WO2021217196A1

WO2021217196A1 - Transportable habitable fold out structure

Info

Publication number: WO2021217196A1
Application number: PCT/AU2020/050405
Authority: WO
Inventors: John Tolhurst
Original assignee: John Tolhurst
Priority date: 2020-04-28
Filing date: 2020-04-28
Publication date: 2021-11-04

Abstract

A building construct is disclosed whereby an insulated cuboidal volume 103 housing various habitation systems forms one side of six sided irregular polygonal prism where the other five edges are insulated panels 104, 105, 107, 128 and 127. The cuboidal volume and polygon is dimensioned and hinged so that it can take two forms: a) a compact form suited to shipping within a sea container and b) a habitable form with a wide floor area and generous ceiling height. The polygon in habitable form is closed at each end by additional panels hinged to the structure in a manner facilitating both the compact form and the habitable form, to deliver adequate structural and thermal performance.

Description

TRANSPORTABLE HABITABLE FOLD OUT STRUCTURE

[0001] The present invention relates to a way of factory building a small habitable structure so it can be folded for transport within a sea container and be used when erected as a relocatable, comfortable ancillary dwelling (‘granny flat’, ‘garden suite’, tiny house’ etc.) for its occupants. The demand for tiny houses is increasing. Tiny houses are typically narrow to allow transport by road and tall to allow a sleeping loft. This brings disadvantages: spaces are narrow and occupants must normally climb a ladder to reach the sleeping loft.

[0002] There is extreme difficulty in providing housing in remote locations, far from resources such as tradespersons and building material retailers. The cost of building is many times higher in remote locations.

[0003] When ancillary buildings are erected, speed and convenience is important. It is better to involve a minimum of tradespersons and create little or no waste, mess or disruption.

[0004] Prior art in pre-built expandable buildings is significant. A main limitation is the use of thin walls that lack insulation, combined with structures that are lightweight and thus lack the thermal mass needed to moderate internal temperatures to a habitable range with the result that most expandable buildings cannot be used as permanent accommodation in any but the mildest of climates without exceedingly high energy costs for heating and cooling. Some prior art includes buildings that have the disadvantage that they lack ceiling heights required for habitable buildings. Some prior art includes methods that apply sea container technology and thus the resultant building has the connotation of a modified sea container. The prior art in building tiny homes usually includes a ladder or at best an exceedingly steep staircase that leads to a sleeping loft. This is problematic for elderly people for whom a fall is more likely. Evidence shows that in the elderly a fall is closely followed by a loss of independent living. Some prior art teaches the use of specialised lifting gantries, winches and cables to erect the building. Few prior art examples are concerned with providing a well-insulated building envelope or reducing the volume of the folded form to the confines of a sea container. Many are transportable as trailers rather than within sea containers, so are not suitable for global trade.

[0005] For example in RU2161228C2, roof layers stored above the central cuboidal volume when sized to fit inside a high cube sea container would leave less than the required height for a bathroom, meaning the central cuboid cannot be used for that purpose and that tradespersons would have to visit the site to install plumbing. And in EP0138722B1 a central cuboidal volume is used to house bathroom facilities, however in this solution cumbersome external gantries must be installed to expand the building by lifting roof ‘wings’ on either side. In CA1296153C a central structure houses a gantry system for activating the folding elements which then interlock to form a rigid structure. In this solution specialised gantry structures must be fabricated to activate the structure rather simply employing the inherent stiffness of wall, floor and roof panels. US2728115A teaches a cylindrical ly-based solution which departs from the forms people are accustomed to living in and it does not employ conventional building materials, nor does it provide for a thick insulation layer. Both US6434895B1 and US8763315B2 employ a six sided hinged polygonal prism with two fold mirror symmetry on the horizontal plane. The invention cannot be scaled into a sea container while including a fixed cuboidal volume for fitting necessary habitation systems. US6434895B1 does not foresee or provide for the use of insulated panels. US5461832A again employs a specialised lifting gantry and does include an insulated building shell; however the floor of the building is anticipated to be a concrete slab requiring the presence of tradespersons and ready-mix concrete and thus it is not relocatable. In US5950568 a folding solution is described but cannot be used with a cuboid volume reserved for services and no mention is made of transportation since the device is scaled to dogs rather than humans. [0006] There are many prefabricated building companies that exploit the size and shipping convenience of the common 20’ or 40’ sea container. These solutions look like sea containers, have poor insulation, low ceiling heights and thus are a poor solution for an ancillary dwelling to a main house. With 140mm insulation the maximum room width is reduced to less than 2m. In CN204001201U and CN103953117B a sea container is built so that some areas of the sea container walls fold down to allow sections of the internal volume to slide out like a drawer. The disadvantage is that construction of the house is in steel which is not easily manipulated or modified and the resultant form is cuboidal. Flashing complexities also arise and to provide an adequate ceiling height roof and floor insulation is minimal. The surface area to volume ratio also facilitates heat transfer thus increasing energy costs of the building. CN104781481B teaches a technique for creating an insulated join between containers.

