BACKGROUND
Recreational Vehicle (RV) campgrounds and parks provide overnight parking accommodations for RV travelers. Some RV sites provide power connections, water connections, and wastewater connections for parked RVs. Some parks provide little more than parking sites, while others may offer a community swimming pool, recreation rooms, and other amenities.
Hotels and resorts provide travelers with private rooms, which can be substantially more spacious and luxurious than the typical RV, and often offer better amenities than an RV park, but often at substantially higher per-night costs. Hotels and resorts are often, but not always, located closer to towns, venues, and other attractions than RV parks.
SUMMARY OF ILLUSTRATIVE EMBODIMENTS
A modular transportable outdoor suite is disclosed that includes a primary room cartridge and a secondary room cartridge. In a shipping configuration, the secondary room cartridge is positioned substantially within the primary room cartridge, such that the suite can be loaded, shipped, unloaded, and positioned substantially as a single unit. Preferably, this single unit has a width and height suitable for over-the-road flatbed trailer and/or railroad transport (e.g., a maximum width of 10 feet and a maximum height of 11 feet is typical in the United States), and a length that allows multiple (preferably three) modules, along with their accessories, to ship together on a single trailer.
Once delivered to a site, the modular transportable outdoor suite is set in place and converted to a deployed configuration, where the secondary room cartridge is moved out of and positioned substantially adjacent the primary room cartridge. Preferably, a tertiary room cartridge deploys from an opposite end of the primary room cartridge from the secondary room cartridge, and can include a hinged floor and one or more hinged/detachable walls that are detached/swung out from the primary room cartridge during the setup process. Preferably, the secondary room cartridge is a fully enclosed space, and can be, e.g., configured as a bathroom. Preferably, the primary room cartridge is roofed, and can alternately be fully enclosed or have one or more open sides. In some embodiments, the tertiary room cartridge is an open-top patio space with one or more open sides.
Methods of deploying and stowing modular outdoor suites are also disclosed. In some embodiments, as-shipped modules are self-unloadable and self-positionable without use of a forklift, crane, etc. In some embodiments, a single worker or pair of workers can, without heavy equipment, deploy, and or stow for shipping, a modular outdoor suite. In some embodiments, the primary room cartridge and/or secondary room cartridge include retractable/variable squat undercarriage wheels that allow the module/cartridge to traverse ramps and/or uneven ground and then rest on solid supports with the wheels retracted. In some embodiments, one or more such wheels provide motorized module positioning. In other embodiments, similar wheel assemblies are accessories that temporarily attach to a module frame to assist in loading, unloading, and deployment, and can then be moved to another module for a similar operation.
In some embodiments, deploying the secondary room cartridge includes rolling or sliding the secondary room cartridge out of the primary room cartridge during deployment, and then shifting the secondary room cartridge downwards until the floors of the primary and secondary room cartridges are substantially aligned, e.g., at a door sill. In some embodiments, a utility box is positioned laterally under the free end of the secondary room cartridge, and provides connections to power, water, and/or wastewater mains that run between multiple such modular suites.
In some embodiments, the tertiary room cartridge comprises an outdoor patio space with a floor and two privacy walls, all of which are stowed flat against the primary room cartridge during transport. In some embodiments, deploying the tertiary room cartridge comprises detaching an end wall from its shipping position, extending a hinged back wall, extending a hinged patio floor, and attaching the end wall to the back wall and patio floor. In other embodiments, the end wall and back wall are hinged together.
