Collapsible Structural Support and Storage Module

Abstract

A rectangular parallelepiped modular structure; size of the structure variable by selection of elements from a plurality of elements; the elements adapted for interconnection to form the structure; the modular structure collapsible for transport and storage; two or more of the modular structures providing stability and support for an overarching roof assembly.

Claims

1. A load bearing rectangular parallelepiped modular structure; size of the structure variable by selection of elements from a plurality of elements; the elements adapted for interconnection to form the structure; the modular structure collapsible for transport and storage; two or more of the modular structures providing stability and support for an overarching roof assembly.

2. The modular structure of claim 1 wherein the selection of elements includes longitudinal stringers and end cross members; pairs of the longitudinal stringers and pairs of the end cross members adapted for interconnection to form rectangular perimeter frames.

3. The modular structure of claim 1 wherein the selection of elements includes upright members; upright members adapted to extend between pairs of upper and lower rectangular perimeter frames.

4. The modular structure of claim 1 wherein the selection of elements includes diagonal bracing members.

5. The modular structure of claim 1 wherein the selection of elements includes intermediate cross members; the intermediate cross members adapted to extend between the pairs of longitudinal stringers of a rectangular perimeter frame.

6. The modular structure of claim 2 wherein the longitudinal stringers and the cross members comprise lengths of channel section; cross sections of both stringers and cross members being the same.

7. The modular structure of claim 6 wherein the lengths of channel section of the longitudinal stringers are provided with attachment plates at opposing outer ends of the channel sections; the attachment plates provided with bolt holes.

8. The modular structure of claim 7 wherein the length of channel section of the longitudinal stringer is further provided at opposing outer ends with projecting tabs at centre of and normal to an external surface of a web of the channel section.

9. The modular structure of claim 6 wherein bolt holes are provided in both the web and the flanges of the longitudinal stringers; the bolt holes providing for bolted connection with intermediate cross members and with upright members.

10. The modular structure of claim 6 wherein bolt holes are provided through a web and flanges of the channel sections of the end cross members proximate opposing outer ends of the cross members.

11. The modular structure of claim 7 wherein the pair of longitudinal stringers and the pair of cross members are assembled into the rectangular frames by bolts passing through the bolt holes of the end plates and the webs of the cross members.

12. The modular structure of claim 3 wherein the upright members include corner upright members and intermediate upright members; each of the corner and intermediate upright members comprising a length of rectangular hollow section (RHS) or other structural profile and a bracket at each outer end of the length of RHS or other structural profile.

13. The modular structure of claim 12 wherein corner upright members are provided at opposing outer ends with a corner bracket.

14. The modular structure of claim 13 wherein each corner bracket comprises an L shaped main plate affixed at the respective outer ends of the corner upright member RHS or other structural profile; auxiliary plates normal to the L shaped main plate affixed at an inner edge of each leg of the L shaped main plate; the width of the leg equal in width to width of the RHS or other structural profile; each leg extending outwardly from adjacent sides of the RHS or other structural profile; each leg and each auxiliary plate provided with bolt holes.

15. The modular structure of claim 12 wherein each bracket of intermediate upright members and intermediate cross members comprises a length of main plate affixed at opposing outer ends the RHS or other structural profile; the main plate being of a length so as to extend outwardly from opposing sides of the RHS or other structural profile; auxiliary plates normal to the main plate affixed along edges of the main plate extending from the RHS; main plate and auxiliary plates provided with bolt holes.

16. The modular structure of claim 15 wherein configuration of the intermediate cross members is identical to that of intermediate uprights.

17. The modular structure of claim 4 wherein diagonal bracing elements include lengths of angle and lengths of flat material; each length of angle and length of flat material provided with bolt holes proximate outer ends.

18. The modular structure of claim 1 wherein the selection of elements further includes a plurality of equi-spaced floor joists; each floor joist comprising a length of channel section of a length to fit between opposing inward facing webs of the pair of stringers of a rectangular perimeter frame.

19-24. (canceled)

25. A method of constructing a rectangular parallelepiped modular structure; the method including the steps of: selecting a set of dimensions from available dimensions of height width and length of the modular structure, assembling a lower rectangular perimeter frame and an upper rectangular perimeter frame from pairs of stringers, pairs of end cross members and one or more intermediate cross members, separating the lower and upper rectangular perimeter frames by insertion of corner and intermediate upright members. arranging diagonal bracing elements between diagonally opposite brackets of corner and intermediate upright members and intermediate cross members.

