US20120180838A1

US20120180838A1 - Method of erecting portable structure and related apparatus

Info

Publication number: US20120180838A1
Application number: US13/349,480
Authority: US
Inventors: Robert Stafford
Original assignee: Individual
Current assignee: Individual
Priority date: 2011-01-13
Filing date: 2012-01-12
Publication date: 2012-07-19

Abstract

A method of erecting a tent includes a plurality of beam members comprising a roof portion and a pair of leg portions. A plurality of base members are securedly fixed to the ground surface. The beam assembly leg portions are pivotally coupled to the base members, pivoted to a vertical position, and secured to the base member to prevent further pivoting of the beam assembly. Extendable purlins couple adjacent beam assemblies to one another. A single piece fabric panel extends between the full length of a pair of adjacent beam assemblies. The fabric panels are tensioned by expanding the plurality of extendable purlins to increase the distance between the adjacent beam assemblies. Fabric panel tensioning is sequenced from the center of the structure outward.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to enclosures and, more particularly, to portable enclosure structures.
2. Description of the Related Art
Fabric-covered portable structures are a relatively common form of semi-permanent shelter. Such structures typically can withstand moderate to severe weather conditions over extended periods of time. However, fabric-covered structures are generally relatively expensive. Specialized equipment and skilled workers are typically required to erect and disassemble the structures. Their components generally are relatively large and difficult to transport.
In addition, the fabric of frame tents is typically only loosely secured to the frame of the portable structure. The loosely secured fabric can flap in the wind, thereby stressing the frame of the portable structure. The flapping of the fabric also generates unwanted noise. In some instances, the frame tent installation can provide a long-term protective structure, such as a military facility, inhabited and used as a working environment in a variety of extreme weather conditions. Such long-term installations can provide inadequate living and working conditions when excessive noise levels exist due to loose fabric installation that responds to high winds and other extreme weather elements. Accordingly, there is a need in the art for an improved portable structure and method of erecting a portable structure.

SUMMARY OF THE INVENTION

According to certain embodiments, a method of erecting a portable structure can comprise securing a plurality of base members to a support surface, assembling a plurality of beam members, wherein each of said beam members has a length and is configured to couple to a pair of said base members, coupling said plurality of beam members to said plurality of base members, and erecting said plurality of beam members about said pairs of said base members. The method of erecting a portable structure can further comprise coupling a plurality of transverse members between adjacent beam members, said transverse members establishing a plurality of spaced distances between said adjacent beam members, coupling a fabric to at least a pair of adjacent beam members of said plurality of beam members, said fabric extending from substantially adjacent a first base member to substantially adjacent a second base member. The method can still further comprise deciding whether to elongate at least one of said plurality of transverse members between said adjacent beam members to increase the length of said transverse member, wherein said increased length would facilitate tautly securing said fabric to said beam members.
In some embodiments, a method of erecting a portable structure can comprise securing a plurality of base members to a support surface, assembling a plurality of beam members, wherein each of said beam members has a length and is configured to couple to a pair of said base members, coupling said plurality of beam members to said plurality of base members, and erecting said plurality of beam members about said pairs of said base members. The method of erecting a portable structure can further comprise coupling a plurality of transverse members between adjacent beam members, said transverse members establishing a plurality of spaced distances between said adjacent beam members, coupling a fabric to at least a pair of adjacent beam members of said plurality of beam members, and elongating said plurality of transverse members in each spaced distance to increase the lengths of said transverse members, wherein said increased lengths facilitate tautly securing said fabric to said beam members. The method can still further comprise sequencing the elongating of said plurality of transverse members to begin at a spaced distance that is substantially centered between the plurality of spaced distances established between the plurality of adjacent beam members, wherein each subsequent elongating of said transverse members occurs at a spaced distance between beam members that is adjacent a spaced distance having elongated transverse members.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand the embodiments of the disclosure and to see how it may be carried out in practice, some preferred embodiments are next described, by way of non-limiting examples only, with reference to the accompanying drawings, in which like reference characters denote corresponding features consistently throughout similar embodiments in the attached drawings.

FIG. 1 is a perspective view of one embodiment of a portable structure in accordance with the present invention;

FIGS. 2A-2L are views of embodiments of a base member of the portable structure of FIG. 1;

FIG. 3 is a front elevational view of a beam assembly of the portable structure of FIG. 1;

FIG. 4 is cross-section view of the beam assembly of FIG. 3;

FIG. 5 is a front elevational view of an apex of the portable structure;

FIG. 6 is a front elevational view of an eave of the portable structure;

FIG. 7 is a front elevational view of a short beam of the portable structure;

FIG. 8 is a front elevational view of a long beam of the portable structure;

FIG. 9 is a front elevational view of a leg of the portable structure;

FIG. 10 is a front elevational view of a base insert of the portable structure;

FIGS. 11A-11D show various features of an adjustable purlin of the portable structure;

FIG. 12 is a front elevational view of a bracing cable of the portable structure;

FIG. 13 is a top plan view of a layout of the base members of the portable structure;

FIG. 14 is a front elevational view of the base member with a registration pin extending through an opening in a base plate thereof;

FIG. 15 is a front elevational view of the base member and registration pin with a stake extending through an opening in each side of the base plate;

FIG. 16 is a top plan view of a layout of various components of the portable structure;

FIG. 17 is a perspective illustration of the assembled beam assemblies of the portable structure;

FIG. 18A is a perspective illustration of a step in the assembly of the portable structure showing a beam assembly fixedly attached to a base member and adjustable purlins attached thereto;

FIG. 18B is a front elevational view of an insert portion and receiving portion for connecting together components of the beam assembly;

FIG. 19A is a perspective assembly view of the base member and a base insert of the portable structure;

FIG. 19B is a perspective view of the base insert pivotally assembled to the base member;

FIG. 20 is a perspective view of the base insert fixedly assembled to the base member;

FIG. 21 is an illustration of the lifting of a first beam assembly of the portable structure;

FIG. 22 is an illustration of the lifting of a second beam assembly of the portable structure;

FIG. 23 is a side view of the bracing cable of the portable structure;

