EP3926114A1

EP3926114A1 - A modular building unit

Info

Publication number: EP3926114A1
Application number: EP21179835.0A
Authority: EP
Inventors: Aidan Pearce; Matthew Eastwood; Adam Sawyer; Sam O'Sullivan; Edward Ward
Original assignee: Portakabin Ltd
Current assignee: Portakabin Ltd
Priority date: 2020-06-18
Filing date: 2021-06-16
Publication date: 2021-12-22
Also published as: GB202009355D0; GB2596130A

Abstract

A modular building unit has a base frame for supporting a floor panel, a roof frame for supporting a roof panel, and upright columns extending between the base frame and the roof frame. Each upright column is connected to the base frame by a floor corner module at junctions therebetween and is connected to the roof frame by a roof corner module at junctions therebetween. Each of the roof corner modules and floor corner modules are provided as sub-assemblies of the modular building unit.

Description

FIELD

The present teachings relate to a modular building unit.

BACKGROUND

Modular buildings are prefabricated buildings that are formed from one or more modular units. These modular building units are manufactured in a factory away from the building site, and then transported to the building site so as to be assembled into a modular building. The modular building units are constructed so as to be capable being attached side-by-side, end-to-end, or stacked, which enables modular buildings to be produced having a variety of shapes and styles using a single repeatable modular building unit.
After the modular building units have been assembled, e.g. using a crane, the modular building units are connected together. It is then necessary to seal the joints between adjacent modular building units, for example to prevent draughts and the ingress of rain water into the modular building, and to increase the thermal insulation of the modular building by reducing heat escaping between the adjacent modular units.
The modular building units are designed to have sufficient strength/rigidity to comply with the local laws of the country in which the modular building is to be constructed. However, existing modular building units may not be suitable to be used in the construction of buildings as they may not comply with local wind, heat, and snow load requirements.
The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

