WO2006133482A1 - Prefabricated modular building - Google Patents

Prefabricated modular building Download PDF

Info

Publication number
WO2006133482A1
WO2006133482A1 PCT/AU2006/000791 AU2006000791W WO2006133482A1 WO 2006133482 A1 WO2006133482 A1 WO 2006133482A1 AU 2006000791 W AU2006000791 W AU 2006000791W WO 2006133482 A1 WO2006133482 A1 WO 2006133482A1
Authority
WO
WIPO (PCT)
Prior art keywords
roof
module
ceiling
walls
pivoted
Prior art date
Application number
PCT/AU2006/000791
Other languages
French (fr)
Inventor
Stephen Muir
Original Assignee
Deployable Structures International Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2005903145A external-priority patent/AU2005903145A0/en
Application filed by Deployable Structures International Pty Ltd filed Critical Deployable Structures International Pty Ltd
Priority to AU2006257759A priority Critical patent/AU2006257759B2/en
Priority to US11/917,643 priority patent/US7647731B2/en
Priority to JP2008516065A priority patent/JP2008544114A/en
Priority to EP06741206.4A priority patent/EP1891277B1/en
Priority to CN2006800195094A priority patent/CN101208484B/en
Publication of WO2006133482A1 publication Critical patent/WO2006133482A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/343—Structures characterised by movable, separable, or collapsible parts, e.g. for transport
    • E04B1/344—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts
    • E04B1/3445—Structures characterised by movable, separable, or collapsible parts, e.g. for transport with hinged parts foldable in a flat stack of parallel panels

Definitions

  • This invention relates to modular building units which are prefabricated and transported to location where they are erected to provide accommodation.
  • RU2240400 describes a shipping container- like structure which concertinas into a flat package for transportation. When erected It constitutes an extremely rudimentary box shaped structure.
  • WO 96/13402 shows a more sophisticated folding structure pivoted to a central unit provided with wheels for transportation.
  • a central unit provided with wheels for transportation.
  • additional modules unfold from either side of the central unit to sit on the bearers.
  • the side modules have gabled roofs and end walls fold out from the sides of the central unit to form closed structures. This construction is costly and only suitable for transportation by towing behind a prime mover.
  • US 4,780,996 teaches a folding portable building construction with a rigid central section and a winching system for the erection of roof members of complementary side modules. Wall members and flooring unfold after the roof members are winched into place. The winching system can be removed after erection which makes the system independent of erecting cranes but adds to the cost.
  • a prefabricated building module comprises a rectangular floor structure with two end walls pivoted about the short sides of the floor structure, a side wall pivoted at its lower end to a long side of the floor structure and a roof structure pivoted at the upper end of said side wall such that said walls and roof structure fold into a flat pack to facilitate transport of the module.
  • the roof structure comprises a ceiling and upright roof trusses pivoted to the ceiling which fold down onto the ceiling for transport.
  • the end walls fold down onto the floor, the ceiling folds down onto the side wall, the trusses fold down onto the ceiling and the ceiling folds down onto the end walls to form a flat pack.
  • the walls, the ceiling structure and the roof trusses have mechanisms which lock them in place when erect.
  • the walls have provision for doors and windows.
  • the roof is formed from a flexible membrane which is held in sail tracks attached to the roof trusses.
  • the module is adapted to be used in combination with other modules to form habitable buildings of two or more modules.
  • the roof structure comprises rigid batten construction.
  • the floor and roof structure are adapted to extend beyond the building alignment to form external verandahs.
  • a roof structure comprises upright roof trusses which fold down to facilitate transport and a flexible membrane which is held in sail tracks attached to the roof trusses.
  • Figs 1 a to e show perspective views of a prefabricated building module in its various stages of erection from a flat pack to a fully erect structure.
  • Fig 2 is a side elevation of the flat pack in Fig 1 a
  • Fig 3 is a side elevation of the first stage of erection in Fig 1 b
  • Fig 4 is a side elevation of the second stage of erection in Fig 1 c
  • Fig 5 is a side elevation of the third stage of erection in Fig 1d
  • Fig 6 is a side elevation of the fully erect structure of Fig 1 e
  • Fig 7 is a perspective view of two modules joined to form a building which has a rigid roof structure.
  • the prefabricated building modules of the present invention are transported as a flat pack 1 illustrated in Fig 1 a and 2, with the same plan dimensions as a shipping container and with corner post stubs 2 to facilitate stacking.
  • the floor 3 of the module forms the base of pack 1 and end walls 4, side wall 5 and roof structure 6 are folded into flat pack 1.
  • ceiling 8 is raised to its horizontal position with roof trusses 7 vertical and held in place.
  • An auxiliary winch pole (not shown) attaching to the floor structure midway along the outside of wall 5 may be used to raise ceiling 8.
  • end walls 4 which are pivoted to floor 3 are rotated into their vertical positions and lock in place to support roof structure 6.
  • the erected module is structurally self supporting and two modules can be joined at their open ends to form a habitable structure with a plan area of two shipping containers as shown in Fig 7.
  • Roof covering may be provided by drawing a sail type membrane through sail tracks attached to trusses 7 and sealing the join between the two modules with a ridge cap.
  • a conventional rigid roof structure 9 may be provided as shown in Fig 7.
  • An outdoor verandah may be provided by extensions 10 to floor 3 beyond the module alignment and extensions 11 to roof structure 9 may also be provided to cover the outdoor verandah.
  • Walls 4 and 5 are clad with a building material of structural and thermal ratings appropriate to the location. Doors and windows are provided as required and three or more modules can be joined simply by eliminating one or more internal side walls of the modules.
  • the buildings so formed can be used in a variety of applications including living and working accommodation and military uses such as field headquarters and hospitals.
  • the sail type roof structure of the module can also be used independently to provide a roof over, for example, a shipping container.
  • Roof trusses 7 can be pivoted to the top of the container just as they are to ceiling structure 8, rotated from their stowed position and locked in their erect position.
  • a shade membrane can then be drawn into place through sail tracks attached to trusses 7 thus forming a roof over the container.

