U.S. patent application number 11/370177 was filed with the patent office on 2006-09-21 for building using a container as a base structure.
Invention is credited to Harvey D. Lilke.
Application Number | 20060207193 11/370177 |
Document ID | / |
Family ID | 36955343 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060207193 |
Kind Code |
A1 |
Lilke; Harvey D. |
September 21, 2006 |
Building using a container as a base structure
Abstract
A building is formed from two halves each cut from one or more
rectangular metal containers, with the two halves being arranged
with an open face thereof facing inwardly toward one another with a
space therebetween. A roof is formed over the two halves and spans
the space and to an outer face of the halves. A front vertical
panel fills the space at the front between the two halves and
includes a door and a rear vertical panel fills the space at the
rear. Gable panels extend up to the roof. The roof is arched and
formed of a flexible fabric or panel material. The roof and end
walls can be collapsed and stored into the container halves for
transportation. A more permanent construction is formed by inclined
roof panels supported by rafters connected by three or four-way
connector members at the ridge rail.
Inventors: |
Lilke; Harvey D.; (Winnipeg,
CA) |
Correspondence
Address: |
ADE & COMPANY INC.
P.O. BOX 28006 1795 HENDERSON HIGHWAY
WINNIPEG
MB
R2G1P0
CA
|
Family ID: |
36955343 |
Appl. No.: |
11/370177 |
Filed: |
March 8, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60659103 |
Mar 8, 2005 |
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Current U.S.
Class: |
52/79.7 ;
52/79.1 |
Current CPC
Class: |
E04B 1/3483 20130101;
E04B 7/045 20130101 |
Class at
Publication: |
052/079.7 ;
052/079.1 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A building comprising: two halves each formed from one or more
rectangular metal containers; the two halves being arranged with an
open face thereof facing inwardly toward one another with a space
therebetween; a roof formed over the two halves; a front vertical
panel filling the space therebetween and a rear vertical panel
filling the space therebetween.
2. The building according to claim 1 wherein the roof is
arched.
3. The building according to claim 1 wherein the roof is formed of
a flexible material covering a plurality of transverse
supports.
4. The building according to claim 1 wherein the front panel
includes a door.
5. The building according to claim 1 wherein the front panel is
substantially wholly a door.
6. The building according to claim 1 wherein each side is formed by
two halves of a container stacked one on top of the other.
7. The building according to claim 6 wherein the two halves are
hinged together.
8. The building according to claim 1 wherein each side is formed by
one half of a container with the open face of the half facing the
open face or the other half.
9. The building according to claim 1 wherein each container half
has a stiffener member attached along top and bottom edges of the
inwardly facing front face.
10. The building according to claim 1 wherein the stiffener member
along the top edge of the front face includes a truss.
11. The building according to claim 1 wherein the two halves each
define, with the open face facing inwardly, a bottom wall adjacent
the ground, an outer wall opposite to the inner face and standing
upwardly at an outer edge of the bottom wall and a top wall
extending inwardly from an upper edge of the outer wall and wherein
the roof spans over the top wall to a position adjacent the upper
edge of the outer wall.
12. The building according to claim 1 wherein there are provided
front and rear vertical gable panels extending from a top edge of
the front face to the roof.
13. The building according to claim 1 wherein the roof and gable
panels are bolted in place so that they can be dismantled and
stored in the contained when collapsed together and the end faces
connected.
14. The building according to claim 1 wherein there is provided a
strap connecting bottom edges of the container halves at the front
face.
15. The building according to claim 14 wherein the strap is flat so
as to lie flat on the ground.
16. The building according to claim 1 wherein the roof is ridged
formed from two inclined flat panels.
17. The building according to claim 16 wherein the roof includes
rafters and a ridge rail where the rafters are connected to the
ridge rail by three or four-way connector members.
18. The building according to claim 16 wherein the panels are
supported by rafters which have lower ends connected to an outer
edge of the respective half container by a connector member
attached to the half container at the outer edge.
19. The building according to claim 17 wherein the connector
members include separate sleeves each for receiving an end of a
roof member.
20. The building according to claim 16 wherein the flat panels are
formed as sheets of insulating foam material which is clad on at
least one surface by a sheathing material.
Description
[0001] This application claims the benefit of priority under 35
U.S.C.119 from Provisional application 60/659,102 filed Mar. 8h
2005.
[0002] This invention relates to a building structure.
SUMMARY OF THE INVENTION
[0003] It is one object of the invention to provide a building
structure formed inexpensively from available materials.
