MODULAR STRUCTURE AND INFLATABLE ROOF THEREFOR

Description

FIELD

This disclosure relates to modular structures, and inflatable roofs for modular structures.

BACKGROUND

Modular structures typically include a prefabricated building consisting of a number of separate modules constructed offsite, then delivered and installed or assembled on site to allow for quick assembly and disassembly. An advantage of modular structures is the speed in which they can be assembled as well as the versatility in locations they can be installed. However, one concern can be the requirement for cross bracing or support structures needed for raised portions of the modular construction such as roofing. Cross bracing or supports can be difficult to engineer and can require more pieces to assemble onsite, taking away a main draw of the modular structure, the speed and ease of assembly.

In certain cases, existing structures may require the immediate need for a roof, to protect the contents within the structure, but location and environment do not afford the ability to engineer or construct a full roof over the existing structure. This may be the case in a disaster zone, a combat zone, or the like.

Conventional modular structures and associated roofing systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improvements. The present disclosure provides a solution for this need.

SUMMARY

In accordance with at least one aspect of this disclosure, a system includes a housing configured to be placed on top of an existing structure having a first end structure and a second end structure. The housing includes an opening facing the second end structure when it is on top of the first end structure. A deployable roof is included in the housing and includes a first end located adjacent to the opening of the housing and a second end configured to be enclosed within the housing. The deployable roof is adapted and configured for movement between a retracted position in which the entirety of the deployable roof is enclosed within the housing and a deployed position in which the first end of the deployable roof extends out of the housing and the second end of the deployable roof remains at least partially within the housing. An air mover is operatively associated with the housing and in fluid communication with an interior volume of the deployable roof for inflating the deployable roof and moving the deployable roof from the retracted position to the deployed position such that the first end of the deployable roof extends at least partially out of the opening of the housing along a roof axis to form a roof over the existing structure.

In certain embodiments, the roof axis can be a longitudinal axis of the deployable roof parallel to a longitudinal structure axis of the existing structure. The deployable roof can be arch shaped in the deployed position. In certain embodiments, the deployable roof can include a plurality of tubular sections connected to one another and in fluid communication with each other. A tubular section axially closest to the second end of the deployable roof can inflate first, and each subsequent tubular section along the roof axis can inflate one after another inflating the deployable roof and urging the deployable roof along the roof axis until a terminal tubular section axially closest to the first end of the deployable roof can inflate last.

The housing can further include a power source for powering the air mover. In certain embodiments, the power source can be or include a photovoltaic. In certain embodiments, when in the deployed position the deployable roof can extend between the first end structure and the second end structure along the roof axis. The first end of the deployable roof can rest on the second end structure and the housing can remain on the first end structure.

In certain embodiments, the existing structure can further include a first side wall and a second side wall. The first side wall and the second side wall can each extend between the first end structure and the second end structure. The first end structure, the second end structure, the first side wall, the second side wall, and the deployable roof can together form an enclosed volume. The first side wall can include a first ledge and the second side wall can include a second ledge. The first ledge can be defined on a portion of the first side wall opposite a floor and the second ledge can be defined on a portion of the second side wall opposite the floor. The deployable roof can be supported by the first ledge and the second ledge.

In certain embodiments, the existing structure can further include a platform configured to serve as the floor. In certain embodiments, the deployable roof, the first and second end structures, the first and second side walls, and the floor can form an enclosed volume configurable for at least one of a kitchen, a bathroom, classroom, an office, or an event space. A size of the enclosed volume can be configured to accommodate a plurality of adult persons therein. In certain embodiments, deployable roof does not have vertical or lateral cross bracing or any other supports.

In accordance with at least one aspect of this disclosure, a building kit can include a first end structure and a second end structure, a first side wall and a second side wall, configured to be placed extending between the first end structure and the second end structure, where the first end structure, the second end structure, the first side wall, and the second side wall can form a perimeter of a modular structure. The building kit can further include a housing configured to be placed on top of the first end structure.

The housing can have an opening facing the second end structure. The building kit can also include a deployable roof including a first end located adjacent to the opening of the housing and a second end configured to be enclosed within the housing. The deployable roof can be adapted and configured for movement between a retracted position and a deployed position in which the entirety of the deployable roof is enclosed within the housing in the retracted position and wherein the first end of the deployable roof extends out of the housing and the second end of the deployable roof remains at least partially within the housing in the deployed position.