Abstract

A prefabricated building module comprises a rectangular floor structure with two end walls pivoted about the short sides of the floor structure, a side wall pivoted at its lower end to a long side of the floor structure and a roof structure pivoted at the upper end of said side wall such that said walls and roof structure fold into a flat pack to facilitate transport of the module. The roof structure comprises a ceiling and upright roof trusses pivoted to the ceiling which fold down onto the ceiling for transport and the walls have provision for doors and windows.

Description

PREFABRICATED MODULAR BUILDING
FIELD OF INVENTION
This invention relates to modular building units which are prefabricated and transported to location where they are erected to provide accommodation.
BACKGROUND OF THE INVENTION
There are many prior art documents disclosing different methods for achieving prefabricated accommodation. RU2240400 describes a shipping container- like structure which concertinas into a flat package for transportation. When erected It constitutes an extremely rudimentary box shaped structure.
WO 96/13402 shows a more sophisticated folding structure pivoted to a central unit provided with wheels for transportation. When on location supporting bearers extend from the central unit and additional modules unfold from either side of the central unit to sit on the bearers. The side modules have gabled roofs and end walls fold out from the sides of the central unit to form closed structures. This construction is costly and only suitable for transportation by towing behind a prime mover.
US 4,780,996 teaches a folding portable building construction with a rigid central section and a winching system for the erection of roof members of complementary side modules. Wall members and flooring unfold after the roof members are winched into place. The winching system can be removed after erection which makes the system independent of erecting cranes but adds to the cost.
SU1803507 and US 4,912,891 teach further variations on the theme of a rigid central unit with unfolding side modules. However this rigid central unit construction is bulky and difficult to transport. Accordingly there is a need for a prefabricated building which can be transported as a flat package like that of RU2240400 but which provides more habitable accommodation when erected on location. OBJECT OF THE INVENTION
It is therefore an object of the present invention to provide a prefabricated modular building which lends itself to efficient transportation and which is simply erected into habitable accommodation or which at least provides an alternative to prior art systems.
STATEMENT OF THE INVENTION
According to the present invention, a prefabricated building module comprises a rectangular floor structure with two end walls pivoted about the short sides of the floor structure, a side wall pivoted at its lower end to a long side of the floor structure and a roof structure pivoted at the upper end of said side wall such that said walls and roof structure fold into a flat pack to facilitate transport of the module.
Preferably the roof structure comprises a ceiling and upright roof trusses pivoted to the ceiling which fold down onto the ceiling for transport.
Preferably the end walls fold down onto the floor, the ceiling folds down onto the side wall, the trusses fold down onto the ceiling and the ceiling folds down onto the end walls to form a flat pack.
Preferably the walls, the ceiling structure and the roof trusses have mechanisms which lock them in place when erect.
Preferably the walls have provision for doors and windows.
Preferably the roof is formed from a flexible membrane which is held in sail tracks attached to the roof trusses.
Preferably the module is adapted to be used in combination with other modules to form habitable buildings of two or more modules.
Alternatively the roof structure comprises rigid batten construction. Preferably the floor and roof structure are adapted to extend beyond the building alignment to form external verandahs.