[0004] According to one aspect of the invention there is provided a
building comprising:
[0005] two halves each formed from one or more rectangular metal
containers;
[0006] the two halves being arranged facing inwardly toward one
another with a space therebetween;
[0007] a roof formed over the two halves;
[0008] a front vertical panel filling the space therebetween and a
rear vertical panel filling the space therebetween.
[0009] Preferably the roof is arched.
[0010] Preferably the roof is fabric covering a plurality of
transverse supports.
[0011] Preferably the front panel is a door.
[0012] Preferably each side is formed by two halves stacked one on
the other.
[0013] Preferably the two halves are hinged together.
[0014] Preferably each side is formed by one half of a container
with the open face of the half facing the open face or the other
half.
[0015] Preferably each container half has a stiffener member
attached along top and bottom edges of the inwardly facing front
face.
[0016] Preferably the stiffener member along the top edge of the
front face includes a truss.
[0017] Preferably the two halves each define, with the open face
facing inwardly, a bottom wall adjacent the ground, an outer wall
opposite to the inner face and standing upwardly at an outer edge
of the bottom wall and a top wall extending inwardly from an upper
edge of the outer wall and wherein the roof spans over the top wall
to a position adjacent the upper edge of the outer wall.
[0018] Preferably there are provided front and rear vertical gable
panels extending from a top edge of the front face to the roof.
[0019] Preferably the roof and gable panels are bolted in place so
that they can be dismantled and stored in the contained when
collapsed together and the end faces connected.
[0020] Preferably there is provided a strap connecting bottom edges
of the container halves at the front face.
[0021] Preferably the strap is flat so as to lie flat on the
ground.
[0022] In a more permanent construction, the roof is ridged formed
from two inclined flat panels which can be supported by rafters and
a ridge rail where the rafters are connected to the ridge rail by
three or four way connector members. The lower ends of the rafters
can be connected to an outer edge of the respective half container
by a connector member attached to the half container at the outer
edge. This may include a base plate which is welded to or bolted to
the metal container at the outer edge. Connector members of this
type include separate sleeves each for receiving an end of a roof
member. Thus the sleeves will be rectangular for lumber and may be
round for pipe or square for tube.
[0023] The flat panels may be formed as sheets of insulating foam
material which is clad on at least one surface by a sheathing
material, such as sheet metal on the exterior surface.
[0024] These structures would be ideal for construction companies,
etc., where they require a field building to protect equipment,
offices, etc., etc. Also they would be very suitable for farms,
etc. They are shipped in closed container mode whereby all
components including roof components, etc., are packed inside for
rapid assembly. They are easily dismantled and moved to another
site. The steel construction components allow this structure to
remain on permanent basis or as may be required.
[0025] This structure has many unique advantages over the
increasingly popular fabric shelters in the marketplace. The steel
wall construction provides far greater wind resistance, snow load
resistance, fire resistance, less likely to suffer vandalism
whereby fabric structures are easily damaged by sharp objects, etc.
and is cost comparable or less than the full fabric structures.
Additionally the structures could be insulated and heated in
extreme weather conditions.
[0026] As an alternative to the to the transportable building
design, there is also provided a system which furthermore utilizes
common lumber and building materials to transform marine containers
into more permanent storage buildings.
[0027] The arrangement includes a series of connectors that will
enable the roof and other enclosures to be completed with common
lumber materials which are available at any domestic lumber
dealership.
[0028] Included are a variety of metal connector receivers which
include a metal base flange support. This flange connector is
designed to receive, and hold in place, either 2.times.4 or
2.times.6 lumber planks which form the individual truss components
of the roof.
[0029] Three-way connectors are used at both outer truss members.
These upper connectors receive each of the two downwards/vertical
angle truss planks which are inserted in each of the base flange
supports (one on each end). There is also a third
horizontal/directional component part of the three-way connectors
which accepts the upper horizontal truss plank which attaches to
the next adjacent truss member.
[0030] Four way connectors are used for all inside, upper truss
members. These connectors receive each of the two
downwards/vertical angle truss planks which are inserted in each of
the base flange supports, and they include the third and fourth
components which accept the upper horizontal truss planks that
attach to each of the adjacent truss planks.
[0031] A variety of other connectors may be included to complete
the overall design completion of the entire building.
[0032] The system provides all necessary components so that with
the use of common lumber a marine container may be transformed into
a much larger and more practical storage facility at very
reasonable costs, and in most cases the work can be performed by
anyone with basic carpenter skills.
