RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 63/362,281, filed on March 31, 2022. The entire teachings of the above application are incorporated herein by reference.

GOVERNMENT SUPPORT

[0002] This invention was made with government support under Grant Number W91 1QY-19-9-0011 from the U.S. Army Combat Capabilities Development Command Soldier Center. The government has certain rights in the invention.

SUMMARY

[0003] The present disclosure can include a shelter having a support frame. A flexible exterior shelter layer can cover the support frame. The exterior shelter layer can form exterior shelter layer roof and sidewall portions of the shelter. A flexible waterproof floor can be included and have a floor bottom portion and a floor sidewall portion. The floor sidewall portion can extend upwardly above the floor bottom portion. The floor sidewall portion can be removably securable to the exterior shelter layer sidewall portion above the floor bottom portion.

[0004] In particular embodiments, the floor sidewall portion can be removably securable to the exterior shelter layer sidewall portion with a zipper joint that is about 6 inches above the floor bottom portion. A flexible inner shelter layer can extend adjacent to the exterior shelter layer at the exterior shelter layer roof and sidewall portions and can also laterally extend inwardly over and cover the floor bottom portion at perimeter regions of the floor bottom portion in a generally ring-shaped manner. The inner shelter layer can cover the floor bottom portion about 18 inches from outer edges of the floor bottom portion. The inner shelter layer can be secured to the floor bottom portion with hook and loop fastener. The inner shelter layer can further include at least one of EMI shielding, insulation, light reflecting, anti-microbial and infrared reflecting properties, and can include at least one layer. The support frame can include at least two inflatable arch beams connected together by an inflatable ridge beam. Some embodiments can include four inflatable arch beams. The exterior shelter layer can be removably securable to the support frame by releasable support frame straps that extend around the beams at spaced apart locations. The support frame straps can include releasable secondary attachment features for removably securing the inner shelter layer in a spaced relationship relative to the exterior shelter layer. Spacers can attach the exterior shelter layer to the inner shelter layer to maintain about a 1 inch gap between the exterior shelter layer and the inner shelter layer. In some embodiments, the shelter can be a first shelter. The first shelter can include a first complexing member located on at least one end of the first shelter for mating with a second complexing member located on at least one end of a second shelter for joining the first and second shelters together. The first and second complexing members can be configured to form a rain gutter for directing water between the first and second shelters to the ground. In some embodiments, complexing members can be included on opposite ends of each shelter.

[0005] The present disclosure can also include a method of forming a shelter including providing a support frame and covering the support frame with a flexible exterior shelter layer to form exterior shelter layer roof and sidewall portions of the shelter. A flexible waterproof floor can be removably secured to the exterior shelter layer sidewall portion of the shelter. The floor can have a floor bottom portion and a floor sidewall portion. The floor sidewall portion can extend upwardly above the floor bottom portion. The floor sidewall portion can be removably securable to the exterior shelter layer sidewall portion above the floor bottom portion.

[0006] In particular embodiments, the floor sidewall portion can be removably secured to the exterior shelter layer sidewall portion with a zipper joint that is about 6 inches above the floor bottom portion. A flexible inner shelter layer can be provided. The inner shelter layer can extend adjacent to the exterior shelter layer at the exterior shelter layer roof and sidewall portions, and also can laterally extend inwardly over and cover the floor bottom portion at perimeter regions of the floor bottom portion in a generally ring-shaped manner. The exterior shelter layer can cover the floor bottom portion about 18 inches from outer edges of the floor bottom portion. The inner shelter layer can be secured to the floor bottom portion with hook and loop fastener. The inner shelter layer can be provided with at least one of EMI shielding, insulation, light reflecting, anti-microbial and infrared reflecting properties, and can include at least one layer. The support frame can include at least two inflatable arch beams connected together by an inflatable ridge beam. The exterior shelter layer can be removably secured to the support frame with releasable support frame straps that can extend around the beams at spaced apart locations. The inner shelter layer can be removably secured in a spaced relationship relative to the exterior shelter layer with releasable secondary attachment features on the support frame straps. About a 1 inch gap can be maintained between the exterior shelter layer and the inner shelter layer with spacers that attach the exterior shelter layer to the inner shelter layer. The shelter can be a first shelter and include a first complexing member located on at least one end of the first shelter for mating with a second complexing member located on at least one end of a second shelter for joining the first and second shelters together. The first and second complexing members can be configured to form a rain gutter for directing water between the first and second shelters to the ground.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing will be apparent from the following more particular description of example embodiments, as illustrated in the accompanying drawings. The drawings being filed herewith is not necessarily to scale, emphasis instead being placed upon illustrating embodiments.

[0008] FIG. l is a perspective schematic view of an embodiment of a tent, soft wall shelter or shelter system in the present disclosure.

