GB2540620A

GB2540620A - A modular structure

Info

Publication number: GB2540620A
Application number: GB1513078.4A
Authority: GB
Inventors: Marsh Anthony; Homenda Marcin; Cook Peter; Farndale Michael
Original assignee: LH Woodhouse and Co Ltd
Current assignee: LH Woodhouse and Co Ltd
Priority date: 2015-07-24
Filing date: 2015-07-24
Publication date: 2017-01-25
Anticipated expiration: 2035-07-24
Also published as: GB2540620B; GB201513078D0

Abstract

A modular structure 10 comprises a frame 12 that comprises a frame member 14. The frame member comprises a first connector 20. The modular structure also comprises a wall 22 that is engageable with the frame member and the wall comprises a first panel and a second panel 24, 26. The first panel comprises a second connector 32 that is engageable with the first connector to form the wall. The frame may further comprise a second retainer 34 that is engagable with a second primary retainer 36 on the second panel. The second panel may be provided with a second secondary retainer 60 that is engagable with the first panel to retain the second panel relative to the first panel. Also disclosed is a method of installing the modular structure

Description

A MODULAR STRUCTURE

This invention relates to a modular structure, particularly for housing animals such as horses cattle, sheep or pigs.

It is desirable to install a structure, such as a stable, for temporarily housing an animal, such as a horse, at an event or a show. Such a structure must be transported to the event or show and installed on-site for the duration of the event or show, and then dismantled and removed. Such a structure must also be able to withstand the weight of, e.g. a horse, leaning on the side of the structure or kicking out at the structure without the structure collapsing.

Existing temporary structures to house animals on-site are typically installed from large and cumbersome components, thus rendering them difficult to install efficiently and by hand. It is also difficult to transport such large components on pallets which typically have a standard size allowing them to be carried on fork lift trucks. Often, extended forks have to be used on the fork lift trucks to transport the large components, which adds to the cumbersome nature of these existing temporary structures.

According to a first aspect of the invention there is provided a modular structure comprising: a frame comprising a frame member comprising a first connector; and a wall engageable with the frame member and comprising a first panel and a second panel, wherein the first panel comprises a second connector engageable with the first connector to form the wall.

The provision of a frame including a frame member provides a skeletal structure for a wall to engage therewith so as to form the modular structure.

Meanwhile, the wall having first and second panels reduces the size and weight of the components of the modular structure, thus increasing the portability and modularity of the structure. The first and second panels may be sized enable them to fit on standard pallets for ease of transportation.

The first and second connectors being engageable with one another to form the wall provide a means for securing the wall to the frame member so as to prevent collapse of the modular structure in the event that, e.g. a horse leans against or kicks out at the wall.

In particular, engagement of the first and second connectors locks the first panel in position relative to the frame member, thereby increasing the stability and robustness of the modular structure.

In some embodiments of the invention the frame member includes more than one first connector, and some connectors may extend in a different plane from the other connectors.

The frame member may further comprise a first retainer and the second panel may comprise a second primary retainer engageable with the first retainer.

Such an arrangement provides another securing means, in particular to retain the second panel relative to the frame member, and so further increases the stability and robustness of the modular structure.

Optionally the first connector may include an elongate opening adapted to receive the second connector, the second connector being slidable within the elongate opening between a first position and a second position.

Such a first and second connector arrangement permits a robust securing means to secure the first panel to the frame member while reducing the manufacturing complexity of the modular structure. Moreover, the elongate opening compensates for an uneven support surface on which the modular structure may be installed, e.g. on a field.

In addition, the elongate opening receiving the second connector results in a securing means that does not have any protruding parts, e.g. nails, once secured which could otherwise catch and harm an animal contained in the modular structure.

Alternatively, the second connector may include an elongate opening adapted to receive the first connector, the first connector being slidable within the elongate opening between a first position and a second position.

The second connector may be lockable in the second position. This feature provides locking of the first panel to the frame member while reducing the number of parts of the modular structure since the locking means forms part of the existing first connector. Moreover, locking the first panel in this manner reduces the complexity of installing the modular structure.

