OA17048A - Height adjustable shipping container. - Google Patents

Abstract

A height adjustable shipping container usable as a building structure 2400. The container having vertical corner columns 2405 and at least three side walls which may be transported at a reduced height as a shipping container and expanded at the receiving end. At least some of the vertical corner columns 2405 expand in length during expansion of the reduced height shipping container. The shipping container is able to transport therein structural components, such as wall panel 2403, 2404, floor 2401, roof 2402A, 2402B and even fittings to build a building structure that is the equivalent in floor area to that of at least two shipping containers.

Description

Height Adjustable Shipping Container

Field of the Invention

The Invention relates to a Helght Adjustable Shipping Container for use as a building structure, typically for housing and/or mining accommodation.

Background of Invention

A problem with existing methods of shipping standard shipping containers lies In the helght and transport costs of a product which does not take up the full space within the container particularly where the container Is to be used as some form of accommodation or commercial use. In such cases the interior of the container Is often almost empty but because the eventual residential height In the container is full helght the transport costs are high.

Equally, where accommodation which Is greater than the height of a shipping container must be provided the only real option Is to provide it as two containers, one without floor, which must be mounted on top of each other.

Prior References:

Ali references, including any patents or patent applications cited In this spécification are hereby Incorporated by référencé. No admission Is made that any référencé constitutes prior art The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications may be referred to herein; this référencé does not constitute an admission that any of these documents form part of the common general knowledge In the art, in New Zealand or in any other country.

Object ofthe Invention

It Is an object of the Invention to provide a height adjustable shipping container that améliorâtes some of the disadvantages and limitations of the known art or at least provide the public with a useful choice.

-2Summary of Invention ln a fîrst aspect as herein described the invention relates to a height adjustable transportable shipping container usable as a building structure, wherein the transportable expandable shipping container houses during transportation within a minimum of two roofs and two floors such that when the transportable expandable shipping container is expanded for use as a building structure the transportable expandable shipping container makes up a minimum area of that of two standard shipping containers, the height adjustable shipping container having:

(i) vertical corner members and at least interchangeable and relocatable three side walls which may be transported at a reduced height as a shipping container and expanded at the receiving end wherein at least some of the vertical corner members expand in length during expansion of the reduced height shipping container and the shipping container Is capable to house and to transport therein structural components, such as wall panels, floor, roof and even fittings to erect a building structure that is the équivalent In floor area to that of at least two shipping containers;

(ii) at least some part of a side wall is attached to an upper part of the height adjustable container during expansion and at least some other partof an Interchangeable and relocatable side walls is attached to the lower part of the height adjustable container during expansion, the lower part of the interchangeable and relocatable side walls Is substantially high enough to accommodate building components, fittings, fùmlture and fixtures beiow its height; and (Iii) the vertical members Including a horizontally extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart vertical members, wherein further when the container is In an unextended position the height of the container is at a reduced height of at least 50% to that of a standard shipping container and such that when the container is ln the extended position the container is at a height equal to that of a habitable area or greater than the height of a standard shipping container and the erected side walls are coaxially aligned to form outer walls having a flat planar surface along the entire surface area of the outer wall.

Preferably the vertical corner members are vertical rails or columns.

Preferably at least some part of a side wall is attached to an upper part of the height adjustable container during expansion.

-3Preferably at least some other part of a side wall Is attached to the Iower part of the height adjustable container during expansion.

Preferably the Iower part of the side walls Is substantiaily high enough to accommodate fumiture below its height.

Preferably the Iower part of the side walls is substantiaily 0.9 métrés high.

Preferably the upper part of the side walls is substantiaily 0.3 métrés high.

Preferably access points for utility services are at the junctures of the upper and Iower walls.

Preferably at least part of a wall filling the gap between upper and Iower shipping container parts is pulled into place on expansion of the container.

Preferably éléments forming the shipping container walls during transport may be relocated elsewhere within the container after expansion.

Preferably the shipping container top surface is angled with respect to the plane of the floor.

Preferably two such expanded top surfaces may be placed side by side to form a peaked pitched roof.

Preferably the floor of the shipping container may act to receive a pourable settable material and may include éléments acting as reinforcement for the settable material.

Preferably the reinforcement éléments may extend through two adjacent expanded shipping container floors.

Preferably the shipping container corner members may include telescoping portions in which any engagement features in the corner rail top are substantiaily repeated in the top of each telescoping portion.

Preferably in the expanded form the corner members remain capable of supporting vertical loads.

Preferably, the expandable vertical members include a horizontally extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart expandable vertical members.

Preferably, the fioor includes spaced apart openings adapted to receive the tines of a fork lift to allow the unerected shipping container to be easily transported and are adapted when the shipping container is erected to used as service ducts.

Preferably, the vertical comer members hâve an open cross section.

Preferably, the vertical corner members hâve a substantiaily 'L’-shaped cross section.

-4In another aspect as herein described the invention relates to a method of manufacturing a transportable expandable shipping container for use as a building structure, wherein the transportable expandable shipping container during transportation houses within a minimum of two roofs and two floors such that when the transportable expandable shipping container is expanded for use as a building structure the transportable expandable shipping container makes up a minimum area of that of two standard shipping containers, the method includes:

(i) providing a container base and vertical members, providing at least one first vertical wall portion adapted to be attachable to the base and adapted to extend less than the packaged height of the container, providing an upper surface secured at least in one position to an upper portion of a vertical member, providing at least one second vertical wall portion adapted to extend towards the first vertical wall portion from the upper surface the vertical members having a horizontally extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart expandable vertical members;

(il) extending the members to an expanded position;

(iii) attaching at least some part of an interchangeable and relocatable side walls to an upper part of the height adjustable container during expansion; and (ïv) attaching at least some other part of the Interchangeable and relocatable side walls to the lower part of the height adjustable container during expansion whereby the lower part of the side walls is substantially high enough to accommodate building components, fittings, fumiture and fixtures below its height;

wherein when the container is In an unextended position the height of the container Is at a reduced height of at least 50% to that of a standard shipping container and when the container Is In the extended position the container is at a height equal to that of a habitable area or greater than the height of a standard shipping container and the erected side walls are coaxialiy aligned to form outer walls having a fiat planar surface along the entire surface area of the outer wall.