The foregoing general description of the illustrative implementations and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure, and are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. The accompanying drawings have not necessarily been drawn to scale. Any values dimensions illustrated in the accompanying graphs and figures are for illustration purposes only and may or may not represent actual or preferred values or dimensions. Where applicable, some or all features may not be illustrated to assist in the description of underlying features. In the drawings:
FIG. 1 illustrates in plan view a typical parking lot configuration based on current parking code requirements for hotels;
FIGS. 2 and 3 illustrate in plan view the parking lot configuration of FIG. 1 after reconfiguration and deployment of modular outdoor suites according to two possible configurations;
FIG. 4 illustrates in plan view a detailed view of a recreational vehicle site in which a modular outdoor suite is deployed;
FIG. 5 shows a site map for a resort where peripheral parking lot rows have been converted to recreational vehicle sites with modular outdoor suites;
FIG. 6 illustrates in plan view a permanent reconfiguration of 24 parking spots into four recreational vehicle sites with modular outdoor suites;
FIGS. 7 and 8 illustrates in plan view detailed views of recreational vehicle sites in which a modular outdoor suite is deployed;
FIGS. 9A and 9B show, in plan view and right side elevation, respectively, a flatbed trailer shipping configuration for three modular outdoor suites according to an embodiment;
FIG. 10 depicts a trailer unloading operation according to an embodiment;
FIGS. 11 and 12 show elevation views of an embodiment after unloading and prior to set-up at a site location;
FIGS. 13A-D illustrate a retractable wheel assembly useable with embodiments;
FIGS. 14A and 14B show, respectively, a floor plan view and floor frame view of a primary cartridge according to an embodiment;
FIGS. 15A and 15B show, respectively, a floor plan view and floor frame view of a secondary cartridge configured as a full bathroom according to an embodiment;
FIGS. 16A and 16B show, respectively, a floor plan view and floor frame view of the tertiary cartridge, an outdoor patio space attached to the primary module according to an embodiment;
FIG. 17 illustrates a floor plan view of a modular outdoor suite as shipped according to an embodiment;
FIGS. 18-28 contain plan views illustrating steps in the setup of a modular outdoor suite according to an embodiment;
FIGS. 29-33, 34A and 34B, and 35-42 contain elevation views illustrating steps in the setup of a modular outdoor suite according to an embodiment;
FIGS. 43A-C and 44A-C show, for two respective exterior appearances, three-view site elevations after modular outdoor suite deployment;
FIGS. 45-48 illustrate, in floor plan view, additional exemplary as-deployed modular outdoor suite configurations;
FIGS. 49 and 50 show front elevation views, with and without an external wall cutaway, respectively, of an alternate configuration where the primary cartridge deploys as a fully enclosed space;
FIGS. 51A and 51B show left-side elevation views, with and without an external wall cutaway, respectively, of an alternate primary cartridge configuration where the primary cartridge deploys as a fully enclosed space;
FIGS. 52A and 52B show left-side elevation views, with and without an external wall cutaway, respectively, of another alternate primary cartridge configuration where the primary cartridge deploys as a fully enclosed space; and
FIGS. 53A-D show cutaway elevation views of an alternate module embodiment at several points of a setup process.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
The description set forth below in connection with the appended drawings is intended to be a description of various, illustrative embodiments of the disclosed subject matter. Specific features and functionalities are described in connection with each illustrative embodiment; however, it will be apparent to those skilled in the art that the disclosed embodiments may be practiced without each of those specific features and functionalities.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. Further, it is intended that embodiments of the disclosed subject matter cover modifications and variations thereof.
It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context expressly dictates otherwise. That is, unless expressly specified otherwise, as used herein the words “a,” “an,” “the,” and the like carry the meaning of “one or more.” Additionally, it is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer,” and the like that may be used herein merely describe points of reference and do not necessarily limit embodiments of the present disclosure to any particular orientation or configuration. Furthermore, terms such as “first,” “second,” “third,” etc., merely identify one of a number of portions, components, steps, operations, functions, and/or points of reference as disclosed herein, and likewise do not necessarily limit embodiments of the present disclosure to any particular configuration or orientation.
Furthermore, the terms “approximately,” “about,” “proximate,” “minor variation,” and similar terms generally refer to ranges that include the identified value within a margin of 20%, 10% or preferably 5% in certain embodiments, and any values therebetween.
All of the functionalities described in connection with one embodiment are intended to be applicable to the additional embodiments described below except where expressly stated or where the feature or function is incompatible with the additional embodiments. For example, where a given feature or function is expressly described in connection with one embodiment but not expressly mentioned in connection with an alternative embodiment, it should be understood that the inventors intend that that feature or function may be deployed, utilized or implemented in connection with the alternative embodiment unless the feature or function is incompatible with the alternative embodiment.
In the embodiments below, the term “outdoor suite” is used to describe various deployed configurations and embodiments. Each is a suite in that it includes multiple separately recognizable living spaces, e.g., an enclosed full bathroom, a covered outdoor dining space, and an uncovered patio space, in one embodiment. Each is outdoor in that it is deployed as part of an outdoor RV site, although one or more living spaces of the suite is typically enclosed and may be temperature/humidity controlled.
In preferred embodiments, any open walls of the deployed suite face the RV parking spot, and thus when an RV is parked adjacent to the suite privacy is substantially available even in the open-air entertaining areas of the suite. Most embodiments provide a completely enclosed private bathroom that is substantially larger and better-appointed than most RV bathrooms, and can even rival a hotel/resort suite bathroom for design, size, and functionality. Some embodiments provide a second fully enclosed space that can be equipped as a bedroom, living room, or office.
FIG. 1 shows a plan view of a portion of a typically dimensioned four-row parking lot 100, providing two two-way roadways 102 and 104, parking space rows 106, 108, 110, and 112, with a total of 24 parking spaces, and green space borders 114 and 116. Similar parking space configurations are found at many hotels and resorts. Many hotels and resorts contain many more parking spaces than they typically fill on a nightly basis.
