BACKGROUND
In the modular building industry a variety of relocatable structures are provided for residential, commercial, and industrial uses. In some instances steel shipping containers that have been taken out of service are converted into habitable structures. Generally, these structures are prefabricated and then transported to a use site. These structures are satisfactory for their intended purpose, but the usable habitable space is limited to the interior volume of the shipping container. Once converted they usually void their ISO Rating, as the unit is only engineered to be a shipping container and not a purpose built habitable structure with the ability to pass ISO certification requirements. Other types of portable habitable structures have been developed, however, these structures are difficult to assemble by the untrained personnel that are typically in charge of assembly in remote locations. Further, these other structures are difficult to transport since, in order to provide a reasonable amount of habitable space, the structures typically must be registered as oversized-loads.
The present invention has been devised to overcome these and other disadvantages of the prior art.
SUMMARY
The invention generally relates to modular structures that can be easily transported then transformed for housing or other uses. The basic structure has a retracted position for shipping and storage and an expanded position in which people are able to enter and use the structure. Facilities, tools, and equipment are adapted to fit inside the structure during transportation to provide maximum utility and functionality when the structure is transformed to its expanded position. When not needed, the structures can be cleaned, stocked, and stored. The strength of the structures allows them to be stacked on top of each other during use and storage.
In some embodiments the basic structure has doors, windows, vent holes and sufficient hardware to allow it to be transformed between its retracted position and its expanded position with little or no additional tools, except for the initial positioning. In some embodiments the structure includes an outer appearance or other exterior cover that provides conventional exterior views and interesting shapes to the structure. In some embodiments the structure is dual wired so it can be powered by self-contained solar power or normal utility if available and desired. In some embodiments the interior is enhanced and divided into multiple rooms with interior wall panels. The structure may be adapted to meet all current buildings codes. In some embodiments the floor is treated for comfort and appearance. If public water and sewer are available, connections may be made to the structure and a bath pre-installed. With a minimum of site preparation, a structure can be delivered and set up ready for occupancy the same day, independent of any utility services.
The present invention is suitable for use in a variety of settings, including, as permanent and temporary housing. The structure may also be used as emergency facilities for medical treatment, security personnel, food distribution centers, temporary pharmacy, power generation, communication centers, pumping stations, rest areas, transportation centers, fuel storage, and blanket distribution. Still further, the structure may be used as full scale housing developments, summer cabins, hunting lodges, sheds and storage, and temporary post-offices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-7 are perspective views showing the structure being transformed from its retracted position to its expanded position;
FIG. 8 is a perspective view showing an alternate embodiment having different window placement;
FIG. 9 is a perspective view showing one structure stacked on top of another structure;
FIG. 10 is a perspective view showing an alternate embodiment with a pitched roof;
FIG. 11 is a side view of biomass building material;
FIG. 12 is a cross-section view of the biomass building material taken along line 12-12 shown in FIG. 11;
FIG. 13 is a perspective view of a first hinge;
FIG. 14 is a side view of the first hinge shown in FIG. 13 in use;
FIG. 15 is a perspective view of a second hinge;
FIG. 16 is a side view of the structure with both the first hinge and second hinge in use;
FIG. 17 is a side view of a third hinge in use; and
FIG. 18 is a perspective view showing an embodiment having a pocket behind the outer wall for security or insulation.
DETAIL DESCRIPTION
The present invention is a modular structure 10 having a first (retracted) position and a second (expanded) position. In its first position, the structure 10 is approximately sized and shaped like a shipping container in one embodiment. In its first position it is easily transportable over the road, by rail, by air, or by sea without requiring registration as an oversized load. The structure 10 is capable of transforming to its second position wherein it expands to become a habitable structure as described below.
FIG. 1 shows the structure 10 in its first position wherein it is similar in size, shape, and strength to a conventional shipping container. In other embodiments the structure 10 may have rounded corners or otherwise deviate in size and shape from a conventional shipping container. For example, some embodiments of the structure 10 are smaller than other embodiments depending on the user criteria. The basic support of the structure 10 comes from posts 19 which are strong enough to support multiple structures 10 stacked on top of each other. In one embodiment there are four posts 19, each post 19 being positioned at a corner of the structure 10 as the structure appears in its first position (FIG. 1). In one embodiment the posts 19 are made of steel, however, they can be made of any other suitable material.
