NZ547065A - Collapsible portable structure - Google Patents

Abstract

A collapsible portable structure (10), such as a building or container, that has the ability to be reduced in height for transportation or storage is disclosed. The structure has a roof (20), a pair of opposed end walls, and a pair of opposed side wall panels hingedly connected to each other. Each end wall consists of at least a pair of panels (17) hingedly connected to each other, and the roof is hingedly connected to an adjacent top side wall panel on each side of the roof. The structure has a rigid and non-movable base portion having a base frame (11) including a number of longitudinal and transversely oriented frame members, a pair of opposed upstanding side wall panels, and a pair of opposed and upstanding end wall panels.

Description

Please return form by mail to: Intellectual Property Office New Zealand PO Box 30 687 Lower Hutt New Zealand IP number/s: Current Owner: Norman Ross Watt Your reference: 14341NZ2/RTK-SJR 4 7 0 6 5 *10051196769* Patents Act 1953 Patent No. 5 - Complete Specification (*) Where priority as provided by subsection (2) or subsection (3) of section 11 of the Patent Act 1953 is desired in respect of one or more provisional specifications, quote number or numbers and date or dates.

(*) No.

Date: '"COLLAPSIBLE PORTABLE STRUCTURE" I, Norman Ross Watt of c/- 9 Production Court, TOOWOOMBA, 4350, Queensland, Australia, Nationality - Australian hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: DATED this 10 May 2006 Norman Ross Watt by his Patent Attorneys FISHER ADAMS KELLY intellectual property office of N.Z. 12 MAY 2006 RKOIiVlO 54 70 8 5 1 "COLLAPSIBLE PORTABLE STRUCTURE" This invention relates to a collapsible portable structure such as a building or container which has the ability to be reduced in height for transportation or storage. The structure has a rigid base portion which is not collapsible and which base portion has opposed side walls and end walls.

The structure has a roof which can be collapsed to lie adjacent the rigid base portion during transportation mode.

Current portable buildings on the market are fixed structures that cannot be reduced in height. This creates problems especially when such buildings are being transported on a truck because of stringent transport requirements that apply in regard to a maximum height and width that must be achieved. This also creates problems in storage especially if relevant storage space is restricted to a relatively small volume.

Reference may be made to prior art that deals with portable buildings and International Patent Publication WO 94/20699 refers to a collapsible container or accommodation unit which has a pair of side walls having a pair of side wall panels that can be pivoted inwardly because each of the side wall panels are hingedly connected to each other about an intermediate hinge joint. The container or accommodation unit also includes a pair of end walls that are connected to a bottom hinge so that each end wall may be pivoted from a vertical orientation to a horizontal orientation and vice versa.

There is also provided a roof of a triangular pyramidal shape that is hinged to an adjacent edge of each of the uppermost side wall panels and which has a central lifting point located at its top vertex. There is also provided a floor intellectual property office of n.z. 12 MAY 2006 RECEIVED which is hinged on both sides to an adjacent lowermost side wall panel. The entire structure can be collapsed or folded to a flattened state and can be moved by a lifting crane having a chain and hook which is attached to the central lifting point of the roof. However disadvantages of this collapsible structure is that (i) the provision of the triangular pyramidal roof adds unnecessary height to the structure and (ii) it is necessary to have at least three height adjusting means which are spaced apart from each other for height adjustment of the floor to a level or non-warped surface in order to relieve the pressure on the hinge connections of the structure and thus facilitate the upward pivotal movement of the side walls and end walls to form an erect structure. It will be appreciated that provision of multiple height adjustment means for the floor is not only complicated adding to the cost of manufacture but will be unnecessary in certain situations.

Reference also may be made to Australian Specification 61067/90 which refers to a collapsible building module having a roof section, a floor section, collapsible stanchions or uprights and collapsible wall sections which are all capable of movement between an erect position and a collapsed position. The stanchions when in the erect position support the roof above the floor section to define accommodation space. It will be appreciated however that this collapsible structure is mainly directed to items of furniture and is not designed as a portable building for transportation and storage as it does not have the required stability upon erection.

