U.S. patent application number 10/449419 was filed with the patent office on 2004-12-02 for prefabricated portable flat pack building.
Invention is credited to MacWatt, David MacBeth.
Application Number | 20040237419 10/449419 |
Document ID | / |
Family ID | 33451780 |
Filed Date | 2004-12-02 |
United States Patent
Application |
20040237419 |
Kind Code |
A1 |
MacWatt, David MacBeth |
December 2, 2004 |
Prefabricated portable flat pack building
Abstract
A prefabricated portable building that meets flat pack pallet
standards of the North Atlantic Trade Organization (NATO) is
provided. The prefabricated building, includes 2 end units, wherein
each end unit includes an outer wall, an inner wall, a roof, and a
floor, wherein the outer wall and the floor converge to form an
edge having an angle of less than 90 degrees, and wherein the inner
wall and the floor converge to form an angle of about 90
degrees.
Inventors: |
MacWatt, David MacBeth;
(Carlton le Moorland, GB) |
Correspondence
Address: |
Tobi C. Clinton
Reed Smith Crosby Heafey LLP
P.O. Box 7936
San Francisco
CA
94120-7936
US
|
Family ID: |
33451780 |
Appl. No.: |
10/449419 |
Filed: |
May 30, 2003 |
Current U.S.
Class: |
52/79.1 ;
52/633 |
Current CPC
Class: |
E04B 2001/34389
20130101; E04B 1/34321 20130101 |
Class at
Publication: |
052/079.1 ;
052/633 |
International
Class: |
E04C 003/02 |
Claims
What is claimed is:
1. A prefabricated portable flat pack building, the prefabricated
flat pack building being a single unit building, comprising: 2 end
units, wherein each end unit includes an outer wall, an inner wall,
a roof, and a floor, wherein the outer wall and the floor converge
to form an edge having an angle of less than 90 degrees, and
wherein the inner wall and the floor converge to form an angle of
about 90 degrees.
2. The prefabricated flat pack building of claim 1, wherein
component parts of the prefabricated flat pack building are
configured to be flat pack capable onto a base of the prefabricated
flat pack building.
3. The prefabricated flat pack building of claim 2, wherein the
component parts are stackable upon each other to fit into a pallet
standardized by the North Atlantic Trade Organization (NATO).
4. The prefabricated portable flat pack building of claim 1,
further comprising at least one of: solar protection; insulation
material; nuclear biological and chemical (NBC) lining along
interior surfaces; insect screens for doors and windows; rain water
collection and storage mechanisms; ballistic protection, applique
armor, up to about 7.62 standard NATO ball; load spread plates to
cater for unstable ground; and a multiple solid fuel stove for
cooking and heating.
5. The prefabricated flat pack building of claim 1, wherein the
prefabricated flat pack building includes component parts that are
easily deployable.
6. The prefabricated flat pack building of claim 1, wherein the
prefabricated flat pack building includes component parts that are
mobile.
7. The prefabricated flat pack building of claim 1, wherein the
prefabricated flat pack building is configured to be used in an
environment in which a building structure is desirable.
8. The prefabricated flat pack building of claim 7, wherein the
environment is at least one of: a dressing station; a hospital; a
workshop; a classroom; a field kitchen; a trauma center; an
administration facility; a mobile command center; a store; and an
accommodation.
9. A prefabricated portable flat pack building, the prefabricated
flat pack building being a multiple unit building comprising: 2 end
units, wherein each end unit includes an outer wall, an inner wall,
a roof, and a floor, wherein the outer wall and the floor converge
to form an edge having an angle of less than 90 degrees, and
wherein the inner wall and the floor converge to form an angle of
about 90 degrees; and one or more intermediate units, wherein the
one or more intermediate units share a same angle measurements of
the 2 end units.
10. The prefabricated portable flat pack building of claim 9,
further comprising a joining corridor, wherein the joining corridor
is situated between two rows of the multiple unit building, and
wherein the joining corridor shares inner walls with the two rows
of the multiple unit building.
11. An end unit of a prefabricated portable flat pack building,
comprising: an outer wall; an inner wall; a roof; and a floor,
wherein the outer wall and the floor converge to form an edge
having an outer wall angle of less than 90 degrees, and wherein the
inner wall and the floor converge to form an inner wall angle of
about 90 degrees.