FIGS. 1-7 show the structure 10 as it transforms from its first position to its second position. As shown in FIG. 2, the outer wall 12 of the structure 10 is pivoted outward and downward to become a portion of the floor. In an alternate embodiment the outer wall 12 may pivot outward and upward to become a portion of the ceiling/roof. Next, as shown in FIG. 3, panel 18 is pivoted outward and upward to become a portion of the ceiling/roof (or it may be pivoted outward and downward to become the floor in an alternate embodiment). FIG. 4 shows panel 20 is hingedly attached to panel 18 thereby allowing it to pivot to become a portion of the outer wall. Panel 20 may be combined with and pivot downward from panel 18 (as shown in FIG. 4) or it may be combined with and pivot upward from panel 12 (as shown in FIG. 17). Panel 20 may have a window as shown in FIG. 4. FIG. 5 shows how panel 22 is combined with post 19 and pivots outwardly therefrom to become a portion of the outer wall to form another side of the structure 10. In alternate embodiments panel 22 is packed inside the structure 10 during shipping, but it is not pivotally attached to anything. In this alternate embodiment panel 22 is attached to the structure 10 using mounting hardware such as brackets and bolts. FIG. 6 shows an embodiment wherein panels 14 pivot outward to become a shelter over the front door. In addition to the hinges (described below), brackets and fasteners such as bolts or nails can be used to help secure the panels in their respective positions. As shown in FIG. 7, the same steps are repeated for the other side of the structure 10 thereby creating a finished structure 10 in its second position that is about three times the size of the structure 10 in its first position.
In some embodiments interior walls can be added to divide the interior space of the structure 10 into a bedroom, bathroom, living room, office, kitchen, ect. . . . In other embodiments the structure 10 includes levelers which are adapted to combine with the underside of the structure 10 to help ensure the structure 10 is level after it is transformed to its second position.
FIG. 8 shows an embodiment wherein the windows are arranged in different locations. Further, it should be noted that the external appearance of the structure 10 may include colored siding to increase the aesthetic appearance of the structure 10.
As shown in FIG. 9, multiple structures 10 can be stacked on top of each other. The structures 10 are very strong and are designed for stacking and transportation. As mentioned above, the structures 10 includes support posts 19 which make it easy to place them above ground and stack them for multi-story structures. It should be noted, however, that the modular living structure 10 of the present invention does not need to be combined with other structures 10 in order to work effectively for its intended purpose. In other words, even though several structures 10 can be combined to form a larger structure, a single structure 10 is all that is required for the present invention to function properly.
Some embodiments may contain one or more of the features set forth in this paragraph. The structures 10 may be supplied with everything needed to put them into use. For example, all exterior fittings or attachments can be shipped within the structure 10 ready to be removed and installed along with the tools necessary to assemble the structure 10. Toward this end, desks, beds, and other furniture can be stored and transported within the structure 10. All utilities such as electric power can be from solar panels that are stored inside the structures 10 until needed and are then removed and mounted on the roof. Similarly, in some embodiments, warm water is provided from a flat tank mounted on the roof, with the top side phosphated or otherwise treated to collect heating energy from the sun. In some embodiments the top of the tank is a shallow “V” to help collect rainwater. The structure's 10 toilets may be a composting type so that water and sewer are not required for it to function. In some embodiments lighting is provided by light emitting diodes (LEDs) which are known to provide a very high quality white light with very little power consumption. Blankets, medicine, food and clothing may be stored inside the structure 10 when it is shipped. In some embodiments gray water could be recycled. The original water supply could be loaded into the water holding tank inside the structure 10 when it is about to be transported to its destination. In another embodiment a gray water sump is located under the structure 10 with a similar tank underneath. Service trucks could then deliver water and pump out the sump. A vent could be above the toilet and stove. In especially cold or hot locations, conventional heating or cooling can be utilized. Faucet water pressure may be provided by a demand pump operated from the battery charged by the photovoltaic panels, which may also power the fan for the compost toilet and power the ventilation fan when propane was being used. The roof solar water heater can feed a shower when drain or sump is connected.
In one embodiment, the panels described above (e.g. 12, 14, 18, 20, 22) are hingedly attached to a portion of the structure 10 (such as posts 19 or an adjacent panel). This makes it relatively easy for an untrained workforce to transform the container 10 between its first and second positions because the hinges reduce the possibility that the panels will be incorrectly placed during transformation. Further, the hinge attachment means helps to ensure the panels are not lost or stolen during transportation and set up.