FIG. 24 is a front elevational view of a top panel of the portable structure;

FIG. 25 is a perspective illustration of the installation of a top panel;

FIG. 26 is a perspective illustration of the installation of a top panel;

FIG. 27 is a perspective illustration of the tensioning sequence of the top panels of the portable structure;

FIG. 28 is a front elevational view of an end panel of the portable structure;

FIG. 29 is a perspective illustration of the installation of an end panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIG. 1, a portable structure 10, or a portable tent, is shown. The portable structure 10 includes a width W and a length L, which can include any suitable length directed to a desired application, or installation, of the portable tent structure 10. In the illustrated embodiment, the portable structure 10 includes a plurality of tubular beam assemblies 40 that span the width W of the portable structure 10. The beam assemblies 40 support panels of a fabric material that extend between the beam assemblies 40, including top panels 12 and end panels 14. The plurality of adjacent beam assemblies are coupled to one another by a plurality of adjustable purlins 120. In some embodiments, the portable structure 10 can include separate wall panels (not shown) that extend between the beam assemblies along the substantially vertical portion of the length L portion of the tent structure 10.
With reference to FIGS. 2A-2L, embodiments of a base member 20 are shown. The portable tent structure 10 can include a plurality of base members 20. The tent structure 10 is anchored to the ground by the plurality of base members 20. With reference to FIGS. 2A-2D, in the illustrated embodiment, each base member 20 includes a base plate 22 and a pivot plate 26. The pivot plate 26 is coupled to the base plate 22, and extends substantially perpendicularly and upwardly from the top surface of the base plate 22 along the lengthwise direction of the base plate. At least two apertures, or pivot openings 28, extend through the pivot plate 26. A pivot opening 28 is generally positioned adjacent opposing ends, or portions, of the pivot plate 26, as shown in FIGS. 2A-2L. In some embodiments, the pivot plate 26 is offset from the widthwise centerline of the base plate. The pivot plate 26 can be coupled to the base plate 22 via traditional machining or fabrication methods, e.g. welding, standard machining, or the like.
The base plate 22 includes a top surface 30 and bottom surface 32, where the bottom surface interfaces with the support surface, or ground surface, that the portable tent structure 10 is assembled and installed upon. At least two apertures, or base openings 24, are similarly provided through the base plate 22, generally positioned adjacent opposing ends of the base plate 22. The opening 24 provide the access for coupling the base plate 22 to the support surface below the base member 20. A plurality of supports 34 are disposed on the top surface 30 of the base plate 22, and extend perpendicularly from the pivot plate 26 to an edge of the base plate 22. A smaller registration hole 36 is provided roughly through a center portion of the base plate 22, disposed adjacent a side of the pivot plate 26.
With reference to FIGS. 2E-2L, additional embodiments of the base plate 20′, 20″ are shown. The base plates 20′, 20″ define a larger area base plate that results in a greater contact surface with the support, or ground, surface. The base plates 20′, 20″ can include a greater number of openings 24′, 24″ and provide an increased number of couplings to secure the base plate 20′, 20″ to the ground. The increased number of openings 24′, 24″ and the increased surface area to interface with the support, or ground, surface advantageously provides a more secure attachment, or installation, of the base member 20 to the ground. The larger base plates 20′, 20″ larger contact area provides increased load bearing capacity and can support larger beam assemblies that span a greater width, or larger beam spans. Thus, the larger base plates provide for scalability in the size of the portable structures and maintain functional and structural capability of various sizes of the portable structure. In some embodiments, the base members 20 can include more than four openings 24′, 24″ to secure the base member 20 to the support surface.
In the illustrated embodiment of FIGS. 3-9, a beam assembly 40 and the various components that make up the beam assembly 40 are shown. Each beam assembly 40 includes a roof portion 42 and a leg portion 44 that supports the roof portion 42. In the illustrated embodiment, each roof portion 42 comprises a pair of curved eaves 60, a pair of straight short beams 70, a pair of straight long beams 80, and a curved apex 50. The short beams 70 and long beams 80 are provided for connection between each of the eaves 60 and the apex 50. The leg portion 44 is connected to the lower portion of the eave 60. The leg portion 44 includes a leg 90 and a base insert 100 that is configured to pivotally couple to the base member 20, as described in detail below. In some embodiments, the roof portion 42 can include more or less short beams, long beams, multi-piece leg portions, or any combination thereof, to provide suitable beam assemblies for various portable structure applications.
In the illustrated embodiment of FIG. 4, a cross-section view of the various beam assembly components is shown. The beam assembly components listed above each include a body portion and interconnecting end portions. The body portion, as shown in FIG. 4, includes a generally oval shaped hollow inner diameter portion, structural reinforcement increased wall thickness portions, and a plurality of keder tracks 46, 48. In some embodiments, the shape of the hollow inner portion can be any other geometric shape, e.g. square, rectangular, polygonal, or the like. The beam assembly is generally fabricated from metal, e.g. steel, aluminum, or the like. In some embodiments, the beam assembly is fabricated from extruded aluminum. Each component of the beam assemblies 40, including the apexes 50, eaves 60, short beams 70, long beams 80, and legs 90, defines a pair of outer or upper keder tracks 46 and a pair of inner or lower keder tracks 48 that facilitate installation and securement of the panel fabric material to the beam assemblies 40.
The top-most point, and generally the center point or apex, of the roof portion 42 is established by the apex 50. The apex 50, as illustrated in FIG. 5, includes two generally straight elongate beam portions joined by an arcuate beam portion. The arcuate portion can define a variety of different suitable angles, but is generally an obtuse angle. The center of the arcuate portion includes a bracket 56 that is configured to connect, or couple, to the purlins 120 that span the lengthwise distance between adjacent beam assemblies, top panel 12 sections, or the bay width A (see FIG. 13), of the tent structure 10. The end portions of the apex 50 straight portions define inserts 52 that include a pair of retractable buttons 54 that extend from an outer surface of each insert 52. The inserts 52, which are representative of insert portions comprising the end portions of the remaining beam assembly components, are sized to be received by the hollow interior volume of the body portions of adjoining beam assembly components. In some embodiments, the beam components can include any number of retractable buttons and corresponding receiving apertures, e.g. one, two, three, four, or the like. In some embodiments, the ends of the various beam assembly components can vary between a male insert portion with retractable buttons or a female receiving portion with receiving apertures for the buttons, suitable to assemble together the various beam assembly components to form the full beam assembly 40.
