U.S. patent application number 14/901551 was filed with the patent office on 2016-06-02 for roll-out structure with self-tightening feature.
The applicant listed for this patent is James CURRY. Invention is credited to James CURRY.
Application Number | 20160153199 14/901551 |
Document ID | / |
Family ID | 52142636 |
Filed Date | 2016-06-02 |
United States Patent
Application |
20160153199 |
Kind Code |
A1 |
CURRY; James |
June 2, 2016 |
ROLL-OUT STRUCTURE WITH SELF-TIGHTENING FEATURE
Abstract
A slat for use in a roll-out sheet of construction material is
provided. The slat has an elongated body extending longitudinally.
A projection is disposed at a first lateral end of the body. A
socket is disposed at a second lateral end of the body, opposite to
the first lateral end. The projection and the socket are
structurally complementary to each other. A wedge is formed with
the projection as a self-tightening mechanism. A roll-out structure
is also provided. The roll-out structure has at least two adjacent
slats which are structurally the same. The projection of one of the
slats is insertable into the socket of the other slat to connect
them, and the projection is rotatable in the socket. The rotation
of the projection in the socket allows the wedge to engage the
socket, to lock the slats with each other.
Inventors: |
CURRY; James; (Massapequa,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CURRY; James |
Massapequa |
NY |
US |
|
|
Family ID: |
52142636 |
Appl. No.: |
14/901551 |
Filed: |
June 25, 2014 |
PCT Filed: |
June 25, 2014 |
PCT NO: |
PCT/US2014/043994 |
371 Date: |
December 28, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61840359 |
Jun 27, 2013 |
|
|
|
Current U.S.
Class: |
52/588.1 |
Current CPC
Class: |
E04F 2203/04 20130101;
E01C 9/083 20130101; E01C 9/086 20130101; E04F 15/105 20130101;
E04D 11/00 20130101; E04F 2201/0153 20130101; E04F 15/02038
20130101; E04F 2201/0594 20130101; E01C 5/20 20130101; E01C 2201/12
20130101 |
International
Class: |
E04F 15/02 20060101
E04F015/02 |
Claims
1. A slat for use in a roll-out structure of construction material,
comprising: an elongated body extending longitudinally; a
projection disposed at a first lateral end of the body; a socket
disposed at a second lateral end of the body, the second lateral
end being opposite to the first lateral end, wherein the projection
and the socket are structurally complementary to each other; and a
wedge associated with the projection.
2. The slat according to claim 1, further comprising: a ledge
disposed at the first lateral end of the body; and a shelf disposed
at the second lateral end of the body, wherein the ledge has a
bottom surface and the shelf has a top surface, the bottom surface
and the top surface being substantially vertically aligned with
each other.
3. The slat according to claim 1, further comprising a first
beveled edge disposed at the first lateral end of the body and a
second beveled edge disposed at the second lateral end of the
body.
4. The slat according to claim 1, wherein both the projection and
the socket are substantially cylindrical and have a circular
lateral cross section.
5. The slat according to claim 4, wherein the wedge is integrally
formed with the projection and wherein the circumferential span of
the wedge with respect to the center of the circular lateral cross
section of the projection is at the range of
5.degree.-30.degree..
6. The slat according to claim 5, wherein the circumferential span
of the wedge is 15.degree..
7. The slat according to claim 1, further comprising at least one
hole formed in the body.
8. The slat according to claim 1, further comprising at least one
opening formed in the body, which opening is exposed to a bottom
surface of the body.
9. The slat according to claim 1, wherein the projection comprises
a groove and the socket comprises an elevation, wherein the groove
and the elevation are structurally complementary to each other.