According to a second aspect of the invention there is provided a modular structure comprising: a frame comprising a frame member comprising a first retainer; and a wall engageable with the frame member and comprising a first panel and a second panel, wherein the second panel comprises a second primary retainer engageable with the first retainer to form the wall.

Common features of this aspect of the invention share the advantages set out above in relation to the first aspect of the invention.

The frame member may further comprise a first connector and the first panel may comprise a second connector engageable with the first connector.

Optionally the second panel further may include a second secondary retainer engageable with the first panel to retain the second panel relative to the first panel.

Engagement of the first retainer and the second primary retainer, together with engagement of the second secondary retainer and the first panel, locks the second panel in position relative to the frame member.

In some embodiments of the invention the first retainer may include a guide portion extending outwardly from the frame member to guide the second primary retainer into engagement with the first retainer.

The guide portion permits a degree of movement of the second panel when an operative is securing the second panel to the frame member, thereby allowing the operative to line-up the second panel correctly before securing it to the frame member and/or the first panel.

Preferably the first retainer may include first and second retention elements spaced from one another to form an open-ended channel adapted to receive the second primary retainer.

Such an arrangement permits the second primary retainer to be slid through the channel when an operative is securing the second panel to the frame member. This arrangement is particularly useful to correctly line-up the first and second panels when securing the second secondary retainer to the first panel.

The open-ended channel also permits the second panel to be installed after installation of the first panel if the first panel is positioned below the second panel.

Optionally the frame member may be substantially vertical and the second panel may be positioned above the first panel to form the wall.

Alternatively, the first panel may be positioned above the second panel to form the wall.

In some embodiments of the invention the frame member further includes a frame guide being cooperable with the wall to retain the wall relative to the frame member.

The inclusion of such a frame guide increases the stability and robustness of the modular structure.

The first panel further may include a location formation being engageable with a location formation of the second panel.

The provision of such location formations helps to locate the position of the second panel relative to the first panel when an operative is installing the modular structure.

The frame may include more than one frame member. In such embodiments, the wall may extend between adjacent pairs of frame members. Such an arrangement increases the stability of the modular structure.

There now follows a description of an embodiment of the invention, by way of a non-limiting example, with reference being made to the accompanying drawings in which:

Figure 1 shows a modular structure according to an aspect of the invention;

Figures 2a and 2b show a first and second connector of the modular structure shown in Figure 1;

Figures 3a to 3c show a first retainer and second primary retainer of the modular structure shown in Figure 1; and

Figure 4 shows an intermediate frame member of the modular structure shown in Figure 1. A modular structure according to an embodiment of the invention is designated generally by reference numeral 10.

The modular structure 10 comprises a frame 12 that includes a frame member 14. More specifically the frame 12 includes four frame members 14 which are arranged in four sets of frame member pairs 16 to form a square.

In the embodiment shown, each frame member 14 is a box extrusion 18 and is made from a mild steel with box section dimensions of 50x50 mm and 2.5 mm thick. The box extension 18 is also galvanised. Moreover, each frame member 14 is identical to the other frame members 14.

The frame members may be made from another material such as hard plastics, and/or have different dimensions.

In other embodiments of the invention (not shown) the frame 12 may instead include any number of frame members 14 so to form a different shape, e.g. a rectangle or a triangle. In further embodiments of the invention (not shown), the frame members 14 may take a different form, e.g. a flat-bar or channel extrusion or a pipe.

Each frame member 14 includes a first connector 20. In the embodiment shown, each frame member 14 includes four first connectors 20, two of which extend in one plane and the other two extending in a different plane, at a first connection point 21a on the frame member 14. Moreover, each frame member 14 includes another four first connectors 20, two of which extend in one plane and the other two extending in a different plane, at a second connection point 21b on the frame member 14. More specifically, each face of the box extrusion 18 includes a first connector 20 formed thereon at each of the first and second connection points 21a, 21b.

In other embodiments of the invention (not shown), the frame member 14 may have fewer or more connection points.

The modular structure 10 further includes a wall 22 that is engageable with each frame member 14 and the wall 22 comprises a first panel 24 and a second panel 26.

