EP1636446A1

EP1636446A1 - Ready-to-use containerised house

Info

Publication number: EP1636446A1
Application number: EP03730395A
Authority: EP
Inventors: Andrea Simonetti
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-06-03
Filing date: 2003-06-03
Publication date: 2006-03-22
Also published as: AU2003241075A1; WO2004106669A1

Abstract

The present invention relates to a modular house consisting of a plurality of ISO containers or modules, ready for use from the factory, each of said modules being fitted, from origin, with means for rapid connection and the mechanical, structural and functional continuity of said systems between modules, means for quick coupling, between adjacent modules, means of sealing along the contact walls between modules, means of mechanical connection and adjustment between modules, means of anchoring and adjusting the building to the ground, and, preferably, all the types of technological system, every final architectural finishing, heatproof and soundproof insulation, means of roofing and internal and external finishing and a module containing the technological system machinery serving the house.

Description

READY-TO-USE CONTAINERISED HOUSE

Technical field

The present invention relates to a ready-to-use containerised house and, more in particular, a house consisting of a plurality of modules, for example ISO standardised container-modules, that can be put together according to the most varied requirements, each of said modules being fitted, from the factory, with all the equipment and technological installations and indoor and outdoor architectural finishings, required to construct an entirely finished and perfectly functional house, even of considerable dimensions, that can be swiftly assembled or dismantled and easily transported a number of times without any loss of functionality or repair to any part of it. Background art

Many proposals for the productions of so-called prefabricated types of residential and industrial buildings and the like are known. However, given that it is not easy to obtain high quality constructions, prefabricated buildings have been confined either to low level or temporary housing or for military modules, for construction sites, warehouses and the like, for which it is not strictly necessary to have high comfort and/or considerable dimensions. When, however such characteristics are required or the level of prefabrication is low, consisting essentially in the pre- construction of empty rooms, also of a standardised type, and walls, which are to be assembled it will later be necessary to complete the construction with the necessary heating, plumbing and sanitary systems and with furnishings. Only in certain cases is it foreseen that certain systems and/or equipment be included from manufacture. Moreover, with the exception of very small units, the final product is of a practically fixed type, and any movement of the construction is practically impossible, requiring considerable work for the detachment of modules and the systems that connect them, to one another. United States patent number 6463705 describes a standard container containing a series of panels and elements designed to permit the construction, in the site of positioning, of a prefabricated building. If on the one hand, this solution makes it possible to send the entire construction in a simple way, on the other it requires considerable assembly times, as well as the preparation in the assembly site of the electrical, plumbing, heating, telephone systems and any others that may be necessary for use.

One step forwards is made in the construction described in patent EP0126063, in which a residential module is consisting of a container in which the two largest side walls can be knocked outwards to constitute a floor, whilst further modules contained in the container made to slide telescopically outwards to cover the flooring obtained previously from the rotation of the larger side walls. It is possible to foresee the direct assembly in the factory of only part of the furnishings and the technical systems.

The documents recalled above undoubtedly constitute a step forward in relation to that described traditionally in the state of the art, but nevertheless they still present many weak points. For example, in some of them a certainly long and expensive assembly of the walls, systems and furnishings is foreseen. Others are dedicated to industrial purposes, warehouses or in any case low-quality housing. None of them tackle the problem of swift and safe assembly not only of the units that constitute the final construction, but also the systems (electrical, plumbing, telephone and the like). In the light of this, it is obvious that an innovative type of house is called for, such as that proposed by this present invention, that solves all the abovementioned drawbacks, that is pre-packaged and finished and in every detail, functional, inhabitable and comfortable from the factory, manufactured through the assembly of a limited number of ISO container-modules, which are separable, transportable and re-assemblable with one another several times without problems, preferably furnished to measure and, where necessary, made completely autonomous in its function by a service module.