10. A roll-out structure of construction material, comprising at
least a first slat and a second slat which are structurally the
same, each slat comprising: an elongated body extending
longitudinally; a projection disposed at a lateral end of the body
and a socket disposed at an opposite lateral end of the body, the
projection and the socket being structurally complementary to each
other, wherein the projection of the first slat is insertable into
the socket of the second slat to connect the first slat to the
second slat, wherein a gap is provided between the projection of
the first slat and the socket of the second slat to allow rotation
of the projection in the socket; and a wedge associated with the
projection, wherein the wedge of the first slat engages the socket
of the second slat to lock the first slat and the second slat, upon
rotation of the projection of the first slat in the socket of the
second slat.
11. The roll-out structure according to claim 10, wherein each slat
further comprises: a ledge disposed at the lateral end of the body;
and a shelf disposed at the opposite lateral end of the body,
wherein the ledge has a bottom surface and the shelf has a top
surface, the bottom surface and the top surface being substantially
vertically aligned with each other.
12. The roll-out structure according to claim 10, wherein each slat
further comprises a first beveled edge disposed at the lateral end
of the body and a second beveled edge disposed at the opposite
lateral end of the body.
13. The roll-out structure according to claim 10, wherein both the
projection and the socket are substantially cylindrical and have a
circular lateral cross section.
14. The roll-out structure according to claim 13, wherein the wedge
is integrally formed with the projection and wherein the
circumferential span of the wedge with respect to the center of the
circular lateral cross section of the projection is at the range of
5.degree.-30.degree..
15. The roll-out structure according to claim 14, wherein the
circumferential span of the wedge is 15.degree..
16. The roll-out structure according to claim 10, further
comprising at least one hole formed in the body.
17. The roll-out structure according to claim 10, further
comprising at least one opening, which opening is exposed to a
bottom surface of the body.
18. The roll-out structure according to claim 10, wherein the
projection comprises a groove and the socket comprises an
elevation, wherein the groove and the elevation are structurally
complementary to each other.
Description
BACKGROUND
[0001] This disclosure relates to the field of building materials
and more particularly to a universal modular roll-out building
material with self-tightening features.
[0002] There is a long recognized need for modular construction
material, for example, roofing, flooring, roadways and the like,
which can be delivered from a remote location, rapidly assembled
and deployed, and easily removed when it is no longer required.
[0003] Traditionally, the modular construction material includes a
series of panels which can be linked or jointed to form a roofing
or roadway having a flat surface. The panels are laid according to
a predetermined pattern (for example, side by side) and,
subsequently, assembled with each other by using connectors,
including straps, cords, adhesives, metal fasteners and the
like.
[0004] The known construction material has several drawbacks. For
example, assembly and disassembly of the panels are complex and
require significant amount labor and time. Furthermore, the extra
connectors, required in addition to the panels, incur additional
costs on material and transportation. In addition, secured coupling
of the panels cannot be ensured, because of the potential breakage,
abrasion, erosion or otherwise damage of the connectors;
accordingly, deformation can occur to the deployed roofing or
roadway.
SUMMARY OF THE DISCLOSURE
[0005] Therefore, in order to address these and other deficiencies
in the prior art, provided according to an aspect of the present
invention is a slat for use in a roll-out structure of construction
material. The slat includes an elongated body extending
longitudinally; a projection disposed at a first lateral end of the
body; a socket disposed at a second lateral end of the body
opposite to the first lateral end; and a wedge associated with the
projection. The projection and the socket are structurally
complementary to each other.
[0006] Preferably, the slat further includes a ledge disposed at
the first lateral end of the body and a shelf disposed at the
second lateral end of the body. The bottom surface of the ledge and
the top surface of the shelf are substantially vertically aligned
with each other.
[0007] Preferably, the slat further includes a first beveled edge
disposed at the first lateral end of the body and a second beveled
edge disposed at the second lateral end of the body.
[0008] Preferably, both the projection and the socket are
substantially cylindrical and have a circular lateral cross
section.
[0009] Preferably, the wedge is integrally formed with the
projection and the circumferential span of the wedge with respect
to the center of the circular lateral cross section of the
projection is within the range of 5.degree.-30.degree.. More
preferably, the circumferential span of the wedge is
15.degree..