FIG. 2 shows a plan view of a conversion of the 24-space parking section of FIG. 1 to a four RV-suite site 200 according to an embodiment. The roadways of FIG. 1 have been reconfigured as two one-way roadways 202 and 204 and pushed to the outer edges of the paved section of site 200. Four modular outdoor suites 206, 208, 210, and 212 have been deployed along a central spine of site 200, interleaved with RV parking spots 216, 218, 220, and 222. An additional transverse vehicle parking spot, e.g., 224, can be designated for each site, for convenient parking of a tow vehicle, towed vehicle, or visitor vehicle. Utility boxes 226 provide connections for power, potable water, and waste water between a central connection point (not shown, site dependent) and each outdoor suite.
FIG. 3 shows a plan view of an alternate conversion of the 24-space parking section of FIG. 1 to a four RV-suite site 300 according to another embodiment. The roadways of FIG. 1 have been reconfigured as a single two-way roadway 302 running along a central spine of the paved section of site 300. Four modular outdoor suites 306, 308, 310, and 312 have been deployed along the periphery of site 300, interleaved with RV parking spots 316, 318, 320, and 322. An additional transverse vehicle parking spot, e.g., 324, can be designated for each site, for convenient parking of a tow vehicle, towed vehicle, or visitor vehicle. Utility boxes 326, 328 provide connections for power, potable water, and waste water between a central connection point (not shown, site dependent) and each outdoor suite.
FIG. 4 shows a plan view of a single RV-suite site 400 and adjacent roadway 402, with typical dimensions for an outdoor suite 406, RV parking pad 408, and auto parking pad 410. It can be appreciated that the additional square footage provided by the outdoor suite rivals the existing square footage in a 36-foot motor home.
FIG. 5 shows a site map 500 for a resort offering a variety of amenities for guests. The parking lot 502 has been modified and/or purpose-designed to provide 30 outdoor suite RV sites, e.g., 506. Guests staying at these RV sites enjoy access to their motor home with an adjacent outdoor suite, and can also enjoy the same resort amenities offered to guests staying inside the hotel.
The FIG. 5 outdoor suite installation is intended as a permanent installation, and includes landscaping and permanent utility runs. As will be appreciated from the transportable nature of outdoor suite embodiments described herein, temporary parking lot conversions are also possible (including at or near stadiums, parks, and venues), e.g., during a high season or event, with the site disassembled afterwards and transported to another location for its event or high season.
FIG. 6 shows a prior art two-parking row section 600 with an adjacent roadway 602, and its subsequent conversion to a four outdoor-suite RV site 610. Converted site 610 illustrates that, even after conversion, car parking is still available at unused RV sites, e.g., for valet parking services, and can hold roughly two-thirds of the cars that could previously be accommodated prior to conversion.
FIG. 7 contains a site plan view 700 showing mixed usage and how one might transition from standard parking to outdoor-suite RV sites at a buffer zone 702. In some embodiments, with the passenger (or right) side of a parked RV intended to face the outdoor suite for a given RV site, RV hookups are actually provided on the rear right of the bathroom cartridge of the RV site to the driver (or left) side of the RV. Since the leftmost RV site has no bathroom cartridge to its left, a standalone hookup point 710 is provided and ties into the utility box run 712 that ties to the bathroom cartridges 714. An advantage of this configuration is that it provides an uncluttered pathway between an RV and its assigned module. In other embodiments, RV hookups for a given site are provided on the rear left of the bathroom module for the suite deployed at that site.
FIG. 8 shows an RV site 800 as shown in FIG. 7, but in larger detail. Other features that can be installed at each site include a gas grill 810 and a trash/recycling receptacle 812.
FIGS. 9A and 9B illustrate, in plan view and right elevation view, respectively, a shipping configuration embodiment 900 for three modular outdoor suites 910, 912, 914 (with shipping covers in place) on a standard 48-foot flatbed trailer 902. In a shipping configuration, each modular outdoor suite 910, 912, 914 according to this embodiment is 10 feet wide, 13 feet, 8 inches long, and 11 feet tall, with these dimensions selected to a) allow three modules to be transported together and b) meet height and width restrictions that, were the module size to exceed these, increase the difficulty and/or expense of shipping. Other embodiments, e.g., in other jurisdictions, may have different restrictions, which could be a factor in the selection of an alternate set of form factors for those jurisdictions. Note that, in addition to the stowed suites 910, 912, 914, the truck load also has room for utility runs 920 (three shown, but more could be accommodated), and furniture/accessory crates 930 to hold other pieces needed to complete the suite installation. Some accessories may also be shipped inside each module, or delivered by separate truckload.
In one preferred embodiment, a modular transportable outdoor suite is self-unloading and self-positioning, e.g., no separate crane or heavy forklift is required to unload modules and place them at an RV site. Such an embodiment and its site setup will now be described with respect to FIGS. 10-42. This embodiment deploys as three rooms, shipped as a) a primary cartridge, b) a secondary cartridge that nests within the primary cartridge for shipping, and c) walls and a floor for a tertiary cartridge, which are either hinged to or temporarily attached to the primary cartridge for shipping.
