This invention concerns inflatable structures which are transformable from a collapsed condition for storage to an erect condition for use, and particularly, though not exclusively, for use as a play structure, such as a play house, tent or tunnel or similar for occupation by a child or adult, or by an animal, or such as a goal. However, the invention also concerns inflatable structures more generally.
Play structures, in particular, are often formed so that they can be transformed quickly from an erect condition for use, to a compact collapsed condition for storage. Many such structures include rigid support rods which must be assembled and dismantled, or are of the so-called pop-up kind and include cobble steel frame sections which when released from storage spring into an erect condition to support the structure, the steel sections being contained within sleeves to which are welded or stitched flexible webs of material forming the walls and roof of the structure.
An object of the present invention is to provide a structure which performs in a similar manner but which is transformed into its erect condition by inflation of one or more tubular sections forming a framework for the structure and to which are attached flexible webs to form, for example, walls and/or roof, and possibly also a base or groundsheet. Avoidance of the use of supports rods or steel frame sections results in the structure being lighter in weight and collapsible to a more compact form.
U.S. Pat. No. 4,068,418 discloses a tent transformable by inflation from a collapsed condition for storage to an erect condition for use, the tent comprising an inflatable tubular framework, which when inflated supports the structure in its erect condition, and a flexible wall structure attached to and extending between two or more regions of said inflatable framework. The inflatable tubular framework comprises a plurality of inflatable tubular elements, each of flexible, elastic, air-impermeable material and having a respective inflation valve, and each fitted inside a respective outer sheath of a material which is flexible but non-elastic. Each inflatable tubular element, when inflated, is a snug fit within its respective outer sheath and thereby restrained in outward expansion and prevented from rupturing. The inflatable tubular elements are formed by extrusion from thermoplastic material, such as PVC, and the outer sheaths are formed as separate curving sheaths which are separately cut to shape from woven material and stitched. Four such structural sections, each formed of an inflatable element inside its outer sheath provide four parabolic corner posts radiating out and down from a connector at a centre top location of the tent.
The present invention provides a structure transformable by inflation from a collapsed condition for storage to an erect condition for use, the structure comprising an inflatable tubular framework, which when inflated supports the structure in its erect condition, and at least one flexible web attached to and extending between two or more regions of said inflatable framework. The inflatable tubular framework comprises an outer sleeve arrangement of a material which is flexible but substantially non-elastic and at least one inner inflatable tubular element of flexible, elastic, air-impermeable material and having an inflation valve. The or each inner tubular element is accommodated within the outer sleeve arrangement and is restrained therein upon inflation. Compared to the prior art, the present invention is characterised in that the outer sleeve arrangement is configured to include at least one bifurcation and/or bend and the inner tubular element is formed by cutting and bonding of the air-impermeable material to provide a continuous inflatable compartment having a configuration including at least one bifurcation and/or at least one bend, matching the configuration of the outer sleeve arrangement, the at least one inner tubular element being inserted to fit within the outer sleeve arrangement and substantially fill the outer sleeve arrangement upon inflation.
The inner tubular element, or each inner tubular element where there is more than one, is restrained within the outer sleeve arrangement upon inflation because the maximum diameter of the outer sleeve arrangement is less than the maximally inflated diameter of the or each inner tubular element so that expansion of the or each element upon inflation is restricted to the maximum diameter of the substantially non-elastic material of the outer sleeve.
Use of an inner tube constrained within an outer sleeve to provide the inflatable tubular framework of the structure allows a relatively high internal pressure to be created in the inner tube as it is inflated as far as possible. This results in a particularly firm framework of greater rigidity than can be achieved using tubular sections which have a unitary outer skin, or where there is no pressure limiting outer sleeve. Additionally or alternatively, the tubular sections of the framework structure in accordance with the invention may be of smaller diameter (thinner) than previously required for supporting fabric structures of equal size. This means they contain less air and can feasibly be inflated by simple hand or foot pumps rather than requiring electric pumps or continuous delivery of air, as is the case with some currently known inflatable structures.
Compared to the tent structure disclosed in U.S. Pat. No. 4,068,418, the present invention allows for a much wider range of structure shapes to be produced, not limited to having individual inflatable sections of defined curvature and not limited to use of inflatable tubes produced by extrusion. Production and assembly of structures in accordance with the invention is particularly cost effective.
A characteristic of the structure in accordance with the invention is that it includes at least one inflatable tubular element which is of a branching shape and/or which includes at least one bend. As used in this specification the term “bifurcated” refers to a forked or branched configuration and the term “bend” refers to an abrupt angular change in direction, as distinct from gradual curvature known in the prior art extruded inflatable sections.