In this way it is possible to drastically reduce costs and inconveniences and reduce to just a few hours the onsite assembly operations. Inside the house, according to the present invention it is possible to make homogeneous and repeatable all the characteristics desired and easily obtain perfectly finished products even in locations where specialised manpower and materials are scarce. Moreover, by constructing a house with all the specialised technologies, means and skills available in the factory of origin, it is possible to guarantee qualitative standards and finishings that are decidedly superior to those that can be obtained with the traditional techniques available on site, by choosing them from a vast range of possibilities and personalising them in various ways. Description of the invention

The present invention therefore aims to provide a system of standardised containers in which each container is fitted, from the factory, with electrical, plumbing, telephone, heating, air conditioning, TV system etc. and means for quick connection and the mechanical, structural and functional continuity of said systems between modules, means for fast coupling between adjacent modules, means of sealing along the junction between the modules, mechanical means of connection and adjustment between modules, means of anchoring and adjusting the product to the ground and, preferably, all the equipment and systems and external and internal architectural finishings needed to rapidly build a house, in other words an elegant and comfortable residence, entirely finished and perfectly functional of any size or architecture desired, that is easily transportable, rapidly assemblable or dismantlable and transferable several times without loss of functionality or requiring repairs to any part. Therefore the specific object of the present invention is a transportable house consisting of a plurality of ISO container-modules, not necessarily equally sized, which can be interfaced with one another, complete with external fagade walls/ curtain walls, partition walls, floorings and ceilings with internal and external finishings, of a residential housing type, with thermal and acoustic insulation, indoor and outdoor fixtures, technological systems (plumbing, heating, sanitary, electric, electronic, TV, CCTV, interphones, command and control, telephone, alarm/monitoring, fire extinguishing systems, etc.), and preferably the furnishing of the various functional environments such as the kitchen, bathroom, dining-living areas, bedrooms and night time area, service rooms, flat or sloping roofs, each of said modules being fitted with means for anchoring to the ground, means for fixing the sloping roofs, means for precision coupling between adjacent modules, means of quick connection, for example male and female, for the continuity of the various technological circuits, means of seal along the junctions between adjacent modules, horizontal and vertical adjustments, said means for the mechanical and structural continuity of the systems between modules, for swift coupling between adjacent modules and for the connection and adjustment between the modules each one being, depending on the function it is to fulfil, placed in a univocal position and at a precise height in relation to fixed reference points within the module.

In addition to said, strictly residential, modules, a service container-module could be foreseen, outside the house. This module could contain, for example, drinking water tanks and that containing hot and cold washing water with the respective autoclaves; an air-conditioning unit with filter for air treatment; a generator set with respective fuel and battery pool; a continuity unit for the batteries; an LPG tank; at least one tank for collecting waste water (sewage, washing water, etc.) and any other accessory that experts in the field wish to fit in this module (centralised suction system, compressed air, solar panels, swimming pool filters and pumps, etc.), as well as tubes, cables and anything else for the functional connection of the service module to the house.

Preferably, but not necessarily, the modules constituting the house will be lined up along the longer sides with the main axes of symmetry parallel to one another. According to the invention, if required or desired, the house can be built on two or more floors, by placing the modules on top of one another and connecting them to one another.

Detailed description of the invention The prefabricated house according to the present invention, comprising a plurality of standardised dimensioned modules, not necessarily all equal to one another, is characterised in that each of said modules is designed and built according to the specific position that it will assume when assembled and is already fitted from the factory, with electrical, plumbing, telephone, heating, air-conditioning, TV systems, etc. and means for quick connection and mechanical, structural and functional continuity of said systems between one module and another, means for quick connection between adjacent modules, means of seal along the junctions between modules, mechanical means of connection and adjustment between modules, means for the anchorage and adjustment of the product to the ground and preferably all the equipment and systems and interior and exterior architectural finishings required to build an entirely finished and perfectly functional house, of any size or architecture desired, easily transportable, that can be rapidly assembled or dismantled and transferred several times without any loss of functionality or need to repair any part of it, said means for the mechanical and structural continuity of the systems between one module and another, for the quick coupling between adjacent modules and for the connection and adjustment between the modules being each one, according to the function that it must carry out, placed in a univocal position and at a precise height in relation to fixed reference points within the module.

Preferably, said systems and said means for mechanical continuity, for rapid coupling and for connection and adjustment will be positioned each one within a housing, built in to a wall, that can be easily inspected, and will be fitted with junction terminals with systems and means of the same type on adjacent modules, of a floating type (for example by cables or flexible hosing) so as to compensate any slight imperfections in alignment.

Moreover, the house according to the present invention is equipped with suitable means for fixing, to the upper corner blocks of each module, a roof, for example, sloping and with a load-bearing structure in steel, aluminium, laminar wood or other materials, which can be pre-assembled on the site and, positioned on top of the house, in a single solution, by means of the crane used previously to assemble the container-modules; the same crane can also be used to assemble the same type of roof, but dismantled in a limited number of elements; in any case these operations are performed once the house beneath is perfectly accessible and functional.