In further aspect as herein described the Invention relates to a transportation system for the transportation, packaging and érection of a transportable height adjustable shipping container usable as a building, the transportable expandable shipping container during a transportation mode houses within a minimum of two roofs and two floors such that when the transportable expandable shipping container in a building mode for use as a building structure the

-5transportable expandable shipping container makes up a minimum area of that of two standard shipping containers, the transportation System Inciuding an extemal building shell transformable from the transportation mode to the building mode, when in the transportation mode the extemal building shell falls within same floor dimensions and floor area of a shipping container format, the extemal building shell being height adjustable such that the extemal shell is adapted to be transformed from the transport mode to the building mode by adjusting the height of the extemal building shell to a desired height, when in the transportation mode the internai space within the extemal building shell Includes structural components, such as building components, wall panels, floor, roof fittings, fumiture and fixtures required to erect and fit out a building structure that Is the équivalent in floor area to that of at least two shipping container formats; the external building shell Includes:

a) vertical comer members and at least three interchangeable and relocatable side walls which may be transported at a reduced height as a shipping container and expanded at the receiving end wherein at least some of the vertical corner members expand In length during expansion of the reduced height shipping container;

b) at least some part of an interchangeable and relocatable side walls Is attached to an upper part of the height adjustable container during expansion and at least some other part of the Interchangeable and relocatable side walls is attached to the lower part of the height adjustable container during expansion, the lower part of the side walls Is substantialiy high enough to accommodate the structural components, such as building components, wall panels, floor, roof fittings, fumiture and fixtures, below its height when in the transportation mode; and

c) the expandable vertical members having a horizontally extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart expandable vertical members, wherein the transportation System when In the transportation mode the extemal building shell is at a reduced height of at least 50% to that of a standard shipping container and such that when In the building mode the extemal building shell Is at a height equal to that of a habitable area or greater than the height of a standard shipping container and the erected side walls are coaxially aligned to form outer walls having a fiat planar surface along the entire surface area of the outer wall.

-6Brlef Description

The Invention will now be described, by way of example only, by référencé to the accompanying drawings:

Figure 11s a height adjustable shipping container ln accordance with a first preferred embodiment of the Invention.

Figure 2 is the container of Figure 1 in an expanded position.

Figure 3 is a variation of the container of Figure 1.

Figure 4 is an assemblage of two containers as shown in Figure 3.

Figure 5 is a prefabricated floor assembly suitable for a container.

Figure 6 Is detail of a joint between two prefabricated floor assemblies of Figure 3.

Figure 7 is a detail of a telescoping expanding vertical container rail.

Figure 8 Is a side view of a section of a compacted accommodation container.

Figure 9 is a side view of the container of Figure 8 in expanded form.

Figure 10 Is a perspective view of collapsed containers situated on a truck traiter ready for i 5 transport ln accordance with a second preferred embodiment of the invention.

Figure 11 is a perspective view of one of the collapsed containers shown in figure 10.

Figure 12 is a perspective viewof the container shown in figure 11 in expanded form.

Figure 13 is an end view of the container shown in figure 12.

Figure 14 Is a further altemate end view of the container shown ln figure 12.

Figure 15 is a perspective cut-away view of the container shown ln figure 12.

Figure 16 Is a top view of the container shown in figure 15.

Figure 17 is a perspective view of the lower frame of the container shown ln figure 12.

Figure 18 Is a perspective view of the lower frame shown ln figure 17 without side panels and floor.

Figure 19 Is a top view of the lower frame shown in figure 18.

Figure 20 Is a perspective view of the upper frame of the container shown in figure 12.

Figure 21 a side view detail of a telescoping expanding vertical container column.

Figure 22 Is a detail of the lower and upper portions of the column shown in figure 21.

-7Flgure 23 Is a side cross-sectional view of part of the container as shown in figure 12.

Figure 24 Is a perspective view of a packaged unerected container in accordance with a third preferred embodiment of the invention.

Figure 24A is a perspective exploded view of the container as shown in figure 24.

Figure 24B is a perspective view of the lower part of the packaged unerected container as shown in figure 24.

Figure 24C is a perspective view of the container as shown in figure 24 in an erected state.

Figure 24D is a perspective view of an assembled building.

Figure 24E is a perspective view of a further partialiy assembled building created from two containers as shown in figure 24.

Figure 24F Is a perspective view of a fully assembled building as shown In figure 24E.

Figure 24G Is a perspective view of another assembled building.

Figure 24H Is a perspective view of another partialiy assembled building.

Figure 24i Is a perspective view of the building as shown In figure 24G In a completed state.

Figure 24J Is a perspective view of a container ready for transport.

Figure 24K is an partial exploded view of the container shown In Figure 24J

Figure 25 Is a perspective view of a packaged unerected container in accordance with a fourth preferred embodiment of the invention.

Figure 25A Is a perspective exploded view of the container as shown in figure 25.

Figure 25B Is a perspective view of the lower part of the packaged unerected container as shown In figure 25.

Figure 25C is a perspective view of the container as shown In figure 25 In an erected state.

Figure 25D Is a perspective view of an assembled building.

Figure 26 Is a perspective view of a packaged unerected container In accordance with a fifth preferred embodiment of the Invention.

Figure 26A Is a perspective exploded view of the container as shown in figure 26.

Figure 26B Is a perspective exploded view of the container as shown In figure 26 In an erected state.

-8Figure 26C is a further perspective exploded view of the container as shown in figure 26 in an erected state.

Figure 26D is a perspective view of the lower part of the packaged unerected container as shown in figure 26.

Figure 26E is a perspective view of the container as shown in figure 26 in an erected state.

Figure 26F is a perspective view of an assembled building.

Figure 26G is a perspective exploded view of another partially assembled building.

Figure 26H Is a perspective view of a fully assembled building as shown in figure 26G.

Figure 27 is a perspective view of a container In kit form.

Figure 27A is an exploded view of the container as shown in figure 27.

Figure 28 Is a perspective view of a container in layered schematlc form.