A first aspect of the teachings provides a modular building unit comprising: a floor assembly comprising a base frame for supporting a floor panel thereon; a roof assembly comprising a roof frame for supporting a roof panel thereon; and a plurality of corner assemblies each comprising an upright column extending between the base frame and the roof frame, a floor corner module mounted proximate a lower end of each upright column and a roof corner module mounted proximate an upper end of each upright column, wherein the base frame is formed from a plurality of base frame members extending between adjacent floor corner modules and mounted thereto and/or wherein the roof frame is formed from a plurality of roof frame members extending between adjacent roof corner modular and mounted thereto.
In conventional modular building units, upright corner columns are typically welded directly onto the beams of the roof and base frames. In the present arrangement, corner modules are provided that are manufactured separately from, and mounted to, the upright columns. The corner modules also provide a mounting surface for mounting the base frame and roof frame thereon. This arrangement advantageously enables the corner modules and beams (roof frame members, base frame members and upright corner columns) to be designed independently so as to provide a modular building unit with increase structural strength whilst providing the required functionality/connectivity.
Moreover, providing the corner assemblies as sub-assemblies of the modular building unit has advantageously been found to facilitate assembly of the modular building unit.
One or more of the plurality of floor corner modules may comprise a first alignment member for aligning the modular building unit with a further modular building unit.
The provision of an alignment member/feature facilitates the placement of a modular building unit onto a further modular building unit, and so the facilitates the construction of a modular building assembly.
Providing the first alignment member on a modular self-assembly of the modular building unit enables the member to be constructed separately from the beams. This, in turn, enables the first alignment member to have sufficient structural strength to withstand impacts with further modular building units during assembly, without having to modify the configuration of the beams.
One or more of the roof corner modules may comprise a second alignment member configured and arranged so as to engage with a first alignment member of a floor corner module of a further modular building unit to align the modular building unit with a further modular building unit.
Providing the second alignment member on a modular self-assembly of the modular building unit enables the member to be constructed separately from the beams. This, in turn, enables the second alignment member to have sufficient structural strength to withstand impacts with further modular building units during assembly, without having to modify the configuration of the beams.
The first alignment member may be a male alignment member comprising a projection extending from the floor corner module.
The second alignment member may be a female alignment member, e.g. an aperture or recess, configured to receive the male member therein.
The male alignment member may be tapered, e.g. conical.
The provision of a male alignment member on a floor corner module has been found to facilitate the assembly of modular building units when constructing a modular building assembly. The tapered projection further facilitates the alignment of two modular building units, particularly when the modular building units are positioned using a crane.
The provision of a female alignment member on a roof corner module enables the female member to also function as aperture for receiving an engagement member of a lifting apparatus therein.
Each of the plurality of upright columns may be provided in the form of an L-section beam comprising a stiffening configuration extending along the elongate length of the upright column.
The use of L-section beams for the corner columns enables the space defined between the arms of the L-section beam to be accessible.
The provision of a stiffening configuration on the columns has been found to provide increased stiffness and rigidity to the corner regions, which helps to reducing local buckling effects in the corners of the modular building unit. This, in turn, improves the overall structural performance of the modular building unit.
The stiffening configuration may comprise a stiffening arm extending away from, e.g. perpendicularly away from, one or both side edges of the upright column. The provision of the stiffening arm(s) has been found to provide increased stiffness and rigidity to the corner regions, which improves the overall structural performance of the modular building unit.
The stiffening configuration may comprise a return arm extending away from, e.g. perpendicularly away from, a distal end of the or each stiffening arm.
The provision of the return arm(s) further increases the stiffness and rigidity to the corner regions, which improves the overall structural performance of the modular building unit.
The stiffening configuration may terminate a predetermined distance away from the upper and lower ends of the upright column so as to define upper and lower end regions of the upright column that are substantially L-shaped in cross section.
The roof corner module and floor corner module may be mounted in said upper and lower end regions.
The predetermined distance proximate at the upper and lower ends of the upright column may correspond with a height of the roof corner module and floor corner module, respectively, along an axis parallel with the elongate axis of the upright column.
This arrangement enables the upper and lower corner modules to abut against, and be secured to, and end face of the stiffening configuration. Moreover, this configuration of the upright columns provides a portion of the upright columns to extend around two sides of the corner modules.
This has been found to increase the structural strength of the modular building unit.
The roof corner modules and/or floor corner modules may comprise an upper plate and a base plate connected by two module side walls.
The upper and lower end regions of the upright columns may enclose the two open two side faces of the roof corner modules and/or floor corner modules, respectively.
Each roof frame member may define a channel forming a gutter for draining water, and wherein one or more of the upright columns comprises a drainage conduit extending therealong for draining water received in the gutter.
The drainage conduit may extend between a roof corner module and a floor corner module of a corner assembly.
Through this arrangement, the roof frame of the modular building unit is able provide drainage to drain rain water away from the roof assembly.
Providing a drainage conduit, i.e. a drain pipe, that is positioned within, or contained within, an upright column of the modular building unit further improves the ability of the modular building unit to drain rain water away from the roof assembly without any additional components being mounted to the modular building unit.
Each roof frame member may comprise opposing inner and outer walls connected by a base to define a channel therealong.
Each roof corner module may define a flow path therethrough for connecting the channels of adjacent roof frame members such that the gutter is connected to the drainage conduit via one a roof corner module.