In this embodiment, the primary cartridge has underframe front and rear wheel sets that are independently retractable and squattable. One (or both) wheel sets can be fitted with drive motors, as will be described shortly. Retraction/squat and forward/rear drive can be controlled remotely, e.g., via a wired controller that plugs into the module, or a wireless controller (or app for a general-purpose device, e.g., a phone or tablet) that can pair with the module for unloading and positioning. During shipping, the wheel sets are retracted and the module rests on its frame.
FIG. 10 illustrates a module 1000 being unloaded from a flatbed trailer 1010 during delivery. After the module 1000 is unstrapped from the trailer 1010, front wheel set 1020 and rear wheel set 1030 are deployed to a minimum engaged setting (as shown in FIG. 10 for rear wheel set 1030). The module 1000 is driven off the rear of trailer 1010 onto unloading ramp 1050. As the module progresses onto the ramp 1050, the squat angle of the front wheel set 1020 is progressively adjusted to extend the front wheel set, allowing the module to clear the breakover point 1040 at the top of the ramp 1050 and maintain a nominal level configuration during unloading. As the module 1000 progresses off the ramp 1050, either front wheel set 1020 can be squatted, rear wheel set 1030 can be extended, or some combination of the two motions can be combined to transition to level ground.
FIG. 11 shows, in front and left-side elevations, cross-sections of a module embodiment 1100 in an unloaded and maneuverable configuration. Front wheel set 1110 comprises left front wheel assembly 1112 and right front wheel assembly 1114, shown in a fully deployed position. Rear wheel set 1116 comprises two similar wheel assemblies (occluded and not visible in the left-side elevation).
Module embodiment 1100 includes a primary cartridge that includes: a floor frame 1120 to which wheel sets 1110 and 1116 attach; a floor 1122; a front wall 1124; a rear wall 1126; and a roof 1128. The primary cartridge also includes secondary cartridge unloading ramps 1170 hinged to floor frame 1120 and folded against the right side of the primary cartridge.
Module embodiment 1100 also includes a secondary cartridge, shown in a shipping configuration, that includes: a floor frame 1130, with attached wheel sets 1132, 1133, and 1134; a floor 1136; a front wall 1138; a rear wall 1140; a right wall 1142; a left wall 1144; and a roof 1146. The secondary cartridge ships inside the primary cartridge, resting on primary cartridge floor 1122 (a protective surface can be placed on floor 1122 during shipping). As shown, with the wheel sets 1132, 1133, and 1134 fully retracted, the wheel sets are still weight bearing. In other configurations, fully retracting the wheel sets places some or all of the weight of the secondary cartridge on frame members, rubber bumpers, or temporary supports that will be removed at the installation site.
The secondary cartridge in this embodiment is outfitted at a factory as a full bathroom, with a shower 1150, a water closet 1152, a bathroom sink/sink cabinet 1154, a mirror 1156, and a bar/sink cabinet 1158, with appropriate fixtures and plumbing preinstalled (visible in other views to be discussed below).
Prior to deployment, module embodiment 1100 includes the following connected tertiary cartridge panels: a left exterior wall 1160 attached temporarily to the left side of the primary module; a back wall 1162 hinged to rear wall 1126 of the primary cartridge and folded flat against the left side of the primary module; and a floor 1164 hinged to the floor frame 1120 of the primary cartridge and folded flat against the left side of the primary module.
FIG. 12 shows, in front and left-side elevations, the same cross-sections of module embodiment 1100 as FIG. 11, but in a second unloaded and maneuverable configuration. As shown in FIG. 12, with the wheel sets 1110 and 1116 fully squatted, the wheel sets are still weight bearing and allow the module 1100 to be repositioned. During shipping, rubber or wooden bumpers or temporary supports can be placed between frame supports and the trailer floor such that with the wheels retracted the wheels are not weight bearing. Such bumpers/supports can be strapped or otherwise attached to the module 1100 for shipping prior to loading, such that the drive wheels are not used for factory loading (loading can be via forklift, overhead crane, or similar lifting machinery). Once at the installation site, wheel sets 1110 and 1116 may be raised slightly to allow removal of temporary supports such that the module 1100 can be driven off of the trailer.
FIGS. 13A-D show a wheel assembly 1300 according to an embodiment. FIGS. 13A and 13B each depict a side elevation of assembly 1300, with the assembly fully raised in FIG. 13A and fully retracted in FIG. 13B. FIG. 13C shows assembly 1300 in front elevation, and FIG. 13D shows assembly 1300 in plan view. Wheel assembly 1300 includes an axle 1302 attached transversely near an end of an articulating arm 1304, with wheels 1306, 1308 attached to each end of axle 1302. Optionally, bearings (not shown) may be placed either where axle 1302 and arm 1304 meet, or where axle 1302 attaches to each of wheels 1306, 1308.
