1. Field of the Invention
This invention relates to a modular assembly capable of converting from a shipping container into a building unit with utility connections, and from a building unit into a shipping container. From the shipping container configuration, a plurality of frame and unit panels are selectively positioned to form the floor, walls, and ceiling of the building unit configuration thereby forming a living and/or commercial structure complete with electrical, water and sewage connections. The building unit can then also be folded and converted into the shipping container configuration for transport to and from various sites.
2. Description of the Related Art
Building units are an essential part of everyday life. Houses come in all shapes and sizes, and can be made in various ways from various types of materials. Traditionally, building units are constructed from the ground up in a specific location, for that location. These types of building structures can take weeks or months to construct, requiring many different types of materials and construction phases to complete. Once complete, the building structure remains at its specific location as a then permanent fixture of the landscape.
Recent developments in materials and structural engineering have allowed home builders to construct “mobile” homes: pre-fabricated, full-sized housing structures that can be transported to a specific location. These mobile homes are assembled in substantial part before being delivered to the specific location. Mobile home transportation requires a “wide-load” configuration involving tractor-trailers as well as lead and follow vehicles. Once at the home site, the mobile home must be furnished and connected to local utilities, such as electrical, water and waste removal systems. The mobile home, once delivered to a specific location, becomes a permanent fixture of the landscape. The advantage to pre-fabricated housing structures lies in the ease of construction. Mobile homes are not constructed at a specific location over weeks or months, but are constructed in a factory, and simply shipped to the specific location. The disadvantages include complex and tenuous transportation.
Portable building units have been around for decades. Lightweight, easily transportable structures provide temporary shelter from the outdoor environment. However, natural disasters and other catastrophes can destroy dwellings, thereby creating a need for fully equipped emergency shelters. These emergency shelters need be easily transported and easily set up in matter of hours. The disadvantages thus far to portable, foldable building units have been numerous: difficult to transport folded configurations; multiple loose panels, multiple unit sections, and difficult hinging and fastening mechanisms; difficult to assemble panels and elements; and a lack of utilities inside the unit. Many recent attempts at portable, foldable building units have led only to exterior structures; once unfolded, the building unit provides a shell dwelling with none of the necessary amenities most homes require. Previous attempts at portable building units have also afforded hard-to-assemble structures that require special tools and sectional construction . . . .
Accordingly, there is a need in the portable building units industry for a modular assembly capable of convenient transport, and ready for easy assembly by as little as one person with no special tools or equipment, and fully equipped with utilities necessary to properly, and immediately, house occupants. The building unit need be large enough to occupy as a dwelling, yet compact and portable enough to be transported to and set up on many different locations. The building unit also need be equipped with utility connections to immediately take advantage of water, sewer, and electrical utilities.
The present invention relates to a modular assembly, which may be selectively disposed and oriented into either a shipping container configuration or a building unit configuration. From the shipping container configuration, a plurality of unit panels that form the building unit floor, walls, and ceiling are unfolded and fastened together. The building unit configuration is also complete with electrical, water and sewage connections. From the building unit configuration, the unit can be then folded and converted into a shipping container configuration for transport by a variety of appropriate transportation means. Moreover, the modular assembly of the present invention can be stored and/or transported when in the shipping container configuration. In the various preferred embodiments of the modular assembly, both the shipping container and the building unit configurations comprise a frame at least partially defined by a plurality of support members that form a box-like or other appropriately shape. The support members preferably comprise elongated, relatively high strength material members preferably, but not exclusively, in the form of steel rectangular tubes welded together to collectively comprise the stable, rigid frame.
Once the modular assembly is located at a construction or assembly site, it is ready for disposition into the building unit configuration. Accordingly, the modular assembly of the present invention includes a plurality of frame panels as well as a plurality of unit panels each at least initially disposed in a closed orientation on or within the box-like frame. In at least one preferred embodiment the frame panels and unit panels are formed from a load-bearing material such as corrugated steel or other appropriate material.
In order to facilitate the disposition of the modular assembly into either the building unit configuration or the shipping unit configuration an erection assembly is provided and selectively disposed in either a stored position or an operative position. The erection assembly comprises a plurality of erection members removable from their stored location within the frame and disposed exteriorly on the various portions of the frame. The erection assembly may also include a pulley and cable assembly cooperatively connected to the plurality of erection members, when in the operative position, to facilitate the positioning of the frame and or unit panels in either their closed or opened positions.
The plurality of frame panels include at least one but preferably two side panels each of which may define the “long sides” of the frame when in the shipping container configuration. These frame panels, may also define the long sidewall portions of the building unit configuration when so assembled. Accordingly, the one or more frame panels are pivotally or hingedly attached at their lower most longitudinal end to the frame and are selectively positioned or pivoted outwardly therefrom. When in the intended operative position, they define the floor portions of the building unit configuration. Further, each of the side panels include panel segments initially disposed in overlying confronting relation to respective ones of the frame panels. The panel segments of corresponding ones of the frame panels or side panels are hingedly or pivotally attached so as to extend outwardly from the corresponding frame panels into a substantially upright position. As such each of the combined or directly associated frame panels and panel segments collectively define a corresponding floor portion and long sidewall portion of the building unit configuration.
