  12  are formed from a thermoplastic material which has sufficient structural strength to retain ballast material within the cavity  14  therewithin. The base portion  12  extends at both ends having base connectors  16  and  18  attached thereto. The base connectors  16  and  18 , when the elongated wall base  12  is filled with ballast, hold down underlying structural elements and stabilize the overall construct.  
         [0050]    The plastic base portion  12  is an adaptation of the Barrier System, manufactured for Barco Products Company, Batavia, Ill. 60510-1961. For receiving ballast into cavity  14  and for removing ballast therefrom, the wall base has a fill port  20  and a drain port  22 . Materials suitable for ballast  24  include water, sand and gravel. The present structure is designed for a fluid aqueous ballast. For a dry ballast, minor adjustments are optionally made to adapt the unit to the use of dry ballast. These include, for example, the replacement of the overflow pipe with a bunghole-type arrangement. The keyway portions  16  and  18  also include interlocking keyways or joints  26  and  28 , respectively, similar to mortise and tenon joinery, to fit with the adjacent base connector portion described, infra.  
         [0051]    In the embodiment shown, both the base connector and the wall base are stepped configurations which fit together so that the upper portion of the wall base overlies the lower portion or steps of the base connector when the upper portions of both units are in a substantially abutting relationship. This occurs when the spline and keyway are interengaged. While the keyway portions here are shown as semicircular indentions in cross-section, any number of shapes may be employed so long as the male and female interlocking portions thereof fit readily one within the other and enable the various subcomponents joined together to be in sliding and locking engagement with each other.  
         [0052]    Referring now to FIGS. 4 and 5 a universal base connector  30  is shown having a male segment or spline  32 . Additional male segments  34  and  36  are attachable to base connector  30  using inserts  36  molded into base connector  30  and attaching hardware  38 . Relative to x-axis  40  and y-axis  42  as establishing an initial reference plane, these are set at 90°, 180°, and 270°. While a single, universal base connector  30  with attachable male segments  34  is shown, it is within the contemplation of the invention to include a straight connector with premolded male segments at 0° and 180°; T-connectors with premolded male segments at 0°, 90° and 180° or at 0°, 180° and 270°; and L-connectors with male segments at 0° and 90° or at 0° and 270°.  
         [0053]    To interlock with joints or splines  26  and  28  corresponding fittings  32  are molded into the connector base and attachable male fittings  24  are employed as required. As shown in this embodiment the joints  26  and  28  are female and the corresponding fittings  32  and  34  are male; however, it is within the contemplation of this invention that fittings  26  and  28  are male and  32  and  34  are female. The base connectors  30  each have an open-ended sleeve  44  within the central bore  46  along longitudinal axis  40  therethrough and, when the portable garage is erected, the longitudinal axis  40  of the central bore  46  is substantially vertical. In the present embodiment, the sleeve  44  is a 3-inch square aluminum tube. During manufacture of the base connectors, the tube  44 , which runs throughout the entire height of the base connector  30 , forms the interior portion of the mold therefor. The sleeve  44  is captured into the base connector by retainer grooves  47  at both ends of the tube. The thermoplastic material of the base connector upon reaching a molten state flows into grooves  47 . After curing, the sleeves are held captive by the base connector  30 .  
         [0054]    A column or support member  48  is constructed to be retained by the base connector  30 . In the example at hand, the opening of the square metal tube  44  is 2¾ inches square (approx.) and is adapted to accommodate support member  48  which is an aluminum extrusion dimensioned so as to telescopically fit within the sleeve. The support member  48  is a four-sided extrusion with a screw boss  50  running longitudinally along each side. The support member  48  is adjustably attached to sleeve  48  by corresponding inserts  52  molded into the base connector  30  and attaching hardware  54 . The adjustability enabled by inserting the attaching hardware  54  into a selected position on the screw boss provides for levelling of the upper ends  56  of support members  48 . On the lower surface  58  of base connector  30 , jacking screws  59  are provided. Upon installation, the use of the jacking screws  59  provides for levelling of the base connector  30  and consequently for truing the support members  48  to vertical alignment.  
         [0055]    Referring now to FIG. 6, the elongated wall bases  12  are shown interlocked with the base connector  30 . From the illustration, it is seen that the stepped configuration of both components upon installation interlock with one another. The lower portion of base connector  30  extends below the upper portion  62  of elongated wall base  12  and upon ballast  24  being added to cavity  14 , locks the structure together. For added rigidity, indents or ribs  63  reinforce and stiffen wall bases  12 . For drainage purposes, drainage passages  65  are provided at the bottom of the wall bases  12 .  
         [0056]    The framing for the walls is completed by horizontal beams or wall caps  64  and intermediate stringers  66 , FIG. 7, which beams are preferably of the same construction as the columns  48  and are attached thereto by attaching hardware  68  and  70 , respectively. To complete the walls, glazing or prefabricated wall panels  72  are mountable and demountable to and from the framework formed by columns  48 , wall caps  64  and stringers  66 .  
         [0057]    Atop the wall cap  64 , a roof structure is formed using any one of numerous configurations. Typifying such installations is the arrangements shown in FIG. 8. Here an extruded aluminum fascia  74  having an integral gutter  76  is emplaceable upon the wall cap  64 . The gutter  76  incorporates weep holes  78  for drainage of water therefrom. As with the wall structure, the roof structure consists of prefabricated roofing panels  80  that are readily mountable and demountable to and from the upper framework. Depending upon the roof configuration selected additional roof supports may be added as required.  
         [0058]    In the construction of the portable garage, the assembly and, conversely, the disassembly is accomplished with simple hand tools such as a screwdriver and a wrench. First a site is selected or formed having a relatively flat surface or with a slope maintaining, after adjustment of the support members, the horizontal disposition of the wall caps. The emplacements of the base portions and the universal base connectors are established and interconnected. The wall framing elements together with the roof fascia components are next laid out and connected on the ground. The lower ends of the columns are inserted through the base connectors and attached loosely to the flanged collars. The wall units are then righted to a vertical alignment and interconnected with the adjacent walls. The columns about the garage are next adjusted so that the desired alignment of the roof line is achieved. With the base frame completed the prefabricated wall panels and roofing components are attached. The ballast cavities are next filled with water so as to provide the necessary weighting of the unit. The construction is thus completed without any foundation therebelow or attachment thereof to footing at the site.  
         [0059]    The disassembly and erection of the portable shelter at another site proceeds by essentially reversing the erection procedure described above. After emptying the ballast cavities, the garage components are moved to the new site, the erection procedures are followed, and the ballast is replenished.  
         [0060]    Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.