Foldable Prefabricated Modular House Structure and Related Methods

Abstract

A foldable prefabricated modular house structure is provided, comprising a core module that can be compacted to a size similar to an international shipping container, external extension unit that fold out to form extended living spaces on either side of the core module, internal extension unit to complete the side wall enclosure of the extended living spaces, and a deployable roof unit to cover the side walls of the extended living spaces. The roof system allows for efficient utilization of available space while maintaining structural integrity and case of assembly. Optional features such as pre-installed doors and windows, integrated locking mechanisms, and pre-built fittings for the kitchen and bathroom contribute to a simplified construction process and enhance user enjoyment.

Claims

1. A foldable prefabricated modular house structure, comprising: a core module configured with a plurality of panels; wherein the plurality of panels comprises: a floor panel, an anterior panel, a posterior panel, a pair of vertical side panels, and a roof panel; an external extension unit hinged to top edges of a vertical sides of floor panel to unfold and form extended living spaces on either side of the core module; wherein each of the external extension unit comprises an auxiliary floor member and an auxiliary side wall member, coupled together via a plurality of hinges; an internal extension unit hinged to each vertical edges of the pair of vertical side panels, wherein each of the internal extension unit are configured to unfold outwards to complete the enclosure of the extended living spaces; and a deployable roof unit comprising a plurality of stacked planks deployed to cover the roof of the enclosure of the extended living space; wherein the deployable roof unit is secured to the internal and external units by a locking system, the locking system including a corner groove configured to fully accommodate a roller attached to at least a plurality of planks of the deployable roof unit.

2. The foldable prefabricated modular house structure of claim 1, wherein the deployable roof unit comprising the plurality of stacked planks and at least a plurality of rollers deployed to cover the roof of the enclosure of the extended living space.

3. The foldable prefabricated modular house structure of claim 1, wherein the plurality of stacked planks is connected to each other through hinge connection.

4. The foldable prefabricated modular house structure of claim 1, wherein the internal extension unit and the auxiliary side wall member is configured with at least one additional groove and a corner groove to receive the plurality of rollers.

5. The foldable prefabricated modular house structure of claim 1, wherein plurality of stacked planks comprises an edge plank, at least one adjoining plank and at least one alternate plank.

6. The foldable prefabricated modular house structure of claim 1, wherein the locking system secures the auxiliary side wall member and internal extension unit in position, when the house structure is in an unfolded state.

7. The foldable prefabricated modular house structure of claim 1, wherein plurality of planks is connected to each other through water proof connection.

8. The foldable prefabricated modular house structure as claimed in claim 1, wherein the core module is configured to be compacted to a size comparable to an international shipping container.

9. The foldable prefabricated modular house structure of claim 1, further comprising a divider separating the length of the floor panel of the core module into a kitchen space and a bathroom space.

10. The foldable prefabricated modular house structure of claim 1, wherein the vertical side walls of the core module include windows and doors.

11. The foldable prefabricated modular house structure of claim 1, wherein the members of the external extension unit are configured to unfold outwards by 90 degrees to form the floor and side walls of the extended living spaces.

12. The foldable prefabricated modular house structure of claim 1, further comprising pre-built bathroom and kitchen fittings integrated into the core module.

13. The foldable prefabricated modular house structure of claim 1, wherein the internal extension units are configured to unfold outwards by 90 degrees to form the width wise side walls of the extended living spaces.

14. The foldable prefabricated modular house structure of claim 1, further comprising home automation systems and energy-efficient lighting integrated into the structure.

15. The foldable prefabricated modular house structure of claim 1, further comprising eco-friendly materials and design elements, including solar panels or green roofing, incorporated into the structure.

16. A method of deploying prefabricated modular house structure, the method comprises of following steps: installing a core module configured with a plurality of panels at a predefined area; unfolding an external extension unit hinged to a plurality of bottom edges of a pair of vertical side panels to form an extended living space on either side of the core module; unfolding an auxiliary side wall member to form vertical side wall for the extended living space; unfolding an internal extension unit hinged to each vertical edges of the pair of vertical side panels, wherein each of the internal extension unit are configured to unfold outwards to complete the enclosure of the extended living space; and deploying a deployable roof unit comprising a plurality of stacked planks and a plurality of rollers to cover the roof of the enclosure of the extended living space.

17. The method as claimed in claim 16, wherein the core module configured with a plurality of panels, wherein the plurality of panels comprises a floor panel, an anterior panel, a posterior panel, the pair of vertical side panels, and a roof panel.

18. The method as claimed in claim 16, wherein the method comprising locking mechanisms for securing the auxiliary side wall member and the internal extension unit in position when the modular house structure is in an unfolded state.

