U.S. patent number 3,832,811 [Application Number 05/150,420] was granted by the patent office on 1974-09-03 for relocatable building module.
Invention is credited to Ernest M. Briel, Jr..
United States Patent |
3,832,811 |
Briel, Jr. |
September 3, 1974 |
RELOCATABLE BUILDING MODULE
Abstract
A relocatable building module apparatus and shipping crate for
shipping a disassembled module. A folded module can be placed in
position on location and walls erected in their upright position
relative to the floor by rotating the walls on hinged points on the
floor and locking them in place. A roof can then be attached to the
walls and several modules can be aligned together in a positive
alignment.
Inventors: |
Briel, Jr.; Ernest M.
(Satellite Beach, FL) |
Family
ID: |
26847628 |
Appl.
No.: |
05/150,420 |
Filed: |
June 7, 1971 |
Current U.S.
Class: |
52/69; 52/73;
52/79.13; 52/79.5; 52/143 |
Current CPC
Class: |
E04B
1/3483 (20130101); E04B 1/3445 (20130101); E04B
2001/34389 (20130101) |
Current International
Class: |
E04B
1/344 (20060101); E04B 1/348 (20060101); E04b
007/16 () |
Field of
Search: |
;52/234,79,66,64,70,71,69,126,585 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Murtagh; John E.
Attorney, Agent or Firm: Duckworth, Hobby & Allen
Claims
I claim:
1. A relocatable building module comprising in combination:
a. a floor section having structural members supporting a
floor;
b. wall members having structural members hinged to said floor
section structural members and adapted to be moved from a folded
position to upright erected position.
c. locking means for locking said wall members to said floor
section structural members when in said erected position, said
locking means having a plurality of slotted plates attached to said
wall members structural members and a plurality of bolt members
attached to said floor section structural members located to fit
into slots in said slotted plates when said wall members are in an
upright position whereby said bolt members can be tightened to lock
said wall members in an upright position, and said locking members
being located in said floor section structural members when said
wall members are in an upright position;
d. roof section having structural members removably attached to
said wall member when said wall members are in their erected
position, said roof section having utility conduits attached
therein for connection between modules;
e. a plurality of leveling members attached to said floor section
structural members for leveling said module; each said leveling
member having a threaded rod adjustably attached through the bottom
of said floor section structural members and having a bottom plate
whereby said floor section can be leveled;
f. alignment means for aligning at least one other relocatable
building module with said relocatable building module, said
alignment means having a plurality of tapered pins on one side of
said module for engagement with openings in predetermined locations
in a second module, each said tapered pin having an annular ledge
for stopping the insertion of said tapered pin in said opening in a
second module at a predetermined point thereby providing
predetermined spacing between modules, whereby a folded module can
be placed in position, leveled, said wall members erected and
locked in an upright position and said roof section emplaced.
2. The apparatus according to claim 1 in which each said module
includes a detachable canopy overhang attached to the exterior of
the said module.
Description
BACKGROUND OF THE INVENTION
The present invention relates to modular prefabricated relocatable
building structures. It has frequently been a requirement,
especially by governmental units, for buildings which are required
to be assembled rapidly where materials or skilled labor are not
available such as in overseas areas, in severe weather conditions
or when ultimate or frequent relocation is required. It is
accordingly an object of the present invention to provide a modular
prefabricated relocatable building structure which can be factory
produced for rapid assembly and disassembly and which will also
have a rugged long life under a variety of environmental conditions
and require a minimum of maintenance along with the ease of
erection and disassembly in a rapid manner by semi-skilled labor
with simple tools and in severe weather conditions. In recent
years, the rapidly increasing cost of materials and labor for
building houses has resulted in great interest in the development
of large numbers of modile type homes which are factory
manufactured and placed on a chassis with wheels for movement to a
desired location. There has also been great interest in development
of modular type homes which are factory built for placement upon
the beds of lowboy trucks or similar vehicles for transportation
from the factory to the building site and which usually have two
sections for attaching together to form a complete house. However,
these prior art units are not adapted for shipment by other means
such as on ships to foreign countries because of their bulk in
their assembled form. There have been many types of prefabricated
units in which sections of a building such as the walls, floor and
ceiling are packed aboard a vehicle for shipment to the building
site where it is assembled by skilled labor. This reduces the
overall labor required and it decreases the time span required to
assemble a house but still requires a fairly large amount of
skilled labor to assemble the prefabricated house. These prior art
building units are meant for permanent installation except for some
of the mobile home units which can be moved on their wheels to
different locations.