[0009] FIG. 2 is a perspective view of another embodiment of a tent, soft wall shelter or shelter system in the present disclosure.

[0010] FIG. 3 is a top schematic view thereof.

[0011] FIG. 4 is a floor plan thereof.

[0012] FIG. 5 is a side view thereof.

[0013] FIG. 6 is a side sectional view thereof.

[0014] FIG. 7A is an end sectional view thereof.

[0015] FIGs. 7B-7D show enlarged detail portions of FIG. 7A.

[0016] FIG. 8A is a schematic drawing of the attachment of the inner and exterior shelter layers to a beam.

[0017] FIG. 8B is a cross sectional drawing of another embodiment of attaching the inner and exterior shelter layers to a beam.

[0018] FIGS. 9 A and 9B are end views of opposite ends thereof.

[0019] FIG. 9C is a schematic drawing of a portion of 2 tents or shelters connected together.

[0020] FIG. 9D is a schematic drawing of another embodiment of 2 tents connected together. [0021] FIG 10 is a perspective view of an embodiment of an inflatable air beam support frame structure or skeleton.

[0022] FIG 11 is a top view thereof.

[0023] FIG 12 is a side view thereof.

[0024] FIG 13 is an end view thereof.

DETAILED DESCRIPTION

[0025] A description of example embodiments follows.

[0026] An example embodiment of a soft wall expeditionary shelter system 10 for the US Army is shown in FIG 1. The example embodiment includes a support frame structure or skeleton 15 in the form of a series of air beams 12 in the shape of a faceted arch that span 10’- 0” laterally, and the air beam arches are spaced 7’-0” on center from each other creating repeated structural bays. The air beam arches 12 are so aligned to create an extruded form in the shape of the arches. Specialized multi-layered, multi-performative shelter fabric 14 spans from air beam arch 12 to air beam arch 12 creating the shelter enclosure specifically designed for military uses. The example embodiment includes a secondary structure of a collapsible fiberglass rod X-bracing system 16 between each of the air beam arches 12 to provide additional structural stability and to keep the fabric tight.

[0027] 1. Air-Beam Arches:

The air beams 12 can be in the shape of a faceted arch that span 10 feet laterally. The air beams can be 8” in cross-sectional diameter, have two vertical legs of the arch that are 7’ -6” tall and slope inward toward the center of the shelter l’-0” from the bottom to the top of the legs, and each arch has a center-spanning air beam connecting to the top of the two legs and spanning 8’-0” and with a peaked high point at the center of the span that is 8’-6” above the floor.

[0028] The air beam includes an internal polyurethane air bladder and an outer protective fabric sleeve layer. The sleeves can include a zipper or Velcro® hook and loop fastener seam to replace the bladders. The air beams can be inflated manually or with an air compressor through an integrated air valve 18. The air beam bladders can be inflated to about 3-5 psi with a light tactical vehicle compressor. The air pumped into the air beam arches creates a pressure that automatically raises the walls and roof of the shelter into their occupiable shape. The air valves can be opened to release the air for taking down and folding up the shelter for storage. Each air beam arch can be connected to the other air beam arches by a U” diameter air tube 20 with a valve to pinch off or open up the possible passage of air. The air beam arches resist gravitational snow loads and lateral forces that are parallel to the span of the arch. The valves on the air beams allow rapid inflation and deflation.

[0029] 2. Fabric Shelter Enclosure:

In the example embodiment, there may be two types of fabric for the soft wall expeditionary shelter enclosure system: one type for the floor, and the other type for the rest of the shelter enclosure. In this embodiment, the floor 22 is a very durable waterproof fabric, and this fabric has a sidewall portion 22b that extends up to connect to the vertical walls of the shelter 6” above the floor 22 to create a “bathtub effect” to keep out water. The floor fabric can be polyurethane coated for durability and include embedded aerogel for thermal performance and insulation. There can be a zipper joint 46 and a waterproof protective flap of fabric at this 6” above-the-floor datum to connect the floor 22 to the rest of the shelter enclosure above. This allows the floor fabric to be removed and replaced if it becomes too damaged from wear and tear. The floor can be staked to the ground with stakes 24, through loops or openings 24a extending from floor 22.

[0030] In one example embodiment, the fabric 14 for the shelter enclosure can include three primary layers. The outer layer is waterproof with waterproof seams, has anti-microbial capabilities, and is camouflaged in appearance. The middle layer has complete electromagnetic interference (EMI) shielding capabilities and has a high thermal resistance due to an integrated layer of flexible aerogel. The inner layer has anti-microbial and infrared light energy reflective capabilities and is light in color to best reflect the interior lighting. The shelter can be 15 ft long by 10 ft wide, having 150 ft ² of of floor fabric, 330 ft ² of wall/roof fabric and 144 ft ² of end wall fabric, including fabric doors. This can result in a total of 624 ft ² or 69.2 sq yrds of fabric.