[0007] Pre-fabrication is a traditional approach in the house construction industry. Current developments see entire wall units shipped in sea containers, while various building forms can be achieved the structural elements must be installed by crane and many tradespersons are still required to complete the construction. Open top sea containers are available but on site cranes are still required which can be difficult for on-site access.

[0008] As a result of the review of prior art it is clear there are no solutions that produce a permanent comfortable habitable cottage type ancillary structure that meets western building codes that can be fully factory made and shipped within a sea container for easy erection on site with limited local resources.

[0009] The technical problem is how to create a factory-built cottage requiring a minimum of on-site works whose compact folded form can be loaded into a sea container while the form when erected has the features most suitable for use as an ancillary dwelling to a main house, including but not limited to: a roughly square- proportioned living space at least 3m long on its shortest side; a ceiling height of at least 2.4 m; a gable roof of at least 3m high; a gable roof with equal roof pitch on each side; and a net floor area of between 20m2 and 40m2 that meets many regulations worldwide for ancillary buildings.

[0010] The technical problem is also how to allow features to be preinstalled if required, obviating the need for associated tradesmen on the building site when it is erected, including but not limited to: fully plumbed bathroom; kitchen bench; overhead cupboards; photovoltaic panels; power inverter; battery storage; all wiring and electrical systems; all plumbing; any necessary electric motors needed to power the unfolding procedure; air conditioning system; ventilation system; atmospheric water generator, etc.

[0011] The technical problem is also how to allow for components to be removable and replaceable including but not limited to: fully plumbed bathroom pod; kitchen bench unit; overhead cupboards unit; photovoltaic panel set; air conditioning system; ventilation system; and atmospheric water generator.

[0012] The technical problem is also how to provide space for transport of necessary parts for completing the house that must be installed in the usual fashion, including but not limited to: bearers, stumps and ground anchoring systems; ridge capping and guttering; and veranda structure and roofing.

[0013] In summary, the goal is to create a wholly factory-built house that can be shipped safely and entirely within a sea container and be erected by one person in one day without specialised gantry equipment or the involvement of specialised tradespersons.

[0014] A solution is to factory-build a house in a folded up format using insulated wall, floor and roof panels that can unfold to form a building of a scale and disposition usually found acceptable for permanent, comfortable and convenient accommodation on one level. [0015] This invention overcomes the limitations of the present art, by providing a building that can be fully constructed in a factory, transported within a sea container, erected by one of limited experience and when erected have a form that provides significant internal volume.

[0016] In this invention a long rigid cuboid, close the height of the sea container end opening, half its width and a length between 40% and 90% of the container length forms one side of the building, into which is fitted all plumbing, bathroom pod, all air conditioning and ventilation services, most electrical services and any other required systems.

[0017] To ensure rigidity and to provide insulation, the structure comprises Structural Insulated Panels (SIPs), or panels or wall and floor systems with similar insulative and structural performance. The invention functions for wall thicknesses up to and including 165mm and bathroom pods up to 1.1m internal width.

