NZ738075B - A Building - Google Patents

Abstract

is known to provide buildings in disassembled form for ease of transport and for subsequent erection on site. However at least some buildings of this type still take up an undesirably large amount of space when in a freight-ready form and can be difficult to transport. It is an object of a preferred form of the invention to go at least some way towards addressing this problem. In the preferred embodiment there is a flat-pack building comprising a base panel 1, a roof panel 2, a fastening means 8 and wall panels 3a, 3b and 3c. The wall panels being pivotally connected to the base panel so that the building can be assembled by elevating the roof panel 2, swinging the wall panels 3a, 3b and 3c about the base panel 1 until they are in an upright disposition, lowering the roof panel 2 and then connecting the roof panel with the wall panels. The flat-pack building having the fastening means 8 arranged at the base panel 1 such that they can engage with the base panel fastening means of a further identical flat-pack building when they are both collapsed. erred form of the invention to go at least some way towards addressing this problem. In the preferred embodiment there is a flat-pack building comprising a base panel 1, a roof panel 2, a fastening means 8 and wall panels 3a, 3b and 3c. The wall panels being pivotally connected to the base panel so that the building can be assembled by elevating the roof panel 2, swinging the wall panels 3a, 3b and 3c about the base panel 1 until they are in an upright disposition, lowering the roof panel 2 and then connecting the roof panel with the wall panels. The flat-pack building having the fastening means 8 arranged at the base panel 1 such that they can engage with the base panel fastening means of a further identical flat-pack building when they are both collapsed.

Description

COMPLETE SPECIFICATION Title A Building Field of the Invention A preferred form of the invention relates to a flat-pack building, optionally having the same footprint as an ISO freight container.

Background It is known to provide buildings in disassembled form for ease of transport and for subsequent erection on site. However at least some buildings of this type still take up an undesirably large amount of space when in a freight-ready form. It is accordingly an object of a preferred form of the invention to go at least some way towards addressing this problem. While this object applies to a preferred embodiment, it should be understood that the object of the invention in its broadest form is simply to provide the public with a useful choice. Therefore any objects or advantages applicable to any preferred embodiment should not be read into claims expressed more broadly.

The term “comprising” or “comprises” if and when used in relation to a combination of features simply indicates minimum features and does not rule out the option of there being further unnamed features.

Summary of the Invention According to one aspect of the invention there is provided a flat-pack building comprising a base panel, a roof panel, wall panels, and a fastening means, the wall panels being pivotally connected to the base panel, the building being such that it can be assembled by: • elevating the roof panel; • swinging the wall panels about the base panel until they are in an upright disposition; • lowering the roof panel; and • connecting the roof panel with the wall panels. wherein the fastening means is arranged such that it is engageable with the fastening means of another identical or substantially similar building.

Optionally the roof panel connects to the wall panels by way of clips.

Optionally the clips are internal with respect to the building overall.

Optionally the fastening means is arranged at the base panel.

Optionally the fastening means comprises one or more corner castings.

Optionally the corner castings have a height equal to or greater than the height of the building when in flat-pack form.

Optionally the base panel has at least one water channel.

Optionally the wall panels have a lip.

Optionally when in flat-pack form, the building is substantially in the footprint of an ISO freight container.

Optionally there is a plurality of flat-pack buildings, where one building is stacked on at least one other building.

Optionally the plurality of flat-pack buildings are stacked to collectively assume, substantially, the dimensions of an ISO freight container.

Optionally the plurality of flat-pack stacked buildings are fastened together by the way of the fastening means.

Optionally the plurality of flat-pack buildings at least one ISO freight container above and/or below the stack.

Optionally the plurality of flat-pack buildings are fastened to the container above and/or below the stack by way of the fastening means.

According to a further aspect of the invention there is a method of assembling a building as above comprising the steps of: • elevating the roof panel; • swinging the wall panels about the base panel until they are in an upright disposition; • lowering the roof panel; and • connecting the roof panel with the wall panels.

Drawings Some preferred embodiments of the invention are described below with reference to the accompanying drawings, of which: Figure 1 is an isometric view of a building in flat-pack form; Figure 2 is an isometric view of the building partially erected; Figure 3 is an isometric view of the building in a more advanced state of erection; Figure 4 is an isometric view of the building in a further advanced state of erection; Figure 5 is an isometric view of the building in a still further advanced state of erection; Figure 6 is a side view of a stack ten of the buildings, all in flat-pack form; Figure 7 is an end view of the stack; Figure 8 is an isometric view of a fastening means; Figure 9 is a transverse view of a base panel and wall arrangement; and Figure 10 is a side view of a twist lock tool.