Figure 28A is an exploded view of the container as shown In figure 28.

Description of the Preferred Embodiment(s):

The following description will describe the invention in relation to preferred embodiments of the invention, namely a height adjustable shipping container The Invention is in no way limited to these preferred embodiments as they are purely to exemplify the invention only and that possible variations and modifications would be readily apparent without departing from the scope of the invention.

The inventive construction System is applicable for use as residential housing, domestic garages, machinery & farm sheds, emergency accommodation, etc.

The Invention relates to a new System for the construction and transportation of accommodation that has many benefits compared to existing Systems. The proposed System possesses a significant réduction in the net cost of production, and it addresses and résolves issues in the 25 Systems currently available.

Generally the invention pertains to an extemal building shell that is delivered and erected in minimum time, which may be as little as a few hours in some construction cases (eg: garages). As the building sheli Is fully enclosed, there are no weather limitations on the construction timeline. Local tradesmen may be engaged to do the Internai installations thus promoting the 30 local construction industry and stimulating the local economy, which is desired by counciis and govemments. The highly skilled local workers are likely to be more efficient than low-skilled,

-9cheaper workers from foreign économies, and as weather conditions would not be a factor, these local workers would be more able to work with optimum efficiency and remain economically compétitive compared to the global market. The Inventive System Is formatted around the ISO shlpping container design, and is easily transported and positioned using equipment that is readily available. Due to the simplicity of the on-site setup of the building shell, for uncomplicated projects a low skill set is necessary to complété the required assembly. The finished erected building meets international bush fire building régulations.

In emergency accommodation situations, the ease of building érection and fully enclosed nature of the System mean that homeless people can hâve Immédiate sheiter and security. In the collapsed container state, the Inventive System can also be used to transport and store emergency relief materials, such as food and building resources, within the collapsed container. Due to the versatility of the inventive System, induding the potential to connect many individual containers together, it Is possible to quickly create a large, sheltered and secure space that can be used for a variety of purposes, such as a hospital, a food storage facility, or for occupancy by many families. This latter use could also promote a sense of community living, helping to provide comfort to people affected by disasters.

The side panels that are used as braclng when the building unit Is being transported can be relocated to the outer shell of the erected frame to create a combination of extemal walls, Windows and door openings. The panels, Windows and doors are interchangeable, and able to create a large number of different formats as desired.

Tuming now to the drawings that exemplify the invention.

Figure 1 shows a height adjustable shipping container 101 in which vertical corner rails extend to trucking and lifting points 102 at each end. Vertical walls on the exterior extend to eut line 105 forming partial end panel 103, partial side panel 104 and top panel and top side partial panels 106.

Figure 2 shows the container of Figure 11n expanded form in which telescoping rails 107 hâve been expanded, a panel 110 formerly behind panel 103 has been pulled up Into place and a window 108 formerly packed inside the container with Windows 109 has been placed in the gap formed by expansion. Other panels or equipment which may hâve been packed within the container, such as doors, roller doors, ventilators, tables, etc can be fltted to the expanded container. Still others may be permanently fltted to the container before dispatch, such as lighting or plumbed fltments.

-10Figure 3 shows a container 111 with a tilted top forming part of a peaked pitched roof 112 and an end panel 113. Cut lines 105 are offset, providing for different panel fitments at each eut. Typically any services requîred in the container (plumbing, electrical) are located adjacent a joint line to allow easy serviclng and testing on Installation. Figure 4 shows two containers such as that of Figure 3 butted together before being expanded Into a single larger accommodation structure. Various of the walls may be shifted In position when expanded, so that for instance the end panels 113 may be relocated to fill the other end leaving one end open for access.

In an alternative the two containers may be spaced apart and parts for bridging the gap between may be packed with the containers. This may include, for instance, flooring and a roof ventilation bridge.

Figure 5 shows a view of a floor pan for a container which ls Intended to be static. It consiste of an edge structure 501 and reinforcing bars 502 to allow the pouring of concrète or some other settable pourable material into the pan at the final site, producing a reinforced concrète pad within the container.

Figure 6 displays a method of carrying the reinforeïng 603 through containers abutted and secured together as In Figure 4 so that edge rails 601,602 are adjacent to render the concrète pad continuous.

Figure 7 shows a view of a telescoping pôle In expanded form. A lower portion 701 with engagement feature 703 for trucking or lifting has a cap 702 which slîdes down over portion 701. When slid down the engagement features 704 align with those at 703 to allow lifting the compacted container.

Figure 8 shows a side view of the interior of an accommodation container. Extemal panels 801, 802 hâve a cut line between them allowing compacting of the container onto chair 803, sink and faucet 804, desk 805 and lights 806, 807. Plumbing, electricity and any other utility services for the lights, wail power and sink may be located In areas 808 at the junctures of the cut line, providing access to services before the container is collapsed and after it is expanded. These services may be located within channels at the top of bottom of a wall attached to the container structure.

The cut line for such accommodation is preferably at 900mm above the floor with panel 801 being 300mm high to give a compacted height for the container of 1200mm compared to the full standard height of 2500mm or 2900mm. This means that normal fumiture can be accommodated within the compacted container.

-11 Figure 9 shows the same container In expanded form with the eut lines spaced apart by panels 810. Before panels 810 are finally placed the services are connected, for instance by cables from lights 808, 807 being connected to a central connection board within areas 808 by sockets or by connecter block. This has the advantage that access Is relatively easy while the container Is being expanded on site.

It Is important that the compacted container still adhères te the measurements of a standard shlpping container which means that in some cases a coilapsed telescoping pôle will still stand above part of the structure of a containerised building, as in Figure 3.

Figure 10 shows a truck transporting the shlpping containers ofthe invention. Each container 1001 to 1006 is of a coilapsed and reduced size or height relative to a standard shipplng container. Each shipplng container 1001 to 1006 inciudes all the components, including framing, walls, panels, etc., required to erect a building structure such as for mining, accommodation and/or commercial purposes.