12. The end unit of claim 11, wherein the outer wall angle is
between about 86 degrees and 88 degrees.
13. The end unit of claim 11, wherein the outer wall angle is a
slight angle inward.
14. The end unit of claim 11, wherein the outer wall and the roof
converge to form an edge having a roof-outer wall angle of between
about 98 degrees and 100 degrees, and wherein the inner wall and
the roof converge to form an edge having a roof-inner wall angle of
between about 83 degrees and 85 degrees.
Description
RELATED APPLICATION
[0001] The present application is related to U.S. Patent
Application No. ______, entitled "System and Method for Assembling
Prefabricated Portable Flat Pack Building", by inventor David M.
MacWatt, filed on the same date as the present application, having
Attorney Docket No. 358031.00200, which is hereby incorporated by
reference in its entirety.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains
material which is subject to copyright protection. The copyright
owner has no objection to the facsimile reproduction by anyone of
the patent document or the patent disclosure, as it appears in the
Patent and Trademark Office patent file or records, but otherwise
reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to portable
buildings and, more particularly, to prefabricated portable
buildings that meet designated standards for flat pack
transportation.
[0005] 2. Discussion of Background
[0006] People typically use prefabricated portable buildings for
emergency situations. For example, the military may be in a
situation where it needs to construct a hospital in a matter of
hours. A permanent building structure would be impractical.
Consider a situation where hospital facilities are needed-in a
desert of the Middle East. A building most suitable for military
purposes would likely be some type of prefabricated portable
building that can be quickly erected with all the necessary
hospital facilities.
[0007] Manufacturers prefabricate portable buildings in a
controlled factory environment and ship the building pieces to the
designated site for assembly. Users install these portable
buildings at the designated site for temporary, as well as
permanent, applications.
[0008] The industry has its beginnings in the post World War II
era, when the huge demand for housing for returning GI's
overwhelmed the construction industry's ability to deliver. The
U.S. developed prefabricated portable housing as a solution to this
demand. Other countries with severe commercial building needs
following the war, also developed simplistic modular construction
techniques. In the following decades, technological advances have
increased the quality of those initial efforts, as well as opened
the door to new applications of modular construction.
[0009] Today, people use prefabricated construction in almost every
industry and walk of life, including construction offices,
educational facilities, medical facilities, industrial uses, prison
and correctional housing and administration, branch financial
offices, real estate offices, government buildings, and general
commercial offices.
SUMMARY OF THE INVENTION
[0010] When users disassemble a prefabricated building, they often
need to place the pieces of the building into a "flat-pack" pallet.
The flat pack form of a portable building is basically the walls,
floors, roofs, and fittings of the building broken down into their
smallest portable package. A flat-pack pallet sets limits on the
building's specifications, such as size, weight and strength.
Moreover, the North Atlantic Trade Organization (NATO) has their
own guidelines on the specifications of a standard flat-pack
pallet. Thus, engineers are faced with the challenge of designing a
structure that is not only portable, but is also compliant with
NATO guidelines and any other guidelines.
[0011] It has been recognized that what is needed is a
prefabricated flat pack building that meets flat pack pallet
standards of the North Atlantic Trade Organization (NATO). Broadly
speaking, the present invention fills this need by providing a fast
response building, which is a building designed, among other
things, to meet the flat pack standards of NATO. It should be
appreciated that the present invention can be implemented in
numerous ways, including as a process, an apparatus, a system, a
device or a method. Several inventive embodiments of the present
invention are described below.
[0012] In one embodiment, a prefabricated portable flat pack
building that is a single unit building is described. The
prefabricated building, comprises 2 end units, wherein each end
unit includes an outer wall, an inner wall, a roof, and a floor,
wherein the outer wall and the floor converge to form an edge
having an angle of less than 90 degrees, and wherein the inner wall
and the floor converge to form an angle of about 90 degrees.
[0013] In another embodiment, a prefabricated portable flat pack
building that is a multiple unit building is described. The
prefabricated building comprises 2 end units, wherein each end unit
includes an outer wall, an inner wall, a roof, and a floor, wherein
the outer wall and the floor converge to form an edge having an
angle of less than 90 degrees, and wherein the inner wall and the
floor converge to form an angle of about 90 degrees; and one or
more intermediate units, wherein the one or more intermediate units
share a same angle measurements of the 2 end units.