The building kit can include an air mover operatively associated with the housing and in fluid communication with an interior volume of the deployable roof for inflating and moving the deployable roof from the retracted position to the deployed position such that the first end of the deployable roof extends out at least partially out of the housing along a roof axis to form a roof over the modular structure, wherein the housing includes a power source for powering the air mover. In certain embodiments, the power source can be or include a photovoltaic power source. In certain other embodiments, the power source can be or include an electrical power source. The deployable roof can be arch shaped in the deployed position.

In certain embodiments, the deployable roof can include a plurality of tubular sections connected to one another and in fluid communication with each other. A tubular section axially closest to the second end of the deployable roof can inflate first, and each subsequent tubular section along the roof axis can inflate one after another inflating the deployable roof and urging the deployable roof along the roof axis until a terminal tubular section axially closest to the first end of the deployable roof can inflate last.

In certain embodiments, the first side wall can include a first ledge and the second side wall includes a second ledge. The first ledge can be defined on a portion of the first side wall opposite a floor and the second ledge can be defined on a portion of the second side wall opposite the floor. The deployable roof can be supported by the first ledge and the second ledge.

In certain embodiments, the building kit can further include one or more additional end structures and/or one or more side structures and/or one or more walls. The one or more additional end structures and/or the one or more side structures and/or the one or more walls can be configurable to produce one or more of: kitchen, a bathroom, classroom, an office, or an event space within the modular structure. The housing, first end structure, second end structure, first side wall, second side wall, and floor can be easily assembled and disassembled. housing, first end structure, second end structure, first side wall, second side wall, and floor can be easily transported.

In accordance with at least one aspect of this disclosure, a modular structure can include a first end structure and a second end structure, a first side wall and a second side wall configured to be placed extending between the first end structure and the second end structure, where the first end structure, the second end structure, the first side wall, and the second side wall can form a perimeter of a modular structure.

The modular structure can include a housing configured to be placed on the first end structure. The housing can have an opening facing the second end structure. The modular structure can also include a deployable roof including a first end located adjacent to the opening of the housing and a second end configured to be enclosed within the housing. The deployable roof can be adapted and configured for movement between a retracted position and a deployed position in which the entirety of the deployable roof is enclosed within the housing in the retracted position and where the first end of the deployable roof extends out of the housing and the second end of the deployable roof remains at least partially within the housing in the deployed position. The modular structure can also include an air mover operatively associated with the housing and in fluid communication with an interior volume of the deployable roof for inflating and moving the deployable roof from the retracted position to the deployed position and deflating and moving the deployable roof from the deployed position to the retracted position, such that the first end of the deployable roof extends at least partially out of the housing along a roof axis to form a roof over the modular structure.

These and other features of the embodiments of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is an environmental view of an embodiment of a roofing system, showing the roofing system installed on an embodiment of a constructed modular structure;

FIG. 2 is an environmental view of an embodiment of a roofing system, showing the roofing system installed on another embodiment of a constructed modular structure;

FIG. 3A is a side elevation view an embodiment of a roofing system installed on a constructed modular structure, showing a deployable roof in the fully deployed position;

FIG. 3B is a front cross-sectional view of the roofing system of FIG. 3A taken along line 3B-3B, showing a shape of the deployable roof in the deployed position;

FIG. 3C is a rear end view of the roofing system of FIG. 3A, showing an entrance to a modular structure having the roofing system deployed thereon;

FIG. 3D is a plan view of a modular structure having the roofing system of FIG. 3A deployed thereon;

FIGS. 4A-4F show a progression of construction of a modular structure shown in FIG. 1 and deployment of the roof system shown in FIG. 1, wherein;

FIG. 4A shows placement of a floor;

FIG. 4B shows placement of a first and second end structures on the floor;

FIG. 4C shows placement an installation of first and second side walls on the floor and between the first and second end structures;

FIG. 4D shows placement of a housing having the roofing system therein;

FIG. 4E shows deployment of the roofing system from the housing over the modular structure; and

FIG. 4F shows a fully constructed modular structure having the roofing system installed thereon;

FIG. 5A is a plan view of an embodiment of a modular structure, showing a configuration of an interior of the modular structure;

FIG. 5B is a plan view of an embodiment of a modular structure, showing another configuration of an interior of the modular structure;

FIG. 5C is a plan view of an embodiment of a modular structure, showing another configuration of an interior of the modular structure;

FIG. 5D is a plan view of an embodiment of a modular structure, showing another configuration of an interior of the modular structure;

FIG. 5E is a plan view of an embodiment of a modular structure, showing another configuration of an interior of the modular structure;