[0031] There can be several 12” x 12” integrated waterproof of EMI shielding flaps 26 to allow service lines to penetrate the shelter enclosure and still maintain EMI shielding with a fixed seam at the top and a hook-and-loop style or other coupling element at the two sides and bottom edges to secure the flaps 26 to the exterior of the shelter enclosure. There can be D- shaped zippered door fabric panels 28 at each end of the extruded shelter form, each with two zippers that travel in opposite directions when unzipping to open the fabric door panels. The door zippers also have waterproof and EMI shielding protective flaps. The door panels can provide about 6’6” tall and up to 3’6” wide openings.

[0032] 3. Collapsible Fiberglass Rod X-Bracing System:

The example embodiment may include a collapsible fiberglass rod X-bracing system 16 that extends between each air-beam arch leg and between the central spanning beam, thus there are three X-braces per structural bay. This system resists lateral forces against racking and gravitational snow loads at the roof. At the intersection of the X, there may be a flexible rubberized rod connector that can fold to reduce the length of the X bracing in half when the shelter is taken down for storage. Also, the ends of each X-brace are connected to the adjacent X brace by a flexible rubberized rod connector creating a continuous network of X-braces the full length of the shelter.

[0033] The fiberglass rod X-bracing system may be slipped into fabric sleeves that are sewn integrally to the shelter enclosure fabric so the fiberglass rods and hinges stay in place. Once the air is pumped into the air beam arches and automatically raises the walls and roof of the shelter into their occupiable shape, the collapsible fiberglass rod hinges can be manually pushed outward to create tension within the rods and the shelter enclosure fabric to make tight the shelter enclosure fabric. To take down the shelter, the collapsible fiberglass rod hinges can be manually pushed inward to fold the X-braces in half to minimize the length of the shelter when it is folded up for storage. A collapsible skeleton for a 4 ft long packed length can be provided.

[0034] Example Features

[0035] 1. An example feature of this soft wall expeditionary shelter system is its unique combination of integrated structural and shelter enclosure technologies, including the air beam arches, multi layered shelter enclosure, and fiberglass rod X-bracing systems.

[0036] 2. Example embodiments include a combination of these systems to provide for a rapidly deployable, self-actuating shelter set up, waterproofed, high-thermally performing, EMI shielding, and infrared reflecting shelter system.

[0037] 3. This shelter system is designed to be under 150 pounds so it can be lifted up and easily transported by just three people.

[0038] 4. This shelter system is designed to be set up by just three people, for example, in under five minutes and to be taken down by just three people, for example, in under five minutes.

[0039] 5. The shelter enclosure fabric may integrate thin layers of high-thermal resisting layers of flexible aerogel.

[0040] Example Advantages [0041] Example advantages of this soft wall expeditionary shelter over existing shelter systems include its unique combination of performative attributes that are specifically designed for military operations:

[0042] 1. it is lightweight and compact when rolled up and stowed for ease of transport, lifting, and handling;

[0043] 2. the structure is self-actuating and rapidly deployable by inflating the air beam arches;

[0044] 3. it has a unique combination of air beam arches and a fiberglass rod X-bracing system that is structurally rigid to resist gravitational loads up to 10 Ibs./sf snow load, and, in an example embodiment, to resist 60 mph lateral wind forces;

[0045] 4. the shelter enclosure system may have a unique combination of visual camouflage, waterproofing, a snow and rain shedding form, high thermal performance down to -60°F and up to +140°F, infrared reflecting, anti-microbial properties, and EMI shielding capabilities; and

[0046] 5. the shelter may have an easily deployable waterproof and EMI-shielded system of fabric flaps that can be folded through the door of one shelter into another for connecting two shelters together to easily enlarge the overall square footage of interior space.

[0047] Example Uses

[0048] 1. This soft wall expeditionary shelter may be designed specifically for the use of small and fast moving tactical groups of US Army soldiers.

[0049] 2. It may be designed to be easily stowed in military vehicles for transport into active battle zones, and to weigh under 150 lbs. so it may be easily carried and handled by three soldiers.

[0050] 3. It is designed to be rapidly set up to provide the necessary environmental and enemy-detection protection, and to be rapidly taken down, rolled up, and stowed back into a military vehicle.

[0051] 4. The air beam structure can be inflated using the air compressor that is already integrated into military vehicles for its self-actuating set-up process, or it may be manually inflated using a hand pump.

[0052] 5. Two shelters can be easily connected together to increase the overall interior square footage.