With reference to FIG. 6, an eave 60 is shown. The eave 60 includes two generally straight elongate beam portions, an upper end and a lower end, joined by an arcuate beam portion. The arcuate portion can define a variety of different suitable angles, but is generally an obtuse angle and generally a smaller angle than the apex 50. In some embodiments, the eave 60 arcuate portion angle can be the same or greater than the apex 50 arcuate portion angle. The upper end straight portion of each eave 60 defines an insert 62. A pair of retractable buttons 64 extends from an outer surface of each insert 62. The opposing lower end of each eave 60 includes a bracket 56, as described in detail above, and a pair of openings 66. The opening 66 is configured to receive the retractable buttons of the leg 90. The lower end of each eave 60 can further include a flared portion of the keder tracks 46, 48 that provide an entry location for the keder into the keder tracks 46, 48.
With reference to FIGS. 7 and 8, the short beam 70 and the long beam 80 are shown. Both the short beam 70 and the long beam 80 include an elongate body portion. The long beam 80 generally includes a body that is longer than the body of the short beam 70. The short beam 70 includes an insert 74 at a first end that includes a pair of retractable buttons 76 that extend from an outer surface of the insert 74. A pair of openings 72 are disposed at a second end thereof. The short beam further includes a bracket 56, as described above, adjacent the insert 74 at the first end of the short beam 70. The long beam 80, by contrast, includes a pair of openings 84 at a first end portion and a pair of openings 82 at a second end portion of the elongate body portion. The openings 72, 82, 84 are configured to receive the retractable buttons of the adjoining components of the beam assembly 40. The long beam 80 further includes a bracket 56 adjacent the pair of openings 82 at the second end portion of the long beam 80.
In the illustrated embodiment of FIG. 9, the leg 90 is shown. Similar to the components described above, the leg 90 includes an elongate body portion and an upper end portion insert 92 that includes a pair of retractable buttons 94 that extend from an outer surface of the insert 92. The leg 90 includes a flared portion 98 of the keder tracks 46, 48 to provide ready access to insert the keders 170 into the vertical portion of the beam assembly for loading the top panels 12.
With reference now to FIG. 10, a base insert 100 configured to couple to the lower end of leg 90 is shown. The base insert 100 includes an insert portion 102 and a pivot plate 104 at an end of the insert portion 102. The insert portion 102 includes a pair of retractable buttons 106 that extend from an outer surface of the insert portion 102. The insert portion 102 is sized to be received by the hollow interior volume of the leg 90. The pivot plate 104 extends generally perpendicularly to the insert portion 102 and has rounded corners 108 at a lower end thereof. An opening 110 is provided through opposing sides of the pivot plate 104.
With reference to FIGS. 11A-11D, the adjustable purlin 120 is shown. The adjacent beam assemblies that extend generally parallel to one another are coupled together by a plurality of transverse connector members, or the adjustable purlins 120. The adjustable purlins 120 are configured to have a variable length. The purlins 120 include a drop-in end 124, an extending end 122, an elongate body member 126, and an extension assembly 128. The drop-in end 124 and extending end 122 are configured to removably couple to the brackets 56 positioned along the length of the beam assembly 40. The drop-in end 124 and the extending end 122 can be threadingly engaged in the end portions of the elongate member portion 126. In some embodiments, the drop-in end 124 can be replaced with a fixed end 125, as shown in FIG. 11B, that can be fastened to the beam assembly 40 or the brackets 56 rather than dropped into the brackets 56.
The extension assembly 128 functions to extend or contract the longitudinal length of the adjustable purlin 120. The extension assembly includes a rotating body 130, a hexagonal portion 132, a first threaded portion 134, and a second threaded portion 136. The hexagonal portion 132 defines at least a portion of the outer surface of the rotating body 130. The rotating body 130 includes a threaded inner diameter that extends all of the way through the inner portion, or center, of the body 130. The first threaded portion 134 is fixedly attached to the extending end 122. The second threaded portion 136 is fixedly attached to the body member 126. The diameters of the threaded portions 134, 136 are generally the same size. The internally threaded rotating body 130 receives the first threaded portion 134 in a first end and the second threaded portion in a second end of the rotating body 130. The distance between the extending end 122 and the body member 126 can be varied by rotating the rotating body 130 about the first and second threaded portions 132, 134. The rotating body 130 can be rotated by using a conventional tool such as a wrench, or can be rotated by hand.
FIG. 11B illustrates the extension assembly 128 in a fully compressed configuration. The extension assembly 128 compresses when the body 132 rotates by turning hexagonal portion 132 to draw the first threaded portion 134 and the second threaded portion 136 into the inner threaded portion of the body 130. FIG. 11C illustrates the extension assembly 128 in an expanded configuration after the body 130 is rotated in an opposite direction to rotate the first and second threaded portions 134, 136 out of the inner threaded portion of the body 130.
The adjustable purlin 120 can provide for a wide range of variable extension lengths, according to the suitable application of the purlin. In one embodiment, the adjustable purlin 120 can vary in length between approximately 0.5 and 5 inches, or more particularly between approximately 1 and 2 inches, or even more particularly between approximately 1 and 1.5 inches. For example, the rotating body can be lengthened to be capable to receive a longer threaded portion 134, 136, thereby allowing greater extension and compression of the extension assembly 128. In some embodiments, the adjustable purlin 120 can vary the extension length via multiple extension assemblies 128. In the assembled state, the adjustable purlins can maintain any given length established by the extension assembly 128 without changing length, or reciprocating between lengths anywhere from a fully extended and fully contracted position due to environmental loads on the portable structure 10. Thus, the adjustable purlin 120 is always in a fixed, or locked, configuration, regardless of the established length determined by the extension assembly 128.
With reference to FIG. 12, the bracing cable 140 for the portable tent structure 10 is shown. The bracing cable 140 includes a turnbuckle 142, a cable 144, an eyelet 146, and a clevis 146. The bracing cables 140 provide structural support to the vertically oriented beam assemblies 40 of the portable structure 10, and secure the beam assemblies 40 during construction of the portable structure 10. The bracing cable 140 couples to the facing surfaces of adjacent first and second beam assemblies in a zig-zag fashion as the cable extends back and forth from a first beam assembly to a second beam. The bracing cable 140 extends in the zig-zag manner from the lower portion of the first leg 90, up to the apex 50, and back down to the lower portion of the adjacent second leg 90.