This arrangement provides an inlet to the drainage conduit within a roof corner module, which helps to facilitate drainage of collected rain water along a flow path within the modular building unit.
The modular building unit may comprise an overflow outlet at or near an upstream end of the drainage conduit.
The overflow outlet enables rainwater to be discharged out of the modular building unit in the event that the drainage outlet and/or drainage conduit become blocked. The overflow outlet may be provided on a roof corner module.
The modular building unit may comprise a drainage outlet at or near a downstream end of the drainage conduit for discharging water received in the gutter out of the modular building unit.
The drainage outlet may be provided on the floor assembly, e.g. on a base plate of a corner assembly.
Providing a drainage outlet enables the collected rain water to be discharged from the modular building unit in a controlled way. The outlet may enable the collected rainwater to be discharged outside of the modular building unit, for example into a tank for storage, or into a further modular building unit or below the modular building unit.
Providing a drainage outlet in the base assembly enables the water to flow down to the bottom of the modular building unit, which allows the water to be drained into a unit below, if the modular building unit is stacked on top of another unit.
The modular building unit may comprise an attachment arrangement for attaching the modular building unit to an adjacent modular building unit, wherein the attachment arrangement is adjustable on the modular building unit for aligning with an attachment arrangement of an adjacent modular building unit.
The provision of an alignment arrangement facilitates the assembly of a modular building from several modular building units.
The attachment arrangement may comprise an aperture for receiving a fastener therethrough, said aperture being moveable relative to the modular building unit.
The aperture may be provided eccentrically on a sleeve that is rotatably mounted to the modular building unit.
The sleeve may be mounted to an upright column.
Each floor corner module may comprise a base plate having an aperture for receiving a lashing member therein, and wherein the aperture is provided on a recessed region of an upper surface of said base plate.
The provision of the recessed aperture for a lashing member helps to ensure that the lashing member does not contact any internal parts of the modular building unit, e.g. the rest of the base frame of the wall panels etc., apart from the base plate.
Each of the plurality of roof frame members may comprise a stiffening configuration.
The provision of a stiffening configuration on the roof members has been found to provide increased stiffness and rigidity to the roof frame, which helps to reducing local buckling effects in the roof frame. This, in turn, improves the overall structural performance of the modular building unit.
Each roof frame member may be in the form of a substantially U-shaped beam defining inner and outer walls, and wherein the stiffening configuration comprises a stiffening wall extending away from, e.g. perpendicularly away from, a distal end of the outer wall.
The stiffening configuration may comprise a return arm extending away from, e.g. perpendicularly away from, a distal end of the stiffening wall.
The stiffening configuration may comprise an end return extending away from, e.g. perpendicularly away from, a distal end of the return arm.
The modular building unit may comprise a seal attached to an upright column, the seal comprising a compressible seal body configured to seal against the upright column and a surface of a further modular building unit, seal further comprising a lip extending from the compressible seal body and defining a mounting surface for attaching the seal to the modular building unit.
The compressible seal may extend substantially along an entire elongate length of the upright column.
The use of a seal having a compressible body to sealingly engage a surface of a further modular building unit helps to reduce the ingress of water between two modular building units.
Providing a projecting lip for attaching the seal to the modular building unit enables the seal to be attached without the attachment means (e.g. a fastener) impacting the compressibility of the seal. This has been found to improve the seal formed against a further modular building unit.
The compressible seal body may comprise an air cavity arranged to be interposed between the upright column and a surface of a further modular building unit, in use.
The provision of an air cavity within the seal between the upright column and further modular building unit helps to increase the compressibility of the seal, which in turn helps to improve the seal formed between the two modular building units.
The compressible seal body may comprise a serrated or undulating surface arranged to engage a surface of a further modular building unit, in use.
Providing a seal surface that is rough/uneven/non-planar has been found to improve the seal formed between the modular building units.
The seal may comprise a deformable material, for example a rubber such as ethylene propylene diene monomer (EPDM).
Each base frame member may be in the form of a box-section beam.
The use of box-section beams for the base frame has been found to provide increased stiffness and rigidity to the base frame, which helps to reducing local buckling effects in the base frame. This, in turn, improves the overall structural performance of the modular building unit.
A second aspect of the teachings provides a modular building unit comprising: a floor assembly comprising base frame for supporting a floor panel thereon; a roof assembly comprising roof frame for supporting a roof panel thereon; a plurality of corner assemblies each comprising an upright column extending between the base frame and the roof frame; and a seal attached to an upright column, wherein the seal comprises a compressible seal body configured to seal against a surface of a further modular building unit and a lip extending from the compressible seal body, the lip defining a mounting surface for attaching the seal to the modular building unit, optionally wherein the compressible seal extends along substantially along an entire elongate length of the upright column.
A third aspect of the teachings provides a modular building unit comprising: a floor assembly comprising base frame for supporting a floor panel thereon; a roof assembly comprising roof frame for supporting a roof panel thereon; a plurality of corner assemblies each comprising an upright column extending between the base frame and the roof frame; and an attachment arrangement for attaching the modular building unit to an adjacent modular building unit, wherein the attachment arrangement is adjustable on the modular building unit for aligning with an attachment arrangement of an adjacent modular building unit, optionally wherein the attachment arrangement comprises an aperture for receiving a fastener therethrough, said aperture being moveable relative to the modular building unit, optionally wherein the aperture is provided eccentrically on a sleeve that is rotatably mounted to the modular building unit, optionally wherein the sleeve is mounted to an upright column.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which:

Figure 1 is an isometric view of a modular building unit;
Figures 2A and 2B are isometric views of upper and lower parts of a corner assembly, respectively, of the modular building unit of Figure 1;
Figure 3 is an isometric view of a base plate of the corner assembly of Figure 2B;
Figure 4 is an isometric underside view of a base plate of a corner assembly of the modular building unit of Figure 1;
Figure 5 is an isometric view of an upright column of the corner assembly of Figures 2A and 2B;
Figure 6 is a cross-sectional view of the upright column of Figure 5;
Figure 7 is an isometric view of a modular building unit attachment sleeve;
Figure 8 is an isometric view of a modular building unit seal; and
Figure 9 is a cross-sectional view of a part of a modular building assembly.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a modular building unit is illustrated and indicated generally at 10.
The modular building unit 10 has a floor assembly including a base frame 14. The floor assembly also includes a floor panel (not shown) supported on the based frame 14. The modular building unit 10 has a roof assembly including a roof frame 20. The roof assembly includes a roof panel 22 supported on the roof frame 20.
The modular building unit 10 is substantially rectangular in shape, and includes a corner assembly at each corner thereof. Each corner assembly includes an upright column or corner column 26. The corner assemblies extend between the floor assembly and the roof assembly 14. Put another way, the four upright columns 26 extend between the base frame 14 and the roof frame 20. As is discussed in more detail below, each corner assembly includes a corner module mounted to the upper and lower end of the upright column 26. The upper and lower corner modules provide a mounting surface to mount the roof frame members 24 and base frame members 16 to the corner assemblies. The corner assemblies (i.e. the columns 26 and the upper and lower corner modules) are provided as sub-assemblies on the modular building unit 10, which facilitates the assembly of the modular building unit 10.
The modular building unit 10 is provided with four side walls 28 substantially enclosing the modular building unit 10. In alternative arrangements, one or more of the side walls 28 may be omitted, for example to enable two or more modular building units 10 to be assembled together to form a modular building assembly.
The base frame 14 is formed from four elongate base frame members 16 arranged so as to form a substantially rectangular base frame 14. It will be appreciated that in alternative arrangements, the shape of the base frame 14 (and the number of base frame members 16) may vary to suit the application.
Each base frame member 16 is provided in the form of an elongate box-section beam. The base frame 14 (i.e. the base frame members 16) are configured to support a floor panel thereon. In the illustrated arrangement, each of the base frame members 16 has an inward projection (not shown) for supporting a floor panel (not shown) thereon. The inward projection may be provided in the form of a substantially L-shaped member or as a plate that is attached, e.g. welded, to the base frame members 16.
The roof frame 20 is formed from four elongate roof frame members 24 arranged so as to form a substantially rectangular roof frame 20. It will be appreciated that in alternative arrangements, the shape of the roof frame 20 (and so the number of roof frame members 24) may vary to suit the application.
Each roof frame member 24 is provided in the form of substantially U-shaped beam. Put another way, each roof frame member 24 includes opposing inner and outer walls connected by a base to define a channel.
Each roof frame member 24 includes a stiffening configuration to increase the stiffness and rigidity thereof. Although not illustrated, the stiffening configuration includes a stiffening wall (not shown) extending away from, e.g. perpendicularly away from, a distal end of each wall of the U-shaped beam. The stiffening configuration also includes a return arm (not shown) extending away from, e.g. perpendicularly away from, a distal end of the stiffening walls. The stiffening configuration may also include an end return (not shown) extending away from a distal end of each of the return arms. This stiffening configuration has been found to provide increased stiffness and rigidity to the roof frame 20, and so to the overall modular building unit 10. In some arrangements, the stiffening configuration may only include the stiffening wall, or may only include the stiffening wall and return arm.
The four elongate roof members 24 are arranged end-to-end such that they form a gutter extending at least partially around the roof frame 20. The gutter (i.e. the channels of the roof frame members 24) extends around an entirety of the perimeter of the roof panel 22, such that rain water falling onto the roof panel 22 will flow into the gutter.
Although not illustrated, the upper surface of the roof panel 22 is pitched in order to facilitate drainage of rain water off the roof panel 22. In the illustrated arrangement, the roof panel pitch is in the range of 1° to 2°, but it will be appreciated that any suitable pitch angle may be used. The roof panel may have a double pitched upper surface, or may have at least four contiguous and converging angled planes.
Referring now to Figures 2A and 2B, a corner assembly is illustrated.
Each upright column 26 includes a lower corner module, or floor corner module, 30 mounted to a lower end thereof. The lower corner module 30 provides a mounting surface to mount the base frame members 16 to the upright column 26. Put another way, the floor assembly mounts onto the lower corner module 30 so as to connect the floor assembly to the corner assemblies.
Each upright column 26 includes an upper corner module, or roof corner module, 32 mounted to an upper end thereof. The upper corner module 32 provides a mounting surface to mount the roof frame members 24 to the upright column 26. Put another way, the roof assembly mounts onto the upper corner module 32 so as to connect the roof assembly to the corner assemblies.