Detailed Description Referring to figure 1, when in a freight-ready state the building is in flat-pack form. It has base panel 1, a roof panel 2 and wall panels 3. Referring to figure 2, the roof panel is raised by a series of corner jacks 4. It is lifted a little more than its intended finished height, to allow for the walls to swing into place. More specifically and referring to figures 3 and 4, the back wall panel 3a is swung up on hinges (not shown) that connect it to the back edge of the base panel 1, to assume a vertical disposition. The front wall panel 3b is swung in like-fashion, on hinges 5 that connect it to the front edge of the base panel 1. The end walls 3c are then swung up into place by way of hinges that connect them to the edge of the base panel 1. More specifically, the wall panels 3 swing up to the outer dimensions of the base panel 1 to maximize space inside the building.

When all of the walls are standing vertically and are secured to one another the roof panel 2 is lowered by the jacks 4 to meet them, as shown in figure 5. The roof panel 2 is connected to the wall panels 3, preferably by way of releasably locking clips such as quick release clips or over centre latches. The clips are formed from at least two parts and respective parts are attached to each of adjacent panels to be connected when the panels meet and form a join. The clips are preferably flush mounted to recesses in the panels 2, 3 so that they are flush with panel surfaces.

As illustrated, the front wall has ready-made window spaces 6 and a door 7. In some embodiments of the invention one or more of the other panels may have windows and/or a door depending on end user requirements. The jacks 4 are attached on the outside at each end of the building and can be operated by hand and or be driven by pressurized air, electricity or hydraulics. The jacks 4 are shown still in place, but once the wall and roof panels have been secured to one another the jacks can be removed.

In some forms of the invention one or more of the base, roof and/or wall panels 1,2,3 may be formed from sub-panels. While this is an option, it is not the preferred embodiment.

The building can be disassembled to revert to a flat-pack form by reversing the steps described above.

The hinge 5 is formed from two wings being pivotally connected by a rod or pin that passes through tubular knuckles of said wings. Respective wings are attached to each of adjacent panels 1,3. In some forms of the invention the wall panels 3 are detachable by removing the rod from the hinge. The roof panel 1 and or wall panels 3 can be replaced with other roof or wall panels 1,3 that are configured differently or have upgraded features. Such upgrades include but are not limited to lights, solar panels, a water collection and storage system, or canopies. The solar panels are preferably attached to the roof panel and wired to provide electricity to the building. The water collection and storage system include spouting attached to the roof panel 2 so that water run off will flow into the spouting and drain into a water storage tank.

When in its flat-pack form the building preferably has the footprint of a standard ISO -foot freight container. In larger embodiments the building may pack flat to the footprint of a 40-foot ISO container. An advantage of such a footprint, in either case, is that several of the buildings, all in flat-pack form, can be stacked to collectively have dimensions compatible with normal shipping protocols. In the example shown in figures 6 and 7 there is a stack of ten of the buildings, to give freight container dimensions. However, it should be appreciated that the building can be of virtually any footprint or size to suit the role it is desired for.

Referring to figures 1 – 5, the building has corner castings 8 that can be locked to other suitable locking mechanisms on other structures, such as other buildings, freight containers or transport means (e.g. the shipping platform of a ship, train or trailer unit).

Corner castings can be ISO standard corner castings. In a preferred embodiment of the invention, there will be two ISO standard corner castings 8 joined or formed together, as illustrated in figure 8. The corner castings 8 are formed from a hollow block made of steel or another suitable material. The block has apertures 9 shaped to receive standard corner casting locking tools that lock respective corner castings 8 together.

Referring to figure 10, one such tool is a standard twist lock style tool 15 that is commonly used with ISO corner castings. The tool has at least two connected locking parts 16. Each locking part 16 is shaped to fit into an aperture 9 of a corner casting 8 when they are aligned. When a locking part 16 is inserted into the aperture 9, a lever 17 can be pulled to turn the locking parts 16 so they do not fit back through the aperture 9 and are obstructed from being pulled out. The tool can be used to lock two corner castings 8 at the same time when engaged with a locking part 16 each. The corner casting 8 of figure 8 has an aperture 10 on the bottom surface, allowing corner castings 8 to be stacked in a series one above another and then locked together with a tool.