With reference now to FIG. 13, a layout of the base members 20 is shown. The layout of the base members 20 can be determined prior to assembling the portable structure 10 based upon the number and configuration of the beam assemblies 40. One base member 20 is provided for each side of each beam assembly 40. In some embodiments, portable structures that exceed 20 feet in width can include a base member 20 provided at each end of the portable structure 10, halfway between the base members 20 of the end beam assemblies 40.
The location of one of the corner base members 20 preferably is determined first. A registration pin 36 (see FIGS. 2A-2L) is inserted into the ground to mark the desired location of the first comer base member 20. By measuring distances from the first registration pin 36, the locations of the base members 20 of a first side or first end of the portable structure 10 are established and also marked with registration pins 36. The spacing between the base members 20 determines the width of the individual bays, that are determined by the spaced width between adjacent beam assemblies and the width of the top panels 12. The locations of the remaining base members 20 are determined and marked with registration pins 36 by measuring from the registration pins 36 of the first side or end. In some embodiments, the spacing between base members along the length of the portable tent structure 10 can vary, e.g. narrower bays in the center and wider bays near the ends of the portable structure, vice versa, or the like, or any combination thereof.
After the locations of the base members 20 have been properly marked, the base members 20 are placed over the registration pins 36 so that the registration pins 36 extend through the registration holes 34 in the base plates 23, as illustrated in FIG. 14.
The base members 20 are secured to the ground to provide a rigid, fixed connection for the beam assemblies 40. The base members 20 can be secured to the ground with anchors, or stakes, 44 that extend into the ground through the openings 30 in the base plates 24, as illustrated in FIG. 15. The base members 20 can be secured to any form of underlying support, or ground, surface. The base members 20 can be secured to a support surface comprising dirt, asphalt, concrete, grass, vegetation, or the like. The type of stakes used can vary according to the particular type of underlying support surface, e.g. strength, shape, length, diameter, sharpness, or the like. For example, the stakes can comprise concrete anchors when assembled on a concrete support surface, or elongate stakes when assembled on a non-concrete support surface. As described above, the base member 20 can vary in surface area size. A high load environment and application can implement the larger surface diameter base member of FIGS. 21-2L, and be coupled to the ground surface by four or more stakes. The registration pins 36 can be removed after the base members 20 are securedly fixed in a suitable position for installation of the portable structure 10.
With reference to FIGS. 16 and 17, the beam assemblies 40 are shown. The beam assemblies 40 can be assembled in place, flat on the ground prior to erecting each beam assembly 40 to a vertical position. The various components of the beam assemblies 40 are laid out on the ground and arranged in relation to the base members 20 for assembly. For example, the components of each beam assembly 40 can be spaced apart between the corresponding base members 20 to which the beam assembly 40 will be attached. The arrangement shown in FIG. 16 is one embodiment, advantageous because it requires the least ground surface area. Generally, the beam assemblies are assembled by inserting the smaller diameter, or cross-section, portion of one component into the larger inner diameter, or inner cross-section, portion of the adjoining component. The two joined components are secured to one another by retractable buttons of the smaller cross-section insert portion extending through openings extending through the wall thickness of the larger inner diameter portion of the adjoining component.
The roof portion 42 is preferably assembled beginning at one of the eaves 60. The insert 62 of the eave 60 fits into a first end of the short beam 70. The assembly preferably is carried out by two persons. One person holds the eave 60 and retracts the retractable buttons 64 extending from the insert 62 while the other person slides the first end of the short beam 70 over the insert 62. As illustrated in FIG. 7, a pair of openings 72 are provided near the first end of the short beam 70. When the insert 62 of the eave 60 is fully inserted into the hollow interior diameter of the short beam 70, the buttons 64 are aligned with the openings 72 and engage the openings 72 to lock the short beam 70 to the eave 60.
The insert 74 of the short beam 70 fits into a first end of the long beam 80. The pair of openings 82 are provided in the first end of the long beam 80, as illustrated in FIG. 8. When the end of the long beam 80 is slid over the insert 74, the retractable buttons 76 are aligned with the openings 82 and engage the openings 82 to lock the long beam 80 to the short beam 70.
Referring again to FIG. 5, an insert 52 is also provided at each end of the apex 50. Each insert 52 includes the pair of retractable buttons 54 that extend from an outer surface of the insert 52. The insert 52 fits into a second end of the long beam 80. The pair of openings 84 are provided in the second end of the long beam 80, as illustrated in FIG. 8. When the second end of the long beam 80 is slid over the insert 52, the buttons 54 are aligned with the openings 84 and engage the openings 84 to lock the long beam 80 to the apex 50. In some embodiments, the arrangement of the short beam and long beam can vary, e.g. short beam connected to the apex 50 and the long beam connected to the eave 60, or the like.
The other side of the roof portion 42, extending from the opposite eave 60 to the apex 50, is assembled in a similar fashion. After the roof portion 42 is assembled the leg portions 44 are assembled to the roof portion 42 to complete assembly of the beam assembly 40. The leg 90 is connected to each of the eaves 60 by sliding the insert 92 of the upper end of the leg 90 into the lower end of the eave 60 so that the buttons 94 are aligned with the openings 66. The retractable buttons 94 engage the openings 66 to lock the leg 90 to the eave 60.
With reference to FIG. 19A, the base member 20, base insert 100, and lower end of leg 90 are shown. The base inserts 100 are connected to the lower end of the legs 90. The pair of openings 96 provided at a lower end of each of the legs 90 are configured to receive the retractable buttons 106 of the base insert 100. The insert portion 102 of the base insert 100 is slid into the lower end of the leg 90 so that the retractable buttons 106 of the base inserts 100 are aligned with the openings 94 and engage the openings 96 to lock the base inserts 100 to the legs 90.