[0018] The following outline of the building applies to its folded form. Pivotally connected to the long top edge of this rigid cuboid is a roof panel, which hangs down. To its lower edge is pivotally connected a second roof panel, which stands up and sits adjacent to the first. When the building is erected the pair of roof panels is inverted to form a gable roof. The floor of the building forms the lower edge of the cuboid form, which projects out under the roof panels. To this edge is pivotally connected a floor panel, which stands up beside the roof panels. To the top edge of this floor panel is pivotally connected a second floor panel, which hangs down. The pair of floor panels drop down to form a floor when the building is unfolded. The lower edge of the second floor panel is pivotally connected to the lower edge of the front wall. The two roof panels, the two floor panels together with the long cuboid and the wall panel sit together as a block for transport. The front wall is split horizontally, with the upper part pivotally connected to the lower part. For convenience the split may occur above door height. The upper part of the front wall is immovably fixed to the upper edge of the second roof panel in the conventional manner. When the wall is pulled out, the floor folds down then the roof folds up. Gable ends are lifted into position. End walls complete the form, hinged to the structure in the fashion of large doors.

[0019] Thus, one side of the long cuboid has attached to it the panels that unfold to form a large space. The cuboid contains services. The other side of the cuboid comprises the exterior of the building. A removable panel in that exterior wall allows a bathroom pod to be installed or replaced when the building is in either its folded or unfolded form.

[0020] The invention includes the ability for the building when folded to fit entirely within a 20 foot high-cube sea container. The invention includes a procedure whereby a winch is mounted on the lower edge of the upper front wall panel. From this position the winch is used in a particular sequence to erect or unfold the building or to fold it. The winch is connected as follows: a) to lower the floor panels, b) to stand the front wall and c) to invert and hoist the roof panels. In this invention, the dimensions of the panels can be controlled so that all the moveable or foldable panels comprise a tight fitting stack when folded, yet when unfolded comprise a symmetrical gable roof form.

[0021] When unfolded, the building contains an open and clear floor area up to 3.4m wide and between 5m and 10m long, with an average ceiling height of 2.8m, in addition to areas set aside for bathroom and kitchen services. The invention includes the ability to complete all plumbing and all electrical work, all internal finishes, all cabinetry, all external wall finishes, windows, photovoltaic panels and so on within a factory environment before loading into the container.

[0022] In summary, the invention meets all the requirements stated in the technical problem. [0023] The advantageous effect of this invention is to be able to supply and install a factory-crafted economical buildings that deliver advantages such as:

• ability to provide a comfortable living quarters on one level in a variety of climates.

• ability to construct in the lowest economic environment.

• ability to deploy in the remote and very remote situation even where there are very few local resources.

• ability to deploy rapidly, erecting the entire house in one day is feasible.

• ability to mass produce.

• ability to adjust the floor area as required, from 20 to 45m2.

• low cost factory controlled quality construction across all trades work.

• able to be fitted with various components that are removable and replaceable.

• able to accommodate miscellaneous items needed to complete the construction on site.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a floor plan of the unfolded building

Figure 2 is a floor plan of the folded building

Figure 3 is a cross-section of the folded building

Figure 4 is an isometric projection of the folded building

Figures 5 to 13 are cross sections of the building as it transforms from its folded arrangement to its unfolded arrangement. Figure 14 is a roof plan Figure 15 is an east elevation Figure 16 is a north elevation Figure 17 is a west elevation Figure 18 is a south elevation Figure 19 is an isometric projection

Figures 20 to 25 are cross sections of a variation of the building as it transforms from its folded arrangement to its unfolded arrangement.

Figure 26 is a floor plan of a variation of the preferred embodiment with internal partition walls.

DESCRIPTION OF EMBODIMENTS

[0024] The invention may be better understood with reference to the illustrations of its preferred embodiment.