[0014] In still another embodiment, an end unit of a prefabricated
portable flat pack building is described. The end unit comprises an
outer wall; an inner wall; a roof; and a floor, wherein the outer
wall and the floor converge to form an edge having an outer wall
angle of less than 90 degrees, and wherein the inner wall and the
floor converge to form an inner wall angle of about 90 degrees.
[0015] Prefabricated portable flat pack buildings have many
advantages. A significant advantage of prefabricated construction
is time savings. Manufacturers may build prefabricated flat pack
buildings on a controlled timetable in a factory environment. On
the other hand, site-built buildings are subject to weather
conditions, subcontractor deals, waits for permits, and labor
shortages. Prefabricated construction also provides cost savings
due to standardization of the engineering process, bulk purchase of
building materials and the controlled factory construction
environment. Users of portable buildings gain an additional
advantage in the quality of construction. A standardized
construction method at the factory with skilled and knowledgeable
labor means a building is not dependent on the vagaries and
availability of the local labor market.
[0016] Another significant advantage of prefabricated portable flat
pack buildings is economy of space. When disassembled in their flat
pack form, prefabricated portable flat pack buildings may be stored
at any appropriate location, including a warehouse, outdoors, or
any location that may be substantially smaller than the building in
its assembled form. A prefabricated portable flat pack building
according to the present invention can be broken down into an
economically small space for easy transport and storage.
[0017] The invention encompasses other embodiments of a system, a
method, and an apparatus, which are configured as set forth above
and with other features and alternatives.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention will be readily understood by the
following detailed description in conjunction with the accompanying
drawings. To facilitate this description, like reference numerals
designate like structural elements.
[0019] FIG. 1A and FIG. 1B show perspective views of a single fast
response building (FRB), in accordance with an embodiment of the
present invention.
[0020] FIG. 2 shows a side view of the end unit, in accordance with
an embodiment of the present invention.
[0021] FIG. 3 shows perspective views of segments of an FRB flat
packed into a pallet, in accordance with an embodiment of the
present invention.
[0022] FIG. 4A and FIG. 4B show perspective views of a multiple
unit FRB, in accordance with an embodiment of the present
invention.
[0023] FIG. 5A and FIG. 5B show perspective views of a multiple
unit FRB with a joining corridor, in accordance with an embodiment
of the present invention.
[0024] FIG. 6 through FIG. 52 combine to show an assembly process
of a multiple unit FRB with a joining corridor, in accordance with
embodiment of the present invention.
[0025] FIG. 53 shows examples of the clips and pins used to join
the panels of the FRB together, in accordance with an embodiment of
the present invention.
[0026] FIG. 54 shows an example of a clip component that is wired
to the welded clip component with a wire, in accordance with an
embodiment of the present invention.
[0027] FIG. 55 shows an example of a locking pin, in accordance
with an embodiment of the present invention.
[0028] FIG. 56 shows an example of a foot-type pin, in accordance
with an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] An invention for a prefabricated portable flat-pack building
is disclosed. Numerous specific details are set forth in order to
provide a thorough understanding of the present invention. It will
be understood, however, to one skilled in the art, that the present
invention may be practiced without some or all of these specific
details.
[0030] General Overview
[0031] Fast response buildings (FRB's) are prefabricated portable
buildings designed to be transported in flat-pack pallets. An FRB
takes only about 4 people fifteen minutes to construct into a rigid
structure for immediate use. No screws, no nuts, no special tools
and no ground preparation are needed. An FRB is fully insulated for
use in extreme climatic conditions. The FRB system is economical to
transport by air, sea, road or rail.
[0032] FRB units are made from individual lightweight sections
which interlock to form a rigid structure. Individual components
make it easy to handle and maneuver, allowing each unit to be
constructed in the most difficult locations. FRB can be situated
virtually anywhere, including forests, mountains, desert sand,
snow, ice and most types of terrain. FRB units can be transported
and positioned by helicopter, as flat pack system or a complete
constructed unit. FRB units are compatible with any conventional
cargo transportation system. Alternatively, each individual
sections can be carried to site and constructed.
[0033] Relocating without dismantling is achieved by 3 specially
designed ski-bars located at the base of the unit. The base unit
provides for 2 couplings, which can be attached to a tow-bar by
rope or chain allowing the building to slide and move in position.
A vehicle such as a Land Rover is capable of achieving this sliding
task on average ground conditions.