Alternatively a method is provided whereby the roof structure and the walls of a prefabricated building fold down sequentially onto the floor structure of the building to form a flat pack for transport.
Alternatively a roof structure comprises upright roof trusses which fold down to facilitate transport and a flexible membrane which is held in sail tracks attached to the roof trusses.
BRIEF DESCRIPTION OF THE DRAWINGS
Figs 1 a to e show perspective views of a prefabricated building module in its various stages of erection from a flat pack to a fully erect structure. Fig 2 is a side elevation of the flat pack in Fig 1 a
Fig 3 is a side elevation of the first stage of erection in Fig 1 b Fig 4 is a side elevation of the second stage of erection in Fig 1 c Fig 5 is a side elevation of the third stage of erection in Fig 1d Fig 6 is a side elevation of the fully erect structure of Fig 1 e Fig 7 is a perspective view of two modules joined to form a building which has a rigid roof structure.
DETAILED DESCRIPTION OF THE INVENTION
The prefabricated building modules of the present invention are transported as a flat pack 1 illustrated in Fig 1 a and 2, with the same plan dimensions as a shipping container and with corner post stubs 2 to facilitate stacking. The floor 3 of the module forms the base of pack 1 and end walls 4, side wall 5 and roof structure 6 are folded into flat pack 1.
In the first stage of erection of the module shown in Fig 3, side wall 5 which is pivoted to floor 3 at its inner lower end and ceiling 8 which is pivoted at the inner upper end of wall 5, are rotated up out of pack 1 and wall 5 is locked in its vertical position by means of locking struts 12, shown in Fig 7. In the second stage shown in Fig 4, roof trusses 7 are rotated out of the plane of ceiling 8 and locked in position at right angles to ceiling 8.
In the third stage of erection shown in Fig 5, ceiling 8 is raised to its horizontal position with roof trusses 7 vertical and held in place. An auxiliary winch pole (not shown) attaching to the floor structure midway along the outside of wall 5 may be used to raise ceiling 8. In the final stage shown in Fig 6, end walls 4 which are pivoted to floor 3 are rotated into their vertical positions and lock in place to support roof structure 6.
Accordingly the erected module is structurally self supporting and two modules can be joined at their open ends to form a habitable structure with a plan area of two shipping containers as shown in Fig 7. Roof covering may be provided by drawing a sail type membrane through sail tracks attached to trusses 7 and sealing the join between the two modules with a ridge cap.
Alternatively a conventional rigid roof structure 9 may be provided as shown in Fig 7. An outdoor verandah may be provided by extensions 10 to floor 3 beyond the module alignment and extensions 11 to roof structure 9 may also be provided to cover the outdoor verandah.
Walls 4 and 5 are clad with a building material of structural and thermal ratings appropriate to the location. Doors and windows are provided as required and three or more modules can be joined simply by eliminating one or more internal side walls of the modules. The buildings so formed can be used in a variety of applications including living and working accommodation and military uses such as field headquarters and hospitals.
The sail type roof structure of the module can also be used independently to provide a roof over, for example, a shipping container. Roof trusses 7 can be pivoted to the top of the container just as they are to ceiling structure 8, rotated from their stowed position and locked in their erect position. A shade membrane can then be drawn into place through sail tracks attached to trusses 7 thus forming a roof over the container. VARIATIONS
It will be realized that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. For example various mechanical equivalents could be substituted for pivoting and locking components without departing from the inventive concept .
Throughout the description and claims to this specification the word
"comprise" and variation of that word such as "comprises " and "comprising" are not intended to exclude other additives components integers or steps.