[0053] Referring to FIGS. 2-7D, another embodiment of a flexible soft wall tent, shelter, or shelter system 30 is depicted. Shelter 30 can have a first layer consisting of a waterproof flexible outer or exterior shelter layer, enclosure or fabric 32. The exterior shelter layer 32 can be supported by an inflatable and collapsible air beam support frame structure or skeleton 15. The support frame 15 can include a series of inflatable air beam arches 12, for example four, that are connected together by an inflatable ridge air beam 13. The exterior shelter layer 32 can form exterior shelter layer sides, sidewalls or sidewall portions 32a, roof or roof portions 32b and ends 31 of the shelter 30. In some embodiments, the ends 31 can be considered sidewall portions 32a. The sides 32a can extend along the lower portions, legs or facets 12a of the air beam arches 12, and the roof 32b can extend along the upper portions, peaks or facets 12b. Each end 31 can have a large zippered D - shaped door 34 with a smaller zippered roll up door 36 integrated therein. A flexible waterproof floor 22 can be removably secured to the exterior shelter layer 32 above the ground 8 to prevent standing water from entering the shelter 30. A series of openings or loops 24a can be extend from the floor 22 for stakes 24 to stake shelter 30 to the ground 8.

[0054] A flexible second, interior or inner shelter layer liner or fabric 42 can be attached inside the interior of the shelter 30 for extending next to or adjacent to the exterior shelter layer 32, on the ends 31, sidewalls 32a and the roof 32b. The inner shelter layer 42 can include an insulating layer formed of aerogel, an EMI shielding layer, a white light reflecting layer, and include infrared reflecting properties and anti-microbial properties. The inner shelter layer 42 can be secured to the support frame 15, the exterior shelter 32 and the floor 22. The inner shelter layer 42 can extend laterally inwardly over the floor 22 to cover a perimeter ring region and can be secured to the floor 22 with a series of spaced apart paired fasteners 44 such as Velcro® hook and loop fastener patches or dots.

[0055] Two sets of service ports can be included on opposite sides 32a and near opposite ends 31. Each set can include two large ports 38 for air-conditioning or heating, and one small port 40 for electrical or communication wires or cables.

[0056] Referring to FIGS. 5 and 7A-7D, the waterproof floor 22 can have a rectangular floor bottom portion 22a that contacts the ground 8, and an integral floor sidewall portion or curb 22b for extending upwardly above the floor bottom portion 22a on all four sides to form a seamless waterproof basin, bathtub or boat hull structure to keep out standing water. The floor sidewall portion 22b can extend 4-8 inches or about 6 inches above the floor bottom portion 22a, and the upper perimeter edge of the floor sidewall portion 22b can be removably securable to the bottom perimeter edge of the exterior shelter layer 32 by a securem ent joint or arrangement such as a zipper joint or structure 46. The zipper joint 46 can extend laterally around the perimeter of the shelter 30 on all sides, between the bottom of the exterior shelter layer 32 and the top of the floor sidewall portion 22b. A flap 47 securable with Velcro® hook and loop fastener can extend around the perimeter of shelter 30 and cover the zipper joint 46 for sealing out water or falling rain.

[0057] Referring to FIGS. 3, 4, 6 and 7A-7D, the lower end or bottom of the inner shelter layer 42 can extend downwardly adjacent to the exterior shelter layer 32 and the floor sidewall portion 22b until reaching the floor bottom portion 22a. The bottom of the inner shelter layer 42 can then extend laterally inwardly over and cover the floor bottom portion 22a at perimeter regions of the floor bottom portion 22a in a lateral rectangular ring-shaped manner. The lateral rectangular ring-shaped portion of the inner shelter layer 42 can be secured to the floor bottom portion 22a by spaced apart pairs of fasteners such as Velcro® hook and loop fastener dots 44 that can be arranged with one dot 44 of each pair being positioned near the floor sidewall portion 22b at the edge of the floor bottom portion 22a, and the other dot 44 of the pair being positioned inwardly near the terminal inner edge of the inner shelter layer 42 that forms the inner perimeter of the inner shelter layer 42. In some embodiments, the inner shelter layer 42 can laterally overlap and inwardly cover about 18 inches of the perimeter of floor bottom portion 22a. With the inner shelter layer 42 having EMI shielding, this can be a sufficient distance to prevent electromagnetic interference from entering shelter 30 through the floor 22, since the underlying ground can prevent electromagnetic interference from entering the floor 22 in more laterally inward locations of the floor bottom portion 22a. Consequently, the sidewalls 32a, roof 32b, ends 31 and floor 22 of shelter 30 can be effectively EMI shielded by inner shelter layer 42. In some embodiments, the Velcro® fastener dots 44 in each pair can be spaced about 3 inches from both the sidewall portion 22b and a terminal edge of the inner shelter layer 42 to be about 12 inches apart from each other laterally inwardly. Each pair of dots 44 can be spaced apart about 20 inches from each other extending in the perimeter direction. In some embodiments, a floor liner 23 can cover the floor bottom portion 22a and have a peripheral lip or edge 23a that can overlap the terminal inner edge of the inner shelter layer 42 (FIG. 7B). Velcro® hook and loop fastener 62 can secure the feet 12c of air beam arches 12 to the floor bottom portion (FIG. 7D).