26-66. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0079] Embodiments of the present invention will now be described with reference to the accompanying drawings wherein:

[0080] FIG. 1 is a perspective view of one configuration of a collapsible structure according to a first preferred embodiment of the invention;

[0081] FIG. 2 is a partial perspective view of a lower perimeter frame and a corner upright of the collapsible structure of FIG. 1;

[0082] FIG. 2A is a perspective view of one element of the collapsible structure of FIG. 1;

[0083] FIG. 3 is a partial perspective view of a lower perimeter frame and an intermediate upright of the collapsible structure of FIGS. 1 and 2;

[0084] FIGS. 4 to 6 are further perspective views of examples of different configurations of the collapsible structure of FIGS. 1 to 3;

[0085] FIGS. 7 and 8 are perspective views of examples of shelter arrangement using two of the collapsible structures of FIGS. 1 to 6;

[0086] FIG. 9 is a perspective view of a series of shelters using three of the collapsible structures of FIGS. 1 to 6;

[0087] FIG. 10 is a perspective view of elements making up a perimeter frame in which end frames are preassembled according to a further preferred embodiment of the invention;

[0088] FIG. 11 is a perspective view of a lower perimeter frame and flooring of another preferred embodiment of the invention.

[0089] FIG. 12 is a perspective view of a further preferred embodiment of a multi-bay structure according to the invention,

[0090] FIG. 13 is a detailed perspective view of a column element of the structure of FIG. 12,

[0091] FIG. 14 is a view of a base structure of the multi-bay structure of FIG. 12.

DESCRIPTION OF EMBODIMENTS

First Preferred Embodiment

[0092] With reference to FIGS. 1 to 3, the collapsible, load-bearing structure 10 according to the invention, is in the form of a rectangular parallelepiped modular structure which is variable in dimensions and configuration by a selection of elements from a plurality of available elements. The arrangement shown in FIG. 1 is of a two-bay structure, but the modular arrangement with elements provided in a selection of different lengths allow the structure to be formed as multiple bays as shown for example in FIGS. 4 to 6.

[0093] The selection of elements includes longitudinal stringers 12 and end cross members 14 which provide for interconnection to form a lower rectangular perimeter frame 16 and an upper rectangular perimeter frame 18. The selection of elements further includes upright members adapted to extend between upper and lower perimeter frames. Other of the selectable elements include one or more intermediate cross members 20 extending between pairs of longitudinal stringers 12 of the perimeter frames and diagonal bracing members.

[0094] Both the longitudinal stringers 12 and the end cross members 14 are formed of channel section, either in steel or aluminium, with both the stringers and cross members being of the same cross section. The web 22 of the channel section of the longitudinal stringers 12 may be provided with a number of bolt holes to allow connection of intermediate cross members 20 at a selection of locations.

[0095] Likewise, the flanges 24 of the channel section of the longitudinal stringers 12 may be provided with pairs of bolt holes to allow connection with upright members.

[0096] As best seen in FIG. 2A the lengths of channel section of the longitudinal stringers 12 are provided at opposing outer ends with attachment plates 26; each with a number of bolt holes. The longitudinal stringers 12 are further provided at their outer ends with projecting tabs 28 normal to the external surface of the web of the channel section. These tabs also are provided with bolt holes. As well both the web and the flanges of the longitudinal stringers are provided with bolt holes for connection of intermediate cross members and upright members.

[0097] The end cross members 14 are also provided with bolt holes through both the web and the flanges of the channel section as shown in FIG. 2 with the bolt holes through the web matching the bolt holes of the attachment plates 26 of the longitudinal stringers, allowing the longitudinal stringers and the end cross sections to be bolted together into the upper and lower perimeter frames of the structure 10.

[0098] Upright members of the structure include corner upright members 30 and intermediate upright members 32, each of which are formed of a length of rectangular hollow section (RHS) or other structural profile and with a bracket at each outer end of the RHS or other structural profile.

[0099] In the case of the corner upright 30, with reference to FIG. 2, the bracket is a corner bracket 36 comprising an L shaped main plate 38 with legs of the L shaped plate of the same width as the width of the RHS or other structural profile. Each leg extends outwardly from adjacent sides of the RHS or other structural profile and is provided with a bolt hole. The corner bracket 36 further includes auxiliary plates (similar to those of the intermediate upright shown in FIG. 3, but hidden in FIG. 2) normal to the L shaped main plate affixed at an inner edge of each leg of the main plate 38, with these auxiliary plates also provided with bolt holes.