[0034] FRB flexible and unique modular units can be used to
construct anything, from a single leisure home or storage unit, to
a large emergency hospital complex or emergency re-housing due to a
disaster. Each unit can sleep up to 10 people. Principally designed
for Emergency accommodation for Peace Keepers and Military
requirements, an FRB's applications are endless.
[0035] Types of Fast Response Buildings
[0036] FIG. 1A and FIG. 1B show perspective views of a single FRB,
in accordance with an embodiment of the present invention. The
single building comprises two end units 102, including an outer
wall 106, an inner wall 108, and a roof 104, among other
things.
[0037] FIG. 2 shows a side view of the end unit 102, in accordance
with an embodiment of the present invention. The roof 104 and the
base 110 (or floor) have the same dimensions. However, the outer
wall 106 and the inner wall 108 do not have the same dimensions.
The height of the inner wall 108 is slightly greater than the
height of the outer wall 106. Angle .theta. is set to be about 90
degrees. While angle .phi. is set to be less than 90 degrees,
specifically between about 86 degrees and 88 degrees. Accordingly,
the outer wall 106 leans at a slight angle inward.
[0038] Established rules of trigonometry set limitations on
allowable measurements for angles .omega. and .rho.. Angle .omega.
is accordingly less than 90 degrees, for example, between about 83
and 85 degrees. Angle .rho. is accordingly greater than 90 degrees,
for example, between about 98 and 100 degrees.
[0039] Important features of the FRB is the slight inward tilt of
the outer wall 106, the height of the inner wall.108 being slightly
greater than the height of the outer wall 106, and the equality in
dimensions of the roof 104 and the base 110 (or floor). This
combination creates unique building measurements that allow the FRB
to be disassembled neatly into a standard NATO flat pack
pallet.
[0040] It should be noted, however, that the present invention is
not limited to the specific measurements provided above. The
specific measurements provided above are primarily for exemplary
purposes to show the inward lean of the outer wall 106.
[0041] Clips and Pins Assembly System
[0042] FIG. 53 shows examples of the clips 204 and pins 202 used to
join the panels of the FRB together, in accordance with an
embodiment of the present invention. These clips and pins are
unique-to the system and replace bolts, nuts and screws. In the
example of FIG. 53, the clips are welded and/or clipped to the
respective panels and are extremely difficult to damage or lose. In
particular, the clips 204 and pins 202 lock the whole FRB together
in a manner that is robust yet retains a degree of flexibility.
Assembly of the FRB using clips 204 and pins 202 is less time
consuming than assembly of a structure that uses conventional
fixings, such as bolts, nuts and screws.
[0043] As shown in FIG. 53, the pins 202 are inserted where
required in order to prevent horizontal and vertical movement. As
such, the pins 202 are an integral part of the system. The pins 202
and clips 204 are used throughout the FRB structure to lock wall to
wall, wall to gable, wall to roof, roof to gable, etc.
[0044] FIG. 54 shows an example of a clip component 302 that is
wired to the welded clip component 204 with a wire 304, in
accordance with an embodiment of the present invention. The wired
clip component 302 locks the FRB superstructure in place.
[0045] FIG. 55 shows an example of a locking pin 402, in accordance
with an embodiment of the present invention. This locking pin 402
with the locking feature is used to secure the probes (which-
connect the base sections together), the skids, the legs (when flat
packed assembled), the veranda (or step) and the mast stabilizer to
the FRB. The locking pin 402 includes a washer 406 having a slot.
To the fix the locking pin 402, the locking pin 402 is placed in
the base runner using the handle 408 at the top of the locking pin
402. The locking pin 402 is maneuvered to allow the slot in the
washer 406 to pass through the seg 404, which is attached to the
base runner. When the handle is released the locking pin 402 turns
and will not free itself. Note that the sizes and diameters shown
here are for explanatory purposes, and may vary.
[0046] FIG. 56 shows an example of a foot-type pin 502, in
accordance with an embodiment of the present invention. The
foot-type pin is another way of locking components (e.g., gable,
base, wall, and roof) of the FRB into place. The foot-type pin 502
is maneuvered into the appropriate hole and slides into place. In
this example, a wall is shown being locked to the base 110. Note
that the sizes and diameters shown here are for explanatory
purposes, and may vary.