[0010] Preferably, the slat further includes at least one hole
formed in the body.
[0011] Preferably, the slat further includes at least one opening
formed in the body, which opening is exposed to a bottom surface of
the body.
[0012] Preferably, the projection includes a groove and the socket
includes an elevation. The groove and the elevation are
structurally complementary to each other.
[0013] A roll-out structure of construction material is provided
according to another aspect of the present invention. The roll-out
structure includes at least a first slat and a second slat which
are structurally the same. Each slat includes an elongated body
extending longitudinally; a projection disposed at a lateral end of
the body and a socket disposed at an opposite lateral end of the
body; and a wedge associated with the projection. The projection
and the socket are structurally complementary to each other. The
projection of the first slat is insertable into the socket of the
second slat to connect the first slat to the second slat, and a gap
is provided between the projection of the first slat and the socket
of the second slat to allow rotation of the projection in the
socket. The wedge of the first slat engages the socket of the
second slat to lock the first slat and the second slat, upon
rotation of the projection of the first slat in the socket of the
second slat.
[0014] Preferably, each slat further includes a ledge disposed at
the lateral end of the body and a shelf disposed at the opposite
lateral end of the body. The bottom surface of the ledge and the
top surface of the shelf are substantially vertically aligned with
each other.
[0015] Preferably, each slat further includes a first beveled edge
disposed at the lateral end of the body and a second beveled edge
disposed at the opposite lateral end of the body.
[0016] Preferably, both the projection and the socket are
substantially cylindrical and have a circular lateral cross
section.
[0017] Preferably, the wedge is integrally formed with the
projection and the circumferential span of the wedge with respect
to the center of the circular lateral cross section of the
projection is within the range of 5.degree.-30.degree.. More
preferably, the circumferential span of the wedge is
15.degree..
[0018] Preferably, each slat further includes at least one hole
formed in the body.
[0019] Preferably, each slat further includes at least one opening
formed in the body, which opening is exposed to a bottom surface of
the body.
[0020] Preferably, the projection includes a groove and the socket
includes an elevation.
[0021] The groove and the elevation are structurally complementary
to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features, benefits and advantages of the
present invention will be made apparent with reference to the
following detailed description and accompanying figures, where like
reference numerals refer to like structures across the several
views, and wherein:
[0023] FIG. 1 is a schematic perspective view of a roll-out
structure according to an exemplary embodiment of the present
invention;
[0024] FIG. 2 is a schematic perspective view of a single slat of
the roll-out structure shown in FIG. 1;
[0025] FIG. 3 is a sectional view along lines 3-3 of FIG. 2,
showing the detailed structure of the slat;
[0026] FIG. 4 is a sectional view of two adjacent slats showing the
insertion of one slat into the other;
[0027] FIG. 5 is a schematic perspective view of the two adjacent
slats showing the slats locked with each other;
[0028] FIG. 6 is a front view of a roll-out structure according to
another exemplary embodiment of the present invention;
[0029] FIG. 7 is a front view of two adjacent slats according to
FIG. 6, showing the insertion of one slat into the other; and
[0030] FIG. 8 is a front view of the two adjacent slats showing the
slats locked with each other.
DETAILED DESCRIPTION OF DISCLOSURE
[0031] FIG. 1 illustrates a roll-out structure 10, which can be in
the form of a rollable sheet, according to an exemplary embodiment
of the present invention. The roll-out structure 10 includes a
plurality of slats 100, which are structurally the same or similar.
Any two adjacent slats of the roll-out structure 10 are connected
to each other to permit the roll-out structure 10 to be deployed in
a rollable manner.
[0032] As shown in FIG. 1, a three-dimensional coordinate system is
defined. In this coordinate system, each slat extends
longitudinally along the X-axis; the jointed slats extend laterally
in a rollable manner along the Y-axis; and each slat extends
vertically in its thickness along the Z-axis. Preferably, the slats
100 have identical longitudinal, lateral, and/or vertical
dimensions, to ensure interchangeability of the slats.