A corner module is provided at each intersection/junction between the upright columns 26 and the base frame 14 and roof frame 20. It will be appreciated that in the illustrated embodiment, each of the four upright columns 26 is connected to the base frame 14 by four lower corner modules 30 and is connected to the roof frame 20 by four upper corner modules 32.
Each of the corner modules 30, 32 are separate from the upright columns 26 and are mounted thereto. Manufacturing the corner modules 30, 32 separately from the upright columns 26 and the base and roof frames 14, 20 enables both the corner modules 30, 32 and the upright columns to be designed independent of each other, so as to be capable of providing the corner assembly increased structural strength whilst maintaining the required functionality.
The floor corner modules 30 are formed from a floor top plate 34 and a floor base plate 36 that are connected via two side plates or side walls 38. The plates 34, 36, 38 are mounted to the upright column 26 and together, e.g. via welding or any other suitable means. The two side plates 38 provide a mounting surface for mounting, e.g. via welding, the base frame members 16 to the floor corner module 30.
The upright columns 26 are configured and arranged extend around a part of the floor corner module 30. In this way, the upright columns 26 are arranged so as to enclose the remaining two faces of the floor corner module 30. In alternative arrangements, it will be appreciated that the floor corner modules 30 may include three or four side walls 38.
The roof corner modules 32 each are formed from a roof top plate 40 and a roof base plate 42 that are connected via two side plates or side walls 44. The plates 40, 42, 44 are mounted to the upright column 26, e.g. via welding or other suitable means. The two side plates 44 provide a mounting surface for mounting, e.g. via welding, the roof frame members 20 to the roof corner module 32.
The upright columns 26 are configured and arranged extend around a part of the roof corner module 32. In this way, the upright columns 26 are arranged so as to enclose the remaining two faces of the roof corner module 32. In alternative arrangements, it will be appreciated that the roof corner modules 32 may include three or four side walls 44.
The roof corner module 32 is configured for connecting to an engagement member of a lifting apparatus (not shown). The top plate 40 of the roof corner module 32 includes an attachment member 60 for connecting to an engagement member of a lifting apparatus (not shown). The attachment member is provided in the form of an aperture 60 in the roof top plate 40 for receiving an engagement member of a lifting apparatus (not shown) therein. The roof top plate 40 includes a bore 59, e.g. a threaded bore, for receiving a fastener (not shown) therethrough to secure the roof corner module 32 to a floor corner module of a further modular building unit.
As discussed above, the roof frame 20 of the modular building unit 10 includes a gutter for draining water. Each of the roof corner modules 32 is positioned between adjacent roof frame members 24. In order to enable water flow around substantially an entirety of the perimeter of the roof panel 22, the roof corner modules 32 include a flow path therethrough for enabling water to flow between the roof members 24. The corner assembly includes a drainage conduit 46 extending along the length of the upright column 26 for draining water received in the gutter. The drainage conduit 46 extends from a roof corner module 32 to a floor corner modules 30. The roof corner module 32 is configured such that water flows into said module 32 from the gutter, and flows into the drainage conduit 46 via the roof corner module 32. In this way, the modular building unit is able to drain rain water away from the roof assembly. It will be understood that the rain water is able to flow around the gutter until it reaches an inlet aperture 48 in a roof corner column 32 (i.e. in a roof lower plate 42) and flows down the drainage conduit 46.
The drainage conduit 46 may be formed from separate sections including an upper section (shown in Figures 2A) and a lower section (shown in Figures 2B) that are connected by an intermediate section (not shown). In alternative arrangements, the drainage conduit 46 may be provided as a single component extending between a floor corner module 30 and a roof corner module 32.
Each corner assembly includes an overflow outlet 54. The overflow outlet 54 is positioned at or near an upstream end of the drainage conduit 46 (i.e. proximate or adjacent to the inlet aperture 48). In the illustrated arrangement, the overflow outlet 54 is provided as an aperture in the upright column 26. In alternative arrangements, the overflow outlet 54 may be provided in the roof corner module 32 or on the roof assembly (i.e. on the roof frame 20). The overflow outlet 54 enables rainwater to be discharged out of the modular building unit 10 in the event that the drainage outlet and/or drainage conduit become blocked.
The corner assembly includes a drainage outlet 50 at a downstream end of the drainage conduit 46 for discharging water out of the modular building unit 10 (e.g. to a storage tank, an external drainage system or a modular building unit below). In the arrangement shown, the drainage outlet 50 is provided as an aperture in the floor base plate 36. It will be appreciated that the drainage outlet 50 may be provided as an aperture on the floor assembly 12 (i.e. on the base frame 14) or in one of a corner column 26.
It will be appreciated that a drainage conduit 46 may not be provided in each corner assembly. In such corner assemblies, the inlet aperture 48 of the roof lower plate 42 and the drainage outlet 50 may be omitted.
Referring now to Figure 3, the base plate 36 of a floor corner module 30 is illustrated.
As discussed above, the base plate 36 includes an aperture 52 that aligns with the drainage conduit 46 so as to form a drainage outlet of the corner assembly.
The base plate 36 includes an aperture 62 for receiving a lashing member of a lifting apparatus (not shown) therein. The aperture 62 is provided on a recessed region 64 of an upper surface of the base plate 36. Providing the aperture 64 on a recessed portion 64 of the base plate 36 provides sufficient spacing between a lashing member and the internal parts of the modular building unit 10, such as the base frame or the wall panels etc..