[0058] Referring to FIGS. 6-8B the exterior shelter layer 32 can be releasably secured to the air beam arches 12 and ridge air beam 13 of the support frame 15 by series of releasable support frame or air beam securement members, fasteners or straps 48 that can extend around the beams 12 and 13 at spaced apart locations. Straps 48 can be secured or attached to the exterior shelter layer 32 and include an overlapping portion having a fastener 49 such as a Velcro® fastener. The inner shelter layer 42 can also be releasably secured to the beams 12 and 13 by secondary inner shelter layer or liner releasable securement members, fasteners, attachment features or straps 54, for securing the inner shelter layer 42 in a spaced relationship relative to the exterior shelter layer 32. The fasteners 54 can be attached to outer surfaces of the straps 48 to provide secondary fastening to the inner shelter layer 42 through securement members or loops. The strap 48 wraps around beams 12 and 13 to provide secure structural attachment to the exterior shelter layer 32. In addition, the inner shelter layer 42 can be secured around beams 12 and 13 to also provide secure structural attachment to the beams 12 and 13, as well as to provide thermal insulation properties. Intermediate spacers, spacing members or straps 56 (FIGS. 7C and 8A) can be attached between the exterior shelter layer 32 and the inner shelter layer 42 to maintain a consistent gap G there between, for example, ’A to 2 inches or about 1 inch. A 1 inch gap can provide good thermal insulation and is narrow enough to prevent air convection between the layers 32 and 42 which can affect thermal insulation properties. In some embodiments, Velcro® hook and loop fastener straps 56 can extend through plastic loops 56a attached to the inner shelter layer 42. Referring to FIG. 8B, in some embodiments, the straps 48 can be secured to the exterior shelter layer 32 with Velcro® hook and loop fastener 48a. The straps 54 can be secured to the inner shelter layer 42 through plastic loops 54a sewn or attached to the inner shelter layer 42. Straps 54 can be attached to straps 48 at locations that provide the 1 inch gap between the inner 42 and exterior 32 shelter layers, and can include Velcro® hook and loop fastener for securement through loops 54a.

[0059] Referring to FIGS. 9A-9C, the ends 31 of the shelter 30 can have mirror image door configurations at ends A and B, to allow the A and B ends of two shelters 30a and 30b to be complexed or joined together. Each end A and B can include a securement or complexing member or flap 50A and 50B extending from exterior shelter layer 32 that can have the same or similar shape or outline of an air beam arch 12. Two flaps 50A and 50 B can be secured together with a fastener 51 such as a Velcro® hook and loop fastenerjoining or complexing the shelters 30a and 30b together. Flaps 50A and 50B can be configured or shaped to form a rain gutter 52 between shelters 30a and 30b to direct water to the ground. The flaps 50A and 50 B can have or form a concave trough to collect and direct the water. Consequently, the flaps 50A and 50B can join two shelters 30a and 30b together, as well as form a rain gutter. In some embodiments, more than two shelters 30 can be joined together. FIG. 9D depicts another embodiment and in more detail. Flaps 50A and 50B can be attached or sewn to the ends A and B of respective shelters 30a and 30b. Flap 50A can include the loop portion 51a of fastener 51, and flap 50B can include the hook portion 51b of fastener 51, to mate and secure together. Hook and loop fastener 53 can also be mounted or attached to the ends A and B to secure the flaps 50A and 50B to ends A and B when not used for complexing. Hook portion 53a can be attached or mounted to end A for mating and securing to loop portion 51a on flap 50A to secure flap 50A in place when not in use, and loop portion 53b can be attached or mounted to end B on an exterior adjacent face of flap 50B for mating and securing to hook portion 51b on the distal end of flap 50B to secure flap 50B in place when not in use. In some embodiments, the placement of the loop portions 51a/53b and hook portions 51b/53a can be reversed.