Figure 11 shows a shipping container 1000 In Its storage and transportation state. The container has a châssis 1010 with side beam 1011 and end beam 1012. Side beam 1011 has at least two spaced apart fork lifting pocket openings 1013. The side and end beams 1011,1012 connect with lower standard ISO corner element 1054 at the base of column 1050. The column 1050 Inciudes a lower section Interleave guide part 1051 and an upper section interleave guide part 1052 where the upper section interleave guide part 1052 télescopes within the lower section Interleave guide part 1051 such that the height of the container 1000 can be adjusted in order to form a building structure when transported to the desired location. The container 1000 has side walls 1060, end walls 1030 and roof 1040. The column 1050 has an upper standard ISO corner element 1053,

Figures 12 and 13 show the container 1000 in an erected state In which the columns 1050 are fully extended. The erected container is shown with end wall panels 1031,1032, side wall panels 1062,1063,1064,1065,1067,1068 and door 1066, 1082. End wall panel 1031 and side wall panels 1063,1064 are fixed in place whereas end wall panel 1032 and side wall panels 1065,1065,1067 & 1068 are removable. Side panels 1061,1062 open out to form eaves, awnlng or shade panels and can be connected to another adjacent container to form a shelter walkway/porch area.

Figure 14 shows a variation to the container 1000 shown in figure 13 In that figure 14 inciudes a plumblng drainage component 2300 beneath the floor of an assembled and erected container 1000. Preferably the plumbing draining 2300 Is transported within the container and connected in place once the container is sited and erected In the desired place.

-12Figures 15 and 16 show a cutaway view of an assembled and completed container 1000. The container 1000 is shown to Include a bedroom 2101, lounge area 2102, kitchen area 2103, bathroom 2104 and toilet 2115. Preferred fittings, appliances and amenities shown are microwave 1805, fridge 1806, hot water tank 1807, locker 1808 and water closet 1809. It Is envisaged that other fittings, appliances and amenities can be utilised to suit the purpose to which the erected and completed container Is to be used for.

Figures 17 and 18 show the lower frame 1000A of the container. Figure 17 shows the lower frame In an assembled state with floor LA, side panels, and end panels in place. The end walls 1030,1070consistof end beams 1012,1015 and structural service duct supports 1701,1708 connected to and spaced apart by lower section interleave guide columns 1051. The side walls 1060,1080 Include side beams 1011,1014 connected tothe lower part of lower section interleave guide columns 1051. The structural service duct supports 1702,1705,1707,1709, 1712,1714 are spaced respectively above the side beams 1011,1014 by the combination of the lower section interleave guide columns 1051 and vertically extending door posts 1703,1704 and structural service duct supports 1706,1710,1711,1713 to form sub frames to define walls for panels and Windows and openings 1069A, 1085Afor doors. The upper structural service duct supports, 1701,1702,1705,1707,1708, 1709,1712,1714 can include slotted holes In which Windows and wall panels can be Inserted and held in place wlthout the need to use fasteners or the like to hold Windows and panels In place.

Figure 19 shows the floor F of the container. The floor consists of a frame Including side beams 1011,1014 and end beams 1012,1015 that are connected at the ends to the base of columns 1050. At spaced Intervals between side beams 1011,1014 are connected floor joists 1016. Situated equally spaced apart from the centre of the floor frame are fork lifting support compression plates 1017 that are hollow to accommodate the forks of a fork lift. The floor F as shown In figure 19 Is Included in the unerected container and is assembled and erected onto ground or piles or the like at the desired location upon which the container Is then lowered and erected thereto. A pourable, settable medium such as cernent is then poured (or this can be done prior to the container being put In place) to form a concrète floor.

To construct the floor, reinforcement steel is fixed Inside the container and positioned so that concrète or another setting medium can be installée) immediately and under cover. The skill requirement for floor construction Is low as there Is a relatively small distance between the form boards, which are of a unifomn height. This allows for easy levelling of the concrète. The cernent for the concrète can also be transported within the collapsed container shell. Concrète would also provide a floor capable of being easily decontaminated and cleaned, which Is essential for use in hospitals.

-13Fîgure 20 shows the upper trame 1000B of the shipping container. The upper trame 1000B conslsts of upper slde section structural members 1091,1094 connected to upper end section structurai member 1092,1093, upper standard ISO comers 1053 of upper section Interleave guide columns 1052. Structural service duct supports 1095 are situated spaced a part between the upper side section structural members 1091,1094 in order to provide structurai support. Lower upper side section structurai members 1097,1098 extend spaced beîow the upper section structural members 1091,1092,1093,1094. Structurai service duct supports 1099 extend between the upper side section structural members 1091,1094 In order to provide further structural Integrity to the upper frame 1000B. Depending down from the Lower upper side section structural members 1097,1098 are door post spigots 1096 situated In position where a door Is to be situated and supported there under. The upper frame 1000B can include fork lifting support compression piates (not shown) similar to the compressions plates 1017 In figure 19. These compression plates that are hotlow accommodate the forks of a fork lift to aliow the upper frame to be raised and situated In place when erecting a building structure.

Figures 21 and 22 show aspects of the expandabte column 1050. The column is attached at its base to the side beam 1011 by standard ISO corner 1054. The column 1050 consists of three telescoplng hoilow interleave guide columns 1051,1055 and 1062. Lower section Interleave guide column 1051 is connected at Its lower end to standard ISO corner. Centre section interleave guide column 1055 Is of a smaller diameter to that of both Interleave guide columns 1051 and 1052 such that centre section interleave guide column 1055 Is able to telescope within interleave guide coiumns 1051,1052 such that when the container is in a storage and transport state centre section interleave guide coiumn 1055 is fully enclosed within interleave guide columns 1051,1052. Upper Interleave guide column 1052 is attached to the upper standard ISO corner 1053 and also can be of a smaller diameter to that of lower section interleave guide column 1051 such that In the unerected state part of upper section interleave guide column 1052 fits within lower section interleave guide column 1051.

The standard ISO corners 1053,1054 include holes 1056,1057 that are able to act as lifting points so that the Interleave guide columns 1052,1055 can be raised and lowered relative to lower section interleave guide column 1051.