Practical embodiments of the structure according to the invention, such as playhouse structures, typically include two inner inflatable tubular elements, each having a branching configuration which may also include at least one abrupt angular bend, and each providing a respective continuous inflatable compartment, inflated by a separate inflation valve. These two tubular elements provide a split inner framework. Together they match the overall configuration of the outer sleeve arrangement and they are fitted within respective parts of the outer sleeve arrangement, so as to have closed ends of each of the two elements confronting each other or other locations on the same or the other element. Thus, together these inner tubular elements, upon inflation, substantially fill the outer sleeve arrangement. Small gaps may remain at locations between confronting ends of the respective inflatable compartments or between a closed end confronting a different part of the same or the other tubular compartment. However, it is preferable that upon inflation these closed ends of the branching or bent configuration of each inflatable element touch against the part of the same or other compartment which they confront. Such contact enhances the structural stability of the inflated framework.
The concept of the invention can be applied more widely to many other structures and many structural shapes. Some embodiments within the scope of the invention may include only a single inner inflatable tubular element, thus a single inflatable compartment, of appropriate branching and/or bent configuration. Some embodiments may include one inner inflatable tubular element of branching and/or bent configuration and one or several other inner inflatable tubular elements which are merely individual straight or curving (that is to say not branching or abruptly bending) inflatable compartments. Yet other embodiments may include any number of branching or abruptly bending inner tubular elements, each a separate inflatable compartment, and any number of individual straight or curving inflatable elements/compartments. The complexity and cost of manufacture is the only limit and the design possibilities are endless. Thus, the concept of providing structures with inflatable frameworks in accordance with the present invention may be applied not only to various playhouses, tents, tunnels, shelters, goals, but also to decorative structures, such as for domestic use, for example to support storage pockets, or purely for decoration within bedrooms and other living areas, and also to items of furniture.
In order that the inflatable framework in accordance with the invention provides sufficient rigidity and stability to the structure it is important in respect of many embodiments that the outer sleeve arrangement is configured to include at least one continuous loop portion. Thus, where the flexible web extending between regions of the inflatable framework provides walls of the structure it is a feature of many embodiments that the outer sleeve arrangement is configured to surround at least one wall of the structure. Since the inner tubular element or elements fit within the outer sleeve arrangement to substantially fill it upon inflation, respective inflatable frame sections of the or each inner tube, constrained within the outer sleeve arrangement, also surround the wall to provide a substantially encircling frame or loop. However, these inner tubular elements do not provide a completely closed loop in the sense of a continuous loop inflated compartment. One, or more typically two, inner tubular elements are provided in characteristic branching or bending configuration, as already described, to substantially fill the outer sleeve arrangement, and the closed ends of the element or the respective tubular elements confront each other or confront other locations on the same or the other tubular element or elements. Accordingly, although a closed loop is provided in terms of structure, the internal inflated compartment this discontinuous because of the presence of the closed ends. In the typical case, mentioned above, where two inner tubular elements are provided, respective sections of each of the two tubular elements typically provide respective sides of the loop or frame such that the loop or frame is formed from parts of two separate inflatable compartments. However, in other embodiments, such a loop or frame, which surrounds a wall region, may be provided by sections of just a single inner tube, or by sections of more than two inner tubes.
As used in this specification the term “section” or “frame section” is defined as any straight or curving portion of any inner tubular element. An inner tubular element provides a continuous inflatable compartment. Thus an element which is bifurcated or bent at an angle will consist of several frame sections, each portion of the compartment between next closest bends or bifurcations being designated a frame section.
A typical wall of an inflatable structure in accordance with the invention is rectangular and may be supported by inflatable frame sections extending in the manner of an approximation to a closed loop or frame on all four sides, as just described. However, structures where walls have three sides maybe envisaged, and these may be supported by inflatable sections extending around all three sides in an approximation to a closed triangular loop shape. Yet other wall configurations may be envisaged where one or more sides of the wall are curved, but the same principle applies that a surrounding framework of inflatable sections (whether provided as parts of one, two or more inner tubes) is preferable. Such surrounding frames or loops of inflatable sections are desirable for more than one wall of any structure. For example, for a soccer goal structure the respective ends are preferably each surrounded by inflatable sections in a triangular loop shape. For more complex structures, such as playhouses of various forms, it is desirable that several walls are surrounded by inflatable sections to provide structural rigidity.
Provision of inflatable inner tubular elements as completely closed loops, i.e. continuously connected frame sections, is not feasible as this would necessitate, during production, the formation of the outer sleeve arrangement around the inflatable closed loop. This cannot be done with sufficient reliability either by stitching or by bonding. In particular, stitching risks puncture of the inner tube and bonding is insufficiently consistent, given the requirement reliably to restrain inflation of the inner tubular element, and also places constraint on the material of the outer structure, which needs to be cost-effective.
Therefore, the invention is most typically put into practice using an outer cover which is sewn together and includes the outer sleeve arrangement and webs extending there between to provide walls. The inflatable part of the framework is split into two or more parts, each being an inner tubular element of branching and/or angularly bent form, and the respective inflatable compartments provided by these tubular elements is fed through respective parts of the outer sleeve arrangement to substantially fill it, including by closed ends confronting each other or other regions of the same or other compartment within looped, wall-surrounding areas of the framework. The outer sleeve arrangement incorporates openings as access points at various positions to allow the feeding through of the respective inner tube elements.