[0100] With reference now to FIG. 3 the brackets 40 of the intermediate uprights 32 comprise a length of main plate 42 of a width equal to that of the RHS or other structural profile and of a length so as to extend outwardly from opposing sides of the RHS or other structural profile. Auxiliary plates 44 normal to the main plate are affixed along edges of the main plate extending from the RHS or other structural profile with both the extensions of the main plate and the auxiliary plates provided with bolt holes.

[0101] As can be seen from FIGS. 1 and 2 the intermediate cross members 20 are of identical configuration to that of the intermediate uprights being also formed of the same RHS or other structural profile and having identical brackets at each outer end.

[0102] As can also be seen from FIGS. 1 and 2, the diagonal bracing elements of the structure may be formed from lengths of flat 46 or of angle 48 or as in the examples shown, a combination of both. In each case the bracing elements are of a length to suit the diagonal separation between bolt holes of the various brackets of corner uprights 30, intermediate uprights 32 and intermediate cross members 20 as well as the tabs 28 projecting from the longitudinal stringers 12.

[0103] Preferably, the structure may be provided with a plurality of equi-spaced floor joists 50 as shown in FIG. 1, each formed of a length of channel section of lengths to fit between opposing inward facing webs of the pair of longitudinal stringers 12 of a lower rectangular perimeter frame 16. The floor joists 50 are secured to the inward facing webs by angle brackets 52 provided with bolt holes as shown in FIG. 3A. The joists 50 provide support for panels of a floor with the panels 54 fitting between inward facing webs of the longitudinal stringers and end cross member of the lower rectangular perimeter frame.

[0104] The members of the modular structure of the present invention thus provide a method of constructing a rectangular parallelepiped 10 in a variety of length, width and height from a selection of elements. The method includes the steps of: [0105] selecting a set of dimensions from available dimensions of height width and length of the modular structure, [0106] assembling a lower rectangular perimeter frame 16 and an upper rectangular perimeter frame 18 from pairs of stringers, pairs of end cross members and one or more intermediate cross members, [0107] separating the lower and upper rectangular perimeter frames by insertion of corner 30 and intermediate 32 upright members. [0108] arranging diagonal bracing elements between diagonally opposite brackets of corner and intermediate upright members and intermediate cross members

[0109] The lower perimeter frame is firstly assembled by aligning ends of each of the end cross members with a suitably spaced apart pair of longitudinal stringers and bolting through the corresponding bolt holes in the attachment plates of the stringers and the bolt holes at the ends of the end cross members. Any desired intermediate cross members are added.

[0110] The upper perimeter frame is similarly assembled.

[0111] If a floor is to be provided, floor joists are installed between the longitudinal stringers of the now complete perimeter frame. Floor panelling may also be best installed at this stage.

[0112] Corner and intermediate uprights are now bolted to the longitudinal stringers of the lower perimeter frame, and the upper perimeter frame lifted into position onto these upright members and bolted to them.

[0113] Finally diagonal cross bracing elements are fitted. As shown in FIGS. 1 and 4 to 6, cross bracing may be omitted from one of the side bays of the structure to allow for access to the interior of the structure if it is to be used for storage for example.

[0114] If desired, the structure may be enclosed by external cladding.

[0115] It will be appreciated that all the elements which combine to form the structure 10 are readily transportable and able to be compactly stored as a flat pack so that the size of the structure which may be erected at a site for use is not limited in the manner in which a preassembled structure such as a shipping container is.

[0116] Referring now to FIGS. 7 to 9, the structures are designed to be load bearing for the purpose of providing shelters, for example for plant and equipment, in the form of an overarching roof assembly 96 when two of the structures are positioned parallel one to the other and spaced apart commensurate with the span of the roof assembly. In such an arrangement, the outer edges 98 of the roof assembly may be supported and fastened to outer edges of the supporting structures as shown in FIGS. 7 and 8, or to the inward facing edges as in FIG. 9. As can also be seen in FIG. 9, three or more structures can be arranged so as to form a daisy chain of shelter areas between each adjoining pair of structures. It is to support the weight of these roof assemblies and the lateral thrust applied by them, that the elements making up the structure are of a size considerably in excess of that required to form an enclosure of comparable size. It will be appreciated that although examples shelters in the drawings are in the form of arched roofs, skillion or other roof configurations may be employed.