Reference also may be made to Australian Specification 44980/89 which describes a portable foldable shelter having a floor, opposed side walls and a flat roof with a depending rim providing an open bottomed box in which the floor and side walls are stored in the collapsible unit. The roof and floor are connected by two opposed side walls each having a transverse fold line enabling each side wall to fold between the roof and the floor. This is a relatively fragile structure which is not adapted for use as a portable building which can withstand adverse weather conditions and which is extremely stable and durable upon erection. Similar comments apply to Australian Specification 37525/85 which refers to a portable building comprising four hinged frames connected to allow folding to a rectangular shape in a concertina manner.

Reference also is made to US Patent 4,166,343 which refers to a collapsible structure having a top, base, sides and ends which can be collapsed to a folded structure in which the ends extend parallel to and beneath the top and in which the sides are folded so as to be located next to the ends between the bottom and the top. The sides comprise an even number of hinged panels joined by hinges to a frame or frame elements of the top. This structure is complicated in structure requiring the frame or frame elements of the top and is considered to be relatively fragile not having the necessary durability or strength to be effective in use.

Reference may also be made to US Patent 4,165,117 which refers to a multi-purpose expandable transportation apparatus convertible into a camping trailer, house trailer, truck camper or self-propelled mobile home having solid wall panels hingedly connected to each other so that in a closed position substantial storage space is provided within the transportation 11/09 2007 15:06 FAX 61 7 3221 0597 FISHES ADAMS KELLYt~|NTpi t FOTUAL PROPERTY OFFICE OF N.Z. 11 SEP 2007 RECEIVED @010/012 4 apparatus. There is also provided a hollow box like base structure supported by ground engaging wheels which provides the relevant storage space. This reference also discloses single end wall panels which are stored underneath the roof of the camper when the camper is in a collapsed 5 condition.

It is therefore an object of the invention to provide a collapsible structure which may at least reduce to some extent one or more of the abovementioned disadvantages of tie prior art.

The collapsible structure of the invention includes a pair of opposed 10 end walls, a roof and a pair of opposed side walls wherein each side wall has a plurality of side wall panels hingedly connected to each other and each end wall includes at least one pair of end wall panels hingedly connected to each other and the roof is hingedly connected to an adjacent top side wall panel on each side of the roof characterised in that there is provided a rigid and non 15 movable base portion having a base frame including a plurality of longitudinal and transversely oriented frame members, a pair of opposed upstanding side wall panels and a pair of opposed and upstanding end wall panels.

It will be appreciated that non of the prior art discussed above has the rigid and non movable base portion characterised above and thus the 20 collapsible structure of the present invention is considered to be extremely strong and durable in use with the ability to withstand heavy winds and have a high operational longevity.

Thus the term "non movable" in regard to the base portion means that the base portion is not provided with ground engaging wheels. Thus the 25 collapsible portable structures of the invention only include within their scope prefabricated or portable buildings or shipping containers and do not include caravans or movable structures as contemplated by US Patent 4,165,117. Thus in other words the collapsible portable structures of the invention can only be transported by separate transportation apparatus such as a truck, lorry or trailer hitched to a prime mover.

Each side wall preferably comprises a lowermost panel which corresponds to one of the pair of side wall panels of the rigid and non movable base portion and a plurality but more preferably two uppermost side wall panels which are all hingedly connected to each other. The arrangement may be such that each of the uppermost side wall panels can be collapsed inwardly as shown in the preferred embodiment hereinafter to lie atop or adjacent the rigid and non movable base portion.

Each end wall may preferably comprise a lowermost end wall panel which corresponds to one of the pair of end wall panels of the rigid base portion and an uppermost end wall panel which may be hingedly connected to the lowermost end wall panel so that it may be pivoted inwardly into a hollow interior of the collapsible structure.

In another aspect of the invention there may be provided a method of transportation of structures which method includes the steps of: (i) attaching one or more stacking frames to a first structure whereby the or each stacking frame completely surrounds the first structure; (ii) loading the first structure with stacking frame(s) attached thereto onto a vehicle; and (iii) loading one or more further structures onto the vehicle in stacked relationship with the first structure of step (i) wherein said one or more further structures each has one or more stacking frames attached thereto which are each attached to a lowermost stacking frame of an adjacent structure.

In this aspect of the invention the structures are preferably collapsible and steps (i) and (ii) are applied to these structures when in a collapsed state.