FIGS. 13-17 show several types of hinges which may be used with the modular structure 10. FIGS. 13 and 14 shows a first hinge 50 which may be used with some embodiments of the invention. The first hinge 50 has a first portion which is adapted to pivot relative to a second portion (about pivot axis P) and is also adapted to allow generally linear movement between the two portions. In one embodiment, the first portion is a bracket 51 having a pivot axis P and at least one opening 52. The second portion is at least one retainer member 54, such as a bolt, which is adapted to be retained within the opening(s) 52 and move relative to the bracket 51. The member(s) 54 preferably have a head which is larger than the opening(s) 52 to help ensure the member(s) 54 are retained in the opening(s) 52. The opening(s) 52 may be any suitable shape including round, oval, square, and rectangular, however, the openings 52 are preferably oblong with the longer portion aligned with the preferred linear direction of travel of the member(s) 54. FIG. 2 shows that the first hinge 50 is typically used between the ends of the panels, however, the first hinge 50 may be used at the ends of the panels if desired.
In one embodiment, the plate 51 is adapted to be fixedly combined with a portion of the structure 10 such as a post 19 or the floor of the base (center) section. The members 54 are combined with one of the panels such as the outer wall 12 (which becomes the floor 12 in the second/expanded portion). The members 54 are retained within the opening(s) 52 and move relative to the plate 51 thereby allowing the wall/floor 12 slide into place after pivoting downward from its wall position to its floor position. The linear sliding action is shown by the arrow in FIG. 14 wherein a gap exists between panel 12 and post 19 after panel 12 is pivoted down to its second position due to the panel's 12 position on top of the center floor section when in its first position. The hinge 50 allows for linear movement of panel 12 toward the edge of the main center floor section after the wall/floor 12 has been pivoted downward about pivot point P to help eliminate the gap between the post 19/center floor section and the panel 12.
FIG. 15 shows a second hinge 60 that may be used in some embodiments of the invention to connect the roof 16 of the main base (center) section of the structure 10 with the roof 18 of the expanded room section of the structure 10. This hinge 60 is adapted to allow the two roof sections 16, 18 to combine at different angles to create a pitched roof. The hinge 60 generally comprises a plurality of plate sections 61 wherein each plate section 61 is joined to an adjacent plate section 61 by a hinge 62 able to pivot along an axis. A retaining pin 64 is adapted to be combined with the hinge 60 to intersect the hinges 62. The pin 64 is secured in place against the hinge 60. If the pin 64 is inserted across the entire hinge 60 to intersect all of the hinges 62, then all of the plates 61 remain flat (in the same general plane). However, if the pin 64 is not inserted across the entire hinge 60 such that it does not intersect some of the hinges 62, then the non-intersected hinges 62 are able to pivot. Thus, the shape of the hinge 60 is adjustable to multiple configurations by inserting one or more pins 64 to intersect various numbers of hinges 62. As shown in FIG. 16, the hinge 60 is used to combine the two roof sections 16, 18. One or more pin(s) 64 is inserted to intersect three hinges 62 from one side and three hinges 62 from the other side thereby allowing some of the plates 61 to pivot relative to the other plates 61 about the third hinge 62. This allows the hinge 60 to help combine and support two roof sections 16, 18 that are angled with respect to each other. In some embodiments, the pin 64 is prefabricated to the same angle of the preferred bend in the hinge 60. For example, if it is desired to have the hinge 60 bend at forty degrees (as roughly shown in FIG. 16), then the pin 64 is fabricated with a forty degree bend before being combined with the hinge 60 to maintain the hinge 60 at the same angle as the pin 64 (and the same angle as the two roof sections 16, 18).
FIG. 17 shows a third type of hinge 70 which may be used with some embodiments of the invention. The third hinge 70 is similar to the first hinge 50 in that the third hinge 70 allows a first portion of the structure 10 to be moved in two different directions (angular and linear) relative to a second portion of the structure 10. The first portion can move generally linearly relative to a second portion in addition to rotational movement about pivot axis P. As described above, this is advantageous to allow the panels (e.g. 12, 14, 18, 20, 22) to move between their first and second position without leaving a gap between the panels. The third hinge 70 is shown to have a first portion combined with a first panel and a second portion combined with a second panel. FIG. 17 shows an embodiment wherein the first hinge portion is a bracket 74 combined with post 19. The second hinge portion is one or more members 72. The bracket 74 has at least one opening adapted to receive at least one member 72. The opening(s) are larger than the shaft of the member(s) 72 thereby allowing the member(s) 72 to move within the opening(s). The member(s) 72 preferably have a head which is larger than the opening(s) to help ensure the member(s) 72 are retained in the opening(s). The opening(s) may be any suitable shape including round, oval, square, and rectangular, however, the opening(s) are preferably oblong with the longer portion of the opening(s) aligned with the preferred linear direction of travel of the members 72 relative to the opening(s).