[0060] Referring to FIGS. 10-13, the inflatable air beam support frame structure or skeleton 15 in one embodiment can include a series of spaced apart inflatable air beam arches 12, such as four, which can be structurally and inflatably connected together by an elongate inflatable ridge air beam 13 that extends along an upper central longitudinal axis Lx at the peak. Each air beam arch 12 can include two generally upright lower portions, legs or facets 12a, that form the underlying structure and support for the sidewalls 32a of shelter 30, and two angled upper portions or facets 12b that form the underlying joist support structure for the roof 32b. The upper portions 12b of each air beam arch 12 can be joined to opposite sides of the ridge air beam 13, in fluid or gas communication therewith. The lower portions 12a can be close to vertical, and can be angled inwardly upwardly at about 81° to horizontal. The upper portions 12b can be angled inwardly upwardly at about 30° to horizontal. The feet 12c of each lower portion 12a of the air beam arches 12 can be aligned along respective lower longitudinal axes L ₂ located on opposite lateral sides of longitudinal axis L The lower 12a and upper portions 12b of each air beam arch 12 can be symmetrical about a vertical axis V which bisects each air beam arch 12, and intersects longitudinal axis L The feet 12c of each lower leg portion 12a of each individual air beam arch 12 can be aligned along respective horizontal axes H that can be at a right angle or orthogonal to longitudinal axes Lx and L ₂ . An inflate/deflate valve 18 can be positioned on opposite ends and sides of support frame structure 15 in the lower portions 12a of the air beam arches 12 at the ends. By inflatably connecting the air beam arches 12 together with only the ridge air beam 13, the weight of the support frame structure 15 and shelter 30 can be kept to a minimum, for example, under 150 pounds.

[0061] Further details of an embodiment of a tent or shelter 30 in the present disclosure follow. The tent or shelter can be a new, lightweight, rapidly deployable, soft wall shelter 30 for the US Army. The primary structure can be an inflatable air beam support frame structure or skeleton 15 comprised of four, parallel, faceted, air beam arches 12 that span lO’-O” and are interconnected to a perpendicular, 15 ’ -0” long, central air ridge beam 13. The air beam skeleton defines a lO’-O” wide x 15’-0” long space that is an extruded form of the shape of the faceted arches. The total floor area can be 150 square feet.

[0062] The air beam skeleton 15 can be contained within, and structurally supports, an exterior shelter layer or fabric enclosure 32. The exterior enclosure can have large zippered doors 34 at both short ends approximately in the shape of a “D,” having a zipper 66 and fabric ties 62. Each “D” door 34 can have a smaller, rectangular, zippered, roll-up door 36 within its profile having zipper 66 and fabric ties 64. There can be two groups of three service portals 38 and 40 on both long sides of the fabric enclosure, six total, to bring in conditioned air and electrical services from the outside.

[0063] There can also be an inner shelter layer or fabric liner 42 that attaches to the air beam skeleton 15 and the outer enclosure 32 using Velcro® fasteners. This inner shelter layer liner 42 can be comprised of three layers: an outermost thermal resistance layer; a middle electromagnetic interference (EMI) shielding layer; an innermost layer to protect the other two from direct contact. The inner shelter layer 42 liner can also have large zippered doors 34a to correspond directly to the large exterior doors 34, with a smaller roll-up door 36a within the larger door profile 34a, and service ports that correspond to the service ports in the outer or exterior shelter layer 32 enclosure.

[0064] The support frame structure air beam skeleton 15 can be a continuous and bladderless volume, i.e., the exterior fabric is impermeable and holds air that is under 3psi to 6psi air pressure. The air beam skeletonl5 can be inflated manually or with an air compressor through integrated inflate/deflate air valves 18. When inflated, the air beam skeleton 15 can resist both gravitational snow loads and lateral wind forces.

[0065] The shape of the air beam 12 arches can be comprised of four straight facets or partitions: two lower legs, portions or facets 12a that touch the ground lO’-O” apart and rise 6’-0” at an 81° angle from the horizontal; two upper portions or facets 12b that spring from the top of the lower facets 12a at a 30° angle from the horizontal, and connect to the central air ridge beam 13. All of the air beam arch facets 12a and 12b can be 9” in diameter. The air beam arches 12 can be spaced 4’-9” on center apart from each other. The central air ridge beam 13 can be l’-0” in dimeter, and the top of the ridge beam can be 8’-4” above the ground. There can be an inflate/deflate valve l’-6” above the ground at both ends of the air beam skeleton 15, two total, and can be kitty-comer from each other.

[0066] The exterior shelter enclosure layer 32 can be attached to the air beam skeleton 15 by a series of nylon straps 48 with Velcro® fastener strips for bonding. These straps 48 can be sewn onto the exterior shelter layer 32 enclosure to be at the bottom, middle, and top of all four air beam arch facets 12a and 12b, and along the air ridge beam 13. This allows for either the air beam skeleton 15 or exterior shelter layer enclosure 32 to be demounted and replaced if damaged.