19. The method as claimed in claim 16, wherein the method comprising separating the length of the floor panel of the core module into a kitchen space and a bathroom space modular house structure by dividers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] These and other features, aspects, and advantages of the present invention will become better understood with regards to the following description, appended claims, and accompanying drawings where:

[0034] FIG. 1 an isometric view of the prefabricated modular house structure is illustrated in completely folded state, compacted to a core module, in accordance with the embodiments of the present invention disclosed herein;

[0035] FIG. 2 shows an isometric view of a first stage of an unfolding process of the folded core module, in accordance with the embodiments of the present invention disclosed herein;

[0036] FIG. 3 shows an isometric view of the first stage of the unfolding process of the folded core module with the external extension unit unfolded along the floor panel, in accordance with the embodiments of the present invention disclosed herein;

[0037] FIG. 4 shows an isometric view of a second stage of the unfolding process in accordance with the embodiments of the present invention disclosed herein;

[0038] FIG. 5 shows an isometric view of a third stage of the unfolding process, indicating the internal extension unit in the process of unfolding, in accordance with the embodiments of the present invention disclosed herein;

[0039] FIG. 6 shows an isometric view of the third stage of the unfolding process, with the internal extension unit completely unfolded, in accordance with the embodiments of the present invention disclosed herein;

[0040] FIG. 7 shows an isometric view of the house structure, indicating a deployable roof unit, in accordance with the embodiments of the present invention disclosed herein;

[0041] FIG. 8 shows an isometric view of the house structure, demonstrating a fourth and final stage of the unfolding process of the deployable roof unit, in accordance with the embodiments of the present invention disclosed herein;

[0042] FIG. 9 shows an exploded view of the house structure, indicating the components associated with the locking system, in accordance with the embodiments of the present invention disclosed herein; and

[0043] FIG. 10 shows an isomeric view of the house structure in fully unfolded state with the extended living spaces, in accordance with the embodiments of the present invention disclosed herein.

[0044] FIG. 11 shows a flow diagram of a method of deploying prefabricated modular house structure in accordance with the embodiments of the present invention disclosed herein.

[0045] Common reference numerals are used throughout the figures and the detailed description to indicate like elements. One skilled in the art will readily recognize that the above figures are examples and that other architectures, modes of operation, orders of operation, and elements/functions can be provided and implemented without departing from the characteristics and features of the invention, as set forth in the claims.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENT

[0046] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.

[0047] Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.

[0048] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term and/or includes any combinations of one or more of the associated listed items. As used herein, the singular forms a, an, and the are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

[0049] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0050] The terms first, second, and the like are used herein to describe various features or elements, but these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present disclosure.

[0051] Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, the foldable prefabricated modular house of the present invention is described in detail with an emphasis on its advantageous features and optional elements that contribute to enhanced ease of construction and user enjoyment.

[0052] FIG. 1-FIG. 10 demonstrate various stages of an unfolding process of a foldable prefabricated modular house structure 100, in accordance with the preferred embodiment of the present invention. The prefabricated modular house structure 100 comprises a floor panel 102, an anterior panel 104, a roof panel 106, an auxiliary floor member 108, an auxiliary side wall member 110, an internal extension unit 112, a door 114, at least one window 116, a double door 118, at least one additional groove 120, a first open ended groove 122, a second open ended groove 124 and a pair of vertical side panels 126, an edge plank 128, at least one adjoining plank 130, at least one alternate plank 132, rollers 134, and a pocket 136.

[0053] Referring to FIG. 1, an isometric view of the prefabricated modular house structure 100 is illustrated in completely folded state, compacted to a core module. The foldable prefabricated modular house structure 100 comprises of the core module having a plurality of panels. The plurality of panels includes a floor panel 102, an anterior panel 104, a posterior panel (not shown in figure), a pair of vertical side panels 126 (as shown in FIG. 5), and a roof panel 106. The core module of the present invention has similar dimensions to an international shipping container when in a folded state. In the folded state, the core module is suitable for transportation and storage, significantly reducing associated costs and enabling efficient logistics for housing projects.

[0054] The core module forms a cuboid shape with the floor panel 102, the anterior panel 104, the posterior panel, the pair of vertical side panels 126, and the roof panel 106. A divider (not shown in the figures) may optionally separate the length of the floor panel 102 into a kitchen space and a bathroom space, both equipped with pre-built fittings, electronics, and plumbing for enhanced ease of construction and user enjoyment.

[0055] In one of the embodiments of the present invention, the anterior panel 104 associated with the core module includes a window and/or door.