The first and second panels 24, 26 have substantially the same width and thickness as one another. The thickness of the first and second panels 24, 26 is no greater than each frame members 14.

In the embodiment shown, the first and second panels 24, 26 have a panel body 28 and a panel frame 30 extending around the perimeter of the panel body 28. The panel frame 30 is made from an edging section with a U-shaped profile (not shown) to receive the panel body 28, thus obviating the need for fasteners such as rivets or screws (which could damage an animal and weaken the panel body 28). The dimension of the edging section is typically 10-38.1 mm and is 2.95 mm thick. There is a gap between the inner surface of the edging section and the outer surface of the panel body 28 of around 10.16 mm. Such a gap permits the panel body 28 and/or edging section to expand in heat. The panel body 28 and frame 30 are made from different materials, in particular the panel body 28 is made from a recycled plastic, while the panel frame 30 is made from mild steel. Examples of suitable plastic material are 10 mm Stockboard, 4 to 6 mm thick Polystone G or 6 to 10 mm thick Polystone P Foamlite (PE-1+D). Each of the aforementioned materials may have a different thickness than stated. The panel body 28 and the panel frame 30 may be made from the same material. The panel body 28 could instead be made from a plywood or from a recycled plastic coated plywood.

The first panel 24 includes a second connector 32 that is engageable with the first connector 20 to form the wall 22. The second connector 32 is shown more clearly in Figure 2a.

In the embodiment shown, the first panel 24 includes two second connectors 32 at opposite ends of the first panel 24, and each second connector 32 is engageable with any of the first connectors 20 of any of the frame members 14.

The frame member 14 further includes a first retainer 34, and the second panel 26 includes a second primary retainer 36 that is engageable with the first retainer 34.

In the embodiment shown the second panel 26 includes two second primary retainers 36 at opposite ends of the second panel 26, each second primary retainer 36 is engageable with any of the first retainers 34 of any of the frame members 14.

Moreover, the second primary retainers 36 are the top edge of the second panel 26, and more particularly the top edge of the panel frame 30.

Turning to Figure 2a, each first connector 20 takes the form of an elongate opening 38 that is formed on a respective face of the frame member 14. The elongate opening 38 includes a first end 40a and a second end 40b that are integrally formed with one another.

The first end 40a is shaped to receive the second connector 32 in a first position of the second connector 32, while the second end 40b is shaped to lock the second connector 32 in a second position of the second connector 32.

In the embodiment shown, the second connector 32 has a locking member 42 that extends laterally from the first panel 24 and includes a locking face 44. The second connector 32 also includes a head 46 that extends beyond the locking face 44. In the embodiment shown, the locking member 42 and the head 46 have a circular cross-sectional profile and the head 46 has a larger diameter than that of the locking member 42.

Meanwhile, the first end 40a of the elongate opening 38 includes a hole 48 that has a larger diameter than that of the head 46. The second end 40b of the elongate opening 38 includes a slit 50 that has a width similar to the diameter of the locking member 42. As such, the slit 50 provides a friction fit to the locking member 42 via the locking face 44.

In other embodiments of the invention (not shown) the elongate opening 38 may instead be formed on the first panel 34 and the second connector 32 may extend from the frame member 14.

Referring to Figure 3a, the first retainer 34 includes a first guide portion 52 that extends outwardly from the frame member 14. Moreover, the first retainer 34 includes first and second retention elements 54a, 54b that are spaced from one another to form an open-ended channel 56. In the embodiment shown, the first guide portion 52 is integrally formed with the first retention element 54a.

In the embodiment shown, the second retention element 54b includes a second guide portion 58 that extends outwardly in the opposite direction to that of the first guide portion 52. Only one of the retention elements 54a, 54b may include a guide portion in other embodiments of the invention (not shown).

The first and second guide portions 52, 58 extend outwardly from the frame member 14 by an angle of between 35° to 38°.

The first and second retention elements 54a, 54b are made from a metal plate, in particular 40x3mm flat mild steel plate, and the first and second guide portions 52, 58 are formed by bending each retention element 54a, 54b to the desired angle. The second retention element 54b is longer than the first retention element 54a so as to guide the second panel 26 into position during assembly of the modular structure 10.