[0033] FIG. 2 is a schematic perspective view showing the structure
of a slat 100. The slat 100 is substantially flat and elongated,
extending in the longitudinal direction. For example, the length of
the slat in the longitudinal direction is substantially larger than
the width in the lateral direction and the thickness in the
vertical direction.
[0034] FIG. 3 is a sectional view of the slat 100 along lines 3-3
in FIG. 2. The slat 100 has an elongated body 101, which has a top
surface 102 and a bottom surface 104. The top surface 102 and the
bottom surface 104 are substantially flat and parallel with each
other, to define the thickness T of the slat 100. Alternatively,
part or all of the surfaces 102 and 104 can be concave or convex,
or angled with respect to teach other, which allows the roll-out
structure 10 to be other than flat when deployed. In this and other
figures, clearances are exaggerated to show the parts of the
embodiments, and the figures should not be interpreted as being to
scale.
[0035] As shown in FIG. 3, the slat 100 includes a ledge 106 and a
projection 108 provided at a first lateral end of the slat 100,
which in combination serve as a male component for joining the slat
with an adjacent slat. The slat 100 further includes a socket 110
and a shelf 112 provided at an opposite second lateral end of the
slat 100, which in combination serve as a female component for
joining the slat with an adjacent slat.
[0036] For example, the projection 108 is structurally
complementary to the socket 110, which permits adjacent slats 100
to be rotatably assembled with each other to form the roll-out
structure 10. In the shown embodiment, the projection 108 is
substantially cylindrical in the longitudinal direction. The
projection 108 has a substantially circular lateral cross section,
which is substantially consistent along the length of the slat 100.
The socket 110 defines a complementary space S for operatively
receiving the projection 108. The space S is also substantially
cylindrical in the longitudinal direction, and properly dimensioned
to permit insertion of the projection 108 with force into the space
S and rotation of the projection 108 within the space S.
[0037] Other complementary configurations of the projection and the
socket are within the scope of the present invention. For example,
the socket can be a rounded "bull-nose" notch, and on the opposite
lateral side, the projection can be a "bull-nose" tab dimensioned
to snugly mate with the notch.
[0038] The ledge 106 and the shelf 112 are preferably structurally
complementary to permit the ledge to sit on the shelf of an
adjacent slat, which enhances the integrity and strength of the
roll-out structure 10. In the shown embodiment, the ledge 106 has a
flat bottom surface 114 and the shelf 112 has a flat top surface
116. The bottom surface 114 and the top surface 116 are
substantially aligned vertically, yet spaced from each other
laterally, such that when two adjacent slats are rotated with each
other to deploy the roll-out structure, the ledge of one slat sits
on the shelf of the other slat. However, the complementary bottom
surface of the ledge and top surface of the shelf can be curved or
otherwise non-flat. The top surface of the ledge 106 forms a part
of the top surface 102 of the elongated body 101, or is continuous
with the top surface 102. The bottom surface of shelf 112 forms a
part of the bottom surface 104 of the elongated body 101, or is
continuous with the bottom surface 104.
[0039] As shown in FIG. 3, the slat 100 includes a first beveled
edge 120 extending between the top surface 102 and the outer
circumferential surface 122 of the projection 108. The first
beveled edge 120 and the top surface 102 define an angle a in the
range of 90.degree.-180.degree., preferably in the range of
120.degree.-150.degree.. The beveled edge 120 allows the slats to
have a greater degree of rotation upwardly.
[0040] Alternatively or additionally, the slat 100 includes a
second beveled edge 124 provided at the opposite lateral side of
the first beveled edge 120. The second beveled edge 124 extends
between the top surface 102 and the inner circumferential surface
126 of the socket 110. The second beveled edge 124 is inclined
oppositely with respect to the first beveled edge 120. The second
beveled edge 124 and the top surface 102 define an angle .beta. in
the range of 90.degree.-180.degree., preferably in the range of
120.degree.-150.degree.. The beveled edges 120 and 124 are
dimensioned to beneficially reduce storage size required for the
roll-out sheet.