[0025] Looking at the building plan in Figure 1, the rear portion of the building, shown as the left side of the building, takes the form of a long narrow cuboid, with fixed structural panels on five sides and an opening on its long right side. The rear cuboid comprises an end wall 8 fixed to the back wall 9 that includes a removable section 12 shown double hatched, and which is fixed to an internal dividing partition 39, and to matching end wall 13. The rear cuboid is fixed to floor panel 19 and is capped with roof panel (see 75 in Figure 4 and 207 in Figure 14). During transport, steel cross bracing is placed between wall 30 and wall 39 and between wall 39 and wall 8 along the plane of the open side of the cuboid. Thus the rear cuboid is a stiff structure where equipment or facilities can be installed without risk of damage caused by the structure flexing during transport. [0026] It is a feature of the invention that the space within the rear cuboid is reserved for whatever facilities may be called for in any particular application. In the current embodiment the following is demonstrated:

• apertures 11 allow the heat exchange unit 38 to vent externally. The rear cuboid contains bathroom pod 40 with hybrid composting toilet and is built on floor panel 19;

• the rear wall comprises a removable panel 12 to allow the bathroom pod 40 to be removed whether the building is in the folded or unfolded form;

• the rear cuboid also includes a kitchen bench 37 and overhead cupboards 46 with a sink or other facilities that could include a water absorption unit and air conditioning system; and

• in proximity to the kitchen bench can also be housed a photovoltaic DC power inverter and battery system for powering the building without connection to utilities.

[0027] The rear cuboid volume can be deployed for various purposes for example in an alternative embodiment as a classroom, desks, chairs and other teaching equipment could be shipped within the building; as a health clinic appropriate furniture and facilities could be included.

[0028] Figure 1 shows floor panels 19, 20 and 21, each pivotally joined to its neighbour(s). The hinging axis between floor panels 19 and 20 is approximately flush with the top of the floor panels. The hinging axis between floor panels 21 and 20 is approximately flush with the bottom of the floor panels. Thus by lifting at the join between 21 and 20 those two panels will sit vertically side by side when folding the building. [0029] The back wall 9 contains window 10. The end wall 6 is hinged at 7 to the side of the rear cuboid 8 and the end wall 15 is hinged at 14 to the other side of the rear cuboid at 13.

[0030] Proceeding now to the right or front of the building, 1 is a front wall in which there is a window 2 and door 3. The front wall 1 is hinged at 4 to the end wall 5. The end wall 17 is likewise hinged at 36 to the front wall 1.

[0031] In the preferred embodiment, the volume of the cuboid has sufficient free volume to also contain elements to construct a veranda, including support structures 30, 31, 32 and 33 as well as veranda roofing, 35 and a veranda deck 45. Additional shading can be installed on wall 17, supports are shown at 26 and 28 and the extent of the veranda roof at is shown at 27. Because wall 17 is pivotally connected to wall 1 at 36, wall 17 can be opened as shown by arrows 43 and 29 to allow massive cross ventilation for tropical climates, including when the same is done with wall 5 where it pivotally connects to wall 1 at 4. When wall 17 is moved along arc 43 to its open position 17A then veranda shading 27A can be applied to shield veranda deck 45. Veranda supports 26 and 28 or 26A and 28A are connected to wall 17 or 17A respectively.

[0032] Figure 1 also shows the location in plan of the winch 41 permanently fixed above the wall split of wall 1 and which is used to control the unfolding process.

[0033] When the building is prepared for shipping and packed within the allowed volume of a high cube shipping container, Figures 2, 3 and 4 illustrate the folded positioning of the several floor, roof and wall panels that connect to the rigid cuboid.

[0034] Figure 2 shows the internal floor perimeter of a 40’ shipping container 51. Bearers needed to mount the building on the ground are shown at 66 and show that the entire building including support structures and veranda is within half of the footprint of a 40’ sea container. Thus two buildings could be shipped in one container, or one building stretched to produce the floor area required for particular accommodation needs. Figure 3 at 50 shows the width and height of the doors of a high cube sea container and demonstrates that the building when folded is within those dimensions given that the drawing is to scape with 165mm wall, floor and 220mm roof panels.