FIG. 17 shows an example wherein panel 12 has been pivoted to its second position (about pivot point P), yet a gap exists between panel 12 and post 19. The hinge 70 allows the panel 12 to move horizontally toward the post 19 to eliminate the gap. FIG. 17 shows the third hinge 70 used between panel 20 and panel 12 (where panel 20 pivots upward from panel 12 instead of downward from panel 18 as shown in FIG. 4). The gap between panel 20 and panel 12 has been closed by moving panel 20 vertically along the third hinge 70 as shown by the arrows.
A structure 10 may use only one of hinge 50 and hinge 70, however, the hinges 50, 70 are preferably used together on the same structure 10. FIGS. 2 and 4 show that the third hinge 70 is typically used on the ends of adjacent panels while hinge 50 is typically used between the ends (i.e. underneath or in the middle of the panels). The first hinge 50 and the third hinge 70 work together since they are used to combine the same components in some embodiments. In other words, both hinges 50, 70 allow the same pivoting and linear movement between the two components at the same time.
It should be noted that the linear movement described with respect to the first hinge 50 and the third hinge 70 may occur during or after the two portions (12 and 19, 12 and 20, ect. . . . ) are pivoted relative to each other. In other words, the linear movement may occur while the first portion is at an angle relative to the second portion (during the pivot) or when the first portion is perpendicular to the second portion (after the second portion has been fully pivoted to its second position).
FIG. 18 shows an embodiment wherein at least one outer wall has two panels 20, 21 with a pocket 23 therebetween. The pocket 23 is sealed around most of its periphery, however, an opening exists to allow the pocket 23 to be filled with sand, water, or other suitable materials capable to helping to protect the structure 10 from projectiles, such as flying debris during a tornado or ballistics from small arms fire. The pocket 23 can be filled by the user after the structure 10 is transformed to its second position. One or more drainage openings 25 may be located nearly the bottom of the wall 21. The openings 25 can be opened or closed to selectively allow the material to drain from pocket 23 if the protective quality is no longer desired or if the structure 10 is to be transported to a new location.
The panels (e.g. 12, 14, 18, 20, 22) may be made of any suitable material, however materials having low thermal conductivity (i.e. capable of providing significant amounts of insulation) are preferred to help keep heating and cooling costs down. In some embodiments, the panels may be made of a Styrofoam core having an R value of about 5 per inch. FIGS. 11 and 12 show an example of a building material 30 that may be used to help build, strengthen, and insulate any habitable structure, including the structure 10 described above. The building material 30 is comprised of bio-based fibers 32 encapsulated by a membrane 34. The bio-based fibers can be any suitable biomass, including sugarcane, grass, wheat, straw, or rice. The biomass captures carbon dioxide which is sequestered inside the membrane 34 thereby providing the user of the material with the opportunity to obtain “carbon credits”.
The building material 30 may be manufactured as follows. First, the biomass 32 is cut or shredded to a desired size. The biomass 32 particles are then blown through the air where they are coated with a plastic matrix. The plastic matrix may be epoxy, a thermosetting plastic (most often polyester or vinylester), thermoplastic or any other suitable matrix. The plastic matrix is sprayed onto the biomass 32 particles as they float through the air toward the collection area. The coated biomass 32 particles settle in the collection area where they are compressed to a desired volume and thickness before the plastic matrix (acting as a glue) dries. After the plastic matrix dries, the biomass 32 is cut into pieces of desired length and thickness. Finally, the pieces are coated with the membrane 34.
In some embodiments the membrane 34 is applied to the outer layer (walls and roof) of the structure 10. The membrane 34 may comprise a polymer material or cement based or bio-based material. The membrane 34 is preferably highly reflective of infrared energy helps seal the internal insulation material from the elements. The membrane 34 applied to the biomass 32 particles serves several purposes. First, it helps to strengthen the biomass 32 in the same way that fiberglass is strengthened by adding a chemical solution to the individual glass filaments. Second, if the outer membrane 34 is punctured, the membrane 34 coating the biomass 32 serves to prevent the infiltration of air and water beyond the area immediately surrounding the puncture.
As mentioned above, the building material 30 may be used in the structure 10. In some embodiments, one or more of the panels (e.g. 12, 14, 18, 20, 22) are made of the building material 30. In other embodiments, the outer surface (when the structure is in its second position) of one or more of the panels is constructed of a traditional material such as metal, plywood, or siding, and the building material 30 is used in conjunction with the traditional material to help strengthen and insulate the panels.
Having thus described the invention in connection with the preferred embodiments thereof, it will be evident to those skilled in the art that various revisions can be made to the preferred embodiments described herein without departing from the spirit and scope of the invention. It is my intention, however, that all such revisions and modifications that are evident to those skilled in the art will be included with in the scope of the following claims.
Patent Application
20140033619