Figure 23 shows a cross-sectional view of part of an erected container. There Is shown a floor F supported on floor joists 1016 fixed to side beam 1010 that supports a lower wall panel 1063, service duct support 1705, upper wall panel/window 1067 that ail form part of side wall 1060. Side panel 1061 fastened to side wall 1060 during transport made by fasteners 1716 is used as an awning or extended eave or shutter when and once the container is erected and assembled. Side panel 1061 also acts during transport as a shock absorber and as a brace. A celling panel

- 141720 extends transversely from and connected to, via corner internai coving 1715, the top of wall panel/window 1067 and Is situated below roof 1040. An air gap exists between the ceiling panel 1720 and roof 1040 which can be used as part and connected to an air conditioning System.

Figures 24 and 24A show a packaged container 2400 ready for transport (minus the side panels), The container 2400 consists of a floor base 2401, roof sections 2402A, 2402B, further wall/roof sections 2403,2404 and columns 2405. Figure 24B shows a partial assembled container 2400 In which the roof section has yet to be raised relative to the base 2401 by adjusting the columns 2405. Figure 24C shows the container in a fully erected state ready to be fit out and completed. Figure 24D shows a building structure of an area equally to area of two containers 2400, 2410 joined side by side to the form a building structure. Figures 24E & 24F show two assembled containers 2400, 2410 joined together by a covered roof/walkway 2420. Whilst In the lower un raised position such as that shown in Figure 24E roofing, eaves and other roof and ceiling related components and fittings for ease of assembly and occupational health and safety requirements. Figure 24G & 24I shows a building structure 2430 having two levels and equal In area to that of that of eight shipping containers. Figure 24H shows a building structure 2440 equal in area to that of that of three shipping containers. Figure 24J & 24K shows a container 2400 in ready condition and configuration for transportation showing floor base 2401 A, 2401 B, roof sections 2402A, 2402B, columns 2405 and wall panel sections 2406, 2407,2408, 2409. It Is envisaged that one container indudes enough components to build a building structure the équivalent in floor area to that of at least two shipping containers.

Figures 25 and 25A show a packaged container 2500 ready for transport (minus the side panels), The container 2500 consists of a floor base 2501 A, 2501 B, roof sections 2502A, 2502B, further wall/roof sections 2503,2504 and columns 2505. Figure 25B shows a partial assembled container 2500 In which the roof section has yet to be raised relative to the base by adjusting the columns 2405. Figure 25C shows the container 2500 in a fully erected state ready to be fit out and completed. Figure 25D shows a building structure 2520 formed and equal in area to that of that of eight shipping containers.

Figures 26 and 26A show a packaged container 2600 ready for transport (minus the side panels), The container 2600 consists of a floor base 2601, roof sections 2602A, 2602B, further wall/roof sections 2603,2604 and columns 2605. Figures 26B & 26C shows exploded views of the container 2600 in an erected state. Figure 26D shows a partial assembled container 2600 in which the roof section has yet to be raised relative to the base by adjusting the columns. Figure 26E shows the container in a fully erected state ready to be fit out and completed. Figure 26F shows a building structure 2620 formed and equal in area to that of that of four

-15shlpping containers. Figures 26G & 26H shows a building structure 2630 formed and equal in area to that of that of four shipping containers and has a covered walkway/roof.

Figures 27 & 27A show the container 2700 In kit form Identifying the key components required to build a building structure of at least equal in area to the floor area of two shipping containers combined. The kit Includes floor base 2701 A, 2701 B, 2701 C, 2701 D, roof sections 2702A, 2702B, columns 2705, centre roof panels 2706,2707, extra columns 2708, and eave panels 2709, 2710.

Figures 28 & 28A show the container 2800 in a layered schematic form identifying the key components required to build a building structure of at least equal In area to the floor area of two shipping containers combined. The kit includes floor base 2801 A, 2801 B, 2801 C, 2801 D, 2801 E, 2801F, 2801 G, roof sections 2Θ02Α, 2802B, 2802C, 2802D, columns 2805, centre roof panels 2806,2807, extra columns 2808, and eave panels 2809.

The columns may include a horizontal steel channel to support a beam between the columns. The beam could be of concrète, steel, wood or similar suitable material adapted to bear and support a load such that of an upper floor.

The fork lift pockets can be used for the carriage of services once the floor is concreted

The upper and lower frame parts can be delivered together to eliminate sequence confusion that currently exists with known methods.

The unassembled parts can be transported on a frame so that they can be assembled at the point of destination and thus allowing the transportation of a greater floor and roof area

High quality extemal finishes, such as cladding or brickwork, can be installed to create a more traditional appearance. Paint and/or texture patterns, such as roof tiles or bricks, could also be printed Into the steel panels. Internai walls can also be easily constructed including insulation, plaster board and paint.

If a wider building Is desired, additional Infill sections may be Installed on the roof and floor, connecting two housing module units on either side.

The building units may be used to rapidly and cheaply construct a double garage.

Multi-storey buildings are envisaged whereby building shells can be erected on top of another. Floor pans can be installed to the concrète sections for the construction of a second-storey concrète (or other medium) floor, which can also be fire rated.

Any existing building format can be replicated. Eaves, valleys, hips and other traditional building features are designed into the system.

-16Builders can program projects without the weather constraints that currently exist. This would maximise efficiency of labour and capital, and as progress is not limited by adverse weather conditions, it would create more stable cash flows and a more stable and predictable building industry.

in 2011, the prefabricated housing market in America alone produced 185,000 units and was worth US$8-€ billion. This is a big market, and this method will significantly reduce the cost of the building shell, and could potentially revolutionise the industry by supplying more efficient, affordable housing.

The versatiîity of the construction design enables the Inventive system to be used to create a vast variety of buildings for different applications including, but not limited to, residential housing, storage units, sheds, garages, and buildings for emergency relief, public or commercial use.

The new inventive building system has many applications for portable/ modular buildings, and a major use for such buildings is in mining camp accommodation.

The modular building industry Is less than five years old and has undergone many developments that hâve led to greater efficiencies over this time. However there Is a need for even more efficient and serviceable products. The new and inventive system for the construction and transportation of portable housing accommodation has many benefits and improvements compared to existing Systems. The proposed inventive system possesses a significant réduction in the net cost of production, and It résolves issues In the Systems currently available.