[0041] FIG. 4 is a sectional view showing an alternative
configuration of two adjacent slats 200 and 300. In this
configuration, the slats 200 and 300 are jointed with each other;
the slats 200 and 300 are ready to lock with each other, to prevent
potential movement of the slats with respect to each other along
the longitudinal direction.
[0042] The slats 200 and 300 have the same structure as the slat
100. Initially, the projection 108 of the slat 300 is inserted into
the socket 110 of the slat 200, while the bottom surfaces of the
slats 200 and 300 define an angle .mu.. The angle .mu. can be in
the range of 15.degree.-75.degree., preferably, about
45.degree..
[0043] When the projection 108 is inserted into the socket 110, the
socket 110 temporarily deforms and expands to allow the projection
108 to be positively and snugly received within the socket 110,
because of the resilience of the material for forming the slats.
Certain tolerance is provided between the jointed projection and
the socket, i.e., between the outer circumferential surface 122 of
the projection 108 and the inner circumferential surface 126 of the
socket, to allow the slat 300 to rotate with respect to the slat
200. For example, after the projection 108 of the slat 300 is
inserted into the socket 110 of the slat 200, a gap G (shown in
FIG. 5) of about 0.003 inches is provided between the projection
and the socket.
[0044] Each slat 200 or 300 includes a self-tightening mechanism
for implementing or enhancing locking of the two slats. As shown in
FIG. 4, the self-tightening mechanism includes a wedge 130
associated with the outer circumferential surface 122 of the
projection 108. The wedge 130 is preferably formed with the
projection 108 through a material extrusion process. For example,
the wedge 130 can be a single piece of material, extending along
the entire length of the projection 108; alternatively, the wedge
130 can be disposed discretely at certain predetermined location(s)
along the length of the projection 108.
[0045] The wedge 130 is properly dimensioned, such that when the
slat 300 is rotated clockwise (or the slat 200 is rotated
counterclockwise) from the insertion position, the wedge 130
progressively engages the inner circumferential surface 126 of the
socket 110 to create a cam type lock between the slat 200 and the
slat 300. When the slat 300 is rolled to align vertically with the
slat 200, the cam type lock prevents the slats 200 and 300 from
moving longitudinally with respect to each other, as shown in FIG.
5. As a result, the final product will not become loose. According
to another aspect of the invention, the slats can be pre-connected
and packaged in a compact manner in a roll. During the deployment
of the slats for forming a roofing (for example), the adjacent
slats can be simply rolled to form a flat surface of the roofing;
at the same time, the slats are locked consequently, as the slats
are rolled, to achieve a self-tightened roofing.
[0046] In addition, the cam type lock created by the wedge 130 will
eliminate the gap G between the projection 108 and the socket 110,
when the slats 200 and 300 are vertically aligned. Without the gap,
any potential lateral movement between the adjacent slats is
prevented, which in turn further enhances the integrity, stability
and torsional strength of the roll-out structure. Alternatively or
additionally, stop pins can be provided to achieve or enhance the
locking result.
[0047] The wedge 130 can have a variety of shapes and profiles. For
example, the wedge can be crescent-shaped to permit easy
progressive engagement between the wedge and the socket.
Furthermore, the position of the wedge 130 on the projection 108
and the circumferential span of the wedge 130 with respect to the
center of the projection 108 are properly determined, such that
when the projection 108 is inserted into the socket 110, no
obstruction occurs. As shown in FIG. 4, the wedge 130 has a
circumferential span defined by .pi., which is between 5.degree.
and 30.degree., preferably 15.degree..