[0067] There can be two types of fabric for the exterior enclosure system, one for the floor 22 and the other for the walls 32a, doors 34, 36, protective zipper flaps 34a and 36a, service portal flaps 38a, 340a, and roof 32b. The floor 22 can be a very durable waterproof, antimicrobial fabric to resist wear and tear from the environmental condition of the ground and soldiers walking on it. The floor fabric 22 cab extend up the vertical walls of the shelter 6” to create a “bathtub effect” to keep out water. There can be a zipper joint 46 and a waterproof protective fabric flap 47 kept in place with Velcro® fastener strips at 6” above the ground to connect the floor bathtub to the rest of the exterior enclosure above. This allows the floor fabric 22 to be demounted and replaced if it becomes damaged.

[0068] The exterior enclosure walls, doors, service ports, and roof can be formed of a waterproof, antimicrobial fabric with a camouflage pattern on the exterior and a black blackout surface on the interior. The zippers for the large “D” doors 34 and small roll-up doors 36 can have protective flaps 34a and 36a of this same fabric and can be held in place by Velcro® strips. There can be two groups of three service portals 38 and 40 on both long sides of the fabric enclosure, six total, to bring in conditioned air and electrical services from the outside. Two of the portals in each group can be l’-4” in diameter and the third portal can be 4” in diameter. Each portal 38 and 40 can shed water by being covered by a “dryer vent” service flap on the exterior of the enclosure.

[0069] There can be complementary complexing flaps 50A and 50B that follow the profile of the air beam arches 12 at each end of the exterior enclosure so two soft wall shelters 30a and 30b can be joined at their doors to create one large and continuous interior space (called complexing) while preventing ambient air, wind, rain, or snow intrusion. Flaps 50A at one end A are designed to receive Flaps 50B of another soft wall shelter 30, thereby creating a sealed gutter 52 that will direct any moisture around the door openings and down to the ground. Additionally, there can be nylon loops 24a sewn onto the exterior enclosure at the foot and shoulder of each air beam arch 12 to be able to stake the shelter 30 down with stakes 24 in high wind environments. Guy wires can be attached to the shoulder loops 24a so they be angled down to reach the ground 8 and be staked in.

[0070] The inner shelter layer or fabric liner 42 can attach to the air beam skeleton 15 using the same straps and Velcro® fasteners that attach the air beam skeleton 15 to the exterior shelter layer 32 enclosure so it can be demounted and replaced if damaged. There can be additional connection points 56 between the exterior shelter layer or outer enclosure 32 and inner shelter layer liner 42 to prevent the inner liner from sagging and impinging on the interior space. If desired, the inner liner can be removed and stowed and the shelter would still maintain its protection from weather and wind.

[0071] The inner shelter layer liner 42 can be a composite of three fabric layers: an outermost thermal layer; a middle electromagnetic interference (EMI) shielding layer; an innermost layer to protect the other two from direct contact. The thermal layer can be fabricated from a flexible aerogel. The EMI shielding layer can be an existing product that contains a metallic weave that denies through-transmission of EMI signals. The inner layer is white to best reflect interior light sources and can have antimicrobial and infrared-light shielding capabilities to minimize heat signatures.

[0072] There can be lightweight straps 58 sewn onto the inner shelter layer 42 to support a string of lights to illuminate the interior. There can also be heavy “D-rings” 60 sewn onto the inner shelter layer that are aligned with each air beam arch 12 to support straps to hang equipment.

[0073] Unique Features

[0074] Unique features are generated by the integration of the soft wall shelter systems 30 described above. The integration of the primary shelter systems and their subsystems creates unique performative synergies and are enumerated here:

1) The soft wall shelter system 30 can weigh under 150 pounds so it can be lifted and easily transported by just three people. There are no rigid components so the shelter 30 can be folded up into a compact form for ease of lifting and transporting.

2) The deployment of the soft wall shelter 30 can be self-actuating creating an extremely easy and intuitive user interface. When the shelter 30 is folded up in its compacted state, air can be pumped into the air beam skeleton 15 providing an internal pressure that automatically unrolls the shelter 30 then raises the walls and roof into their occupiable shape. Conversely, the infl ate/ defl ate air valves 18 are opened to release the air for taking down and folding up the shelter 30 for storage. The air beam skeleton 15 can be inflated or deflated in two minutes when using an air compressor, thus providing very easy and rapid deployment. ) The exterior shelter layer enclosure 32 can act in tension to resist the lateral spread of the feet 12c of the air beam arches 12 when the air beam skeleton 15 is being inflated. In turn, the outward force exerted by the air beam skeleton 15 on the exterior shelter layer enclosure 32 constantly maintains the full volume of usable interior space. ) The exterior shelter layer enclosure 32 follows the faceted shape of the air beam arches 12 to shed water and snow off of the roof 32b. If snow does accumulate on the roof 32b, the exterior shelter layer enclosure 32 that spans from arch-to-arch transfers the gravitational snow load through the air beam arches 12 to the ground, while the air ridge beam 13 will act in compression and prevent the arches 12 from collapsing towards each other under the loads. ) The exterior shelter layer enclosure 32 can distribute the lateral forces generated from high winds across the whole air beam skeleton 15, and the faceted shape of the air beam arches 12 can help deflect the wind up and over the shelter 30. ) The faceted shape of the air beam arches 12 can also allow for the use of the full floor area without encumbering headroom or movement throughout the shelter. ) The 1 ’ air gap between the exterior shelter layer 32 and inner shelter layer liner 42 creates an additional thermal barrier by minimizing significant convection activity between the exterior shelter layer enclosure 32 and inner shelter layer liner 42 due to its narrowness, thereby, creating a better insulating layer. (A wider gap would allow an easier flow of air that would invite greater convection that would wick away heat energy at a much greater rate.) ) The 1” gap between the exterior shelter layer 32 and inner shelter layer liner 42 also minimizes significant thermal bridging between the exterior and interior, thereby increasing the shelter’s overall thermal performance. ) All of the shelter systems and subsystems are demountable and replaceable to maintain top overall performance without having to dispose of the whole shelter. In only minutes a component that is damaged can be swapped out for a replacement component.