[0035] The following numeric references apply to Figures 2, 3 and 4. Two end walls 52 are pivotally connected to front wall 53 at 79 and 82 respectively. The upper edge of front wall 52 is pivotally connected at its top to roof and wall-top element 55; and at the bottom to floor panel 68 at 77. Describing the two folding floor panels, 68 is pivotally connected to 67 at 54 and 67 is pivotally connected to floor panel 82 at 78. Floor panel 82 is fixed to wall panel 63, which is fixed to roof panel 75. Roof panel 75 is pivotally connected to roof panel 69 at 83 and is pivotally connected to roof element 55 at 74.

[0036] Short end walls 56 and 64 shown on Figure 4 and 3 are pivotally connected at 80 and 81 to the rigid cuboid.

[0037] Figure 3 also notes some of the fixtures installed, or additional equipment shipped in the preferred embodiment, namely veranda roofing 71, triangular gable end fills 72, veranda structure 73, dividing wall within the rear cuboid 58, air conditioning or heat recovery ventilation unit 62, and overhead cupboards 61.

[0038] Figures 5 through to 13 illustrate the process of extracting the building from a sea container and erecting same. Props, cleats and wall end 141 mentioned in the singular refer also to the same elements duplicated on the other end of the building but not shown.

[0039] In Figure 5 is shown in black hatching 125 the container entry, within which is the folded building 101. Bearers 126 along with stumps or ground anchoring system are extracted from the container and set up level on the site in the usual fashion 102, 124. The floor of the container must be level and at the same height as the bearers. Use a vehicle to tow the folded building out of the container onto the bearers. A concrete slab, strip footing or other bearers suitable to the location could be used according to the advice of those practiced in the art.

[0040] Figure 6 shows the folded building mounted on the bearers. Note retaining cleat 109, fixed to prevent the building sliding any further during its erection.

Note also cleat 114 and 115, which are holding the package together. The folding structure is essentially a six sided figure hinged at the vertices. The sides are labelled anticlockwise beginning with the main cuboid structure as 103, 127, 128, 107, 105 and 104; connected respectively with hinges 117, 113, 118, 110, 116 and 109. The first step in erecting the building is to check that cable 112 is connected between the winch 111 and floor panel 127 adjacent to hinge 113 and that cable 112 is taught.

[0041] In figure 7, main cleat 114 is removed, allowing the package of elements to expand as shown. Apply a lever at 123 if necessary. The structure expands until the winch cable 122 is taught and preventing the floor panels from lowering.

[0042] Lower the floor panels safely using the winch 132 as shown in Figure 8 until the hinge 131 is resting against the bearers. Note that the foot of the front wall panel is now at 133. Secure the floor panels to the bearer.

[0043] Figure 9 shows the preparations for the second step. Pivotally fix a prop to the position shown at 144. The end resting on the ground will drag as the front panel is stood up and will assist to hold the structure in position. Open the centrally placed window in the front wall 145 to pass winch cable 142 through and fix it to a vehicle or a stake in the ground or equivalent at some distance from the building as shown. Now remove cleat 143. Using the winch, pull the front of the building forward until wall panel 145 is vertical. End panel 141 and its counterpart not shown are each rotated 180 about a vertical axis where they are hinged to the front wall 145.

[0044] As shown in figure 10 continue pulling front wall 155 past vertical until the structure is shown at the key position with the front wall 155 tilting forward about 20 degrees from vertical. Without entering the building, check and ensure the efficacy of prop 152. Install stake at 154 to secure the foot of prop 152. Install prop 156. Ensure the above is complete before entering the building.

[0045] Figure 11 shows the articulated polygon of the building prepared for the final move. With props 168 and 169 in place gradually release tension on winch cable 153, Enter the building and install a compression member 164 attached as shown with tension members 162 and 163 forming an inverted tetrahedron with underside of roof panel 168 as the base. Ensure tension members 162 and 163 are installed to create a tetrahedron with a wide base. Attach winch cable 166 to the lower vertex of tetrahedron 161.

[0046] In Figure 12 the final move of the articulated polygon is complete using the winch. Once the roof is erect 171, fit prop 173, then leaving the winch cable in place, fit tie rod(s) 174 before removing winch 172, prop 173 and the tetrahedral structure 175.