[0033] The system can provide a transportable building which can be
readily demounted and transported to a new location for erection.
However using the various connectors disclosed herein, the
containers may be transformed into more permanent building
structures which can be made from common lumber by use of various
multi directional connectors.
[0034] The roof may be either arched or gable design and completed
with either metal tubing and tarpaulin type enclosure materials, or
with common lumber by use of various multi directional connectors
as disclosed herein.
[0035] The roof may be fabric cover over metal tubing or otherwise
common lumber such as 2.times.4 or 2.times.6 truss planks fitted
inside the multi directional connectors and thereafter enclosed by
lumber or insulated panels, or other.
[0036] The buildings may be single container high, or double
container high.
[0037] Gable enclosure may be completed with fabric material or
otherwise lumber, insulated panels or other.
[0038] The containers are not usually recycled for scrap at this
time as they have use for general storage however the increasing
use of containers and high demand for steel may eventually create
greater demand for the steel than their current usage.
[0039] By being able to transform containers into high use storage
buildings, the value of containers will be greater than scrap
steel.
[0040] Presently the China imports are increasing every day and
this means that there are countless, and increasing number of used
marine containers arriving in North America every day. Soon there
will be so many containers they will be cut up and used for the
scrap value of the steel which is in very high demand
internationally. According to the system disclosed herein all used
marine containers would have a very beneficial use as
buildings.
[0041] In a first version, where the roof is made from tubing and
tarpaulin rather than PC panels, this model can be assembled and
disassembled as required and as such, it would be complete with all
parts.
[0042] In a second version, the system provides a more permanent
building the design is arranged in order to substantially reduce
the price to make it more practical for all potential buyers who do
not require disassembly/re-assembly feature. Thus the building
concept is expanded so that it can be assembled more economically
and very easily by the buyers as a permanent installation.
[0043] The design uses two-way, three-way, and four-way connectors.
These connectors are heavy duty connectors and are arranged as
round connectors to receive appropriate size, round tubing, or as
square connectors designed to accept wood 2.times.4 or 2.times.6
lumber planks. Many farmers, construction companies, etc., can use
these storage buildings as a permanent structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
[0045] FIG. 1 is an isometric view of a building according to the
present invention.
[0046] FIG. 2 is an isometric view similar to that of FIG. 1
showing a modified arrangement.
[0047] FIG. 3 is a side elevational view of the building of FIG.
2.
[0048] FIG. 4 is a front elevational view of the building of FIG.
2.
[0049] FIG. 5 is a cross sectional view of the building along the
lines 5-5 of FIG. 4.
[0050] FIG. 6 is an isometric view of a further embodiment of
building of according to the present invention having a gable roof
for a more permanent construction.
[0051] FIG. 7 is an isometric view of a further embodiment of
building of according to the present invention using the gable roof
of FIG. 6.
[0052] FIGS. 8, 9 and 10 are scrap views showing the connectors to
be used in the roof structures of FIGS. 6 and 7.
[0053] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION
[0054] In FIGS. 1 through 5 is shown a first construction of the
building. This is based upon a pair of conventional cargo or
transportation containers which are welded steel structures with
corrugated walls to provide the necessary structural strength. The
steel structures are generally rectangular and when using road
transportation containers, the container is conventionally 8 feet
wide, 40 feet long and 7.5 feet high. Such containers are widely
available and manufactured in huge numbers for use in road
transportation. Used containers are readily available as they are
conventionally replaced after a number of years but are still
serviceable as a steel structure.
[0055] Recycling of such steel transportation containers is
problematic and conventionally their used simply for scrap which
requires them to be cut into pieces and fed into the smelting
process for recovery.
[0056] The conventional container is cut along a center line so
that the front wall is cut, the bottom wall is cut, the top wall is
cut and the rear wall is cut to form two independent halves of the
container. In FIG. 1 a hinge structure is applied along the center
line of the top wall so that one half can be hingedly lifted and
tilted to a position on top of the other half. Thus the height of
the finished structure is 15 feet or double the original height and
the width is 4 feet or one half of the original width. The length
remains of course at 40 feet. This provides a double height shell
structure with one piece standing stably on top of the other and
connected by the hinge line along the centre. Straps are provided
on the side wall so that straps bridge the junction between the two
parts. The straps thus hold the structure stable and prevent the
upper half from toppling toward the hinge line. The straps can be
provided as over center latches or similar arrangements which
simply provide a connection across the junction which is
sufficiently strong to prevent toppling and holds the structure
tightly together.