In addition to the above, the modular assembly further comprises a plurality of unit panels at least some of which are movably connected to the frame and initially disposed on the interior thereof when the modular assembly is in the shipping container configuration. The first set or plurality of unit panels extend outwardly and upwardly into a position which overlies the floor portion, defined by the aforementioned frame panels. The outer longitudinal edge of these unit panels are connected to or supported by corresponding longitudinal edge or portion of the now upright panel segments.
Additional ones of the plurality of unit panels may also be movably connected to the frame and are at least initially disposed on the interior thereof when the modular assembly is in the shipping container configuration. In at least one preferred embodiment these additional ones of the unit panels may be pivotally or hingedly connected along a longitudinal edge or side thereof and may extend outwardly so as to respectively define front wall portions and rear wall portions of the building unit configuration. Dependent on the overall dimensions and configuration of the building unit configuration the location and relative dimensions of the “long sidewalls” and front and rear “end walls” may vary.
The modular assembly further comprises at least one interior partition that is preferably in a fixed position within the frame when the unit arrives on site. An additional partition can be added, by way of example only, by installing an included partition panel assembly in order to define the interior “rooms” or space within the building unit configuration. The partition panel system can be unfolded and secured to the floor, to the interior of the building unit side wall, and to the at least one fixed partition, as set forth above.
In addition, cabinets can be positioned in the kitchen area using tracks installed on the kitchen walls. A water heater can be installed using pre-existing utility pipes in the modular assembly. Kitchen appliances and restroom fixtures such as sinks, toilets, oven and stove units, and refrigerators can be installed into the building unit during assembly. The building unit arrives on site equipped with both interior and exterior connections for water, sewer, and electrical utilities. Further, doors and windows can be installed into the frame and one or more of the frame or unit panels. Also, one or more doors may be pre-installed into the front or other portions of the modular assembly and windows may also be installed in appropriate locations.
These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
Like reference numerals refer to like parts throughout the several views of the drawings.
It is to be understood at the outset that the present invention is susceptible of embodiment in different forms. Of course, there is shown in the drawings and will be described in detail herein at least one specific embodiment, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment or embodiments illustrated.
As shown in the accompanying
Accordingly, the modular assembly 10 includes a frame generally indicated as 12 including a plurality of at least four support members 14 interconnected by cross braces or like additional support structures 15. The support members 14 as well as the cross braces 15 may be made of a high strength material such as, but not limited to, tubular steel or other appropriate materials welded or otherwise interconnected to one another to form a box-like configuration as represented throughout the various Figures.
As will be explained in greater detail hereinafter, the modular assembly includes a plurality of frame panels and a plurality of unit panels movably connected to the frame 12 and/or to one another and selectively positionable into a closed position, as represented in
As set forth above, at least one but preferably a plurality of frame panels 24 are pivotally or hingedly connected at their lower most longitudinal ends to a corresponding portion of the frame 12, as at 26. The aforementioned erection assembly 18, including appropriately positioned erection members 20, may utilize the aforementioned pulley and cable 22 to lower or unfold the plurality of frame panels 24 into the opened position. The fully opened position of the frame panels 24 is represented in
In addition, each of the frame panels 24 includes a panel segment 30 associated therewith. The panel segments 30, as clearly represented in
In addition, the modular assembly 10 includes a plurality of unit panels 32 initially represented in
In addition to the above various appliances or utilities may be included in appropriate portions of the interior of the building unit configuration. Such additional appliances or facilities may include kitchen cabinets which can be affixed to the kitchen or other utility area 52 by means of tracks or like coupling or installation structures. In addition, water, sewer and electric utility connections as well as appropriate sinks, bathing facilities, stove or ranges, refrigerators, air conditioners, etc. may also be appropriately positioned on the interior of the building unit construction as generally represented in both
In addition appropriate windows 70, door(s) 72, doorways, halls or passageways (see
Accordingly, with primary reference to
Thereafter, the other or additional plurality of unit panels 36 and 36′ are next pivotally or otherwise movably disposed from their closed position, as represented in
Further, once the modular assembly 10′ is in the fully assembled position, the erection assembly 18 is dissembled from the exterior, supported position on the frame 12 and is disposed in any convenient stored location, such as on the interior of the frame 12 adjacent to or at least partially within the corner portions 14, as set forth above.
As with the preferred embodiment of the modular assembly 10, a plurality of portal openings 70 and 72 defining windows, doors or like openings may be preformed or otherwise constructed in the front and rear end walls 36 and 36′, the frame 12 and the long side wall portions of the building defined by the panel segments 30.
Because many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.
Now that the invention has been described,
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