Wheel assembly 1300 raises and retracts via operation of a screw motor 1310, screw 1312, and articulating arms 1304 and 1314. Articulating arms 1304 and 1314 each connect to a respective threaded traveler (not visible) that rides on screw 1312, and the bottom of arm 1314 is pivotally attached to arm 1304. Front and rear sections of screw 1312 are threaded in opposite directions such that engaging screw motor 1310 in one rotational direction pulls the tops of the articulating arms 1304, 1314 towards each other, raising wheels 1306, 1308 away from screw 1312, and engaging screw motor 1310 in the opposite rotational direction spreads the tops of articulating arms 1304, 1314 away from each other, lowering wheels 1306, 1308 towards screw 1312.
In this embodiment, wheel assembly 1300 further comprises a drive motor 1320, drive chain 1322, and sprocket 1324 to provide forward/backward powered motion and/or dynamic braking for a module. Sprocket 1324 mounts to axle 1302, and drive motor 1320 is disposed at a position that, based on the travel path of axle 1302, maintains a substantially constant distance from axle 1302 to allow drive chain 1322 to remain tensioned at a variety of wheel positions.
Different wheel features may be included in an embodiment to provide either more or less automation. At one end of the spectrum, each wheel assembly can have its own independently controllable drive motor and screw motor, and a controller coordinates the operation of all motors to maintain a level module position and cause the module to drive straight/turn as commanded by an operator. Independent drive motors may also be included at just two wheels (e.g., the front wheels) with the other two wheels unpowered. The screws at either/both the front and rear of a module can be commonly operated, such that front/rear module pitch can be controlled but roll cannot. Motors may be replaced with brakes, such that descent can be controlled but level movement or uphill movement requires manual or other power. Screw drives may be manually operated, or replaced with cables/ratchets, hydraulics, or other known mechanisms that can be used to raise and lower wheels. Chain/sprocket drive mechanisms may be substituted with pulley/belt drive or direct drive/direct geared mechanisms where a drive motor 1320 attaches to articulating arm 1304.
FIGS. 14A and 14B illustrate, in plan view, further details of a primary cartridge 1400. FIG. 14A illustrates a cartridge floor covered with a flooring material 1402 that has a natural stone appearance, but almost any flooring material that can be affixed to cartridge 1400 so as to survive transport and exposure to the elements could be selected, and placed over, e.g., a plywood, steel, or aluminum subfloor. Under the floor and subfloor, a steel frame 1404 supports wheel assemblies 1300, the subfloor, a solid rear wall 1410, and front wall columns 1420 and 1422. Frame extensions 1406, 1408 support tertiary cartridge components 1430, which will be explained in more detail below, during transport, and can also provide some support to the tertiary cartridge floor when deployed. Ramp attachment points 1440, 1442 will be used to aid in unloading a secondary cartridge from the primary cartridge.
FIGS. 15A and 15B illustrate, in plan view, further details of a secondary cartridge 1500. FIG. 15A illustrates a cartridge floor covered with a flooring material 1502 such as tile, but almost any flooring material that can be affixed to cartridge 1500 so as to survive transport could be selected, and placed over, e.g., a plywood, steel, or aluminum subfloor. Under the floor and subfloor, a steel frame 1504 supports six wheel assemblies 1300, the subfloor, a solid rear wall 1510, a solid front wall 1520, a solid right wall 1530, and a solid left wall 1540 with a door 1542.
Cartridge 1500 is appointed as a bathroom, and includes several factory-installed fixtures, including shower 1550, sink/cabinet 1552, water closet 1554, and sink/bar 1556. Note that sink/bar 1556 is located on the outside of cartridge 1500 and thus will be a part of the primary cartridge room after setup.
Cartridge 1500 includes mechanical features to support the outdoor suite and an RV parked at an adjoining site. A mechanical closet 1560 includes an electrical panel 1562 and a tankless water heater 1564. The mechanical closet 1560 is preferably lockable and accessible from outside of the secondary cartridge. On the outside of rear wall 1510 at the location of closet 1560, RV hookups for electricity 1566, potable water 1568, and wastewater 1570 are provided. Wastewater hookup 1570 also connects to underfloor drain pipes 1572 that serve the shower 1550, water closet 1554, and two sinks 1552, 1556 of the module. Potable water hookup 1568 likewise also connects to underfloor/in wall potable water pipes 1574 that serve the shower 1550, water closet 1554, and two sinks 1552, 1556 of the module. Electricity hookup 1566 comprises one or more standard RV power receptacles, and connects to one or more circuit breakers in electrical panel 1562. Electrical panel 1562 comprises additional circuit breakers connected to module wiring 1576 to power tankless water heater 1564, wheel assemblies 1300, a HVAC (Heating Ventilation and Air Conditioning) unit (not shown in these views, but mounted, for example, above the tankless hot water heater 1564), and lighting, receptacles, and other amenities (also not shown in these views). An underfloor multi-wire socket can be positioned for connection to a mating underfloor socket in the primary cartridge once the cartridges have been set in place, to provide electrical power to, e.g., lighting, fans, HVAC units, receptacles, and other amenities of the primary and tertiary cartridges.