As mentioned previously, each of the modules that constitute the house is specifically designed according to the position that it will assume in the finished house and is equipped from the factory with external perimeter walls and partition walls, windows and glazing, entrance doors, roller blinds, heat and sound insulation, exterior lighting equipment, downspouts for the disposal of rain water, system lines and the relative quick connection means between modules, interior doors, light fixtures, electrical sockets, telephone sockets, TV and various technological circuits/networks/lines, furnishing and any other feature desired or provided for in the project.

The lower corner blocks of each module will be fitted with mechanical means for anchoring to the base (for example of the twist-lock type), in such a way as to make the building monolithic and stable, resistant to any type of stress. To close any remaining space between the house and the ground, light die-cast and painted aluminium sheet flashing can be provided from the factory to be assembled when the house is complete; however it is possible to use any other material, for example stone, available on the construction site.

During assembly, the first container or module is positioned on the relative foundation elements, suitably levelled with the utmost precision; module and foundation elements being fitted with co-operating means for compulsory positioning, in relation to the general plan of the house, of the module, which must function as a guiding element for the assembly of all the other modules. Each of the modules is fitted with means for aligning between modules, for example male/female or sliding type, as well as spacer elements for adjusting the alignment between modules. Lastly, it may also be possible to provide other means, depending on the type of house, its position, the ground etc. to facilitate quick and precise assembly, following the project, of the modules composing the house. With regards to the additional work to be performed on the construction site, it should be noted that even prior to the construction of the house in the factory or simultaneous to it, and without interfering with work, some type of foundation system must be arranged, suited to the ground and the house; it is also possible and advisable to perform all the work necessary for external features such as fences, driveways, flowerbeds, irrigation systems, lighting, tree planting, swimming pool, parking spaces, gazebos or others to be arranged. In actual fact, these operations do not hinder nor are they damaged by, the assembly of the house for which the necessary work is reduced to the use of a crane that lifts the modules from the relative means of transport and positions them on the foundations. The present invention will now be described with reference to one of the preferred embodiments, given as a preferred but not exclusive example, as illustrated in the appended drawings and wherein:

Figure 1 illustrates a plan view of a house built from six standard container- modules, for example of 12.192 mm, (40 feet), in length and 2.438mm in width, for a total gross surface area of approximately 180m²;

Figures 2a and 2b illustrate two front views of the house in Figure 1 ; Figure 3 illustrates a sectional representation of a house, according to the present invention, on more than one level; Figure 4 illustrates a section plan of the interior of a house according to the invention with, highlighted, one of the possible distributions of the interior spaces, provided with technological systems and services module illustrated in fig. 9; Figures 5a and 5b illustrate the sections of modules 1 and 2 of Figure 4 respectively in correspondence with the entrance door and one window of the living room, with highlighted two different solutions for the foundations and roofing; Figure 6 illustrates a section of a corner of a module, which shows one type of foundation and the arrangement, in the wall, of a number of systems of the house, together with a systems inspection and maintenance hatch; Figure 7a illustrates a possible mutual aligning and hooking means between modules together with a rapid connection system for the electrical, TV, Hi-Fi installations between modules;

Figures 7b, 7c and 7c' illustrate the details of the connection striker and adjustment means for the swift assembly of modules in the construction site; in particular, Fig. 7b illustrates possible means for positioning and centring the first module, Figures 7c and 7c' illustrate in detail possible systems for mutual alignment and rapid hooking between modules;

Figure 8 illustrates some of the possible combinations of the container modules in order to form different types and sizes of house;

Figure 9 illustrates the technological installation module complete with some equipment and machines foreseen in the project; Figure 10 illustrates a house, according to the invention, set in its surrounding garden. With reference to Figure 1, (1),(2),(3),(4),(5) and (6) indicate, in a dotted line beneath the plan of the sloping roof, six 40-feet (12.192mm) container-modules in their final position, when house assembly is complete.

Figures 2a and 2b illustrate two side prospects of the house in Figure 1 in the one- residential storey version; the sloping roof (20), if pre-assembled on site, can be immediately lifted, using a crane, and installed on top of the house or, if desired, assembled at a later time as the modules, once they have been interconnected are, by construction, sealed and perfectly inhabitable.

