Prefabricated foldable building module
09611637 ยท 2017-04-04
Inventors
Cpc classification
E04B1/34336
FIXED CONSTRUCTIONS
E04B1/34384
FIXED CONSTRUCTIONS
E04H5/02
FIXED CONSTRUCTIONS
E04H1/12
FIXED CONSTRUCTIONS
E04B1/343
FIXED CONSTRUCTIONS
E04H3/08
FIXED CONSTRUCTIONS
International classification
E04B1/348
FIXED CONSTRUCTIONS
Abstract
A prefabricated foldable building module including a central core comprising first and second opposing fixed walls with roof and floor beams interposed therebetween; a plurality of vertically foldably connected walls mounted upon the first and second walls foldable out therefrom; a pair of roof panels, each foldably connected adjacent said roof beam; a pair of floor panels each foldably connected adjacent floor beam: characterized in that the wall panels, roof panels and floor panels may be folded out from their supporting structures in a defined sequence to form an enclosed/partly enclosed building structure, and may be re-folded in reverse sequence to original configuration. Standard modules can be stretched, or joined side by side, end to end or one on top of the other to form larger buildings.
Claims
1. A prefabricated, foldable building module, including: a central core, including a central roof portion, a central floor portion and two opposing fixed walls extending between the central roof portion and the central floor portion; a plurality of foldable wall panels including side wall panels each foldably connected to one of the opposing fixed walls and foldable out therefrom and end wall panels each foldably connected to one of the side wall panels and foldable out therefrom; roof panels, each being foldably connected to the central roof portion and foldable out therefrom such that the roof panels swing outwards and upwards on opposite sides of the central core; floor panels, each being foldably connected to the central floor portion and foldable out therefrom such that the floor panels swing outwards and downwards on opposite sides of the central core, wherein the module is moveable between, a folded configuration, in which the foldable wall panels, roof panels and floor panels are stowed at least one of partially within and substantially adjacent the central core, and an erected configuration, in which the wall panels are outwardly folded from the central core such that the side walls extend from the two opposing fixed walls and the end walls extend between the respective side walls, the floor panels are outwardly folded from the central core so as to extend from opposing sides of the central floor portion and the roof panels are outwardly folded from the central core so as to extend from opposing sides of the central roof portion, wherein in the erected configuration, the central roof portion is recessed relative to tops of the end wall panels and leading edges of the roof panels are positioned inside of and below the tops of the end wall panels such that the roof panels slope downwardly toward the central roof portion, and wherein the central roof and floor portions are each narrower in plan form than the two opposing fixed walls so as to define recesses between ends of the two opposing fixed walls and side edges of the respective central roof and floor portions, the recesses providing a depth such that the roof panels, floor panels and at least one of the plurality of foldable wall panels are received by the recesses in the folded configuration.
2. The prefabricated, foldable building module according to claim 1, wherein, in the erected configuration, the side walls and the end walls are higher than the roof panels so as to form a parapet above the roof panels.
3. The prefabricated, foldable building module according to claim 2, wherein the parapet is configured to allow multiples of the module to be joined together, one on top of the other, to form multi-level structures.
4. The prefabricated, foldable building module according to claim 1, wherein, in the erected configuration, the leading edges of the roof panels are coupled to the end wall panels below the tops of the end wall panels.
5. The prefabricated, foldable building module according to claim 1, wherein in the erected configuration, leading edges of the roof panels are connected by at least one of a pin or clip to the end wall panels below and inside the tops of the end wall panels.
6. The prefabricated, foldable building module according to claim 1, wherein, in the erected configuration, foldably connected edges of the roof panels are at least partially elevated relative to the central roof portion so as to direct water captured by the roof panels to the central roof portion.
7. The prefabricated, foldable building module, according to claim 1, wherein the roof panels each include an upturn at the respective leading edges thereof and the end wall panels each include a corresponding extruded capping sleeve running along an inside top thereof into which the corresponding upturn fits in the erected configuration so as to be weatherproof.
8. The prefabricated, foldable building module, according to claim 1, wherein the central roof portion includes two beams extending along opposing sides of the central roof portion, the roof panels each being connected to a respective one of the two beams.
9. The prefabricated, foldable building module according to claim 1, wherein the central roof portion includes a gutter for directing water captured by the roof panels.
10. The prefabricated, foldable building module according to claim 1 wherein the central roof portion is arranged to direct water toward at least one of the opposing fixed walls of the central core.
11. The prefabricated, foldable building module according to claim 1, wherein the roof panels and the floor panels are arranged to swing into the erected configuration after the foldable wall panels have unfolded, such that the roof panels and the floor panels are wholly enclosed within the foldable wall panels, and outer edges of the floor and roof panels are supported directly or indirectly by the foldable wall panels.