[0047] Figure 13 shows the structure with the tie rod(s) in place 181 ready for adding the gable ends and folding the end walls into position according to methods prevalent in the art.

[0048] Figures 14 to 19 illustrate the completed building in the preferred embodiment.

[0049] Figure 14 shows the roof plan, with photovoltaic panels installed at 208 and 203. The veranda extent is shown at 204 and 205. The roof of the cuboidal volume 207 is pivotally connected at 209 to the gable roof formed by 206 and 202

[0050] Figure 15 is an east elevation is showing veranda 213 and photovoltaic panels 211. Additional photovoltaic panels can also be fitted at 212. The end of the cuboid volume is shown at 218 with a hinge connection 214 to end wall panel 217. End wall panel 216 is hinged at 219 and meets wall panel 217 at 215. Figure 16 is a north elevation showing location of window 221, veranda post (typical)

222 veranda 223 and a veranda attached to the west end wall 224. North-facing photovoltaic panels 225 are shown. Figure 17 is a west elevation showing west facing veranda 231. North facing veranda 232 photovoltaic panels 233 and 234 as well as bearers supporting the building and the veranda floor 235. Figure 18 is a rear or south elevation showing the location of external ducts for ventilation, 241 and 242, approximate location of a window for cross ventilation 243 position of an access panel, in the preferred embodiment, for installing or replacing a bathroom pod 244, location of bearers 246 (typical) and the side view of the west veranda 245.

[0051] Figure 19 is an isometric projection of the North-East corner of the building which shows the resulting traditional architectural form in the preferred embodiment with a gable roof of 30 degree pitch, 251. It can be noted that the preferred embodiment provides a high ceiling space with a symmetrical form.

[0052] In Figure 20 is shown a variation of the building in which the cuboidal volume removed and replaced with a m irror copy of the other five elements to create a pivoting decahedral prism. The sandwich pack of panels, of a cross sectional size to be accommodated in a sea container, is shown mounted on bearers ready for unfolding.

[0053] In Figure 21 the left and right wall panels are pushed out and the floor panel pairs are lowered generally in the manner previously described for Figures 7 and 8. [0054] In Figure 22 the left and right wall panels are pulled to a vertical orientation in the manner previously described in Figures 9 and 10.

[0055] In Figure 23 the left pair of roof panels are prepared for lifting in the manner described in Figure 11.

[0056] In Figure 24 the right pair of roof panels are prepared for lifting in the manner described in Figure 11.

[0057] In Figure 25 the erected position of the roof panels is shown in readiness for tie rods or other structural bracing to be installed.

[0058] In Figure 26 is shown a longer form of the preferred embodiment wherein internal partition walls are shown. Partition wall 301 swings along path 302 into position at 303 and partition wall 311 swings along path 312 into position at 313.

Claims

CLAIMS I claim:

1. An articulated polygonal prism building structure comprising edges of (i) one side of a cuboidal volume, (ii) a pair of articulated roof panels, (iii) a pair of articulated floor panels and (iv) a wall panel; which when folded the roof panels sit sandwiched together and are interleaved with a pair of floor panels that sit sandwiched together and occupy a minimal volume and when unfolded produces a maximal volume habitable building together with a procedure for safely moving the building from its folded shipping form to its unfolded habitable form.

2. The building structure of claim 1 where the polygon edge formed by the cuboid is replaced with a mirror copy of the remaining polygonal elements such that an open floor area building with pitched room can be formed in a like manner.

3. The building structure of claim 1 comprising a traditional symmetrically- pitched, tall gable roof.

4. The building structure of claim 1 constructed with insulated panels.

5. The building structure of claim 1, wherein a simple inexpensive system is employed to allow the prism to be easily unfolded into a building form.

6. The building structure of claim 1, where the folded articulated polygonal prism is integrated with a building of compatible construction that contains various systems to support habitation.

7. The building structure of claim 1 wherein a portion of the exterior wall is removable to allow entire building systems to be removed and replaced whether the building is in its folded or unfolded form.

8. The building structure of claim 1 together with any combinations of claims 2, 3, 4, 5 or 6 sized in its folded form to be transported within a sea- container.