Figure 3 illustrates the possibility of placing on top of the ground floor (16) a second level (15), that can be identical in plan to the first floor or, if preferred, different with regards to both the interior distribution and the net surface area. The light and sturdy metal structures, which constitute the frames of the modules, make it possible to place more storeys on top, up to six or more. Internal or external stairs(24), not shown in the figure, or mechanical hoisting equipment (lifts, etc.) are provided for accessing the upper levels. Figure 4 illustrates, as a preferred but not exclusive example, a section of the house in Figure 1, modules (1),(2),(3),(4),(5) and (6), with one of the possible distributions of the environments, where, the conventional symbols also indicate some of the interior furnishings and equipment. By observing Figure 4 in detail, (L1) and (L2) represent the bedrooms, (WC1) and (WC2) the bathrooms, (K) the kitchen, (C) the corridor, (D) a box room, (St) a studio, (So) the living room and (P) the dining area.

The bedrooms (L1) and (L2) can advantageously contain furnishings such as beds, wardrobes, chests of drawers, bed-side tables etc.: the bathrooms, (WC1) and (WC2), will be preferably be fitted with all the plumbing, heating, sanitary equipment and accessory furnishings; the kitchen (K) can be fitted with modular furniture complete with various electrical appliances such as the refrigerator, built- in oven, hob, sink, dishwasher, washing machine, etc.; the same applies for the other daytime environments (P), (So) and (St); it is equally obvious that in order to avoid damage during transport, particular measures will be taken in order to ensure the stability of the furnishings and equipment.

Lastly, as the only temporary operation of the building, during transportation, the temporary protection of the surfaces visible on the sides of the modules is provided for using waterproof tarpaulins or rigid enclosures. As can be shown in Figure 4 along the dotted lines that represent the lines of demarcation between one container-module and another, there are not generally foreseen important or irremovable structures, such as bathroom fittings, doors, undismantlable wardrobes, etc. so that, on dismantling, nothing must be moved from the original position, except part of the furnishing.

Conversely, where said dotted lines of demarcation between one container and another meet, in the points indicated with (x-x), interior walls and in the points (y-y) the exterior vertical closures, light cable runs are provided for the walls and furnishings, which can be sectioned in those points, for the furnishings; the same considerations apply for the ceilings and false ceilings.

The precise alignment and continuity of the flooring, along the junctions between modules, will be assured, primarily, by the previously mentioned male (41) and female (42) precision strikers (SP) in figure 7a, 7c and by the adjustments (43) in Fig. 7c', (cylindrical screw spacers, SPR), of which the modules are equipped and that allow correct positioning identical to the original position established and tested in the factory; moreover, even in the factory the solutions of continuity along those lines will be made invisible, thus resolving the problem at the origin, regardless of whether the flooring is in carpet, parquet, resistant tiles or other materials.

In Figure 9, (60) indicates the ISO technological system container-module, detached from the house, which can contain, according to specific needs, one or more silenced generator sets (65), the drinking water tank with autoclave (66), the continuity unit and relative batteries (67), the air-conditioning machinery (68), the LPG tank (69) and any other auxiliary installations such as central suction system, compressed air, pool filters, etc.

Preferably such a module will be positioned out of view from the house, partially underground, hidden by vegetation or in any case ecologically integrated into the environment. The chamber that can be inspected and removable from outside (27) in Figure 4 contains all those terminals and fast connections to system lines afferent to it or from the technological installation module (60) from the fixed distribution network. The buried inspection channel (73) is designed to house the bundle of cables and flexible hosing that, initially contained in and then unrolled from the module (60) terminate in a chamber (27) as designed; in the same position it is also possible to foresee connection to the waste water disposal network. In particular reference to Figure 5a, illustrating a section of the modules (1) and (2) in Figure 4 in correspondence with the corridor (C), (36) indicates a pavement arranged previously on site, running all around the perimeter of the house, designed to overcome the height difference that could arise between the height of the position of the same and the level of the countryside. In Figure 5b, one observes how the same result can be obtained using lightweight die-cast and painted aluminium sheet flashing (37), arranged in the factory for quick click-in or slide in assembly.

Returning to Figure 5a, (39) indicates the front door, (38) the heat insulated flooring, wall and ceiling material, (34) a type of foundation, on posts, with (31) a sloping roof, (33) the means for locking the roof to the modules below.