The product requires minimal οπ-site setup, with fully complété interior fittings and services. The collapsed building shell simply needs to be placed, erected and centre panels inserted, which takes minimal time

The Inventive system allows for the access of ail services with ease, and allows for upgrading, testing and repair if required at any time.

The inventive system addresses occupational health and safety issues and reduces the risk of personnel injury during construction. As it has been fully designed considering safety.

The inventive system is formatted around the ISO shipping container and Is easily transported and positioned using readily available equipment.

The storage space required is reduced by 50%, so transportation costs are also reduced by up to 50% or more, which is a considérable cost advantage. Furthermore, twice as many units can then be delivered in the same amount of time.

-17The manufacturing process has been designed so that different components may be constructed at different sites, and services can be installed depending on the local govemment standards, e.g. wiring colours, plumbing, etc. Installation of services and amenities would occur at the final assembly stage.

Covered walkways and balconies can be included in the design.

The inventive System can be used for mining and military accommodation, and emergency relief, and it is light enough that It could be air dropped from a cargo plane

As the fuel and transport costs are greatly reduced, the inventive System is ‘greener' than current Systems and would be eligible for carbon crédits

The inventive System has been designed to be mass produced using a similar method as is used in the automobile industry.

It is estimated that over the next 5 years, accommodation will be needed for miliions of mine workers.

The location of service ducts horizontally are at the level that services are required i.e. at bench helght 900mm approx and then a 1150 mm approx spacing panel and then another service duct for lighting and then a top panel above to the ceiling junction. The roof section is situated in place last and thus capturing the panels in position and then fastening the roof section to the columns for transport.

As the inventive System allows for more than one building shell to be transported multiple and Individual building sections can be coupled together to create a wider building structure.

The finished building structure can hâve a sloping roof that would be more aesthetically pleasing and allow water or snow to run off the roof and also create a void between the ceiling and roof for ventilation and a more efficient insulation roof area.

The inventive System can utilise spreader pièces to the roof and floor and thus increase the overall width of a completed building where two or more building shells are to be jolned together to form a single building structure.

By encloslng the extemal faces of the transported container sections with protection panels that can be relocated to complété the extemal walls, the protection panels serve the purpose as a bracing component and a shock absorber to absorb destructive energy during transport caused by pot holes or bumps in road surfaces and other unknown factors during transport. These panels could be installed In such a way to allow window and door openings. This provides an exterior shell of a building that could then be completed in a conventional manner. A concrète

-18floor slab as the base gives the building mass to hold the building down. A concrète slab can be added to the top of the container when used in a high rise situation.

The columns can also be filled with concrète or other suitable material from the top. Reinforcement material such as steel rods can also be Installed inslde the columns. Thus the finished building will hâve the sufficient structural Integrity and fire rating capacity.

The inventive system generally cornes with a horizontal roof which Is easier to store, transport and Install and can be stacked to many levels if required

The Inventive system can be transported 2,3 or more high on a truck or carnage in a near complété state (see figure 10)

The Inventive system can be pre certified and easily adapted to suit ali régions worid wide

The Inventive System requires minimal on-site setup, with fuily completed interior fittings and services. The inventive system simply needs to be piaced, erected and centre panels inserted reducing commissioning times and reducing costs.

The Inventive system allows for easy access of ali services, and allows for upgrading, testing and repair if required at any time.

The manufacturing process has been designed so that different components may be constructed at different sites, and services can be Installed depending on the local govemment standards, eg: wiring colours, plumbing, etc. installation of services and amenities would occur at the final assembiy stage.

Covered walkways and balconies can be Included in the design by utilizing the side panels.

The product can be used for mining and military accommodation, and emergency relief, and it is light enough that It could be air dropped from a cargo plane

The inventive system has been designed to be mass produced using a similar method as is used ln the automobile Industry. There is nothing of this kind on the market.

Eave overhangs, valley panels and other sections that may be required can be installed to the building.