[0047] FIG. 3 shows perspective views of segments of an FRB flat
packed into a pallet, in accordance with an embodiment of the
present invention. All of the component parts flat pack on to its
own base 110 (or floor). The flat pack segments may then stack upon
each other. Accordingly, when flat packet, one half of the base 110
of the unit becomes the pallet. The components of the FRB are
placed on top of that half of the base 110. The remaining half of
the base 110 is stacked on top of the components with the leg
sockets 602 of the top half of the base 110 situated to be in line
with the leg sockets 602 of the bottom half of the base 110. The
legs 604 are then inserted. The resulting box-like unit is locked
together with the locking pins.
[0048] FIG. 4A and FIG. 4B show perspective views of a multiple
unit FRB, in accordance with an embodiment of the present
invention. The multiple unit building comprises 2 ends and the
intermediate units 302 are inserted as required. FIG. 3 shows 4
intermediate units 302. However, the number of intermediate units
302 that can be inserted is, in theory, infinite. For example, an
intermediate unit 302 may be about 2.25 m in length. These
intermediate units 302 may be added such that the length of the FRB
is a multiple of 2.25 m. Note that the present invention is not
limited to these specific dimensions, and other appropriate
dimensions for intermediate-units 302 may be used.
[0049] FIG. 5A and FIG. 5B show perspective views of a multiple
unit FRB with a joining corridor, in accordance with an embodiment
of the present invention. The multiple unit building with a joining
corridor comprises 4 end units 102. The intermediate units 302 and
corridors 402 are inserted as required. Note that segment walls,
floors, and ceilings of all the FRB units have the same dimensions
and will flat pack onto a NATO pallet for easy portability.
[0050] Assembly Process of a Fast Response Building
[0051] The sequence FIG. 6 through FIG. 52 steps through an
assembly process of a multiple unit FRB with a joining corridor, in
accordance with embodiment of the present invention. The assembly
process starts in FIG. 6 with a floor segment. The assembly
finishes in FIG. 52 with a fully assembled multiple unit FRB with a
joining corridor. Intermediate figures FIG. 6 through FIG. 51
sequentially step through the assembly of the multiple unit
FRB.
[0052] Additional Features and Advantages of a Fast Response
Building
[0053] A fast response building (FRB) may be equipped to suit any
environment. An FRB may be provided with added solar protection. An
FRB may be equipped with added insulation. An FRB can also have
nuclear biological and chemical (NBC) lining along its interior. An
FRB may have mosquito or fly screens for doors and windows. An FRB
may have mast stabilizers for wind generators or aerials. An FRB
may have rain water collection and storage mechanisms. An FRB may
have ballistic protection, applique armor, up to, but not limited
to, about 7.62 standard NATO ball. An FRB may have load spreader
plates, to cater for dessert or wet ground. An FRB may have a multi
solid fuel stove for cooking and heating.
[0054] FRB's have many advantages. FRB units are easily deployable.
As can be seen in the sequence FIG. 6 through FIG. 52, FRB units
are easily assembled on any type of terrain. Adjustable legs
produce a level platform. FRB's can be erected quickly.
[0055] FRB's are mobile. FRB's are transported in flat pack pallets
and can be moved by air, sea, vehicle and on their own wheels. No
significant wear and tear occurs during transport and assembly of
the FRB pallets and FRB infrastructure because their made of rugged
steel. An FRB is designed to be stacked outside when not in use,
and can withstand harsh weather conditions while stored outside. An
FRB can be manufactured and repaired substantially anywhere,
including countries having only low tech facilities. Even if a
particular locale does not have the necessary facilities and parts
to repair the FRB locally, the particular locale can send out for
spare parts without difficulty. Alternatively, parts of an FRB can
be repaired locally by using ordinary metallurgy techniques, for
example, ordinary welding techniques. Thus, if a part of an FRB
fails, the user of the FRB does not have to idly wait around for a
new FRB to arrive.
[0056] FRB's have many applications. FRB's can be used
individually, extended or interconnected to create field dressing
stations, hospitals, workshops, classrooms and stores as well as
accommodations.
[0057] In the foregoing specification, the invention has been
described with reference to specific embodiments thereof. It will,
however, be evident that various modifications and changes may be
made thereto without departing from the broader spirit and scope of
the invention. The specification and drawings are, accordingly, to
be regarded in an illustrative rather than a restrictive sense.
* * * * *