Returning to Figure 1, the second panel 26 further includes a second secondary retainer 60 that is engageable with the first panel 24 to retain the second panel 26 relative to the first panel 24.

The second panel 26 includes three second secondary retainers 60, but may include few or more second secondary retainers 60.

Each second secondary retainer 60 includes a pair of secondary retention elements 62 that extend downwards from opposite faces of the second panel 26 so as to abut respective faces of the first panel 24 in use.

The second secondary retainers 60 are formed by welding a metal plate to the panel frame 30 of the second panel 26. The second secondary retainers 60 may instead be integrally formed with the second panel 26.

Each frame member 14 is substantially vertical and the second panel 26 is positioned above the first panel 24 to form the wall 22. In other embodiments of the invention (not shown) the first and second panels 24, 26 may be the other way round.

Each frame member 14 further includes a frame guide (not shown) positioned between the first and second connections points 21a, 21b. The frame guide consists of first and second frame guide portions secured to the frame member 14 so as to extend towards the wall 22. The first and second frame guide portions are spaced from one another to form a channel within which the first panel 24 is received.

Each frame member 14 may include any number of frame guides and one or more of said frame guides may be positioned between the first connection point 21a and the first retainer 34 (i.e. so as to receive the second panel 26).

The first panel 24 further includes a location formation 64 that is engageable with a location formation (not shown) of the second panel 26. The location formation 64 of the first panel 24 can be seen in Figure 2b and takes the form of a protrusion with a circular cross-sectional profile. The location formation of the second panel 26 is an aperture (not shown) that receives the protrusion. The first and second panels 24, 26 may have any number of location formations 64.

As shown in Figure 1, first and second panels 24,26 can be secured to adjacent frame member pairs 16 so as to form a side wall 66. Such first and second panels 24, 26 are identical to one another save from the second panel not having any second connectors 32.

First and second front panels 68, 70 are secured to adjacent frame member pairs 16 via an intermediate panel 72 to form a front wall 74. The intermediate panel 72 includes a door 76 to enter and exit the modular structure 10. The first and second front panels 68, 70 are shorter than the first and second panels 24, 26 of the side wall 66, although this may not be the case in other embodiments. The length of the intermediate panel 72 is such that the front wall 74 equals the length of the side wall 66.

The first and second front panels 68, 70 share the same features of the first and second panels 24, 26 of the side wall 66, and identical features are shown by the same reference numerals. Moreover, the intermediate panel 72 includes an intermediate frame member 78 that shares features of the frame member 14 described hereinabove.

The intermediate frame member 78 further includes an intermediate retainer 80 to secure the intermediate frame member 78 to the adjacent, i.e. front wall 74, as shown in Figure 4.

The intermediate retainer 80 is formed from first and second retainer elements 80a, 80b that are spaced from one another to form a retainer channel 82. The first and second retainer elements 80a, 80b are joined to one another and to the intermediate frame member 78 by a joining portion 84. In the embodiment shown the joining portion 84 extends along the length of the first and second retainer elements 80a, 80b, so as to close the retainer channel 82, but this may not be the case in other embodiments.

The retainer channel receives the second panel 70 of the front wall 74 so as to prevent movement of the second panel 70 relative to the intermediate frame member 78.

The intermediate panel 72 may include another intermediate retainer 80 at both ends of the intermediate panel 72.

The intermediate panel 72 further includes an integrated grill 86 on a top portion of the door 76. In other embodiments of the invention (not shown) the intermediate panel 72 may instead include an insatiable grill on the top portion of the door 76. In further still embodiments of the invention (not shown) the top portion of the door 76 may instead be open.

The installed modular structure 10 may include a PVC roof covering (not shown).

The modular structure 10 is installed by first positioning a frame member 14 vertical relative to a support surface, e.g. the ground, such that the two connection points 21a, 21b are at the lower end of the frame member 14.