The base plate 36 includes a bore 63, e.g. a threaded bore, for receiving a fastener (not shown) therethrough to secure the roof corner module 32 to a floor corner module of a further modular building unit. When stacking a first modular building unit 10 on top of a further modular building unit 10, the bore 63 is arranged to align with the bore 59 in the top plate 40 of the roof corner module 32 such that a fastener is able to be received through the bores 59, 63 to attach the modular building units 10 together.
Referring now to Figure 4, an alternative base plate 36 of a floor corner module 30 is illustrated.
The modular building unit 10 is provided with an alignment arrangement to aid in the alignment of the modular building unit 10 with a structure therebelow, such as a foundation structure (not shown) or a further modular building unit (not shown).
As discussed above, a drainage conduit 46 may not be provided in each corner assembly. In such corner assemblies, the floor corner module 30 includes a first alignment member 56. The first alignment member 56 is provided to aid in the alignment of the modular building unit 10 with a structure therebelow, such as a foundation structure (not shown) or a further modular building unit (not shown).
The roof corner module 32 includes a second alignment member 58 arranged to engage the first alignment member 56 to align the modular building unit 10 with a further modular building unit. The second alignment member 58 is provided to aid in the alignment of the modular building unit 10 with a structure thereabove, such as a further modular building unit (not shown). In the illustrated arrangement, the attachment aperture 60 forms the second alignment member 58, but in some arrangements the attachment aperture 60 and the second alignment member 58 may be provided separately.
The modular building unit 10 includes two alignment arrangements. Put another way, the modular building unit 10 includes a first corner assembly having first and second alignment members 56, 58 at a first corner of the modular building unit 10, and a second corner assembly having first and second alignment members 56, 58 at a second corner of the modular building unit 10. The first and second corner assemblies may be positioned at opposing corners of the modular building unit 10. In alternative, arrangements, it will be appreciated that the modular building unit 10 may include one, two, or three corner assemblies including the first and second alignment members 56, 58. It will be understood that the remaining corner assemblies (not containing the alignment arrangement) of the modular building unit 10 will contain drainage conduits 46, as illustrated in Figures 2A and 2B.
The first alignment member is a male alignment member 56. The first alignment member 56 is provided as a projection extending away from a lower surface of the floor base plate 36 (i.e. extending in a direction away from the roof corner module 32). The first alignment member 56 is tapered, and in the illustrated arrangement the first alignment member 56 is substantially conical. In alternative arrangements, it will be appreciated that the first alignment feature may be provided as any suitable shape, such as hemispherical, a rod, etc.
The second alignment member is a female alignment member 58. The second alignment member 58 is provided as an aperture in the roof corner module 32 (i.e. in the roof top plate 40 of the roof corner module 32). The second alignment member 58 is configured and arranged so as to engage with the first alignment member 56 of a floor corner module 32 of a further modular building unit 10. In the illustrated arrangement, the attachment member aperture 60 forms the second alignment member 58. However, in alternative arrangements, it will be appreciated that the attachment member 60 and the alignment member 58 may be provided separately on the roof corner module 32.
Referring now to Figures 5 and 6, an upright column 26 is illustrated.
The upright columns 26 are provided in the form of L-section beams. The upright columns 26 are provided with a stiffening configuration extending along the elongate length thereof. The use of L-section beams for the corner columns enables the space defined between the arms of the L-section beam to be accessible, for example to access the drainage conduit 46 or to access electrical cables (not shown) passing therealong. The provision of a stiffening configuration on the L-shaped beams helps the upright columns provide increased stiffness and rigidity to the modular building unit 10.
The stiffening configuration extends along the elongate length of the upright column 26. The stiffening configuration is arranged so as to terminate a predetermined distance away from first and second ends 66, 68 of the upright column 26. Put another way, the L-shaped beams of the upright column 26 extends past the stiffening configuration proximate the first and second ends 66, 68 thereof.
The predetermined distance between the first and second ends 66, 68 of the upright column 26 corresponds with a height of the floor corner module 30 and roof corner module 32, respectively along an axis parallel with the elongate axis of the upright column 26. Put another way, the predetermined distance between the first and second ends 66, 68 of the upright column 26 corresponds with the spacing between the upper 34, 40 and base 36, 42 plates of the floor corner module 30 and roof corner module 32, respectively.
This arrangement enables the lower and upper corner modules 30, 32 to abut against, and be secured to, opposing ends of the stiffening configuration. Put another way, a floor top plate 34 and a roof base plate 42 are arranged to abut against, and be secured to, opposing ends of the stiffening configuration. This has been found to increase the structural strength of the modular building unit 10.
Providing a stiffening configuration that terminates a predetermined distance away from first and second ends 66, 68 of the upright column 26 provides a portion of the upright columns 26 (i.e. of the L-shaped beams) that extend around two sides of the floor and roof corner modules 30, 32. This arrangement has been found to further improve the overall structural performance of the modular building unit 10.