While the preferred embodiment of the invention uses corner castings 8 attached to the base panel 1 and locking tools to fasten respective buildings together, this is a preferred embodiment only it should be understood that any fastening means can be used.

The corner castings 8 are at least the same height or higher than the roof panel 2 when it is in flat-pack form, so they can be load bearing and prevent damage to the building when it is stacked.

When two or more buildings are stacked and locked together, they can be transported as if they were a single unit. Preferably, the buildings are stacked together to form the dimensions of an ISO standard freight container and can be transported as if it were one. This includes stacking and locking the stacked buildings in a stack of freight containers. The stacked buildings can be moved or transported by land, sea, or air, or any other way a freight container may be moved or transported. The preferred embodiment of the building is not more than 1500kg in flat-pack form and can be transported by a NATO UH series helicopter.

In some embodiments of the invention the roof panel 2 is on an angle, as illustrated in figures 4 and 5, so that water runs to the outside of the building. The roof panel 2 has drip edge flashings arranged around its outside perimeter (not shown). They are formed from any suitable material and are shaped so that water running off the building drips away from the wall panels 3. Referring to figure 5, a preferred form of the flashing is substantially “L” shaped in transverse cross section and fits to the corner between the upper 13 and side 14 surfaces of the roof panel 2. They have a lip on the lower most edge of the flashing that is bent away from the roof panel 2 so that water drips away from the building.

Referring to figure 9, the wall panels 3 have a lip 12 that extends downwards when the panels 3 are in a vertical disposition. The lip 12 extends past the join between the wall panels 3 and the base panel 1 and toward a water channel 11 to prevent water entering the building through the join. The water channel 11 is below the wall panels 3 and a part of the base panel 1. It collects water run-off from the building and drains it away from the building to prevent water pooling at its base.

In some embodiments of the invention the building may be used as a construction site office, for storage, as a storage shed or as an emergency or otherwise temporary dwelling. In some embodiments the building may be used as a cool storage chamber within a larger building or out in the open.

While some preferred forms of the invention have been described by way of example it should be appreciated that modifications and improvements can occur without departing from the scope of the following claims.

Claims (17)

1. 5 1. A flat-pack building comprising a base panel, a roof panel, wall panels, and a fastening means, the wall panels being pivotally connected to the base panel, the building being such that it can be assembled by: • elevating the roof panel; • swinging the wall panels about the base panel until they are in an upright 10 disposition; • lowering the roof panel; and • connecting the roof panel with the wall panels. wherein the fastening means is arranged at the base panel and such that it is engageable with the base panel fastening means of another identical building when 15 each building is collapsed and stacked one above the other.

2. A flat-pack building according to claim 1, wherein the roof panel connects to the wall panels by way of clips. 20

3. A flat-pack building according to claim 2, wherein the clips are internal with respect to the building overall.

4. A flat-pack building according to any one of the preceding claims, wherein the fastening means is arranged only at the base panel.

5. A flat-pack building according to any one of the preceding claims, wherein the fastening means comprises one or more corner castings.

6. A flat-pack building according to claim 5, wherein the corner castings have a height 30 equal to or greater than the height of the rest of the building when in flat-pack form.

7. A flat-pack building according to any one of the preceding claims, wherein the base panel has a water channel. 35

8. A flat-pack building according to any one of the preceding claims, wherein the wall panels have a lip.

9. A flat-pack building according to any one of the preceding claims, which, when in flat-pack form, is substantially in the footprint of an ISO freight container. 5

10. A plurality of flat-pack buildings, each according to any one of the preceding claims, wherein at least one building is stacked on at least one other building.

11. A plurality of flat-pack buildings according to claim 10, wherein the buildings are stacked to collectively assume, substantially, the dimensions of an ISO freight 10 container.

12. A plurality of flat-pack buildings according to claim 10 or 11, wherein the stacked buildings are fastened together by the way of the fastening means. 15

13. A plurality of flat-pack buildings according to claim 10, 11 or 12, with at least one ISO freight container above and/or below the stack.

14. A plurality of flat-pack buildings according to claim 13, wherein the buildings are fastened to the container above and/or below the stack by way of the fastening 20 means.

15. A building substantially as herein described with reference to figures 1-5.

16. A plurality of buildings substantially as herein described with reference to figures 6 25 and 7.

17. A method of assembling a building as defined in any of claims 1 - 10, comprising the steps of: • elevating the roof panel; 30 • swinging the wall panels about the base panel until they are in an upright disposition; • lowering the roof panel; and • connecting the roof panel with the wall panels. 1, 3