10) The inner shelter layer liner 42 can integrate the high-thermal resisting layer of flexible aerogel.

11) All of the shelter components can fully perform at extreme temperatures down to - 60°F and up to +140°F.

[0075] Advantages, Improvements, Problems Solved

[0076] The advantage of the soft wall shelter 30 over existing shelter systems is its unique combination of performative attributes that are specifically designed for military operations but applicable to other uses and markets:

1) The soft wall shelter 30 is lightweight and compact when rolled up and stowed for ease of transport, lifting, and handling.

2) The soft wall shelter 30 is self-actuating and rapid deployable by inflating or deflating the air beam skeleton structural system 15, making an easy and intuitive user interface.

3) The air beam skeleton system of the soft wall shelter 30 can resist gravitational loads up to 10 lbs. per square foot snow load, which equals 1200 lbs. given the square footage of the roof 32b, and can resist lateral forces generated by high winds up to 60 mph.

4) The exterior enclosure system can have a unique combination of visual camouflage, waterproofing, a snow and rain shedding form, a demountable and replaceable floor, nylon loops and guy wires to stabilize the shelter against high winds, and the ability to “complex” (connect together) with other soft wall shelters to create a larger continuous interior space.

5) The inner liner system of the soft wall shelter 30 has high thermal performance down to -60°F and up to +140°F, anti-microbial properties, and infrared and EMI shielding capabilities.

[0077] Potential Uses

1) The soft wall shelter 30 is designed specifically for the use of small and fast moving tactical groups of US Army soldiers.

2) The soft wall shelter 30 is designed to be easily stowed in military vehicles for transport into active battle zones, and to weigh under 150 lbs. so it may be easily carried and handled by three soldiers. 3) The soft wall shelter 30 is designed have a self-actuating deployment that provides rapid set up to provide the necessary environmental and enemy-detection protection, and to be rapidly taken down, rolled up, and stowed back into a military vehicle.

4) The air beam skeleton 15 can be inflated using the air compressor that is already integrated into military tactical vehicles for its self-actuating set-up process, or it may be manually inflated using a hand pump.

5) Two shelters 30a and 30b can be easily “complexed,” or connected together to increase the overall interior square footage.

[0078] The design of the soft wall shelter 30 greatly minimizes unnecessary complexity, thus reducing overall manufacturing costs while making the user interface extremely easy and intuitive. The streamlined design also minimizes the general quantities of material per square foot of usable space to match the weight criteria of the US Army. By minimizing complexity and materials, overall manufacturing costs are also minimized.

[0079] The unique combination of the integrated systems, including the air beam skeleton, exterior shelter layer enclosure, and inner shelter layer liner, is specifically tuned to the needs of the US Army for with the following performative attributes:

• Lightweight

• Easy and intuitive user interface

• Self-actuating and rapidly deployable

• Easily “complexed” to join multiple shelters together for the expansion of continuous interior space

• Demountable and replaceable systems and subsystems to maintain top performance

• Infrared and EMI shielding capabilities

• Weatherproofing

• Rain and snow shedding form

• Resistance to extreme temperatures

• Structural resistance to gravitational and lateral forces

[0080] Many of these same attributes would also be desirable for humanitarian, emergency, and recreational uses.

[0081] While example embodiments have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the embodiments encompassed or contemplated herein or in the drawing being filed herewith. Features of different embodiments can be combined together or omitted. Example dimensions of embodiments are described and given in the drawings, However, dimensions can vary depending upon the situation at hand.

Although shelters have been described above to include inflatable beams 12 and 13, in some embodiments, non-inflatable or rigid arch and ridge beams or support frames can be used to support inner and exterior shelter layers.