Preferably is step (i) and in step (iii) there are a multiplicity of stacking frames that are attached to the or each collapsed container at spaced intervals along the length of each collapsed structure. Suitably the or each collapsed structure is a collapsed structure of the invention and each of the stacking frames include a base component attached to a base frame of a adjacent collapsed structure and a U shaped component which engages with the base component at each end thereof and which extends over the top of the adjacent collapsed structure. Each U shaped component may engage with the base component in any suitable fashion such as by plug-socket or male-female interaction or by the use of suitable fasteners extending through co-aligned apertures in mutually adjacent ends of the U shaped component and the base component which is preferably a length of strap, channel, angle or box section rod or bar. Reference may be made to a preferred embodiment of the invention as shown in the drawings annexed hereto wherein: 7 FIG 1 is a perspective view of a foldable building constructed in accordance with the invention in an erected state; FIG 2 is a similar view to FIG 1 showing end panels folded into the building; FIG 3 is a similar view to FIG 1 showing each side wall of the foldable building in a partially folded state allowing lowering of the roof; FIG 4 is a similar view to FIG 1 showing the building in a collapsed condition; FIG 5 is a perspective view of the folded building of FIG 4 having a plurality of stacking frames attached thereto; FIG 6 is a perspective view of three foldable buildings as shown in FIG 4 in a stacked relationship with stacking frames attached thereto; FIG 7 is an end view of the plurality of stacked buildings shown in FIG 6; FIG 8 is a side view of the plurality of stacked buildings as shown in FIG 6; FIG 9 is a top perspective view of the base frame; FIG 10 is a more detailed view of a forklift engagement location of the base frame shown in FIG 9; FIG 11 is a perspective view of a base component of a stacking frame attached to an adjacent transverse frame member of a base frame of a foldable building shown in FIG 1; FIG 12 is a detailed view of a mounting assembly between the base component and the adjacent U shaped component of a stacking frame; FIG 13 is a perspective view of a pair of stacking frames attached to a pair of base frames; FIG 14 is a detailed view of a mounting assembly interconnecting an uppermost stacking assembly to an adjacent base frame; FIG 15 is a sectional view of a hinge assembly interconnecting adjacent side panels; FIG 16 is a similar view to FIG 15 showing each of the adjacent side panels shown in FIG 13 in a partially folded orientation.

FIG 17 is a sectional view of a sealing assembly interconnecting a side wall panel with a roof panel; and FIG 18 is a schematic view showing a join between each base panel and an adjacent side panel of a building shown in FIG 1.

In FIG 1 reference is made to a portable building 10 in an erected state having a base frame 11, opposed side walls 12 including a plurality of side wall panels 13 all hinged to each other along hinge lines 14. There is also provided an end wall 15 having a pair of end wall panels 16 and 17 hinged to each other along hinge line 18 as well as door 19. There is also shown roof 20 and a pair of windows 21 and 22.

FIG 2 shows the building 10 of FIG 1 with end wall panels 16 folded inwardly into the hollow interior 23 of building 10 as indicated by lines 24 shown in phantom.

FIG 3 shows the building 10 with each side wall 12 in a partially collapsed or folded state with each side wall panel being folded along hinge lines 14. This means that the roof 20 is also shown in a partially lowered FIG 4 shows the building 10 in collapsed or "closed" position with the roof 20 lowered to its minimum height with each of side wall panels 13 abutting each other at 25. There is also shown rigid or non-movable base portion 9 comprising opposed end panels 17, opposed side panels 13, base frame 11 and roof 20 with a pair of side panels 13 at each side of building 20 lying in flattened mode on each inwardly folded end wall panel 16.

FIGS 5-8 show the building 10 as shown in FIG 4 encased or surrounded by four stacking frames 26. Each stacking frame 26 includes a U shaped component 27 which engages with a corresponding base component 28 at 29. Each base component 28 is oriented transversely to longitudinal axis 30 of each building and abuts a mating channel member 31 of each base frame 11 of each building 10. It will be noted that each separate building 10 has its own multiplicity of stacking frames 26. Fastening means (not shown) attach each U shaped component 27 to its corresponding base component 28. Each base frame 11 of each building 10 as best shown in FIG 9 has a plurality of transverse channel frame members 31, 32, 33, 34, 35, 36, 37 and 38. In this regard channels 31 and 32 and 37 and 38 are in opposing orientations as shown. Each frame member 33 and 36 has a similar orientation to adjacent frame members 32 and 37 and the two central channels 34 and 35 are in opposed relationship as shown. Each of the channel frame members 31 through 38 are interconnected by longitudinal frame members 40.