Drawings Number Description List

1000 Container

1000A Lower Section

1000B Upper Section

1001 Collapsed Container - Transport Arrangement

1002 Collapsed Container - Transport Arrangement

1003 Collapsed Container - Transport Arrangement

1004 Collapsed Container - Transport Arrangement

1005 Collapsed Container - Transport Arrangement

1006 Collapsed Container - Transport Arrangement

1010 Châssis

1011 Lower Section - Side Beam

1012 Lower Section - End Beam

1013 Fork Lift Pocket Opening

1014 Lower Section - Side Beam

1015 Lower Section - End Beam

1016 FloorJoist

1017 Fork Lift Pockets * Compensation Plate

1030 End Wall

1031 End Wall Panel - Lower Fixed

1032 End Wall Panel - Removable

1033 Side Wall Panel - Upper (Fixed)

1040 Roof

1041 RoofSkin

1042 Roof Skin

1050 Rail/Column

1051 Interleave Guide Rail/Column - Lower Section

1052 Interleave Guide Rail/Column - Upper Section

1053 Standard ISO Corner

1054 Standard ISO Corner

1055 Interleave Guide Rail - Centre Section

1056 Standard ISO Corner Top Opening

1057 Standard ISO Corner Side Opening

1060 Side Wall

1061 Side Panel / Awning

1062 Side Panel / Awning

1063 Side Wall Panel Fixed - Insulated (Sandwich Panel)

1064 Side Wall Panel Fixed - Insulated (Sandwich Panel)

1065 Side Wall Panel Removable - Insulated (Sandwich Panel)

1066 Door

1067 Side Window - Removable

1068 Side Wall Panel Removable - Insulated (Sandwich Panel)

1069 Doorway

1069A Doorway

1070 End Wall

1080 Side Wall

1081 Side Wall Panel Removable - Insulated (Sandwich Panel)

1082 Door

1083 Side Wall Panel Removable - Insulated (Sandwich Panel)

1084 Side Wall Panel Removable - Insulated (Sandwich Panel)

1085 Doorway

1085A Doorway

1091 Upper Side Section Structural Corner Member

1092 Upper End Section Structural Corner Member

1093 Upper End Section Structural Corner Member

1094 Upper Side Section Structural Corner Member

1095 Structural Service Duct Support

1096 Door Post Spigot

1097 Structural Service Duct

1098 Structural Service Duct

1099 Structural Service Duct

1600 Interleave Guide Rail - Collapsed - Section

1660 Interleave Guide Rail - Collapsed - Section

1701 Structural Service Duct

1702 Structural Service Duct

1703 DoorPost

1704 DoorPost

1705 Structural Service Duct Support

1706 Structural Service Duct Support

1707 Structural Service Duct Support

1708 Structural Service Duct Support

1709 Structural Service Duct Support

1710 DoorPost

1711 DoorPost

1712 Structural Service Duct Support

1713 Structural Service Duct Support

1714 Structural Service Duct Support

1715 Internai Coving

1716 Fastener

1720 Ceiling Panel

1801 Internai Wall Panel - Removable

1802 Internai Wall Panel - Removable

1803 Internai Wall Panel - Removable

1804 Internai Wall Panel - Removable

1805 Microwave

1806 Fridge

1807	Hot Water Tank
1808	Locker
1809	Water Closet
1810	Flexible Doors
2101	Bedroom
2102	Lounge
2103	Kitchen
2104	Bathroom
2115	Toilet
2300	Plumbing / Drainage
2400	Container
2401	Floor base

2402A Roof section

2402B Roof section

2403	Wall/roof sections
2404	Wall/roof sections
2405	Column
2406	Wall panel
2407	Wall Panel
2408	Wall Panel
2409	Wall Panel
2410	Container
2411	Floor base
2420	Walkway/roof
2430	Two storey building structure
2440	Container building structure
2500	Container

-232501A Floor base

2501B Floor base

2502A Roof section

2502B Roof section

2503 Wall/roof sections

2504 Wall/roof sections

2505 Column

2520 Building structure

2600 Container

2601 Floor base

2602A Roof section

2602B Roof section

2603 Wall/roof sections

2604 Wall/roof sections

2605 Column

2620 Container building structure

2630 Container building structure with covered walkway

2701A Floor base

2701B Floor base

2701D Floor base

2701G Floor base

2702A Roof section

2702B Roof section

2705 Columns

2706 Centre roof panel

2707 Centre roof panel

2708 Extra columns

2709 Eave panel

2710 Eave panel

2801A Floor base

2801B Floor base

2801C Floor base

2801D Floor base

2801E Floor base

2801F Floor base

2801G Floor base

2802A Roof section

2802B Roof section

2802C Roof section

2802D Roof section

2805 Coiumns

2806 Centre roof panel

2807 Centre roof panel

2808 Extra coiumns

2809 Eave panels

Advantages

a) A height adjustable shipping container Is provided which allows a compacted building to be easily transported and expanded at the destination.

b) Multiple containers can be located together to provide rooms which are larger than a single container.

c) Exterior panels of the container may elther be packed within the container or moved from one position when compacted to another when expanded.

d) Significant réduction In the net cost of providing accommodation.

e) Formatted around ISO shipping container design.

f) Able to create high rise by stacking multiple containers on one another.

g) Able to be used for different applications Including, but not limited to, résidentiel housing, storage units, sheds, garages, and buildings for emergency relief, public or commercial use.

h) The storage space required Is reduced by at least 50%, so transportation costs are also reduced by up to 50%.

I) Twlce as many containers can then be delivered In the same amount of time.

Variations

It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, ail such and other modifications and variations thereto as would be apparent to persons skilled In the art are deemed to fall within the broad scope and ambit of this invention as Is herelnbefore described.

Claims (20)

1. CLAIMS:

   Claim 1: A method of manufacturing a transportable expandable shipping container for use as a building structure, wherein the transportable expandable shipping container during transportation houses within a minimum of two roofs and two floors such that when the transportable expandable shipping container is expanded for use as a building structure the transportable expandable shipping container makes up a minimum area of that of two standard shipping containers, the method includes:

   (i) providing a container base and vertical members, providing at least one first vertical wall portion adapted to be attachable to the base and adapted to extend less than the packaged height of the container, providing an upper surface secured at least In one position to an upper portion of a vertical member, providing at least one second vertical wall portion adapted to extend towards the first vertical wall portion from the upper surface, the vertical members having a horizontally extending channel to support a portion of a ioad bearing beam adapted to extend between two spaced apart expandable vertical members;

   (ii) extending the members to an expanded position;

   (iii) attaching at least some part of an interchangeable and relocatable side walls to an upper part of the height adjustable container during expansion; and (iv) attaching at least some other part of the Interchangeable and relocatable side walls to the Iower part of the height adjustable container during expansion whereby the Iower part of the side walls is substantiaily high enough to accommodate building components, fittings, fumiture and fixtures below its height;

   wherein when the container is In an unextended position the height of the container Is at a reduced height of at ieast 50% to that of a standard shipping container and when the container is in the extended position the container is at a height equal to that of a habitable area or greater than the height of a standard shipping container and the erected side walls are coaxially aligned to form outer walls having a fiat planar surface along the entire surface area of the outer wall.
2. Claim 2: A height adjustable transportable shipping container usable as a building structure, wherein the transportable expandable shipping container houses during

   -27transportation within a minimum of two roofs and two floors such that when the transportable expandable shipping container is expanded for use as a building structure the transportable expandable shipping container makes up a minimum area of that of two standard shipping containers, the height adjustable shipping container having:

   (i) vertical comer members and at least three interchangeable and relocatable side walls which may be transported at a reduced height as a shipping container and expanded at the recetving end wherein at least some of the vertical corner members expand in length during expansion of the reduced height shipping container and the shipping container is capable to house and to transport theretn structural components, such as wall panels, floor, roof and even fittings to erect a building structure that is the équivalent in floor area to that of at least two shipping containers;

   (ii) at least some part of the interchangeable and relocatable side walls is attached to an upper part of the height adjustable container during expansion and at least some other part of an interchangeable and relocatable side walls is attached to the lower part of the height adjustable container during expansion, the lower part of the side walls is substantialiy hîgh enough to accommodate building components, fittings, fumiture and fixtures below its height: and (iii) the vertical members inciuding a horizontally extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart vertical members, wherein further when the container Is in an unextended position the height of the container is at a reduced height of at least 50% to that of a standard shipping container and such that when the container is in the extended position the container is at a height equai to that of a habitable area or greater than the height of a standard shipping container and the erected side walls are coaxially aligned to form outer walls having a fiat planar surface along the entire surface area of the outer wall.
3. Claim 3: The height adjustable shipping container as claimed in ciaim 2, wherein the vertical members are vertical rails or columns.
4. Claim 4: The height adjustable shipping container as claimed in any one of daims 2 to 3, wherein the height adjustable shipping container includes access points for utility services, the access points are situated at the junctures of the upper and lower walls.