[0117] It will be observed that, in use, the roof assemblies are laterally offset from the load-bearing rectangular parallelepiped collapsible structures. Thus each structure must support both a vertical force component and a horizontal force component when supporting the roof assembly.

[0118] Thus there is provided a method of transporting to site rectangular parallelepiped load-bearing structures of a size exceeding structures transportable on a road transport vehicle; two or more of the load-bearing structures supporting one or more overarching roof assemblies; the method including the step of providing the structures as a collapsible load-bearing structures comprising elongate elements selectable from a plurality of elongate elements; the elongate elements including load bearing uprights.

[0119] Preferably the load bearing uprights support both a vertical and horizontal load component.

[0120] Further there is disclosed a load-bearing rectangular parallelepiped structure assembled from structural elements; the structural elements available in a range of sizes and configurations; upright structural elements of the structure configured to support a roof assembly or assemblies when two or more of the parallelepiped structures are positioned in a spaced apart configuration.

[0121] Preferably the structural elements support both a vertical and horizontal load component.

[0122] Preferably the structural elements are in the form of load bearing uprights.

[0123] Also disclosed is a method of supporting a roof assembly extending between two load-bearing rectangular parallelepiped collapsible structures; each parallelepiped collapsible structure variable in dimensions and load-bearing capacities by selection of structural elements from a plurality of available structural elements; the roof assemblies supported by load-bearing columns at corners and intermediate side locations of the parallelepiped collapsible structure.

[0124] Preferably the load bearing columns support a vertical load component and a horizontal load component.

[0125] Preferably each structure exerts both a vertical force component and a horizontal force component when supporting the roof assembly.

[0126] Preferably each structure exerts both a vertical force component and a horizontal force component when supporting the roof assembly.

Second Preferred Embodiment

[0127] In this alternative arrangement of a modular structure according to the invention, some sections of the parallelepiped 100 may be preassembled. For example, as shown in FIG. 10, end frames 80 could be assembled off-site by butt welding RHS or other structural profile corner uprights 82 between a pair of lower and upper cross members 84 and 86. In this arrangement there is no need for the L shaped brackets of the corner uprights as described above but the end frames are just provided with an auxiliary plate 88 welded into the corner at each junction of cross member and RHS or other structural profile upright to provide for attachment of diagonal bracing of the end frame.

[0128] In this embodiment the longitudinal stringers 90 are likewise provided at their outer ends with auxiliary plates 92 to substitute for the auxiliary plate of the corner upright bracket, again to provide attachment points for diagonal bracing of the sides of the structure. As for the first preferred embodiment above, the stringers are provided with end plates with bolt holes matching those at the outer ends of the cross members for bolted attachment stringer to cross member. The structure is completed by the addition of one or more intermediate uprights, intermediate cross members and diagonal bracing, all identical to those of the first preferred embodiment.

[0129] In a further alternative arrangement with reference to FIG. 11, pairs of longitudinal stringers 12 and end cross members 14 could be bolted together to form respectively upper and lower frames (only the lower frame is shown in FIG. 11) of the structure. Preparing particularly the lower base frame 94 off-site is advantageous if the structure is to be provided with floor panels 54, in which the lower base frame is pre-fitted with supporting joists 50 and, if desired, the floor panels 54. In this arrangement all other elements, the corner and intermediate uprights, intermediate cross members and diagonal bracing elements remains as described for the first embodiment above.

Third Preferred Embodiment

[0130] With reference to FIGS. 12 to 14, the collapsible structure 200 according to this preferred embodiment of the invention, is again in the form of a load-bearing rectangular parallelepiped collapsible structure which is variable in dimensions and configuration by selecting elements from a plurality of available elements.

[0131] FIG. 13 shows a base module of the collapsible structure 200 to which further modules or sections can be added as shown in FIG. 12. Although each of the components making up the base module and those which may be added to create a desired length of structure, components may be made available in a selection of lengths and configurations. That is for example, while columns are standardised as I beams, these may be made available in different cross sections to allow for a range of load-bearing capacities.