12. The prefabricated, foldable building module according to claim 1, wherein the roof panels are arranged to swing into the erected configuration after the foldable wall panels have unfolded, such that the roof panels do not require any additional support whilst the foldable wall panels unfold into the erected configuration.
13. The prefabricated, foldable building module according to claim 1, wherein the end walls present a substantially flush outer surface so as to allow abutment with other modules.
14. The prefabricated, foldable building module according to claim 1, wherein the side walls and the end walls each have substantially flush outer surfaces arranged such that multiples of said module in the erected configuration may be joined together at any of the side walls and end walls to create larger structures in a variety of configurations.
15. A prefabricated, foldable building module according to claim 1, wherein the side walls and the end walls have substantially flush outer surfaces such that in the erected configuration multiples of the module may be joined together, side by side, either fully interfaced or partly offset, and where corresponding openings may be made at the interface between modules.
16. The prefabricated, foldable building module according to claim 1, wherein a further module in the erected configuration may be joined together with the module, end on end, and where at an interface of the module and the further module, an end wall panel of the further module may be omitted.
17. The prefabricated, foldable building module according to claim 1, wherein in the folded configuration, the foldable wall panels, the roof panels, and the floor panels lie substantially co-planar to each other adjacent open sides of the central core such that the module presents as a rectangular shaped box structure.
18. The prefabricated, foldable building module according to claim 1, further including associated infill panels and wherein in the erected configuration the infill panels are fitted between the end wall panels.
19. The prefabricated, foldable building module according to claim 1, wherein, the central floor portion is wider in plan form than the central roof portion such that in the folded configuration the roof panels are located within the recesses inwardly of the floor panels.
20. A method of assembling a building from a prefabricated, foldable building module, the method including the steps of: folding wall panels connected to opposing fixed end walls of a central core of the module outwardly from within recesses on opposing sides of the central core to form outer walls of the building, the recesses being provided between ends of the opposing fixed end walls and side edges of a respective central roof and floor portions of the central core, the central roof and floor portions being each narrower in plan form than the fixed end walls, and the wall panels including side wall panels foldably connected to the ends of the opposing fixed end walls of the central core and end wall panels foldably connected to the side wall panels; folding floor panels connected to the central floor portion outwardly from the recesses and downwardly relative to the central floor portion of the central core so as to form a floor between the outer walls of the building; and folding roof panels connected to the central roof portion outwardly from within the recesses and upwardly relative to the central roof portion supported by the fixed walls of the central core so as to form a roof between the outer walls of the building over the floor, the roof panels being supported by and positioned inside of and below tops of the end wall panels such that the roof panels slope downwardly toward the roof portion.
21. The method according to claim 20, further including the step of: securing leading edges of the folding roof panels to inside faces of the end wall panels by at least one of a clip and pin fitted between the end wall panels and the folding roof panels.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DETAILED DESCRIPTION
(21) Referring to
(22) The prefabricated, foldable building module 40 includes a central core 50, including a central roof portion 6, a central floor portion 14 and two opposing fixed walls 10 extending between the central roof portion 6 and the central floor portion 14.
(23) The module 40 includes a plurality of foldable wall panels 52, support by the central core 50, including side wall panels 2 each foldably connected to one of the opposing fixed walls 10 and foldable out therefrom and end wall panels 3 each foldably connected to one of the side wall panels 2 and foldable out therefrom.
(24) The module 40 further includes folding roof panels 7 and floor panels 4 supported by the central core 50. The roof panels 7 are each being foldably connected to the central roof portion 6 and foldable out therefrom such that the roof panels 7 swing outwards and upwards on opposite sides of the central core 50. The foldably floor panels 4 are connected to the central floor portion 2 and foldable out therefrom such that the floor panels 4 swing outwards and downwards on opposite sides of the central core 50. As may be best appreciated from
(25) The module 40 is moveable between, the first folded configuration, in which the foldable wall panels 52, roof panels 7 and floor panels 4 are stowed at least one of partially within and substantially adjacent the central core 50, as is shown in
(26) As is best shown in
(27) In use, the module 40 arrives at the intended erection site via truck or trailer (not shown). The module 40 is then moved into place over pre-prepared in/on ground middle support posts 1. The lower extremities of opposing fixed walls 10 and floor beams 8 are then fixed to the middle support posts 1 as best depicted in
(28) Following the above steps and as best viewed in
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(30) Although the embodiment of the more basic module employs the same opening and closing sequences as the standard module
(31) Standard modules
(32) The module may have a steel, timber or other frame and can be finished in a variety of external claddings and internal lining options. There are a number of different door and window size and location options to suit different applications.