FIG. 5F is a plan view of an embodiment of a modular structure, showing another configuration of an interior of the modular structure;

FIG. 6A is a side elevation view an embodiment of a roofing system installed on a constructed modular structure, showing another deployable roof in the fully deployed position;

FIG. 6B is a front cross-sectional view of the roofing system of FIG. 6A taken along line 6B-6B, showing a shape of the deployable roof in the deployed position;

FIG. 6C is a rear end view of the roofing system of FIG. 3A, showing an entrance to a modular structure having the roofing system deployed thereon;

FIG. 6D is a plan view of a modular structure having the roofing system of FIG. 6A deployed thereon; and

FIG. 7 is a schematic view of a building kit in accordance with the present disclosure.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a roofing system in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other views, embodiments, and/or aspects of this disclosure are illustrated in FIGS. 1-7.

Shown in FIG. 1 is an embodiment of a roofing system 100 shown installed atop an existing structure, for example a modular structure 200 that will be described further below. In FIG. 1, the roofing system 100 is shown installed in an environment for illustration purposes and shown with persons and other existing structures surrounding the modular structure 200 for scale. FIG. 2 shows the roofing system 100 installed on another existing structure, e.g., another embodiment of the modular structure 200, and in a different environment. As an example, the environments shown in FIGS. 1 and 2 could be disaster relief areas, or locations rebuilding after natural disaster, combat, or the like.

Turning now to FIGS. 3A-3D, the roofing system 100 will be described in further detail with reference to the schematic drawings. As shown in FIG. 3A, the roofing system 100 can include a housing 102 configured to be placed on top of an existing structure 104. For the ease of explanation, the existing structure 104 will be described herein as including an embodiment of the modular structure 200, however, in practice, the existing structure 104 need not be the modular structure 200 as described. For example, the existing structure 104 can be the modular structure 200 or can be a naturally occurring structure or formation. The existing structure 104 can have a first end structure 104a and a second end structure 104b. The housing 102 can have an opening 106 facing the second end structure 104b when it is on top of the first end structure 104a. The roofing system 100 can include a deployable roof 108. The deployable roof 108 can have a first end 110 located adjacent to the opening 106 of the housing 102 and a second end 112 configured to be enclosed within the housing 102. The deployable roof 108 can be adapted and configured for movement, e.g., as shown by the arrow in FIG. 4E, between a retracted position, e.g., as shown in FIG. 4D, in which the entirety of the deployable roof 108 is enclosed within the housing 102 and a deployed position. e.g., as shown in FIGS. 3A and 4F, in which the first end 110 of the deployable roof 108 extends out of the housing 102 and the second end 112 of the deployable roof 108 remains at least partially within the housing 102.

The roofing system 100 can include an air mover 114 (e.g., one or more fans or blowers) operatively associated with the housing 102 and in fluid communication with an interior volume 116 of the deployable roof 108 for inflating the deployable roof 108 and moving the deployable roof 108 from the retracted position to the deployed position such that the first end 110 of the deployable roof 108 extends at least partially out of the opening 106 of the housing 102 along a roof axis A, e.g., as shown in FIG. 3A to form a roof over the existing structure 104. The air mover 114 can be within the housing 102 or outside of the housing 102. The air mover 114 can be a single air mover, two air movers, or a plurality of air movers depending on the size of the deployable roof 108. The deployable roof 108 can traverse a distance greater than the height of the deployable roof 108 (e.g., as shown in FIG. 3A) when in the deployed position. In certain embodiments, the air mover 114 can also be configured for sucking air from the deployable roof 108 to deflate and retract the deployable roof 108 back into the retracted position within the housing 102.

As shown in FIG. 3A, in the deployed position the deployable roof 108 can extend between the first end structure 104a and the second end structure 104b along the roof axis A. The first end 110 of the deployable roof 108 can rest on the second end structure 104b and the housing 102 can remain on the first end structure 104a. The roof axis A can be a longitudinal axis of the deployable roof 108, which can be parallel to a longitudinal structure axis B, e.g., as shown in FIG. 3A, of the existing structure 104.

In certain embodiments, e.g., as shown in FIG. 3B, the deployable roof 108 can be arch shaped in the deployed position and can be self-supported without any cross-bracing or internal support structures to maintain the arch shape. In certain embodiments, the deployable roof 108 can include a plurality of tubular sections 118 (e.g., as shown in FIG. 3A) connected to one another (e.g., via seams or any other means of connected the tubular sections) and in fluid communication with each other. A tubular section 118a axially closest to the second end 112 of the deployable roof 108 can inflate first, and each subsequent tubular section 118b . . . 118n along the roof axis A can inflate one after another inflating the deployable roof 108 and urging the deployable roof 108 along the roof axis A until a terminal tubular section 118n axially closest to the first end 110 of the deployable roof 108 inflates last. Any number of tubular sections 118 are contemplated herein depending on the desired size of the modular structure 200.