As is shown more clearly in Figure 6, each of the upright columns 26 includes a stiffening configuration to increase the stiffness and rigidity thereof, so as to increase structural strength of the modular building unit 10.
The stiffening configuration includes stiffening arms 70 extending away from side edges 72 of the upright column 26. In the arrangement shown, the stiffening arms 70 extend substantially perpendicularly away from the side edges 72 of the upright column 26.
The stiffening configuration also includes return arms 74 extending away from distal ends of the stiffening arms 70. In the arrangement shown, the return arms 74 extend substantially perpendicularly away from distal ends of the stiffening arms 70. Put another way, the return arms 74 extend away from the stiffening arms 70 in a direction towards the L-shaped beam of the upright column 26, e.g. so as to be substantially parallel with part of the body of the L-shaped beam.
The stiffening configuration of the present arrangement has been found to provide increased stiffness and rigidity to the columns 26, and so to the overall modular building unit 10. However, it will be appreciated that in some arrangements the stiffening configuration may only include the stiffening arms 70, or may only include a stiffening configuration along one side edge 72 of the upright column 26.
Referring to Figure 7, a sleeve 76 of an attachment arrangement is illustrated.
The modular building unit 10 includes an attachment arrangement for attaching the modular building unit to an adjacent modular building unit.
The attachment arrangement configured to be adjustable, i.e. moveable, on the modular building unit 10 so as to be capable of being repositioned to align with an attachment arrangement of an adjacent modular building unit. This arrangement enables the modular building unit 10 to absorb any misalignment caused by tolerances in the manufacturing process.
The attachment arrangement includes an aperture 78 for receiving a fastener (not shown) therethrough. The aperture 78 is provided on the sleeve 76 that is insertable into an aperture on the modular building unit 10, e.g. on the upright columns 26 of the modular building unit 10.
The aperture 78 is arranged eccentrically (i.e. off-centre) on the sleeve 76, and the sleeve 76 is rotatably mounted to the modular building unit 10. Thus, through rotation of the sleeve 76, the location of the aperture 78 is able to be adjusted relative to the modular building unit 10.
Referring to Figure 8, a seal 80 of the modular building unit 10 is illustrated.
In order to reduce/prevent the ingress of water between adjacent modular building units 10, the modular building unit 10 is configured to sealingly engage an adjacent modular building unit 10. Each of the upright columns 26 are provided with a seal 80 configured to sealingly engage a surface of a further modular building unit 10. The seal 80 is arranged to extend along the substantially all of the elongate length of the upright column 26.
In order to improve the seal formed between adjacent modular building units 10, the seal 80 is provided as a compressible seal. The seal 80 includes a compressible seal body 82 configured to form a seal against a surface of a further modular building unit. The seal 80 also includes a lip 84 extending from the compressible seal body 82, and the lip is provided for attaching (e.g. via an adhesive or a fastener therethrough) the seal 80 to the modular building unit 10.
The body 82 pf the seal 80 contains an air cavity 86 therein. The air cavity 86 is arranged to be interposed between the two modular building units 10. The air cavity 86 increases the compressibility of the seal 80, which helps to improve the seal formed between the adjacent modular building units 10.
The seal 80 includes a sealing surface 88 arranged to abut against a surface of the further modular building unit 10 to form a seal thereagainst. In the illustrated arrangement, the seal surface 88 is provide on the seal body 82.
In the illustrated arrangement, the sealing surface 88 is serrated. In alternative arrangements, the seal surface 88 may not be serrated and instead may define an undulating surface or may be any suitable non-planar configuration. Providing a sealing surface 88 that is rough/uneven/non-planar has been found to improve the seal formed between the adjacent modular building units 10.
In the embodiment, the seal 80 is formed from a deformable material. One such deformable material that may be used is rubber, such as ethylene propylene diene monomer (EPDM), but it will be appreciated that any suitable compressible/deformable material may be used in alternative arrangements.
Referring now to Figure 9, a modular building assembly is illustrated and is indicated generally at 100.
The modular building assembly 100 includes first and second modular building units 10 arranged adjacent to each other (i.e. side-by-side). It will be appreciated that the first and second modular building units 10 may both be modular building units as described with reference to Figures 1 to 7.
As is illustrated, an upright column 26 of each of the modular building units 10 are positioned adjacent to each other.
The sleeves 76 of each of the modular building units 10 have been rotated such that the apertures 78 of each sleeve 76 are aligned. Although not illustrated, a fastener will extend through the apertures 78 in order to secure the modular building units 10 together.
A seal 80 is interposed between the adjacent upright columns 26 so as to reduce/prevent the ingress of water between adjacent modular building units 10.
The seal 80 is attached to a first modular building unit via a fastener (not shown) extending through the lip 84. The seal 80 is arranged such that the sealing surface 88 abuts against a surface of the upright column 26 of the further modular building unit 10. Although not illustrated, it will be appreciated that the seal 80 may be partially compressed between the upright columns 26 of the adjacent modular building units 10.
Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