The beam assemblies can be assembled in any number of sequences, beginning with any component, the apex 50, eave 60, short beam 70, long beam 80, leg 90, or the base insert 100. Of particular importance is assembling all of the components of the beam assembly 40 before erecting any portion of the beam assembly 40 into a vertical position. Additionally, all, or a portion of all, of the beam assemblies can be assembled and laid out on the support, or ground, surface prior to proceeding to erect any of the beam assemblies. In some embodiments, the beam assemblies 40 can be assembled and erected one at a time, rather than assembling a portion or all of the beam assemblies 40 at one time. Upon assembly of the beam assemblies 40, the connection between the beam assembly and the base inserts 20 can be completed and the beam assemblies 40 rotated to a vertical position.
After each of the beam assemblies 40 has been assembled, an assembly cable (not shown) can be attached in a widthwise direction between the eaves 60 of each beam assembly 40. The assembly cables help to hold the beam assemblies 40 together during construction of the portable structure 10, and can later be removed if desired. Each of the eaves 60 can includes a bracket (not shown) for attachment of an end of one of the assembly cables.
With reference to FIG. 18A and 20, an assembled beam assembly 40 with the extension end 122 of the adjustable purlins 120 attached is shown. Before the beam assemblies 40 are rotated into a vertical position, one end of the adjustable purlins that will couple the adjacent beam assemblies 40 together are attached to the first of the two beam assemblies being erected. In one embodiment, a plurality of adjustable purlins 120 are first attached by the extension end 122 to the several brackets 56 of the first beam assembly that are positioned at the apex 50, short beams 70, long beams 80, and the eaves 60 at a side of the first beam assembly 40 that is opposite the second beam assembly 40. Thus, the adjustable purlins 120 coupled to the first beam assembly 40 will subsequently couple to the second beam assembly 40 via drop-in end 124 upon the second beam assembly 40 being erected into the substantially vertical position. The adjustable purlins can be extended or contracted to any suitable length prior to erecting the beam assemblies. In some embodiments, the fully contracted adjustable purlin allows some slack in the fabric when the fabric is coupled to the beam assemblies.
With reference now to FIG. 19B, the beam assemblies 40, while still generally lying flat on the ground, desirably are positioned so that the pivot plates 104 of the base inserts 100 are located at the interior sides of the pivot plates 26 of the base members 20. The lower opening 110 in the pivot plate 104 of each base insert 100 is aligned with the opening 28 closest to the leg 90 in the pivot plate 26 of each base member 20. The beam assemblies are then connected to the base members 20 by passing a bolt 156 through a shackle, or clevis, 158 and the aligned openings 28, 110. This allows the beam assemblies 40 to be pivotally coupled to, and rotate relative to, the base members 20.
With reference to FIGS. 21 and 22, the method of erecting the first and second beam assemblies 40 of the tent structure 10 is shown. The first beam assembly 40 is rotated upwardly from the ground. Preferably the first beam assembly is lifted with a plurality of persons lifting at each side of the apex 50 and pulling on lifting ropes to raise the beam assembly, or pushing and controlling the beam assembly 40 via the remaining adjustable purlins 120. As the beam assembly is rotated upwardly, the pivot plates 104 of the base inserts 100 rotate on the base plates 22 of the base members 20. The rounded comers 122 of the pivot plates 104 facilitate rotation of the base inserts 100 on the base plates 22.
When the first beam assembly 40 is substantially vertical, the second openings 110 in the pivot plates 104 of the base inserts 100 are aligned with the second openings 28 in the pivot plates 26 of the base members 20. The supports 34 on the top surface 30 of the base plates 22 provide a support saddle that positions the pivot plates 104 of the beam assemblies. The supports 34 reduce interference in aligning the fastener elements to couple the pivot plate 104 to the base member 20. The supports 34 provide for a quicker installation and reduced alignment issues, allowing a second bolt 162 to readily pass through the two plates 104, 26. The first beam assembly 40 is then secured to the base members 20 by passing the second bolt 162 through a second shackle, or clevis, 160 and the aligned second openings 28, 110, as illustrated in FIG. 2. Fastening the second bolt and clevis through the opening 28,110 prevents further rotation of the beam assembly 40 with respect to the base members 20.
The second beam assembly 40 is raised in a similar fashion. An adjustable purlin 120 is first attached by the purlin extension end 122 before raising the second beam assembly to the several brackets 56 of the apex 50, short beams 70, long beams 80, and eaves 60 of the second beam assembly 40 at a side of the beam assembly 40 that is opposite the first beam assembly 40. The second beam assembly 40 is then rotated upwardly from the ground, pivoting about the base members 20, as illustrated in FIG. 21. Preferably the beam assembly is lifted with a plurality of persons lifting at each side of the apex 50 and pulling on lifting ropes to raise the beam assembly, or pushing and controlling the beam assembly 40 via the remaining adjustable purlins 120. The second beam assembly 40 is rotated upwardly about the base members 20 pivotally coupled to the base inserts 100 until the second beam assembly 40 is vertical.
With continued reference to FIG. 22, when the second beam assembly 40 is vertical, the second openings 110 in the pivot plates 104 of the base inserts 100 are aligned with the second openings 28 in the pivot plates 26 of the base members 20 with the alignment provided by the supports 34. The beam assembly is then secured to the base members 20 by passing the second bolt 162 through the second clevis 160 and the aligned second openings 28, 110.
The drop-in ends 124 of the adjustable purlins 120 are attached to the raised and vertical second beam assembly 40 by inserting the drop-in ends 124 into the plurality of brackets 56 at the apex 50 of the second beam assembly 40. A purlin lift tool 174 can be used to lift the adjustable purlin 120 into the bracket 56 at the apex 50 of the second beam assembly. The remaining adjustable purlin drop-in ends 124 are then connected to the plurality of brackets 56 located between adjacent corresponding short beams 70, long beams 80, and eaves 60 of the roof portions 42 of the first and second beam assemblies 40, as illustrated in FIG. 21. In some embodiments, either of the adjustable purlin ends 122, 124 can be attached to the first beam assembly 40 before being erected into the vertical position, then the opposing end of the purlin 120 can be connected to the second beam assembly after the second beam is erected into a vertical position.
With reference to FIGS. 22 and 23, a pair of bracing cables 140 is shown. The pair of bracing cables 140 preferably is next attached to the bracket 56 at the apex 50 of the roof portions 42 of each of the first and second beam assemblies 40, as illustrated in FIG. 22. The bracing cables 140 are next attached to the shackles, or devises, 158, 160 at the base members 20 coupled to the first and second beam assemblies 40. The bracing cables 140 are lightly tensioned by adjusting a turnbuckle 142 at an end of each bracing cable 140. Any vertical misalignment of the roof portions 42 can be corrected by adjusting the turnbuckles 142.