Next, a first panel 24 is secured at one end thereof to the frame member 14 at both connection points 21a, 21b via the first and second connectors 20, 32. More specifically, and as shown in Figure 2a, the head 46 of each second connector 32 is inserted into the hole 48 of a respective elongate opening 38 until adjacent side faces of the frame member 14 and first panel 24 abut one another. Both second connectors 32 are in the first position.

The first panel 24 is then slid downwards relative to the frame member 14 and at the same time the locking face 44 of each locking member 42 engages with the slit 50 of the respective elongate opening 38 and slides down the slit 60 to the second position, as shown in Figure 2b. In this position, the first panel 24 is secured to the frame member 14 by the friction fit between the locking face 44 and the slit 50 at each connection point 21a, 21b.

Another frame member 14 is then positioned vertically in the same manner as set out above, and the first panel 24 is secured at the opposite end thereof to this frame member 14 at both connection points 21 a, 21 b in the same manner set out above. As a result, the first panel 24 is secured between adjacent frame member pairs 16 to form an erect frame 12.

This process is repeated for the remaining number of frame members 14 until an erect structure with first panels 24 is assembled. A second panel 26 is then inserted at a top edge of the panel frame 30 (i.e. the second primary retainer 36) through the channel 56 formed by each of the first and second retention elements 54a, 54b. As shown in Figure 3b, the second panel 26 is angled to abut a respective first guide portion 52. The second panel 26 is then guided by each first guide portion 52 through the respective channel 56 so that a top portion of the second panel 26 extends through each channel 56 and beyond each of the first and second retention elements 54a, 54b, as shown in Figure 3c.

The second panel 26 may instead be inserted so as to abut each second guide portion 58. depending on which side of the wall 22 an operative is standing.

The second panel 26 can then be dropped downwards towards the first panel 24 so that the second secondary retainers 60 abut opposite faces of the first panel 24 and so that the location formations 64 of the first and second panels 24, 26 locate one another. The first retainers 34 cooperating with a respective second primary retainer 36, together with the second secondary retainers 60 cooperating with the first panel 24 locks the second panel 26 in position relative to the frame members 14.

The aforementioned steps are repeated to form different walls 22 of the modular support structure 10.

The intermediate panel 72 is then installed via its second connectors (not shown) to an adjacent frame member 14 and its intermediate frame member 78 to an adjacent first panel 70 of the front wall 74.

To disassemble the modular structure 10, the second panel 26 is lifted upwards so that a top portion of the second panel 26 extends through each channel 56 and beyond each of the first and second retention elements 54a, 54b, as shown in Figure 3c.

The second panel 26 is then slid downwards and angled to abut the first (or second) guide portions 52. The second panel 26 being angled allows for it to be removed from the frame members 14.

Next, the first panel 24 is removed from the frame members 14 by lifting the first panel 24 which slides the locking member 42 upwards along the slit 50 towards the hole 48 of the elongate opening 38. The first panel 24 Is lifted upwards until the locking member 42 is in the first position such that the head 46 can be pulled out of the hole 48 of one frame member 14 at a time.

Claims

CLAIMS:

1. A modular structure comprising: a frame comprising a frame member comprising a first connector; and a wall engageable with the frame member and comprising a first panel and a second panel, wherein the first panel comprises a second connector engageable with the first connector to form the wall.

2. A modular structure according to Claim 1 wherein the frame member further comprises a first retainer, and wherein the second panel comprises a second primary retainer engageable with the first retainer.

3. A modular structure according to Claims 1 or 2 wherein the first connector includes an elongate opening adapted to receive the second connector, the second connector being slidable within the elongate opening between a first position and a second position.

4. A modular structure according to Claim 3 wherein the second connector is lockable in the second position.

5. A modular structure comprising: a frame comprising a frame member comprising a first retainer; and a wall engageable with the frame member and comprising a first panel and a second panel, wherein the second panel comprises a second primary retainer engageable with the first retainer to form the wall.

6. A modular structure according to Claim 5 wherein the frame member further comprises a first connector, and wherein the first panel comprises a second connector engageable with the first connector.

7. A modular structure according to Claims 5 or 6 wherein the second panel further includes a second secondary retainer engageable with the first panel to retain the second panel relative to the first panel.