In certain embodiments, the housing 102 can further include a power source 120 for powering the air mover 114. The power source 120 can be photovoltaic (e.g., one or more solar cells as shown in FIG. 3C), or can be or include a battery, or can be or include means of electrically connecting the air mover 114 to existing power infrastructure at an installation site. Any other types of suitable power sources are contemplated herein, including other means of renewable power or self-contained power so as not to require connection to existing power infrastructure.

With continued reference to FIGS. 3A-3D, the existing structure 104 can further include a first side wall 122a and a second side wall 122b. The side walls 122a, 122b can be hinged side walls (e.g., as shown in FIG. 3B) or they can be non-hinged side walls (e.g., as shown in FIG. 3A). The ledges 124a, 124b can be supported by posts between the side walls 122a, 122b. The first side wall 122a and the second side wall 122b can each extend between the first end structure 104a and the second end structure 104b. The first end structure 104a, the second end structure 104b, the first side wall 122a, the second side wall 122b, and the deployable roof 108 can together form an enclosed volume 150. As shown, the first side wall 122a can include a first ledge 124a and the second side wall 122b can include a second ledge 124b. The first ledge 124a can be defined on a portion of the first side wall 122a opposite a floor 125 and the second ledge 124b can be defined on a portion of the second side wall 122b opposite the floor 125. The deployable roof 108 can be supported by the first ledge 124a and the second ledge 124b. In certain embodiments, the floor 125 can be the ground. In certain embodiments, the existing structure 104 can further include a platform 126 configured to serve as the floor 125.

In certain embodiments, such as shown in FIGS. 3B-3D, the existing structure 104 can include one or more panels 127 of the side walls 122a, 122b configured to hinge outward to form awning structures for covered outdoor space. In such embodiments, there may be no “sidewall” forming an enclosed volume 150, but the roof structure would still rest on ledge 124a, 124b of the side walls 122a, 122b, as shown in FIGS. 3A and 3D for example, wherein the ledges are supported by posts 123. The existing structure 104 may also include other modules, such as entrances/exits 129, or ramps 131 if a platform 126 is used, such as shown in FIG. 3D. The modular structure 200 can further include cross bracing 133 (e.g., as shown in FIG. 3C) to provide additional structural support to secure the housing portion 102 of the roofing system 100 to the modular structure 200. Cross bracing 133 does not provide support for the deployable roof 108 since the deployable roof 108 does not require any cross bracing for support. Instead, cross bracing 133 provides means for securing, or tying down the housing portion 102 to the first end structure 104a of the modular structure 200, for example in the case of high wind or other extreme weather conditions.

FIGS. 4A-4F show the installation and deployment of the roofing system 100 onto an existing structure 104. As shown here, the existing structure 104 can be the same or similar to that described above, and can have the same or similar components described above. Accordingly, FIGS. 4A-4F show the construction of the existing structure 104 in addition to the installation and deployment of the deployable roof 108 onto the existing structure 104. In certain embodiments, however, the existing structure 104 may include an already constructed structure, in which case the installation and deployment of the roofing system 100 would begin at FIG. 4D.

Once installed and deployed, the deployable roof 108, the first and second end structures 104a, 104b, the first and second side walls 122a, 122b, and the floor 125 can form the enclosed volume 150. The enclosed volume 150 can be configured in any number of ways. FIG. 3D shows an example configuration that includes a main room, an office space, a bathroom, and a kitchenette. As shown in FIGS. 5A-5F, the enclosed volume 150 can be configurable to include one or more of a kitchen, a bathroom, classroom, an office, or an event space, as will be described further below.