   -28Claim 5: The height adjustable shipping container as claimed in any one of claims 2 to 4, wherein at ieast part of a wall filling the gap between upper and lower shipping container parts is pulied into place on expansion of the container.
5. Claim 6: The height adjustable shipping container as ciaimed in any one of claims 2 to 7, wherein. the side panels are adapted to act as bracing and shock absorbera when the shipping container is being transported
6. Claim 7: The height adjustable shipping container as claimed in claim 6, wherein two such expanded angled top surfaces may be placed side by side to form a peaked pitched roof.
7. Claim 8: The height adjustable shipping container as claimed in any one of claims 2 to 7, wherein the floor of the shipping container may act to receive a pourable settable material and may include éléments acting as reinforcement for the settable material.
8. Claim 9: The height adjustable shipping container as ciaimed in ciaim 8, wherein the reinforcement éléments may extend through two adjacent expanded shipping container floors.
9. Claim 10: The height adjustable shipping container as claimed in any one of claims 2 to 9, wherein the shipping container corner members may Include telescoping portions in which any engagement features in the corner rail top are substantially repeated in the top of each telescoping portion.

   Claim 11 : The height adjustable shipping container as claimed in any one of daims 2 to 10, wherein when In the expanded form the corner members remain capable of supporting vertical loads.
10. Claim 12: The height adjustable shipping container as claimed in claim 2, wherein the side panels can be relocated to an outer sheli of the erected container to create a combination of

    -29extemal walls, Windows and door openings, whereby the panels, Windows and doors are interchangeable, and able to create a number of different formats as desired.
11. Claim 13: The height adjustable shipping container as claimed In claim 8, wherein the floor indudes spaced apart openings adapted to receive the fines of a fork lift to aliow the unerected shipping container to be easily transportée! and are adapted when the shipping container is erected to used as service ducts.
12. Claim 14: The height adjustable shipping container as claimed in claim 2, wherein the vertical corner members hâve an open cross section.
13. Claim 15: The height adjustable shipping container as claimed in claim 2, wherein the lower part of the side wails is substantially 0.9 métrés high and the upper part of the side walis is substantiaily 0.3 métrés high.
14. Claim 16: The height adjustable shipping container as claimed In claim 2, wherein the height adjustable shipping container shipping container top surface that is angled with respect to the plane of the floor.
15. Claim 17: The height adjustable shipping container as claimed in ciaim 14, wherein the verticai comer members hâve a substantially ’L'-shaped cross section.
16. Claim 18: A transportation system for the transportation, packaging and érection of a transportable height adjustable shipping container usable as a building, the transportable expandabie shipping container during a transportation mode houses within a minimum of two roofs and two floors such that when the transportable expandable shipping container in a building mode for use as a building structure the transportable expandabie shipping container makes up a minimum area of that of two standard shipping containers, the transportation system including an extemal building shell transformable from the transportation mode to the building mode, when in the transportation mode the extemai building shell fails within same floor dimensions and floor area of a shipping container format, the extemal building shell being height adjustable such that the extemal shell is adapted to be transformed from the transport

    -30mode to the building mode by adjusting the helght of the extemal building shell to a desired height, when In the transportation mode the internai space within the extemal building shell Includes structural components, such as building components, wall panels, floor, roof fittings, fumiture and fixtures required to erect and fit out a building structure that Is the équivalent In floor area to that of at least two shipplng container formats; the extemal building shell includes:

    a) vertical corner members and at least three interchangeable and relocatableside waiis which may be transported at a reduced height as a shipplng container and expanded at the receiving end wherein at least some of the vertical corner members expand In length during expansion of the reduced height shipping container;

    b) at least some part of the Interchangeable and relocatable side walls Is attached to an upper part of the height adjustable container during expansion and at least some other part of an interchangeable and relocatable side walls Is attached to the lower part of the height adjustable container during expansion, the lower part of the side waiis Is substantially high enough to accommodate the structural components, such as building components, wall panels, floor, roof fittings, fumiture and fixtures, below its height when In the transportation mode; and

    c) the expandable vertical members having a horizontaliy extending channel to support a portion of a load bearing beam adapted to extend between two spaced apart expandable vertical members, wherein the transportation System when In the transportation mode the extemal building shell Is at a reduced height of at least 50% to that of a standard shipplng container and such that when in the building mode the extemal building shell is at a height equal to that of a habitable area or greater than the height of a standard shipplng container and the erected side waiis are coaxially aligned to form outer walls having a fiat planar surface along the entire surface area of the outer wall.
17. Claim 19: The transportation system as ciaimed In claim 18, wherein the lower part of the side walls is substantially 0.9 métrés high and the upper part of the side walls Is substantially 0.3 métrés high.
18. Claim 20: The height adjustable shipping container as ciaimed in claim 18, wherein the vertical corner members hâve an open cross section.

    -31 Claim 21 : The transportation system as claimed In claim 20, wherein the vertical corner members hâve a substantially ‘L’-shaped cross section.
19. Claim 22: The method of manufacturing a transportable expandable shipping container for use as a building structure as claimed in ciaim 1, wherein the method indudes a further step of relocating the éléments forming the shipping container walls during transport elsewhere to and/or within the container after expansion.
20. Claim 23: The height adjustable transportable shipping container usabie as a building structure as claimed in claim 2, wherein the éléments forming the shipping container walls during transport adapted to be relocated elsewhere within the container after expansion.