Claims

1. A prefabricated building module comprising a rectangular floor structure with two end walls pivoted about the short sides of the floor structure, a side wall pivoted at its lower end to a long side of the floor structure and a roof structure pivoted at the upper end of said side wall such that said walls and roof structure fold into a flat pack to facilitate transport of the module.
2. The module of claim 1 in which the roof structure comprises a ceiling and upright roof trusses pivoted to the ceiling which fold down onto the ceiling for transport.
3. The module of claim 2 in which the end walls fold down onto the floor, the ceiling folds down onto the side wall, the trusses fold down onto the ceiling and the ceiling folds down onto the end walls to form a flat pack.
4. The module of claim 2 in which the walls, the ceiling structure and the roof trusses have mechanisms which lock them in place when erect.
5. The module of claim 1 in which the walls have provision for doors and windows.
6. The module of claim 1 in which the roof is formed from a flexible membrane which is held in sail tracks attached to the roof trusses.
7. The module of claim I which is adapted to be used in combination with other modules to form habitable buildings of two or more modules.
8. The modules of claim 7 in which the roof structure comprises rigid batten construction.
9. The modules of claim 7 in which the floor and roof structure are adapted to extend beyond the building alignment to form external verandahs.
10. A method is provided whereby the roof structure and the walls of a prefabricated building fold down sequentially onto the floor structure of the building to form a flat pack for transport.
11. A roof structure comprising upright roof trusses which fold down to facilitate transport and a flexible membrane which is held in sail tracks attached to the roof trusses.
12. A module as herein described with reference to the accompanying drawings.
PCT/AU2006/000791 2005-06-16 2006-06-09 Prefabricated modular building WO2006133482A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
AU2006257759A AU2006257759B2 (en) 2005-06-16 2006-06-09 Prefabricated modular building
US11/917,643 US7647731B2 (en) 2005-06-16 2006-06-09 Prefabricated modular building
JP2008516065A JP2008544114A (en) 2005-06-16 2006-06-09 Modular building made of prefabricated
EP06741206.4A EP1891277B1 (en) 2005-06-16 2006-06-09 Prefabricated modular building
CN2006800195094A CN101208484B (en) 2005-06-16 2006-06-09 Prefabricated modular building

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2005903145 2005-06-16
AU2005903145A AU2005903145A0 (en) 2005-06-16 Prefabricated modular building

Publications (1)

Publication Number Publication Date
WO2006133482A1 true WO2006133482A1 (en) 2006-12-21

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2006/000791 WO2006133482A1 (en) 2005-06-16 2006-06-09 Prefabricated modular building

Country Status (7)

Country Link
US (1) US7647731B2 (en)
EP (1) EP1891277B1 (en)
JP (1) JP2008544114A (en)
CN (1) CN101208484B (en)
PT (1) PT1891277E (en)
WO (1) WO2006133482A1 (en)
ZA (1) ZA200710285B (en)

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WO2011050124A3 (en) * 2009-10-22 2011-09-29 Modular Container Solutions Llc A modular assembly
US8826601B2 (en) 2009-10-22 2014-09-09 Modular Container Solutions Llc Modular assembly

Also Published As

Publication number Publication date
CN101208484B (en) 2012-07-04
US7647731B2 (en) 2010-01-19
CN101208484A (en) 2008-06-25
US20080209820A1 (en) 2008-09-04
EP1891277A1 (en) 2008-02-27
EP1891277B1 (en) 2013-10-23
PT1891277E (en) 2014-01-14
JP2008544114A (en) 2008-12-04
EP1891277A4 (en) 2012-08-22
ZA200710285B (en) 2008-09-25

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