In accordance with at least one aspect of this disclosure, e.g., as shown in FIGS. 1-5F, the modular structure 200 is provided. The modular structure 200 can be or include any one or more components of the existing structure 104 as described above. Therefore, for brevity, the description of common elements that have been described above for existing structure 104 are not repeated with respect to the modular structure 200. In certain embodiments, the roofing system 100 and the modular structure 200 are configured and adapted for use together to form the enclosed volume 150. The process of such construction is shown with respect to FIGS. 4A-4F. For example, as shown in FIG. 4A, a platform 126 can be laid down first to serve as the floor 125. As shown in FIG. 4B, the first and second end structures 104a, 104b can be place on the platform 126. Next, in FIG. 4C, the first and second side walls 122a, 122b can be place between the first and second end structures 104a, 104b. In FIG. 4C, only side wall 122a is shown as sidewall 122b is obstructed. In FIG. 4D, the housing 102 can be placed atop the first end structure 104a. The deployable roof 108 can then be deployed (e.g., as shown by the arrow in FIG. 4E) to cover the modular structure 200. In FIG. 4E, a user is shown urging the deployable roof 108 outward, however this may not be necessary and instead the tubular structures 118 can be connected to one another such that an airflow pattern during inflation urges the tubular sections 118 to inflate in such an order that does not require manual assistance. Finally, the deployable roof 108 is shown in the fully deployed position in FIG. 4F.

Once constructed, the modular structure 200 and roofing system 100 form the enclosed volume 150, which can be used in any number of ways, such as the configuration examples shown in FIGS. 5A-5F. For example, FIG. 5A shows the modular structure 200 configured to be a dining hall and includes a bathroom 252, kitchen 254, main room 256 for “indoor” seating, an office space 258, and covered “outdoor” seating space 260 covered by panels 127. FIG. 5B shows the modular structure 200 configured to be a classroom. FIG. 5C shows the modular structure 200 configured to be a workshop. FIG. 5D shows he modular structure 200 configured to be a café/information center. FIG. 5E shows the modular structure 200 configured to be an exhibition. FIG. 5F shows the modular structure 200 configured to be a strategic planning center. Any use of this modular structure 200 in addition to the examples set forth in FIGS. 5A-5F is contemplated herein. For example, it is contemplated that the modular structure 200 can be used in an emergency, for example, following a natural disaster. The modular structure 200 can further include a water storage unit 128, e.g., as shown in 3A. The water storage unit 128 can be used to supply the enclosed volume 150 with water (e.g., for the kitchen, bathroom, or general use). The modular structure 200 can further include a waste macerator 135. The waste macerator can be connected via piping to a location's existing sewer system, for example. Any one or all embodiments of the modular structure can include one or more of the water storage and/or waste macerator depending on the desired use for the modular structure, and depending on the availability of existing infrastructure.

With reference now to FIGS. 6A-D, another embodiment of a roofing system 300 and modular structure 400 is shown. The roofing system 300 can be like that of the roofing system 100, for example roofing system 300 can have similar components and features with respect to roofing system 100. Similarly, modular structure 400 can have similar components and features with respect to modular structure 200. For brevity, the description of common elements that have been described above for roofing system 100 and modular structure 200 are not repeated with respect to roofing system 300 and modular structure 400 as shown in FIGS. 6A-6D.

Here, the deployable roof 608 can include side panels 633 configured to drape down the side walls 122a, 122b. The side panels 633 may include graphics or lettering such as company indicia, branding, or can be used to indicate the purpose of the structure, such as “FIRST AID,” for example. Also as shown in FIG. 6C, the housing 602 may also include graphics or lettering to convey the same branding or indicia as the side panels 633 or may include different indicia as needed for the purpose of the modular structure 400 and roofing system 300. The side walls 622a and 622b can further include lighting elements 635 placed between an outer facing surface of the side walls 622a, 622b and the side panels 633 to illuminate the graphics on the side panels 633 making them easy to read.

As shown in FIG. 7, in accordance with at least one aspect of this disclosure, a building kit 500 is provided. The building kit 500 can include a roofing system (e.g., roofing system 100, 300) and a modular structure (e.g., modular structure 200, 400) configured and adapted for use together to construct a temporary covered structure.

Those having ordinary skill in the art understand that any numerical values disclosed herein can be exact values or can be values within a range. Further, any terms of approximation (e.g., “about”, “approximately”, “around”) used in this disclosure can mean the stated value within a range. For example, in certain embodiments, the range can be within (plus or minus) 20%, or within 10%, or within 5%, or within 2%, or within any other suitable percentage or number as appreciated by those having ordinary skill in the art (e.g., for known tolerance limits or error ranges).

The articles “a”, “an”, and “the” as used herein and in the appended claims are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article unless the context clearly indicates otherwise. By way of example, “an element” means one element or more than one element.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

The embodiments of the present disclosure, as described above and shown in the drawings, provide for improvement in the art to which they pertain. While the subject disclosure includes reference to certain embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.