Figure 5B illustrates a section on a window (25) with a box for housing a roller blind (26), a second type of foundation with prefabricated plinths (19), flat horizontal roofing (17), with die-cast and painted aluminium sheet flashing (28), also manufactured in the factory for fast clip- or slide in assembly. Figure 6, a vertical-transverse section of a generic module in correspondence with a structural hitch, illustrates the composition of a vertical perimeter wall (48) and the flooring (54); the wall may comprise a first weather-proof layer (50), a heat and sound proof layer with steam barrier (51), an air space (52) an internal finished wall (53); (13) illustrates the sections of the system pipes and the channels that house them, which can be inspected from outside through a hatch (14) corresponding to the male and female junctions; the thickness of the wall can house, although not visible in the figure, the rainwater disposal gutters; the base (54) comprising the metal load-bearing structure (47) of the container-module, a thermal and acoustic insulation layer with steam barrier (51 ) and the foundation (29) of the top flooring layer (49).

Figure 7a, a vertical-transverse section of two generic modules to be connected, shows how, on bringing the adjacent modules together, the boxes containing the male (55) and female (56) quick connection units of the systems are aligned and ready to be connected; (59) is a resistant seal placed all along the contact perimeter between neighbouring modules, which permits a seal against meteorological agents such as humidity, rain, wind, dust, etc. The bringing together of the modules until the connection between the male (41) and female (42) strikers triggers and the reduction in volume, due to pressure, of said seal (59), can be obtained by tightening, between modules, using mechanical means or hydraulic jaws, which can be reused for subsequent assembly. Figure 7b illustrates a system, arranged on the double-T girders (44) of the foundation base, with the cone-shaped (45) and blade (46) precision strikers that are necessary for the perfect self-alignment with the base (57) of the first container in relation to which the adjacent containers will be aligned following mutual tightening. Figures 7c and 7c' illustrate the detail of the fixed striker plugs (41) and screw adjusters (43) to be housed in the seat (42).

Figure 8 illustrates a choice between some of the possible sizes and types of house that can be obtained using the system according to the present invention: (7) indicates a 60m² house, (8) a 90 m²house, (9) a 120m² house, (10) a 180m² house, (11) a 240 m² house and (12) a 270 m² house etc. Figure 10 illustrates the house in Figure 1 , composed of six ISO container- modules and gross surface area of 180m² set in a garden with a swimming pool (70), entrance gate (71), driveway (72), car parking area (74), buried channel (73) connecting the house and the technological system module (60). It is obvious how, by combining according to multiple configurations, the container- modules described above, it is possible to create different houses of varying sizes, suited to any size, performance and cost requirement, very quick to assemble and that can be transported several times.

The present invention has been described, with specific reference to some preferred embodiments, but it should be understood that any variation or modification might be performed by the experts in the field will be considered within the scope of the invention.

Claims

1. Ready-to-use containerised house, comprising a plurality of modules of standardised dimensions to be connected to one another, characterised in that each of said modules is designed and constructed depending on the specific position that it will assume during use, and it is fitted from the factory, with electric, plumbing, telephone, heating, air-conditioning, TV and similar systems and means for quick connection and mechanical, structural and functional continuity of said systems between modules, of means for quick coupling between adjacent modules, means for the seal along the junctions between modules, means for anchoring and adjustment of the product to the floor, said means for the mechanical and structural continuity of the systems between modules, for the quick coupling between adjacent modules and for the connection and adjustment between modules each one being, according to the function to be fulfilled, placed in a univocal position and at a precise height in relation to fixed reference points within the module.

2. The house according to claim 1 , equipped from the factory with all the equipment and internal and external architectural finishings and systems necessary to directly construct an entirely finished and perfectly functional house, of any dimension and architecture desired, easy to transport, quick to assemble or dismantle and transferable several times without loss of functionality or repair to any part of it.

3. The house according to claim 1 , in which said systems and said means for mechanical continuity, for quick coupling and connection and adjustment each one will be placed inside a housing, built into a wall, that can be easily inspected and will be fitted with junction terminals with systems and means of the same type on adjacent modules.

4. The house according to claim 3, in which said junction terminals are of a floating type, elastically connected to the respective systems.

5. The house according to claim 4, in which said terminals comprise cables and flexible hosing.

6. The house according to claim 1, fitted with suitable means to fix to the upper part of each module a roof, be it sloping or flat.

7. The house according to claim 1 , in which the lower part of each module is fitted with mechanical means for anchoring to the base.

8. The house according to claim 7, in which said mechanical means are of the twist-lock type.

9. The house according to claim 1 , characterised in that it comprises standardised dimension modules of different dimensions.

10. The house according to claim 1, fitted with a technological system module detached from the house.

11. The house according to claim 1, in which said modules dimensionally satisfy ISO container standards.

12. The house according to claim 1 in which the modules are covered on the floor, walls and ceiling with furnishing material and do not require any assembly finishing operation.