FIGS. 16A and 16B illustrate, in plan view, further details of a tertiary cartridge 1600. FIG. 16A illustrates a cartridge floor covered with a flooring material 1402 that has a natural stone appearance (and can match the floor material of the primary cartridge), but almost any flooring material that can be affixed to cartridge 1600 so as to survive transport and exposure to the elements could be selected, and placed over, e.g., a plywood, steel, or aluminum subfloor. Under the floor and subfloor, a steel frame 1604 supports the floor and subfloor, and is connected via hinges 1610 to frame 1404 (FIG. 14) of primary cartridge 1400. A step 1620 transitions from a shipping position 1622 to an extended position 1624 at setup, as will be explained below with references to several other figures.
With reference to FIGS. 17-33, 34A and 34B, and 35-42, a method for setting up a modular transportable outdoor suite according to an embodiment will now be described. FIGS. 17 to 28 present the setup process from a top or plan view, and FIGS. 29-33, 34A and 34B, and 35-42 present the setup process from a frontside elevation view. Where plan and elevation view correspond, they will be described together.
FIG. 17, FIG. 29, and FIG. 30 show the process of setting the primary cartridge 1400 in its intended position. Hard points 1702 (FIG. 17) accept the top ends of screw jacks 2902 (FIG. 29) that will be used to support the primary cartridge at its deployed site. Nominally, the screw jacks 2902 are set to an intended floor frame-to-ground clearance such as 6 inches, while wheel assemblies 1300 continue to support the module in an elevated stance, e.g., 18 inches of floor frame-to-ground clearance. Once the screw jacks 2902 are attached and adjusted and the module is over its intended pad location, wheel assemblies 1300 are retracted until the module rests on the screw jacks 2902 (FIG. 30). If the pad is uneven or unlevel, fine adjustments to one or more of the screw jacks 2902 can then be made to level the primary cartridge 1400.
FIG. 18 and FIG. 31 show the tertiary cartridge end wall 1800 set aside in preparation for deploying the back wall and floor of the tertiary cartridge. End wall 1800 ships supported by frame extensions 1406, 1408 and attached to shipping mounts (not shown) on the primary cartridge and/or stowed tertiary cartridge back wall 2000, e.g., by shipping bolts. To prepare end wall 1800 for deployment, screw jacks 3102 (FIG. 31) are attached to hard points 1802 and set to a nominal wall frame-to-ground clearance such as 6 inches. The shipping bolts are removed and back wall 2000 is lifted and placed beyond the pad space 1810 that the tertiary cartridge floor will occupy. If desired, braces 1820 can be used to maintain end wall 1800 in a vertical orientation until it is time to attach the end wall to the module.
FIG. 19 and FIG. 32 show secondary cartridge unloading ramps 1902 and lift boards 1904 deployed and utility box 1906 set in place. The utility box 1906 is set such that it will rest under the end of secondary cartridge 1500 once cartridge 1500 is in final position. Wastewater connector 1910, potable water connector 1912, and electricity connector 1914 are prepared, if necessary after shipment, to receive mating connectors (not visible) under mechanical closet 1560.
FIGS. 20, 21 and 33 show the tertiary cartridge rear wall 2000 swung into position. Rear wall 2000 attaches via hinges 2010 to the rear wall of primary cartridge 1400. To prepare rear wall 2000 for deployment, screw jacks 3302 (FIG. 33) are attached to hard points 2002 (FIGS. 21 and 22) and set to a nominal wall frame-to-ground clearance such as 6 inches. One or more shipping bolts (not shown) may be used to secure rear wall 2000 against stowed floor 2200 during shipping. These are removed and rear wall 2000 is rotated 90 degrees until it is parallel and flush with the rear wall of primary cartridge 1400. Fine adjustments to screw jacks 3302 can be made to account for uneven or unlevel pad surfaces.