[0056] Referring to FIG. 2, an isometric view of a first stage of an unfolding process of the folded core module is illustrated. The prefabricated modular house structure 100 further comprises an auxiliary floor member 108, an auxiliary side wall member 110, and an internal extension unit 112.

[0057] The foldable prefabricated modular house structure 100 further comprises of an external extension unit and an internal extension unit 112, which unfolds to create extended living spaces on both sides of the core module.

[0058] In the embodiment of the present invention, the external extension unit is hinged to a top edge of the vertical sides of the floor panel 102 to unfold along the floor panel 102 and form extended living spaces on either side of the core module. In the embodiment, each of the external extension unit comprises an auxiliary floor member 108 and an auxiliary side wall member 110, having an equal dimension and coupled together via a plurality of hinges. Further, the external extension unit are configured to unfold outwards by 90 degrees to form the auxiliary floor member 108 and the auxiliary side wall member 110 of the extended living spaces.

[0059] In the embodiment of the present invention, the auxiliary floor member 108 and the auxiliary side wall member 110 of the external extension units are constructed from lightweight, durable materials suitable for rapid deployment and retraction.

[0060] Referring to FIGS. 3 and 4, an isometric view of the first stage of the unfolding process of the folded core module, with the external extension unit unfolded along the floor panel 102 and an isometric view of a second stage of the unfolding process are illustrated. The house structure 100 further comprises a door 114, at least one window 116 and a double door 118.

[0061] In one of the embodiments, the auxiliary side wall member 110 is configured with the at least one window 116 and/or the double door 118.

[0062] In one of the embodiments, the internal extension unit 112 comprises an additional or emergency door 114 for additional passage or emergency exit.

[0063] In another embodiment of the present invention, the internal extension unit 112 comprises at least one window 116.

[0064] Referring to FIGS. 5 and 6, an isometric view of a third stage of the unfolding process, indicating the internal extension unit 112 in the process of unfolding and an isometric view of the third stage of the unfolding process, with the internal extension unit 112 completely unfolded. The prefabricated modular house structure 100 further comprises at least one additional groove 120, a first open ended groove 122, a second open ended groove 124 and a pair of vertical side panels 126.

[0065] In the embodiment of the present invention, the core module comprises the internal extension unit 112 hinged to each vertical edges of the pair of vertical side panels 126, wherein each of the internal extension unit 112 are configured to unfold outwards to complete the enclosure of the extended living spaces. In the embodiment of the present invention, the internal extension units 112 are configured to unfold outwards by 90 degrees to complete the enclosure of the extended living spaces.

[0066] In the embodiment of the invention, a plurality of grooves is configured on the internal extension units 112 and the auxiliary side wall members 110. The plurality of grooves comprises a corner groove 138 and at least one additional groove 120. In the embodiment, the at least one additional groove 120 of the internal extension unit 112 may comprise a slant surface.

[0067] In one of the embodiments of the present invention, the slant surface is at one end of the additional groove 120, wherein the additional groove 120 is a rectangular groove.

[0068] In one of the embodiments of the present invention, the corner groove is a rectangular groove.

[0069] In one of the embodiments of the present invention, the plurality of grooves may be of any shape or size.

[0070] In one of the preferred embodiments of the invention, the corner groove 138 comprises a first open ended groove 122 configured in the internal extension unit 112 along the outer end and a second open ended groove 124 configured in the top surface of the auxiliary side wall member 110, wherein the second open ended groove 124 is smaller than the first open ended groove 122. The first open ended groove 122 and second open ended groove 124 facilitate to form a corner groove 138 at a corner of the extended living spaces when each of the internal extension units 112 and the auxiliary side wall members 110 are in an unfolded state. The corner groove so formed with the first open ended groove 122 and the second open ended groove 124 that facilitates strong locking system.

[0071] In the embodiment of the present invention, each top corners of the each of the auxiliary side wall members 110 of the external extension unit comprises the second open ended groove 124 such that complete unfolding of the internal extension unit 112 aligns the first open ended groove 122 configured on an outer end of each of the internal extension unit 112.

[0072] In one of the embodiments of the present invention, the house structure 100 comprises locking system (not shown in figures) with the hinged connections to secure the unfolded external extension unit and the unfolded internal extension unit 112 in position at 90-degree angles, ensuring structural stability.

[0073] In the embodiment of the present invention, the internal extension unit 112 is in fully unfolded state to fit snugly against the auxiliary side wall member 110 formed by the external extension unit. An optional locking system (not shown) may be utilized to secure the edges of the auxiliary side wall member 110 and the internal extension unit 112 in position, contributing to the overall structural integrity of the extended living spaces.