The next to last beam assembly 40 preferably is raised without first connecting an adjustable purlin 120 to the apex 50 thereof. The beam assembly 40 is rotated upwardly from the ground, preferably with one person lifting at each side of the apex 50. When the beam assembly 40 is vertical, the second openings 110 in the pivot plates 104 of the base inserts 100 are aligned with the second openings 28 in the pivot plates 26 of the base members 20. The beam assembly 40 is then secured to the base members 20 by passing the second bolt 162 through the second shackle, or clevis, 160 and the aligned second openings 28, 110. The drop-in end 124 of the adjustable purlin 120 is then connected to the bracket 56 at the apex 50 of the next to last beam assembly 40 using the purlin lift tool 174. The remaining adjustable purlins 120 are connected between adjacent short beams 70, long beams 80, and eaves 60 of the roof portions 42 of the two adjacent beam assemblies 40.
The last, or end, beam assembly 40 preferably is raised in the same direction as the other beam assemblies were raised. In some embodiments, the end beam assembly 40 can be raised in the opposite direction of the previous beam assemblies 40. An adjustable purlin 120 is first pivotally attached to the bracket 56 at the apex 50 of the end beam assembly 40 before raising the end beam assembly 40. The end beam assembly 40 is then rotated upwardly from the ground, preferably with one person lifting at each side of the apex 50 and one or more persons pushing and controlling the roof portion 42 with the remaining adjustable purlins 120. When the roof portion 42 is vertical, the second openings 110 in the pivot plates 104 of the base inserts 100 are aligned with the second openings 28 in the pivot plates 26 of the base members 20. The beam assembly 40 is then secured to the base members 20 by passing a bolt 162 of a second clevis 160 through the aligned second openings 28, 110. The drop-in end 124 of the adjustable purlin 120 is then connected to the bracket 56 at the apex 50 of the next to last beam assembly 40 using the purlin lift tool 174. The remaining six adjustable purlins 120 are connected between adjacent short beams 70, long beams 80, and eaves 60 of the roof portions 42 of the third and fourth beam assemblies 40.
With reference to FIGS. 24 and 28, the top panel 12 and the end panel 14, or fabric, are shown. With the beam assemblies 40 erected vertically and secured to the base members 20, the top panels 12 and the end panels 14 of the portable structure 10 are installed. The top panel 12 is generally rectangular in shape. The long end of the rectangular top panel 12 is substantially long enough to extend the full length of the beam assemblies 40, from one base insert 100, along a first leg portion 44, along the roof portion 42, and along a second leg portion 44 to the second base insert 100. Each of the panels 12, 14 of the portable structure 10, includes a keder 170 that extends along a perimeter thereof. The keders 170 preferably comprise cords that are sewn along the periphery of the panels 12, 14 and fit into the keder tracks 46, 48 to secure the panels 12, 14 to the beam assemblies 40.
The top panels 12 preferably are installed with the beam assemblies spaced apart a spaced distance that is less than the width of the top panel 12. To facilitate installation of the top panels 12, the adjustable purlins 120, which are adjustable in length, as described in detail above, can adjusted to a length that is smaller than the width of the top panel 12 if not previously adjusted to such length. During installation of the top panels 12, the reduced length of the adjustable purlins 120 decreases the distance between adjacent beam assemblies 40. An amount of slack is thereby created in the top panels 12. This serves to facilitate installation of the top panels 12 between the roof portions 42 of the beam assemblies 40.
With reference to FIGS. 25 and 26, the installation of the top panel 12 is shown. After the length of the purlins 120 are reduced, each of the top panels 12 preferably are laid out onto a drop cloth 172 and arranged for installation between adjacent beam assemblies 40, or roof portions 42 and leg portions 44 of the portable structure 10. The keders 170 of the top panel 12 are fed into the upper keder tracks 46 of the beam assemblies 40 starting at keder track flared portions 98 of the legs 90. The wider flared portions 98 (see FIG. 9) of the keder track 48 are provided at a lower portion of each of the legs 90 and at an upper portion of each of the eaves 60 for insertion of the keders 170. Thus, the fabric extending across the spaced distance between adjacent beam assemblies 40 and spanning all three sides of the structure can be a single piece of fabric. A single piece of fabric advantageously reduces the number of steps required to install the fabric material on all suitable sides of the portable structure 10. In some embodiments, the spaced distance can be covered by a plurality of fabric panels, e.g. a pair of leg portion panels and the roof portion panel. In some embodiments, the keders 170 are fed into the upper keder tracks 46 at the flared portions 68 of the eaves 60. The wider flared portions 68 (see FIG. 6) of the keder track 48 is provided at an upper portion of each of the eaves 60 for insertion of the keders 170.
While two people feed the keders 170 into the keder tracks 48 at one side of the portable structure 10, two other people pull the keders 170 through the keder tracks 48 from the other side of the portable structure 10 using ropes 178 attached to the top panel 12, as illustrated in FIGS. 25 and 26. The keders 170 of the top panel 12 preferably are pulled through the keder tracks 48 evenly with concerted 8 to 12 inch pulls on the ropes 178. The panels 12 can be inserted adjacent a lower portion of the legs 90. As such, the panel 12 is centered, the ends of the panel 12 are positioned adjacent the lower ends of the legs 90 at both ends of the first and second beam assemblies 40. In some embodiments, the panels 12 are inserted adjacent the eaves 60, where, accordingly, the panel 12 is centered, the ends of the panel 12 are then fed through the keder tracks 48 at the lower portions of the eaves 60 past the adjustable purlins 120.
Desirably, the radius of curvature of the eaves 60 and apexes 50 is great enough to allow the top panels 12 and end panels 14 to slide through the keder tracks 48 of the eaves 60 and apexes 50 with relative ease. Preferably, the radius of curvature of the eaves 60 and apexes 50 is at least approximately 2 feet.
The panel 12 installation is repeated for each of the portable structure 10 individual bays, or spaced distance, between adjacent beam assemblies 40. The adjustable purlins 120 remain in a shortened, or compressed length, configuration until all of the panels 12 are installed to the beam assemblies 40. The panels 12 can be tensioned by extended purlins to remove any slack that exists between the adjacent beam assemblies and establish a taut, and highly tensioned fabric panel that can withstand significant wind generated loads and generate minimal noise due to fabric flapping about in high winds. In some embodiments, for example, short term installation of the portable structures, the adjustable purlins are not extended to tension the fabric.