In some structures in accordance with the invention an inflated horizontal portion of the framework, for example a portion over 5 feet (1.52 metres) in length as in the crossbar of a soccer goal structure, is required to remain substantially straight over an unsupported length. In order to counteract tendency for downward deflection, most prominent at the centre of such an unsupported length, the outer sleeve arrangement for that part of the structure can be cut and stitched to have an upwardly orientated camber.
Embodiments of the invention will now be described, by way of example only, with reference to the accompany drawings, in which:
Referring firstly to
The inner tube 41 is of thermoplastic material, and may suitably be formed of PVC. It is produced by cutting and welding from sheet material to the required shape of the inflatable framework of the relevant final structure being produced, or to respective parts of the said framework. The welded joints are not shown in
The outer sleeve 42 is of a woven or non-woven fabric. Suitable material is polyester or nylon. As illustrated in
When the inner tube 41 is inflated it reaches the size where its inflation is restricted by the substantially fixed diameter of the outer sleeve 42. Introduction of further air causes the inner tube 41 to have increased internal pressure, thus creating a particularly firm and stable support framework for the structure. Compared to tubular sections of laminated form, tubular sections of such structure may be thinner yet provide same support strength, thus using less material and collapsing down in a deflated condition into a smaller package. Also, because the inner tube 41 has excess fabric compared to the outer sleeve 42 when said inner tube 41 is maximally inflated, the risk of punctures to the overall tubular section is reduced. Any sharp edge or object impinging upon the outer sleeve 42 will tend to cause the fabric of the inner tube 41 to move away, rather than offering resistance and potentially being punctured as might be the case if it was inflated to a tight condition.
The overall advantage of such a structure is that by avoiding the need for solid sections such as steel rods, fibreglass rods etc to provide rigidity for the framework, the completed product may be packed to a much smaller size and of considerably reduced weight thus reducing transportation and display costs. The overall reduction in mass and size of the structure when collapsed is of advantage when used for camping or travelling.
In manufacturing structures in accordance with the invention, such as those shown in
It is a feature of the present invention that the inflatable framework, consisting of the outer sleeve arrangement and the inner tube or tubes positioned therein is of branching configuration or includes abrupt bends in configuration, or both. This is most conveniently achieved by providing two inflatable inner tubes, thus two separate inflatable compartments. These two tubes, each itself being of branching configuration and/or incorporating abrupt bends in configuration, are then inserted into a branching outer sleeve arrangement so that ends of these branching inner tubes approach each other or approach other locations on the same or other tube. Together they substantially fill the outer sleeve. Essentially, however, there is a split in the inflatable inner framework. Upon inflation of the two tubes, via respective inflation valves for each, the ends of the tubes will typically contact the confronting ends or other locations, although a slight gap may sometimes remain.
Reference is now made to the three exemplary embodiments of
The playhouse shown in
As already explained, in a deflated initial condition, during manufacture of the structure, the respective tubes A and B are inserted and fed through the outer sleeve/tunnel arrangement which has been formed on the fabric body. The pathways of the respective sections of the two tubes A and B are illustrated most clearly in
Each inner tube A and B includes sections which surround, as a frame, all sides of a particular wall region of the fabric body, as at each end of the roof of the playhouse and at the end wall opposite to the door 11 (reference
More specifically:
Closed end c of the inner tube A confronts a location of same tube A.
Closed ends d of respective sections of the inner tube B confront locations of same tube B.
Closed ends e of inner tube A confront respective locations on the other tube B.
Closed ends f of inner tube B confront respective locations on the other tube A.
The goal shown in
The tube A′, in the section providing the crossbar, between branch locations g, is required to remain substantially horizontal when inflated in use. To achieve this over such an unsupported length, which may be over 5 feet (1.52 m), the initial outer sheath as cut and stitched is provided with an upward orientated camber to counteract the tendency for downward deflection, particularly at the centre, in the final inflated structure.
The play castle shown in
Separately inflatable structural parts 28 are shown which may be separately affixed to the structure.
In relation to each of these three illustrated embodiments, the framework 10, 18, 20, once inflated, becomes rigid and thus supports the structure in an upright and erect condition. However, when the framework is deflated the entire structure can be folded and reduced to a very compact form for storage, ideally within a drawstring bag or tote bag with handles or the like. Because of the overall configurations of the inflated tubes (A, B, A′, B′, A″, B″) in these structures, and their restraint within respective outer sleeve arrangements, to substantially fill the latter, relatively low air pressures, for example of the order of between 0.2 and 0.5 bar (2.9 to 7.25 psi) have been found sufficient to maintain these structures in erect condition for many days. Moreover, such low pressures minimise the amount of time and energy required for inflation and avoids requirement for electric pumps or other complex requirements.
It is emphasised that the foregoing embodiments are only examples of the very many different structural configurations which are possible within the scope of the present invention.
Number | Date | Country | Kind |
---|---|---|---|
0909969.8 | Jun 2009 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/GB10/50970 | 6/9/2010 | WO | 00 | 10/28/2011 |