FIG 9 shows a perspective view of base frame 11 and FIG 10 shows a more detailed view of a central region 41 for receiving the forks of a forklift for transportation of base frame 11. This central region 41 includes a plurality of longitudinally oriented frame members 42 which interconnect channels 34 and 35. There is also provided a pair of opposed transverse frame members 44 to which frame members 42 are attached. There is also shown a pair of bracing members 43.

In FIG 10 there is also shown slots or cut outs 47 which are used for attachment of an adjacent stacking frame 26 as shown in FIGS 11-12.

In FIG 11 it will be noted that stacking frames 26 have a base component 28 of U shaped or box cross section which is bolted or otherwise attached to an adjoining channel 33. Base component 28 is provided with end walls 48 adjacent respective cut outs 47.

In FIG 12 it is shown that each U shaped component 27 of a stacking frame 26 has a foot mounting assembly 50 including horizontal base plate 51, bracket 52 having attachment apertures 53 that are aligned with corresponding attachment apertures 54 of base component 28 and a bottom part 55 of U shaped component 27 that locates in an associated cut out 47 with bracket 51 resting on a top surface 56 of longitudinal frame member 40.

In FIGS 13-14 are shown attachment of a pair of stacking frames 26 to a pair of base frames 11 with buildings 10 conveniently omitted for clarity. It will be noted that each stacking frame 26A and 26B is connected to an adjacent base frame 11 wherein lowermost stacking frame 26B is attached to bottom base frame 11 as shown in FIGS 11-12. In the arrangement shown in FIGS 13-14 however uppermost stacking frame 26A has a base 11 component 28A which is a piece of flat strap welded to an adjacent surface of channel 33 unlike box section member 28. Base component 28A also functions as a top frame member of stacking frame 26B.

In FIG 15 there is shown a hinge assembly 60 interconnecting a pair of adjacent side wall panels 13. Each panel 13 has a core 61 made from fibreglass and a laminate peripheral area 62. Each side wall panel 13 has complementary engagement surfaces 63 and 64 which are of stepped shaped as shown. Hinge assembly 60 has hinge plates 65 and 66 and hinge or pivot joint 67. FIG 16 shows partial rotation of side wall panels 13.

FIG 17 shows a hinge assembly 60 interconnecting a roof panel 20 and side wall panel 13. Again each of panels 20 and 13 have engagement surfaces 67 and 69 which are of stepped appearance as shown. Seals 70 are also shown in phantom.

In FIG 18 there is shown a pair of rubber seals 70 made out of sponge rubber attached to each of surfaces 63 and 64 by a thermosetting adhesive. A suitable rubber is EPDM tyre tubber having a shape as shown.

The roof 20 has been designed as shown in FIGS 7 and 18 to have an average slope of 2 degrees from the midpoint 20A shown in FIG 7 to the vertex 20B shown in FIG 17. This is to achieve efficient run off of water from rainfall so that water does not pool on roof 20 which would add to the load on roof panel 20 and side wall panels 13.

The floor panel 20C shown in FIGS 5, 7 and 8 is attached to base frame 11 so that floor panel 20C is not directly in contact with the ground when in use. 12 The provision of stepped surfaces 63 and 64 between adjacent floor panels 13 and roof 20 and adjacent floor panel 13 as shown in FIG 17 prevents water running down the outside of panels 13 from seeping through the rubber seals 70 and into hollow interior 23.

The end walls are made up of panels 16 and 17 as shown in FIG 1. The bottom panel 17 is permanently attached to the floor panel 20. The hinges between panels 16 and 17 is the same arrangement as shown in FIG 18 having regard to adjacent side wall panels 13. Handles (not shown) will be attached at the centre of panels 16 so that panels 16 can be pivoted from a horizontal position shown in FIG 2 to a vertical position shown in FIG 1.

Seals (not shown) will also be located at the top of end panel 16 where it will seal each end panel 16 to roof 20. Seals (not shown) will also be located between each end panel 16 with adjacent side wall panels 13.

Cable or chain attachment points (not shown) will be attached to roof 20 at each corner thereof for elevation or lowering of roof 20 as may be required.