[0057] As shown in FIG. 2, two of the divided containers are placed
at spaced positions with the hollow interior facing one another so
as to leave a space therebetween. The space can vary in width
depending upon the requirements for the size of the finished
building. Steel cross braces 10 interconnect between the two
sections 11 and 12 of the container structures thus holding the
structure rigid and rectangular. The steel cross bases are of
sufficient strength to prevent toppling during wind loads so that
the width of the structure holds the completed assembly from
twisting.
[0058] As shown in FIGS. 1 and 2 arched roof trusses are provided
extending over the structure from the outer edges 13 of the
container sections with each roof truss indicated at 43 and
extending across over the open space between the two container
sections to the outer edge of the opposite container section. These
roof trusses are then covered by a fabric layer 15. The building
structure is completed by one or more sliding door structures 16. A
single sliding door is provided between posts 17 and 18 attached to
the inside surfaces of the two inwardly facing container
structures. The posts provide abutting face for the sliding door in
conventional manner. The sliding door bridges across the full width
between the posts.
[0059] In a wider construction the door may fill only a part of the
area between the posts 17 and 18 with the remainder being filled by
panels. The rear (not shown) can also include a similar sliding
door or can be filled with panels. Other types of door structure
can be used including simple small opening doors sufficient in size
merely to pass a person depending upon the end use requirement for
the building structure.
[0060] The fabric panel 15 also includes a part circular front and
rear section indicated at 15A which bridges between a cross beam 19
at the top of the door to the first of the arched roof trusses.
[0061] The option shown in FIG. 7 allows the user/owner the ability
to erect "either" a single high (7.5') wall structure versus the
double high (15').times.40' long. This option would require only a
single container versus two containers which effectively reduces
the costs significantly. An alternative would be railway box cars
which are either a single high (12') versus double high
(24').times.52' long. A buyer may purchase a single high model and
later purchase an additional container structure if they wish to
double the height of these structures.
[0062] Further details of a building of this type are shown in
FIGS. 3, 4 and 5. The building comprises a first container portion
20 and the second container portion 21. These are cut from
preferably the same container so that each defines an outer wall
22, a top wall 23, a bottom wall 24, a front end wall 25 and a rear
end wall 26. These elements are formed from the conventional
container so as to be formed from corrugated steel with
longitudinal ribs 27 which provide strength to the individual
walls. The cutting of the structure defines a front face 28 with
the front faces matching. Across the bottom wall 24 at the front
edge at the front face is provided a bottom stiffening member 29. A
symmetrical top stiffening member 30 is provided at the front edge
of the top wall 23. These stiffening members are welded to the
structure to provide stiffening of the otherwise raw edge of the
container. The container is formed in the conventional manner and
has corner posts 31 and top and bottom rails 32 and 33. This
provides a rectangular structure for the container which is then
filled by the walls panels as described above.
[0063] The addition of the stiffening members holds the front face
fixed and rectangular so that these two front faces can be spaced
apart. To provide additional structural strength, the top
stiffening member is supported by a truss 30A with an upright
portion 30B and inclined braces 30C. This holds the top edge rigid
against sagging. The front faces are held apart by a bottom strap
35 which extends across the bottom rails at the bottom walls 24.
The strap 35 is preferably is simply a flat strap so that it can
lie on the ground and hold the inner faces at the required spacing.
At the top is also provided a panel 36 which attaches across the
front edges. The strap 35 and the panel 36 can be bolted in place
so that it can be readily removed. A conventional door 38 is
provided for closing the space between the strap 35 and the panel
36. The door 38 is formed in individual panels and can open
preferably on a sliding track 39 of a conventional nature. The
track 39 is supported from the top rail 30.
[0064] Over the building structure is provided a roof 40 which
extends from one edge 41 at the outer wall 22 to a second edge 42
at the outer wall 22 of the opposite container half. The roof is
formed preferably from curved arch members 43 which bridge over the
structure from a bottom horizontal rail 44. The arch members are
provided at suitable spaced positions along the length of the
building from a front arch member 43A to a rear arch member 43B.
The arches can be used to support a fabric or a plastic sheeting
material which can be semi-rigid or completely flexible. The arches
can also be used to support panels which are relatively stiff but
can be curved into an arch shape to match the shape of the arched
members.