A modular building unit comprising:
a floor assembly comprising a base frame for supporting a floor panel thereon;

a roof assembly comprising a roof frame for supporting a roof panel thereon; and

a plurality of corner assemblies each comprising an upright column extending between the base frame and the roof frame, a floor corner module mounted proximate a lower end of each upright column and a roof corner module mounted proximate an upper end of each upright column,

wherein the base frame is formed from a plurality of base frame members extending between adjacent floor corner modules and mounted thereto and/or wherein the roof frame is formed from a plurality of roof frame members extending between adjacent roof corner modules and mounted thereto.
A modular building unit according to claim 1, wherein one or more of the plurality of floor corner modules comprises a first alignment member for aligning the modular building unit with a further modular building unit and/or wherein one or more of the roof corner modules comprises a second alignment member configured and arranged so as to engage with a first alignment member of a floor corner module of a further modular building unit to align the modular building unit with a further modular building unit.
A modular building unit according to claim 2, wherein the first alignment member is a male alignment member comprising a projection extending from the floor corner module, and wherein the second alignment member is a female alignment member, e.g. an aperture, configured to receive the male member therein, optionally wherein the male alignment member is tapered, e.g. conical.
A modular building unit according to any preceding claim, wherein each of the plurality of upright columns is provided in the form of an L-section beam comprising a stiffening configuration extending along the elongate length of the upright column.
A modular building unit according to claim 4, wherein the stiffening configuration comprises a stiffening arm extending away from, e.g. perpendicularly away from, one or both side edges of the upright column, optionally wherein the stiffening configuration comprises a return arm extending away from, e.g. perpendicularly away from, a distal end of the or each stiffening arm.
A modular building unit according to claim 4 or claim 5, wherein the stiffening configuration terminates a predetermined distance away from the upper and lower ends of the upright column so as to define upper and lower end regions of the upright column that are substantially L-shaped in cross section, and wherein the roof corner module and floor corner module are mounted in said upper and lower end regions.
A modular building unit according to claim 6, wherein the roof corner modules and/or floor corner modules comprise an upper plate and a base plate connected by two module side walls, and wherein the upper and lower end regions enclose the two open two side faces of the roof corner modules and/or floor corner modules, respectively.
A modular building unit according to any preceding claim, wherein each roof frame member defines a channel forming a gutter for draining water, and wherein one or more of the upright columns comprises a drainage conduit extending between a roof corner module and a floor corner module of a corner assembly for draining water received in the gutter.
A modular building according to claim 8, wherein each roof corner module defines a flow path therethrough for connecting the channels of adjacent roof frame members such that the gutter is connected to the drainage conduit via a roof corner module.
A modular building unit according to claim 8 or claim 9, wherein the corner assembly comprises an overflow outlet at or near an upstream end of the drainage conduit.
A modular building unit according to any preceding claim, wherein one or more of the corner assemblies comprises an attachment arrangement for attaching the modular building unit to an adjacent modular building unit, and wherein the attachment arrangement is adjustable on the modular building unit for aligning with an attachment arrangement of an adjacent modular building unit.
A modular building unit according to claim 11, wherein the attachment arrangement comprises an aperture for receiving a fastener therethrough, said aperture being moveable relative to the modular building unit, optionally wherein the aperture is provided eccentrically on a sleeve that is rotatably mounted to the modular building unit.
A modular building unit according to any preceding claim, wherein each floor corner module comprises a base plate having an aperture for receiving a lashing member therein, and wherein the aperture is provided on a recessed region of an upper surface of said base plate.
A modular building unit according to any preceding claim, comprising a seal attached to an upright column, the seal comprising a compressible seal body configured to seal against the upright column and a surface of a further modular building unit, seal further comprising a lip extending from the compressible seal body and defining a mounting surface for attaching the seal to the modular building unit, optionally wherein the compressible seal extends along substantially along an entire elongate length of the upright column.
A modular building unit according to claim 14, wherein the compressible seal body comprises an air cavity arranged to be interposed between the upright column and a surface of a further modular building unit, in use and/or wherein the compressible seal body comprises a serrated or undulating surface arranged to engage a surface of a further modular building unit, in use.