(33) As illustrated in
(34) Standard modules can easily be joined together side by side or end to end to create larger shelters or dwellings as depicted in
(35) Standard modules can also be stacked to form multi-storey buildings as depicted in
(36) The central core 50 of the standard module depicted in
(37) The central roof portion 6, may be fabricated from steel, aluminium or other suitable roof sheeting material, as may be the two main folding roof panels. Central roof portion 6 is desirably substantially lower than the two adjacent folding roof panels 7 and would desirably have a fall (say 3 degrees) perpendicular to the fall on the two adjacent folding roof panels, falling to a gutter 54 and downpipe (not shown) on one or both of the fixed walls 10. Therefore water will fall from the sky onto one of the two folding roof panels, it will then fall along the folding roof panel 7 and onto the fixed central roof portion 6. From there the water will be guided perpendicularly across the central roof portion 6 and into the gutter 54 or a sump (not shown) and downpipe (not shown) on the outside of one or both of the fixed walls 10. As an alternative method of dealing with rainwater runoff from the roof panels, gutters may be attached along each of the upturned edges of the central roof portion adjacent to the foldably connected edges of the roof panels 49, thus catching the water flow before it reaches the central roof portion and guiding it along the gutters into the said sump (not shown) and downpipe (not shown) on the outside of one or both fixed walls 10.
(38) It will be appreciated that the simple construction sequence of the current invention has the walls on the outside of the collapsed module. Wall panels fold out first so that when the roof and floor panels follow they are wholly contained by the walls. This allows the roof and floor to stabilize the walls and also offers the advantage of using the already erected wall panels to support a simple winch or pulley device to assist in raising the roof panels and lowering the floor panels. Having the walls on the outside of the roof and floor also allows for continuity of material over the entire perimeter of the building. The invention avoids the appearance of floor and roof edges from outside the building and simplifies weather protection of floors. Roof and wall panel junctions must naturally be effectively waterproofed in accordance with existing technology.
(39) During the erection process there is no requirement for temporary support of roof panels while wall panels are swung into the open position. This simpler and safer opening sequence requires minimal lifting equipment, time, manpower and resources on site.
(40) There is no reliance on track and/or wheel systems to position the end walls or requirement for the end walls to be lifted from floor panels or dropped from temporarily supported roof panels as in some prior art systems. Accordingly, there is provided an erection technique, which is simpler, safer and more effective.
(41) The elimination of cave overhangs and most peripheral guttering allows for simple connection of units. This means that any number of units can be positioned and joined together to form a dwelling of any size. Due to the compact size and weight of each unit, only smaller lifting devices are required such as folk lifts or integrated cranes on haulage trucks that deliver the modules.
(42) The overall design and opening sequence of the prefabricated module above described allows for a large floor area and enclosed volume when open, compared to the collapsed volume.
(43) As the bathroom and kitchen areas are preferably central to the module the ceiling level raises towards the external walls where the main living spaces are. The height is hence lower over the utility areas of the bathrooms and kitchens. This provides a more pleasant spacial experience while using the building. It also provides more opportunity for window opening positions on the external walls.
(44) The break-up of walls and resulting weight reduction of each panel may allow manual handling by 2 men to swing the foldable wall panels out into erected position and fix individually to post supports. When the foldable wall panels have been secured in open module position they form a solid element from which roof panels can be raised into place and floor panels lowered.
(45) The present invention results in an aesthetically pleasing building as foldable wall panels fold out before the roof and the floor panels resulting in the roof and floor being contained within the walls, creating a simple boxlike appearance. The top of the walls form a parapet above the roof.
(46) As depicted in the blown up detail of
(47) A variety of different support systems can be used depending on the application of the module. The base of the wall panels fix to support posts to enable structural support and integrity. These support posts can be either permanent or temporary depending on the application of the module. If permanent, the support posts can be set into concrete footings or screw pile type footings can be used. When the wall panels are open the plates at the base sit on and fix to the support posts. Shimming on site between the posts and wall panels accommodates any site tolerances.
(48) The roof 7 and floor panels 4 preferably fix to the wall panels 52 when open to provide structural support for the roof and floor as well as structural integrity to the module 40 as a whole. The floor panels sit on and fix to plates at the base of the wall panels. The roof panels have plates or upturns 62 along the outside edge that fix to the tops 48 of the wall panels 3 in a variety of different ways including bolt fix 13 or hang fix to welded steel D-rings 13.
(49) If modules are joined end to end as in
(50) Where the end wall panels are omitted the outside edges of opposing roof panels meet at the interface of the modules. In this case beams (not shown) at the roof panel edge will need to be increased in size to transfer the load to the side walls and a capping needs to be placed to waterproof the junction between the two upturned roof edges.
(51) Additional modules can be joined together on top of ground engaging modules resulting in multi-level buildings,
(52) It will be appreciated that window and door openings can be positioned in a multitude of locations in any wall of the module. Roof lights can be placed in roof panels. Voids for stairs can be placed in floor panels.
(53) As can be seen the design of the module lends itself to a versatile range of design options and additions, as illustrated in
(54) A road worthy trailer with wheels 30 can be added to the base of the module as depicted in
(55) Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises and comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
(56) The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.
(57) While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein. Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.