[0048] The slats 100, 200 and 300 can be of solid cross-section,
for example if manufactured of plastic, wood or metal. Alternately,
the slats can have hole(s) and/or opening(s) disposed
longitudinally through the slats. Referring to FIG. 1, a plurality
of holes 152 and a plurality of openings 154, exposed to the bottom
surface 104, are provided to the slat 100. The provision of these
holes and openings can effectively reduce the weight of the
roll-out structure, while maintaining the strength of the structure
at a satisfactory level. The holes and openings can be formed
through extrusion of plastic or metal materials. In addition, these
holes and openings can be advantageously filled with other
material, for example one or more of foam or fiberglass, as
insulation against transfer of heat and/or sound, for example.
[0049] FIGS. 6-8 illustrate a slat 400 according to another
exemplary embodiment of the present invention. The slat 400
includes an elongated body 402, which is similar to the elongated
body 101 of the slat 100. Certain parts of the elongated body 402
can be selectively hollowed to reduce the weight and material of
the slat 400, without comprising the structural strength of the
slat 400. The slat 400 also includes a projection 404, which is
provided at an end of the body 402, and a socket 406, which is
provided at the opposite end of the body 402. The projection 404
and the socket 406 have profiles complementary to each other, such
that the projection 404 of a slat can be inserted into the socket
406 of an adjacent slat to join the two slats together, as shown in
FIG. 7.
[0050] The projection 404 has a curved, preferably rounded,
profile. In this embodiment, the projection 404 further includes a
groove 408, which is recessed from the outer circumference of the
projection 404. The socket 406 has a C-shaped profile, which
defines a space to admit the projection 404. The socket 406 is
properly dimensioned to allow the projection 404 to enter the space
of the socket 406 and form a snug-fit with the socket 406. The
socket 406 includes an elevation 410 extending toward the space,
which is located at the edge of the C-shaped socket. The elevation
410 is configured to be substantially structurally complementary to
the groove 408. In operation, after the projection 404 of a slat
has been inserted into the socket 406 of an adjacent slat (as shown
in FIG. 7), the slats are rotated with respect to each other to
allow the elevation 410 associated with the socket 406 to
positively engage the groove 408 associated with the projection
404. The engagement between the elevation 410 and the groove 408
locks the two adjacent slats, as shown in FIG. 8. The projection
404 of the slat 400 can also have a wedge as described in the
previous embodiment.
[0051] The roll-out sheathing and the slat as described above with
respect to FIGS. 1-5 are designed to be customizablely joined with
any number of slats with a minimum of effort and, generally,
without the need for tools. Thus, the roll-out sheathing can be
provided as individual slats, which are later joined on-site by a
contractor or homeowner.
[0052] In an alternative arrangement, a predefined number of slats
may be provided prepackaged, and pre-joined. However, the modular
design of the slats allows the user to easily remove unneeded slats
from the roll-out sheathing or, when necessary, add additional
slats to the ends of the roll-out sheathing.
[0053] The roll-out sheathing described herein has many uses in a
variety of fields, including but not limited to roofing, flooring,
housing, roadways and the like. The present invention is well
suited for deployment as a temporary repair of damaged roofing and
for temporary protection for windows, glass doors and other easily
damaged structures of a residential or commercial structure in
areas prone to hurricanes and other damaging conditions.
Additionally, the present invention can be utilized as permanent
building material for roofing and flooring. Moreover, the present
invention can be utilized as a temporary road surface at
construction and mining sites, where permanent cement or asphalt
road surfaces are impractical. When intended as a surface for use
by heavy vehicles, the slats of the present invention can be
constructed of steel or aluminum and may be solid throughout.
[0054] The present invention has been described herein with
reference to certain exemplary and/or preferred embodiments. These
embodiments are offered as merely illustrative, and not limiting,
on the scope of the invention. Certain other alterations and
modifications may be apparent to those skilled in the art in light
of the present disclosure, without departing from the spirit or
scope of the present invention, which is defined solely with
reference to the following appended claims.
* * * * *