8. A modular structure according to any one of Claims 5 to 7 wherein the first retainer includes a guide portion extending outwardly from the frame member to guide the second primary retainer into engagement with the first retainer.

9. A modular structure according to any one of Claims 5 to 8 wherein the first retainer includes first and second retention elements spaced from one another to form an open-ended channel adapted to receive the second primary retainer.

10. A method of installing a modular structure generally as herein described with reference to and/or as illustrated in the accompanying drawings.

10. A modular structure according to any preceding claim wherein the frame member is substantially vertical and wherein the second panel is positioned above the first panel to form the wall.

11. A modular structure according to any proceeding claim wherein the frame member further includes a frame guide being cooperable with the wall to retain the wall relative to the frame member.

12. A modular structure according any preceding claim wherein the first panel further includes a location formation being engageable with a location formation of the second panel.

13. A modular structure according to any preceding claim wherein the frame includes more than one frame member, the wall extending between adjacent pairs of frame members.

14. A method of installing a modular structure comprising the steps of; erecting a frame that includes a frame member, the frame member comprising a first connector: and forming a wall by engaging a second connector of a first panel with the first connector, wherein the waii comprises the first panei and a second panei.

15. A method according to Ciaim 14 wherein the frame member further comprises a first retainer, the method further comprising the step of engaging a second primary retainer of the second panei with the first retainer.

16. A method of installing a modular structure comprising the steps of. erecting a frame that inciudes a frame member, the frame member comprising a first retainer; and forming a waii by engaging a second primary retainer of a second panei with the first retainer, wherein the wail comprises the second panel and a first panei.

17. A method according to Claim 16 wherein the frame member further comprises a first connector, the method further comprising the step of engaging a second connector of the first panel with the first connector.

18. A modular structure generally as herein described with reference to and/or as illustrated in the accompanying drawings.

19. A method of installing a modular structure generally as herein described with reference to and/or as illustrated in the accompanying drawings. Amendments to the claims have been filed as follows CLAIMS:

1. A modular structure comprising: a frame comprising a substantially vertical frame member comprising a first connector; and a wall engageable with the frame member and comprising a first panel and a second panel, the second panel being positioned above the first panel to form the wall, wherein the first panel comprises a second connector engageable with the first connector to form the wall, and wherein the frame member further comprises a first retainer, and the second panel comprises a second primary retainer engageable with the first retainer, the first retainer including first and second retention elements spaced from one another to form an open-ended channel adapted to receive the second primary retainer, the first retainer further including a guide portion extending outwardly from the frame member to guide the second primary retainer into engagement with the first retainer.

2. A modular structure according to Claim 1 wherein the first connector includes an elongate opening adapted to receive the second connector, the second connector being slidable within the elongate opening between a first position and a second position.

3. A modular structure according to Claim 2 wherein the second connector is lockable in the second position.

4. A modular structure according to Claim 1 wherein the second panel further includes a second secondary retainer engageable with the first panel to retain the second panel relative to the first panel.

5. A modular structure according to any proceeding claim wherein the frame member further includes a frame guide being cooperable with the wall to retain the wall relative to the frame member.

6. A modular structure according any preceding claim wherein the first panel further includes a location formation being engageable with a location formation of the second panel.

7. A modular structure according to any preceding claim wherein the frame includes more than one frame member, the wall extending between adjacent pairs of frame members.

8. A method of installing a modular structure comprising the steps of: erecting a frame that includes a substantially vertical frame member, the frame member comprising a first connector and a first retainer; and forming a wall comprising of a first panel and a second panel, wherein the second panel is positioned above the first panel, by engaging a second connector of a first panel with the first connector and engaging a second primary retainer of the second panel with the first retainer, wherein the first retainer includes first and second retention elements spaced from one another to form an open-ended channel adapted to receive the second primary retainer, and wherein the first retainer further includes a guide portion extending outwardly from the frame member to guide the second primary retainer into engagement with the first retainer..

9. A modular structure generally as herein described with reference to and/or as illustrated in the accompanying drawings.