[0074] Referring to FIGS. 7 and 8, an isometric view of the house structure 100, indicating a deployable roof unit and an isometric view of the house structure 100, demonstrating a fourth and final stage of the unfolding process of the deployable roof unit are illustrated. The house structure 100 further comprises of an edge plank 128, at least one adjoining plank 130, at least one alternate plank 132, rollers 134, and a pocket 136.

[0075] Furthermore, in the embodiment of the present invention, the roof panel 106 is stacked to a deployable roof unit, which comprises of a plurality of stacked planks and rollers 134 that works in association to get deployed and cover the roof area of the enclosure of the extended living spaces.

[0076] In one of the preferred embodiments, the deployable roof unit comprises a plurality of stacked planks on either side of the roof panel 106. In the embodiment, at least one of the pluralities of stacked planks on each side is configured with a roller 134 to facilitate deployment of the deployable roof units over the extended living spaces. In the embodiment, plurality of stacked planks comprises an edge plank 128, at least one adjoining plank 130 and at least one alternate plank 132. The edge plank 128 is one that has the roller 134 and facilitates roofing with the auxiliary side wall member 110 and the internal extension unit 112. The at least one adjoining plank 130 comprises a pocket 136 to accommodate the roller 134 when the deployable roof unit is in folded state. In the embodiment, the at least one adjoining plank 130 facilitates roofing over the pair of the internal extension units 112 and provide the pocket 136 to accommodate the roller 134 of the edge plank 128 or the at least one alternate plank 132. The at least one alternate plank 132 comprises the roller 134 and facilitates roofing over the pair of internal extension units 112.

[0077] In one of the embodiments, the dimension of the pocket 136 is such as to completely accommodate the roller 134 inside the pocket 136 and allow the at least two planks to firmly stacked over each other. In the embodiment, each of the internal extension units 112 comprises a cross section at the top surface. In the embodiment, each of the cross section of the top surface comprises the plurality of grooves to accommodate the rollers 134 associated with the edge plank 128 and the at least one alternate plank 132, when the plurality of planks 134 is deployed over the extended living spaces. In the embodiment, the rollers 134 are firmly accommodated inside the plurality of grooves leaving no gap between the deployable roof unit and the pair of internal extension units 112.

[0078] In one of the embodiments, the at least one additional groove 120 is configured to accommodate the roller 134 associated with the at least one alternate plank 132. In the embodiment, the at least one additional groove 120 comprise the slant surface to safely and smoothly land the roller 134 inside the at least one additional groove 120 of the internal extension unit 112. In the preferred embodiment, the slant surface facilitates smooth landing of the roller 134 configured with the at least one alternate plank 132 of the plurality of stacked planks of the deployable roof unit.

[0079] In one of the embodiments, the plurality of grooves may be of any shape or size to safely accommodate the roller 134. In the embodiment, each of the alternate planks 132 amongst the plurality of planks of the deployable roof unit comprises the roller 134, wherein the roller 134 is accommodated in the at least one additional groove 120 configured at a corresponding position in the top surface of each of the internal extension units 112.

[0080] In one of the embodiments, the corner groove so formed with the first open ended groove 122 and the second open ended groove 124 facilitates strong locking system when the roller 134 of the edge plank 128 gets fully accommodated in the corner groove 138. In the embodiment, the dimension of the corner groove is such as to completely accommodate the roller 134 inside the corner groove.

[0081] In one of the embodiments, the at least one additional groove 120 comprises a sliding mechanism to facilitate rolling of the roller 134 over the slant surface.

[0082] Furthermore, the deployable roof unit extends in view of covering roof area of the enclosure of the extended living spaces. The deployable roof unit comprises of the plurality of planks connected with each other via hinged connections along their lengthwise edges.

[0083] In other embodiment, the plurality of stacked planks is connected to each other through mechanical joint connections, which allows folding of the planks at a pre-defined range. In an alternate embodiment of the present invention, the plurality of planks is connected to each other through water-proof connection.

[0084] In one of the embodiments of the present invention, the deployable roof unit being unfolded all the way to cover the roof area of the extended living spaces and form a sealed interior. The deployable roof unit comprises of a plurality of planks and rollers 134 that works in collaboration to cover the roof area of the enclosure of the extended living spaces, such that when each plank fully extends to form an entirely flat roof surface.

[0085] In the unfolded state, the prefabricated modular house structure 100 of the present invention provides extended living spaces on either side of the core module, creating a spacious and versatile interior configuration. The house structure 100 allows for efficient utilization of available space while maintaining structural integrity and ease of assembly. Optional features, such as pre-installed doors and windows, integrated locking system, and pre-built fittings for the kitchen and bathroom, contribute to a simplified construction process, enhancing both user enjoyment and overall cost-effectiveness. The deployable roof unit is developed to provide enhanced compactness and ease of deployment.