In the illustrated embodiment of FIG. 29, the installation of the end keder 14 is shown. The end panels 14 are installed in the end beam assemblies 40. Each end panel 14 preferably is laid out onto a drop cloth 172 to prevent soiling of the end panel 14, and arranged for installation at an end of one of end beam assemblies 40. The keder 170 of the end panel 14 is fed into one of the lower keder tracks 48 of the beam assembly 40 starting at one of the eaves 60. A wider flared portion of the keder track 48 is provided at an upper portion of the eave 60 for insertion of the keder 170. An attachment ring (not shown) desirably is provided at a curved eave portion of the end panel 14 for attachment of a rope 178. While a first person feeds the keder 170 into the keder track 48 at one side of the beam assembly 40, a second person pulls the keder 170 through the keder track 48 from the other side of the beam assembly 40 using the rope 178, as illustrated in FIG. 29. The end panel 14 is then centered and the ends of the panel 14 are fed through the keder tracks 48 at the lower portions of the eaves 60. In some embodiments, the end panel 14 can include a tension web 182 that can be coupled to webbing 176 to be pulled and tension the end panel 14, as shown in FIG. 28. In some embodiments, the end keder 14 can include an elongate tension member 182, or wire, that can be coupled to webbing 176 and be pulled to tension the end panel 14.
The fabric panels 12 can be tensioned after all, or a portion of, the panels 12 are installed onto adjacent beam assemblies 40. In some embodiments, particularly where the portable structure is only temporarily assembled for a short amount of time, the fabric panels are installed in a loose configuration, and the purlins 120 are not extended, or elongated, after the purlins 120 are installed on the portable structure 10. As will be appreciated by one of skill in the art, in some embodiments only a portion of the purlins 120 are extended. To tension the fabric to a taut surface, the adjustable purlins can be adjusted from the compressed, or fully compressed, position to an expanded length position as illustrated in FIG. 27. The expanded length increases the spaced distance between the adjoining beam assemblies 40 to which the purlins 120 are attached via the brackets 56 and the purlin ends 122, 124.
In the illustrated embodiment of FIG. 27, the sequence of extending the adjustable purlins 120 is shown. The sequence of extending the adjustable purlins 120 can provide a substantially vertical final position for the beam assemblies 40. The centermost bay section (I), or top panel 12, of the portable tent structure 10 is preferably tensioned first. The tensioning of the purlins 120 is shown schematically by the lengthwise directed arrows. The center purlin of the bay section, that couples to the adjacent apexes 50, can be tensioned first by rotating the rotating body 130 such that the threaded portions 134, 136 rotate out of the rotating body 130 (see FIG. 11). The rotating body 130 can be rotated by using a standard tool to grasp the hexagonal portion 132 of the body 130 or, in some embodiments, by hand pressure alone.
As the threaded portions 134, 136 exit the rotating body 130, the length of the adjustable purlin 120 increases. The increased length of the purlin 120 increases the spaced distance between the beam assemblies and tensions the top panel 12 that is fixedly attached to the adjacent beam assemblies via the keder 170 that is securedly encompassed by the keder tracks 46.
After the center purlin 120 is tensioned to remove the fabric panel 12 slack between the beam assemblies at the apex 50 region, the adjacent purlins are extended to tension the remaining portions of the center (I) fabric panel 12. The next adjacent purlins, moving outward toward the legs 90 from the apex 50 on both sides of the apex 50, are sequentially extended and tensioned in the same bay section of the center panel 12. Thus, the top panel 12 is tensioned from the widthwise center location of the beam assembly outward toward the legs 90. For example, after purlin 120 coupled to adjacent apexes 50 are tensioned, the purlins 120 that are coupled to the short beams 70 are tensioned. After the short beam 70 purlins 120 are tensioned, the purlins 120 that are coupled to the long beams 80 are tensioned. Finally, the purlins 120 that are coupled to the adjacent eaves 60 are tensioned. In some embodiments, the order of sequencing the purlins within each bay can vary, e.g. apex 50 first, eaves 60 second, or the like, or any combination thereof.
With continued reference to FIG. 27, the adjustable purlins 120 in adjacent bays can be extended after fabric installed in the center bay (I) is tensioned. In a similar sequential manner of elongating the adjustable purlins 120, the fabric is tensioned in adjacent bays (IIa) and (IIb) after the center bay (I) is tensioned. The tensioning sequence can incrementally move outwardly, away from the center (I) fabric 12, until the end bay sections (IVa) and (IVb) of the portable tent structure 10 are tensioned last. For example, the tensioning sequence can be bay (I), bays (IIa) and (IIb), bays (IIIa) and (IIIb), and then end bays (Iva) and (IVb). In this manner, the center beam assemblies can be positioned in the most vertical position relative to the support, or ground, surface. The adjacent beam assemblies 40 can be angled slightly outwardly, about the base members 20, toward the outer ends of the tent structure 10 in a cumulative manner. Thus, the end beam assemblies 40 can have the greatest angle directed away from the lengthwise center of the tent structure 10. The angle of each beam assembly is generally fixed after the attached adjustable purlins 120 are extended, as the portable structure 10 bay portions that have already been tensioned will generally not move under assorted environmental or assembly loads applied to the structure. As will be appreciated by one of skill in the art, in some embodiments the adjustable purlins 120 in one or more of the bays (I, IIa, IIb, etc.) are not extended or tensioned.
Any lighting, decorations, or other fixtures that are to be hung from the roof portions 42 of the portable structure 10 can be installed next. The lighting and decorations preferably are attached to the brackets 56 at the apexes 50, long beams 80, short beams 70, and eaves 60 of the roof portions 42.
Because the portable structure 10 of the illustrated embodiment is anchored to the ground at the base members 20 during construction thereof, the risk of damage to the portable structure 10 or injury to persons nearby during construction of the portable structure 10 is reduced. The tensioning of the top panels 12 and end panels 14 via the variable length adjustable purlins 120 improves the overall appearance of the portable structure 10 and reduces noise and frame stresses caused by the flapping of the panels 12, 14 in the wind.
The portable structure 10 is easily erected by unskilled workers with minimal specialized equipment. In addition, the tent structure 10 comprises a number of relatively small frame components that can easily be transported from site to site. For a 5,000 square foot portable structure of the illustrated embodiment, the disassembled shipping volume is approximately 480 cubic feet. In contrast, a typical 5,000 square foot fabric-covered structure would have a shipping volume of approximately 1280 cubic feet. The portable structure of the illustrated embodiment is thus well-suited for long-term installations in demanding environmental conditions.
Although the invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.