There will also be provided corner brackets (not shown) located at each corner of building 10 so that panels 13, 16 and 17 may be securely fixed in place. Each corner bracket will be of angle iron or aluminium and will be screwed into the adjacent panels.

In relation to assembly of building 10 after transportation to a particular location, the following procedure is appropriate: 1. One by one the buildings 10 can be lifted off the means of transportation. 13 2. Remove the stacking frames 26. 3. Make sure the building 10 to be assembled is positioned on relatively flat ground. 4. Once the stacking frames 26 are removed, a lifting chain has to be attached to the roof 20 via the four brackets that are specifically for this purpose.

. The roof 20 can then be carefully lifted upwards by a forklift or crane. 6. Once the roof 20 is approximately at the right height, end wall panel 16 can be lifted to the upright position. 7. One by one, the corner support brackets will need to be attached. 8. Once secure and all of the bolts/screws are fixed in place, the chain/cable attached to the roof 20 can be detached and the building 10 is ready for use.

When disassembling the building for transportation purposes the following steps should be followed: 1. Attach the lifting chain/cable to the roof. 2. Use the roof lifting mechanism (forklift, crane etc) to make the chain taut. 3. Take off the corner support brackets. 4. Fold down the top panels 16 of the end walls carefully, making sure the chain is secure with the weight of the roof. Note that all doors 19 should be closed at this point. 14 . Lower the roof 20 while checking the sidewall panels 13 are folded inwards in the correct fashion. 6. Once the roof 20 is lowered, the chain can be detached. 7. Attach stacking frames 26 as appropriate. 8. Lift the building 10 onto the means of transport. 9. Lift the second building 10 on top of the bottom building 10 and then attach further stacking frames 26 to the second building 10.

. Repeat step 9 when stacking on third building 10 onto the second building 10. 11. Ropes may need to be added to secure the top building to the trailer body so that horizontal movement of the top buildings is restricted.

From the foregoing it will be appreciated that the collapsible structure of the invention is useful as a container or accommodation unit because furniture or articles being transported can be retained within the rigid base portion 9 described above.

It will also be appreciated that the provision of stacking frames 26 provide a safe and reliable means of transport of buildings which has not been achieved to date.

In another aspect of the invention there is also provided an assembly of a plurality of collapsed structures 10 and associated stacking frames 26 attached thereto.

Claims (5)

11/09 2007 15:06 FAI 61 7 3221 0597 FISHER ADAMS KELLY INTELLECTUAL PROPERTY OFFICE OF N.Z. 11 SEP 2007 RECEIVED 0011/012 15 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A collapsible structure including a pair of opposed end walls, a roof and a pair of opposed side walls wherein each side wall has a plurality of side wall panels hingedly connected to each other and each end wall includes at 5 least one pair of end wall panels hingedly connected to each other and the roof is hingedly connected to an adjacent top side wall panel on each side of the roof characterised in that there is provided a rigid and non movable base portion having a base frame including a plurality of longitudinal and transversely oriented frame members, a pair of opposed upstanding side wall 10 panels and a pair of opposed and upstanding end wall panels.

2. A collapsible structure as claimed in claim 1 wherein each side wall comprises a lowermost panel which corresponds to one of the pair of side wall panels of the rigid and non movable base portion and a pair of uppermost side wall panels which lowermost panel and pair of uppermost 15 panels are all hingedly connected to each other whereby in use each of the uppermost side wall panels can be collapsed inwardly to lie atop or adjacent the rigid and non movable base portion.

3. A collapsible structure as claimed in claim 1 or 2 wherein each end wall has a lowermost end wall panel which corresponds to one of the pair of 20 end wall panels of the rigid base portion and an uppermost end wall panel which is hingedly connected to the lowermost end wall panel so that it may be pivoted inwardly into a hollow interior of the collapsible structure.

4. A collapsible structure as claimed in any preceding claim wherein the rigid and non movable base portion further includes a base panel attached to 25 the base frame so that the base panel is located above the ground in use. 11/09 2007 15:07 FAX 61 7 3221 0597 FISHER ADAMS KELLY 1012/012 5470 65 16

5. A collapsible structure substantially as herein described with reference to the accompanying drawings. END OF CLAIMS -uHBctualpweStT | OFFICE OF N.Z. 11 SEP 2007 PF.CEIVEP-