[0086] In one the embodiment of the invention, each alternate plank 132 of the plurality of planks is configured with at least one roller 134 and each of adjoining plank 130 of the planks configured with the pocket 136 in view of accommodating the roller 134 in the pocket 136 while the plurality of planks is in folded state.

[0087] In the embodiment of the present invention, the plurality of stacked planks of the deployable roof unit deploys to cover the roof of the extended living spaces by utilizing the plurality of hinge connections. These hinge connections allow folding and unfolding of the planks at a pre-defined range.

[0088] In one of the embodiments of the invention, the top edge of each of the internal extension units 112 comprises at least one additional groove 120 and a first open ended groove 122 to receive the rollers 134, while the plurality of planks is unfolding. The rollers 134 and the grooves 120 facilitate smooth deployment of the deploying roof unit along with providing support to the plurality of planks associated with the deploying roof unit.

[0089] In one of the embodiments of the present invention, at least one additional groove 120 comprises of the slant surface at one side that supports the rollers 134 to manoeuvre along the top edge of the internal extension unit 112, both while the folding and unfolding of the plurality of the planks.

[0090] Referring to FIG. 9, an exploded view of the house structure, indicating the components associated with the locking system is illustrated. Upon successful unfolding of the internal extension unit 112, the edge of the internal extension unit 112 fit snugly to the auxiliary side wall members 110 aligns with the first open ended groove 122 with the second open ended groove 124. The engagement of the rollers 134 with both the first open ended groove 122 and the second open ended groove 124 forms the strong locking system, wherein this locking system secures the auxiliary side wall member 110 and the internal extension unit 112 in position.

[0091] Referring to FIG. 10, an isomeric view of the house structure in fully unfolded state with the extended living spaces is illustrated. In one of the embodiments of the present invention, the foldable fabricated modular house structure 100 comprises locking mechanisms for securing the panels in position when the house structure 100 is in an unfolded state.

[0092] In one of the embodiments of the present invention, the foldable fabricated modular house structure 100 comprises a divider separating the length of the floor panel 102 of the core module into a kitchen space and a bathroom space.

[0093] In one of the embodiments of the present invention, the pair of vertical side panels 126 of the core module includes windows and doors.

[0094] In one of the embodiments of the present invention, the foldable fabricated modular house structure 100 comprises pre-built bathroom and kitchen fittings integrated into the core module.

[0095] In one of the embodiments of the present invention, the foldable fabricated modular house structure 100 comprises home automation systems and energy-efficient lighting integrated into the structure 100.

[0096] In one of the embodiments of the present invention, the foldable fabricated modular house structure 100 comprises eco-friendly materials and design elements, including solar panels or green roofing, incorporated into the structure 100.

[0097] Referring to FIG. 11, a method of deploying prefabricated modular house structure 200 is disclosed which comprises of steps including installing a core module 202 configured with a plurality of panels at a predefined area, unfolding an external extension unit 204 hinged to a plurality of bottom edges of a pair of vertical side panels to form an extended living space on either side of the core module, unfolding an auxiliary side wall member 206 to form vertical side wall for the extended living space, unfolding an internal extension unit 208 hinged to each vertical edges of the pair of vertical side panels, wherein each of the internal extension unit are configured to unfold outwards to complete the enclosure of the extended living space, and deploying a deployable roof unit comprising a plurality of stacked planks, and a plurality of rollers to cover the roof of the enclosure of the extended living space.

[0098] Further, the method of deploying prefabricated modular house structure 200 comprising separating the length of the floor panel of the core module into a kitchen space and a bathroom space modular house structure 200 by dividers.

[0099] Possible improvements may include the integration of smart technology, such as home automation systems and energy-efficient lighting, to further enhance the user experience. Additionally, the structure could incorporate eco-friendly materials and design elements, such as solar panels or green roofing, to reduce the environmental impact and promote sustainable living. These potential enhancements, along with the present invention's novel design, serve to illustrate the versatility and adaptability of the prefabricated housing structure, making it a valuable and innovative solution in the field of modular housing.

[0100] Unless otherwise defined, all terms (including technical terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0101] The disclosed embodiments are illustrative, not restrictive. While specific configurations of the prefabricated house structure have been described in a specific manner referring to the illustrated embodiments, it is understood that the present invention can be applied to a wide variety of solutions which fit within the scope and spirit of the claims. There are many alternative ways of implementing the invention.

[0102] It is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.