Claims

1. A method of erecting a portable structure, comprising:

securing a plurality of base members to a support surface;

assembling a plurality of beam members, wherein each of said beam members has a length and is configured to couple to a pair of said base members;

coupling said plurality of beam members to said plurality of base members;

erecting said plurality of beam members about said pairs of said base members;

coupling a plurality of transverse members between adjacent beam members, said transverse members establishing a plurality of spaced distances between said adjacent beam members;

coupling a fabric to a pair of adjacent beam members of said plurality of beam members, said fabric extending from substantially adjacent a first base member to substantially adjacent a second base member; and

deciding whether to elongate at least one of said plurality of transverse members between said adjacent beam members to increase the length of said at least one of said plurality of transverse members, wherein said increased length would facilitate tautly securing said fabric to said beam members.

2. The method of claim 1, further comprising elongating at least one of said plurality of transverse members between said adjacent beam members to increase the length of said at least one of said plurality of transverse members, wherein said increased length facilitates tautly securing said fabric to said beam members.

3. The method of claim 1, wherein said base members are substantially parallel to one another.

4. The method of claim 1, wherein said erecting said plurality of beam members comprising pivoting an upper portion of said beam assembly about said pair of base clamps.

5. The method of claim 1, wherein said securing said plurality of base members comprising coupling said base members to said support surface by inserting stakes through said base member into said support surface.

6. The method of claim 5, wherein said stakes comprising at least one of concrete anchors or elongate ground stakes.

7. The method of claim 1, wherein said support surface is the ground.

8. The method of claim 1, wherein said support surface is a concrete surface.

9. The method of claim 1, wherein said coupling said plurality of beam members comprising coupling a first end of said beam member to a first base member and a second end of said beam member to a second base member.

10. The method of claim 9, wherein said pair of base members comprising said first base member and said second base member.

11. The method of claim 1, wherein said beam members comprising a plurality of beam member portions, each beam member portion comprising at least one of displaceable protrusions and receiving apertures, to couple said beam member portions to one another.

12. The method of claim 1, wherein said coupling said fabric to said plurality of beam members comprising slidingly inserting said fabric through a plurality of apertures disposed along an outer surface of said beam members.

13. The method of claim 12, wherein said plurality of apertures comprise keder tracks.

14. The method of claim 1, wherein said beam members comprising a plurality of apertures configured to receive the fabric, said apertures disposed about the body of the beam member and extending longitudinally along the length of the beam members.

15. The method of claim 14, further comprising pulling fabric through the apertures along the length of said beam members.

16. The method of claim 1, wherein said plurality of beam members comprising a hollow body.

17. The method of claim 16, wherein said beam members comprising an aluminum body.

18. The method of claim 1, wherein said assembling said plurality of beam members further comprising coupling a plurality of discrete beam member portions to one another, wherein a first beam member portion having a first portion with displaceable protrusions being received by a second beam member, said second beam member having receiving apertures to receive said displaceable protrusions.

19. The method of claim 1, further comprising fixing keders to said fabric panels adjacent an outer periphery of said fabric panel.

20. The method of claim 1, wherein said coupling said beam members to said base members comprising securingly inserting an elongate member through a first aperture in a first portion of said beam assembly and a first aperture of said base member.

21. The method of claim 1, wherein said fabric comprising one of PVC coated canvas or PVC coated polyester.

22. The method of claim 1, wherein said elongating at least one of said plurality of transverse members includes rotating an adjustment portion of said at least one of said plurality of transverse members about a longitudinal axis of said at least one of said plurality of transverse members.

23. A method of erecting a portable structure, comprising:

securing a plurality of base members to a support surface;

coupling said plurality of beam members to said plurality of base members;

erecting said plurality of beam members about said pairs of said base members;

coupling a fabric to at least a pair of adjacent beam members of said plurality of beam members;

elongating at least one of said plurality of transverse members between said adjacent beam members to increase the length of said at least one of said plurality of transverse members, wherein said increased length facilitates tautly securing said fabric to said beam members; and

sequencing the elongating of said plurality of transverse members to begin at a spaced distance that is substantially centered between the plurality of spaced distances established between the plurality of adjacent beam members, wherein each subsequent elongating of said transverse members occurs at a spaced distance between beam members that is adjacent a spaced distance having elongated transverse members.

24. The method of claim 1, wherein said elongating at least one of said plurality of transverse members includes rotating an adjustment portion of said at least one of said plurality of transverse members about a longitudinal axis of said at least one of said plurality of transverse members.