FIG. 22 and FIG. 34A show the tertiary cartridge floor 2200 dropped into position, and FIG. 34B shows deployment of a step 2210 that is hinged to the tertiary cartridge floor. To prepare floor 2200 for deployment, screw jacks 3402 are attached to hard points (not visible) along the folded top edge and left edge of floor 2200 and set to a nominal floor frame-to ground clearance such as 6 inches. Step 2210 is shipped folded under floor 2200. Before the floor 2200 is lowered, step 2210 is swung out to a deployed position 2220, and a screw jack 3442 is attached to each of two or more hard points 2212 on the underside of step 2210. Screw jacks 3442 will generally be smaller than screw jacks 3402, as the step-to-ground distance may only be a few inches.
Next, any shipping bolts that hold floor 2200 in a folded position for shipping are removed and floor 2200 is lowered into a horizontal position level with the floor of the primary cartridge 1400 (in this embodiment, but in other embodiments there could be a step down to floor 2200). Fine adjustments to screw jacks 3402 and 3442 can be made to account for uneven or unlevel pad surfaces. One or more optional fasteners may be used to secure rear wall 2000 to floor 2200.
FIG. 23 and FIG. 35 show the tertiary cartridge end wall 1800 attached to the modular suite. Hidden fasteners such as a tab and slot system may be used to fasten end wall 1800 by dropping tabs on end wall 1800 into complementary slots in the ends of rear wall 2000 and floor 2200. Fine adjustments to screw jacks 3102 can be made to account for uneven or unlevel pad surfaces.
Next, the secondary cartridge will be extracted from its shipping position in the primary cartridge 1400. Any temporary supports or ties that hold the secondary cartridge in place are removed, and if wheel assemblies 1300 are not in a rollable position, they are extended slightly to allow the secondary cartridge to roll.
FIG. 24 and FIG. 36 show the secondary cartridge 1500 as it is rolled out of the primary cartridge 1400 such that the front wheels 3610 have fully descended the ramps 1902 onto lift boards 1904, and the center wheels 3620 are also descending the ramps. As can be appreciated, as the secondary cartridge rolls out of the primary cartridge, front wheels 3610 are progressively extended to maintain a substantially level cartridge position, until the front wheels 3610 contact lift boards 1904.
FIG. 25 and FIG. 37 show the secondary cartridge 1500 extended far enough from the primary cartridge 1400 to allow the ramps 1902 to be dropped flat such that the center wheels 3620 can rest on the ground. At this point, screw jacks 3702 may be inserted at various hard points 3704 to prepare for lowering the secondary cartridge 1500 to its final position.
FIG. 38 shows the secondary cartridge 1500 extended just far enough from the primary cartridge 1400 to allow the rear wheels 3630 to reach the ground and rest on ramps 1902.
FIG. 26 and FIG. 39 show the secondary cartridge 1500 fully extended from the primary cartridge 1400 and ready to be dropped into final position. Additional screw jacks 3902 may be inserted at hard points 3904 along the inner wall of secondary cartridge 1500. At this point, utility connections 3910 to utility box 1906 can be made, e.g., with flexible cables and hoses, and final alignment can be checked.
FIG. 40 (and FIG. 26 again) show the final position of the secondary cartridge 1500. Wheels 3610, 3620, and 3630 are retracted to lower the secondary cartridge 1500 into this position. Screw jacks 3702 and 3902 can be finely adjusted to level the floors of the primary 1400 and secondary 1500 cartridges and account for uneven or unlevel pad conditions. One or more fasteners may be used to secure the secondary cartridge 1500 to the primary cartridge 1400, and electrical connection between the two cartridges can be made.
FIG. 27 and FIG. 41 show the set-up module 2700 with furniture in place and electricity turned on. In this configuration, a dining table 2710 and four chairs 2712 are arranged in the primary (dining) cartridge, under two pendant lights 2714, and four chairs 2720 are arranged around a fire pit 2722 in the tertiary (patio) cartridge, with a strand of hanging lights 2724 for lighting and decoration. A step 2730 from ground level midway up to the dining cartridge has also been installed.
FIG. 28 and FIG. 42 show the set-up module 2800 after installation of optional greenery elements to enhance the look of the module. The elements can be faux plants, real plants, or some combination of the two. In addition to being visually appealing, these can be designed to hide structural elements of the frame, screw jacks, etc.
FIGS. 43A-C show three elevations of a finished permanent module installation according to an embodiment, complete with planted trees and hedges and a gas grill. FIGS. 44A-C show three elevations of a finished permanent module installation according to another embodiment, illustrating that finish material and details can be varied to achieve different looks without changing mechanical aspects of the modules.
Similarly, optional furniture packages can be offered to appeal to different customer preferences. FIG. 45 shows a plan view of a module 4500 where the primary cartridge is configured as a living room with a couch 4510, chairs 4512, an end table 4514, coffee table 4516, and wet bar 4518, and the tertiary cartridge is configured with a hot tub 4520.