[0065] A front gable panel 50 is provided which has a top edge
defined by the front arch member 43A and a horizontal bottom edge
51 extending across the top of the panel 36 and across the top
walls 23 of the container halves. A similar gable panel is provided
at the rear end. Thus the roof bridges over the top walls 23 to
extend to the outer wall of the container halves. This can provide
entry of light into the interior if the gable panels and the roof
are formed of a translucent or transparent material.
[0066] The roof and the gable panels can be collapsed by separation
of the forming rails each from the next so that the roof structure
can be stored with the straps 35 and the panel 36 within the
interior of the two container halves when they are brought together
as a collapsed structure. In this way the whole of the building can
be collapsed into the size of the container with all of the
elements received within the container. The two halves of the
container can be fastened together by buffing the stiffening
members and providing a suitable fastening between the two halves
to hold the open faces together thus enclosing the material forming
the remainder of the building within the interior of the
container.
[0067] As an alternative to the arched roof structure, flat roof
panels converging to a peak along a center line of the building can
be provided with the two flat panels extending outwardly and
downwardly to the outer edge at the outer sides of the container
halves. Also a flat roof can be provided as a yet further
alternative.
[0068] The containers are readily available and the structure can
be formed simply by cutting an existing container into the two
halves, attaching the stiffening members and providing the
remaining elements as a kit of parts can be supplied to attach to
the container to form the building on site where required. The
whole building is thus readily transportable. The whole building is
much more structurally rigid and much more resistant to damage or
vandalism than is simply a building formed wholly from fabric or
panels or sheeting material. The front and rear panels between the
container halves are substantially rigid and much more difficult to
damage or open than is a corresponding fabric material.
[0069] In FIGS. 6 through 10 is shown an alternative arrangement
utilizing the same basic structure including the two sections of
container indicated at 20 and 21. In FIG. 6 the container is
arranged with two sections hinged together as indicated at 20A and
20B and on the other side at 21A and 21B. The same frame structures
as previously described are used to connect the arrangements and
provide a front door 16.
[0070] In this arrangement however, a more permanent roof structure
is provided by roof panels 60 and roof rafters 61 together with a
longitudinal ridge rail 62. The roof panels are formed from
insulating foam material which can be fastened directly to the
upper surface of the rafters. The insulating foam material is
coated on the outside surface by a suitable cladding material which
may be steel or other sheet metal which can be coated with a
resistant and covering coating on the outside. Such sheets are
commercially available and can be used edge to edge to provide a
surface covering the whole of the roof defined by the roof rafters
60.
[0071] The ridge rail 62 is formed from independent sections which
are connected between each pair of roof rafters and the next.
[0072] At the base of each roof rafter where it is connected to the
outside edge of the respective container portion there is provided
a connector member 65. This comprises a base plate 66 which is
bolted to or welded to the side of the container at the outside
edge which faces upwardly so that a sleeve 67 which is arranged at
an angle to receive the rafter 60 to support the lower end of the
rafter and hold it in its position extending upwardly and inwardly
toward the ridge rail. At the center at the ridge rail there is
provided three-way connectors 68 and four-way connectors 69. The
three-way connectors are arranged at the end and provide sleeves 70
and 71 to receive the rafters at the end of the building. A sleeve
72 projects along the direction of the ridge rail so as to receive
an end of the ridge rail section to hold it in place. That ridge
rail section extends to the next four-way connector 69 which
includes a similar sleeve to receive the other end of the ridge
rail section. Two further sleeves 73 and 74 are provided which are
inclined downwardly to receive the upper end of the rafters of the
second set of rafters. A further sleeve projects along the line of
the ridge rails to receive the other end of the next ridge rail
section. Thus the ridge rail is formed from individual sections
connected between each connector 69 and the next. Each connector 69
has a pair of sleeves for supporting the upper ends of the rafters.
In this way the roof can be formed simply by connecting together
simple readily available commercial portions of lumber which may be
2.times.4 or 2.times.6 depending upon the size of the building. Of
course the dimensions of the connectors are arranged to accommodate
the size of lumber selected. The connectors include holes through
the side wall of the sleeve to allow screws to fasten through the
connector and hold the end of the lumber piece within the sleeve to
hold the rafters and the ridge rails sections in place.
[0073] Since various modifications can be made in my invention as
herein above described, and many apparently widely different
embodiments of same made within the spirit and scope of the claims
without department from such spirit and scope, it is intended that
all matter contained in the accompanying specification shall be
interpreted as illustrative only and not in a limiting sense.
* * * * *