[0132] In this embodiment, each upright element or column 210, whether employed at a corner of the structure or at an intermediate side wall position, is identical. As shown in FIG. 13 each column 210 is provided at each outer end with a square mounting plate 211, 212 pre-drilled with holes. These allow the lower plates 211 of the columns to be bolted to a supporting surface for example and allows for the securing of structural elements of a roof assembly to the upper plates 212. In addition, the upper plates 212 permit two structures to be mounted one above the other and bolted together by means of bolting the lower plates of an upper structure to the upper plates of the lower.

[0133] The columns 210 are further prepared with holes 214 drilled through at least one side flange 216 and holes 218 through the central web 220 to allow for bolted connections with other components of the structure. The columns are also pre-prepared with projecting tabs 222 adjacent the lower and upper plates 221 and 222 also provided with pre-drilled holes. These various holes in the web and flange provide for bolted attachment of cross braces 224 and brackets (hidden under the purlins) to support intermediate longitudinal and transverse purlins 226.

[0134] Preferably these intermediate purlins 226 are formed of relatively light weight, roll-formed channel section, and provide support for external wall sheeting as shown in FIG. 12 if required.

[0135] Opposing columns 210 along each side of the structure 200 are further interconnected at their respective upper and lower ends by heavier lengths of longitudinal 228 and transverse horizontal beams 230, preferably in the form of hot rolled parallel flanged channel sections. Transverse beams 230 between opposing side flanges of pairs of adjacent columns are bolted to the projecting tabs 222, while longitudinal beams or stringers 228 are bolted to the holes provided in the side flanges of the columns.

[0136] These longitudinal and transverse horizontal beams, while of the same cross section, may of course be provided in different lengths. The longitudinal 228 and transverse beams 230 are also pre-drilled with holes both in their flanges and webs, both to allow bolting to the tabs 222 or flanges 216 of the columns 200, but also to support brackets, firstly cross brace brackets 232 for attachment of cross bracing 224 and secondly, floor joist brackets 234 as best seen in the enlarged inset of FIG. 12.

[0137] Purlins 226 may double as joists 227 to support sheets of flooring if the structure is to be used for storage and stored material needs to be off the ground. Joists are fixed in between lower longitudinal stringers 228 along opposite sides of the structure by these brackets 234. Another component, a roof purlin 236 similarly formed as a roll-formed channel, is affixed between successive upper transverse horizontal beams 230, to provide intermediate support for transverse roofing sheets where these are desired.

[0138] It can be seen, in particular from the use of substantial I beams for the columns 210 that the load bearing parallelepiped of this embodiment is far stronger than the typical construction for an enclosure of comparable dimensions. This inherent load-bearing strength is demanded for the application of supporting large overarching roof assemblies such as depicted in FIGS. 7 to 9.

[0139] It will be appreciated that this embodiment of the structure is also fully scalable in that the module shown in FIG. 14 can be added to by further combinations of columns, longitudinal and transverse horizontal beams and bracing, to support any extent of overarching roof. Moreover, each of the elements of the structure, that is the columns, purlins, horizontal beams, diagonal braces etc may be provided in sets of different, mutually compatible lengths to suit a selection of dimensions of height, width and depth of the modules of FIG. 12.

[0140] Because all the elements that make up the structure are essentially made up of just elongate elements, all that are required for even multiple bays such as shown in FIG. 13, are easily transportable in a flat pack form even though the assembled structure may be far larger than that which can be accommodated on a transport vehicle.

In UseIndustrial Applicability

[0141] The modular structures 10 or 200 may be used singly or combined in pairs or multiple structures to provide support and stability for overarching roof assemblies 60 for forming shelters 62 as shown in the examples of FIGS. 7 to 9. Two or more modular structures may be placed in parallel, spaced-apart positions with an overarching roof assembly 60 extending, in the example of FIG. 7, from outer longitudinal stringers 12 (or outer columns 210) of the upper rectangular perimeter frame of each of the structures, or as shown in FIG. 8, from the inner longitudinal stringers or columns. Multiple shelter areas can be provided by positioning a number of modular structures with a series of overarching roof assemblies between them as shown in FIG. 9

[0142] In each case, additional stability if required may be provided, either by sufficiently heavy material stored within the structures or by placing ballast, for example sandbags on the floors of the structures.

[0143] All elements may be readily transported in disassembled form to a site for erection without the need for special arrangements as required for example for oversized structures when transported by road.