In still other configurations, the primary cartridge is designed to be fully enclosed. In FIG. 46, a module 4600 is shown in plan view with a fully enclosed primary cartridge configured as a bedroom, with a bed 4610, desk 4612, wardrobe 4614, and flat screen TV 4616. A door 4620 allows secure access into the primary cartridge from the tertiary cartridge, which is now configured as an outdoor living area with a couch 4630, chairs 4632, and fire pit 4634. In this configuration, the wet bar attached to the shared wall of the secondary cartridge has been removed. In its place, a split HVAC unit (not shown) can be attached higher on the wall to heat and cool the primary cartridge. The pendant lights shown can be replaced, e.g., with a ceiling fan in this configuration.
FIG. 47 illustrates in plan view a similar configuration for a module 4700, except with an enclosed primary cartridge configured as an indoor living room with a couch 4710, chair 4712, end tables 4714, and coffee table 4716. In one option, couch 4710 is a sleeper sofa.
FIG. 48 illustrates in plan view still another similar configuration for a module 4800, except with an enclosed primary cartridge configured as an indoor office with desk 4810, chairs 4812, and credenza 4814.
FIG. 49 shows a cross-sectional front elevation of a module 4900 with an enclosed primary cartridge. In this configuration, an HVAC split unit 4910 is installed on rear wall 4920 as part of the setup procedure, and a ceiling fan 4940 is hung on ceiling 4930. A partial upper side wall 4950 is installed against secondary module roof 4960, ceiling 4930, and rear wall 4920 to cover the gap between the two roofs.
FIG. 50 shows a front elevation of module 4900, illustrating the outer appearance and a window configuration according to an embodiment with a fully enclosed primary module.
FIGS. 51A and 51B show a left side elevation of module 4900, respectively in cross-section through the primary module and in exterior view. FIG. 51A shows the appearance of the wall 4980 shared between the primary and secondary modules, according to an embodiment, and FIG. 51B shows the window and door configuration of the left outer wall 4970 of module 4900, according to an embodiment.
FIG. 52A shows a left side cross-sectional elevation of a module such as module 4600, with no bar/sink. This view shows details of an HVAC split unit 4910, ceiling fan 4940, and partial upper side wall 4950. FIG. 52B shows a similar cross-sectional elevation, but for a module 5200 that has an enclosed primary cartridge with a bar/sink.
In some embodiments, the module may not be self-unloading and may require, e.g., a heavy forklift or crane to unload it from its shipping trailer and set it in place. FIGS. 53A, 53B, 53C, and 53D show setup detail elevations for a module 5300 that cannot move on its own. In FIG. 53A and FIG. 53B, screw jacks 5310 are installed under the primary module (e.g., with it temporarily supported by a lift) and set to a nominal height, and then module 5300 is set in place. Fine adjustments can be made to screw jacks 5310 to level module 5300.
FIG. 53C shows next steps in module 5300 setup. The tertiary cartridge floor and walls can be deployed as described in prior embodiments. For the secondary cartridge 5340, instead of ramps, the module ships with longer tracks 5330 that can be deployed and supported by a combination of screw jacks 5332 and the join lip 5334 of the primary cartridge. Secondary cartridge 5340 is rolled out onto tracks 5330.
FIG. 53D shows a final set for module 5300. In this embodiment, secondary cartridge 5340 remains supported by tracks 5330 (FIG. 53C), and the entire assembly is lowered until the secondary cartridge join lip 5342 (FIG. 53C) engages with join lip 5334. The primary and secondary cartridges may then be locked together.
In other embodiments, independent wheel assemblies may be provided to temporarily engage with a module for unloading and positioning. In one basic embodiment, a set of rear wheels are placed under frame extensions 1406, 1408 (FIG. 14B) to hold the rear of the module a minimal clearance from a trailer deck, and a set of motorized height-adjustable front wheels are engaged below the frame of the front of the module, elevated, and then used to drive the module off of the trailer (with appropriate height adjustments to navigate a ramp). Once the module is in place, it can be lowered onto screw jacks and the wheel assemblies are removed for use on another module.
Such a motorized height-adjustable wheel set can also be used to extract a secondary cartridge such as the embodiment of FIG. 53A/53B. In one embodiment, small platforms can be deployed to temporarily support the rear of the secondary cartridge, the secondary cartridge can be rolled partway out to allow the motorized wheel set to engage with the front end of the cartridge, and then the secondary cartridge is fully extracted, supported by the motorized wheel set in the front and the small platforms in the rear. The cartridge is then lowered onto screw jacks (note that the utility box would have to remain out of the way of the wheel set until it is disengaged).
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present disclosures. Indeed, the novel methods, apparatuses and systems described herein can be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods, apparatuses and systems described herein can be made without departing from the spirit of the present disclosures. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the present disclosures. As but one example, utility boxes can run underground and/or be routed such that a module can be sited at a pull-through RV site.
Patent Application
20250019960