There have been a number of folding and relocatable type building
structures. Typical of these units is U.S. Pat. No. 2,592,610 for a
PREFABRICATED FOLDING BUILDING, which is a building construction
which can be manufactured at a factory and assembled at a site, and
provides a wall unit in which the floor and roof pivot therefrom
for assembly; U.S. Pat. No. 3,012,291, for a COLLAPSIBLE PORTABLE
BUILDING, teaches such a building which can be partially collapsed
to reduce the size of the building while it is being moved; and
U.S. Pat. No. 2,751,635, for a PORTABLE PREFABRICATED SHELTER, and
has a building section hinged to fold much like a folded paper
carton; U.S. Pat. No. 3,103,709, for BUILDING STRUCTURES, provides
a building unit which can be collapsed to a low height and formed
into a compact bundle for transporting to a site and then assembled
to form a building; U.S. Pat. No. 2,701,038, for a PORTABLE HOUSE,
teaches a portable building which can be folded into a flat unit
for stacking of the units for transporting the unit to a site; and
U.S. Pat. No. 3,517,962, illustrates a KNOCK-DOWN MOBILE HOME
ASSEMBLY, in which the mobile home has collapsible walls which fold
over to its floor structure, and a roof which is mountable to the
walls in an erected position.
SUMMARY OF THE INVENTION
The present invention relates to a modular prefabricated
relocatable building structure into a shipping crate for shipping
such a structure. The relocatable building module has a floor
section having metal structural members supporting the floor and
wall sections having similar metal structural members which are
hinged to the floor section structural members so that the walls
can be folded onto the floor and then moved to an upright erected
position. A locking assembly provides for a rapid locking of the
wall sections to the floor section in its erected position and the
roof section is removably attached to the wall sections when the
wall members are in their erected positions. A plurality of
leveling members are attached to the floor section structural
members for leveling the floor section and hence the building
module on its site and alignment means attached to the module allow
a plurality of the modules to be rapidly interconnected. A folded
module can be placed in position and quickly leveled, the wall
members erected and locked in their upright position and the roof
section placed thereon. Several modules can be aligned together and
interconnected to provide one large unit of side by side modules
and can also provide for a plurality of levels with the heating and
air conditioning ducts and other facilities interconnecting on the
individual modules. The shipping crate for shipping the relocatable
building module has a base made up of structural members attached
together and has a plurality of upright structural members attached
to the base. The base has crates for placement of wall partitions
and related building hardware, and the like, attached thereto. The
upright structural members have brackets attached thereto for
placing a roof section, and a set of removable brackets for
attaching floor section with walls attached thereto, when such
walls are in a folded position. The upright members also have
lifting hook connections thereon for lifting these crates fully
loaded. The walls, floor and roofing sections are adapted for being
wrapped in plastic, while in the shipping crate. The upright
members can be interconnected for greater strength and can have
means for bolting the upright members to another similar shipping
crate upright members for combining upper and lower levels together
in one shipping unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of this invention will be
apparent from a study of the written description and the drawings,
in which:
FIG. 1 is a perspective view of an assembled building made with a
plurality of modules in accordance with the present invention;
FIG. 2 is an exploded view of the upper and lower level modules in
accordance with the present invention;
FIG. 3 is an exploded view of a loaded shipping crate in accordance
with the present invention;
FIG. 4 is a perspective view, with portions cut awaw, of foundation
connection and wall hinge lock for a lower level module in
accordance with the present invention;
FIG. 5 illustrates an interconnection joint for connecting upper
and lower module units; and
FIG. 6 illustrates an alignment guide for aligning a pair of
modules.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention deals with a modular prefabricated
relocatable building structure which can typically be built 10 feet
long by 24 feet wide. Assembled modules can have first floor and
second floor modules followed by a roof and in which only the
latrine module needs to be shipped in an erected position. Each
module may have a steel floor deck material over a structural steel
frame and the insulated wall panels may be integral with the
vertical structural columns and fold down horizontally for
packaging. Second floor module can be similar to the first floor
module except that the lay-in ceiling for the first floor is
attached to the under side of the floor structure and a utility
space containing all air conditioning ducts, air handlers, electric
power supply and communications space is suspended to run
longitudinally down the center of a building through a plurality of
modules. The roof structure may contain similar features for the
second floor area and all environment insulation may utilize foam,
applied polystyrene beneath the first floor, polystyrene sandwiched
within the walls and rigid board type insulation on the roof.
Latrine modules, which are not illustrated, may be constructed to
be shipped fully erected with all features in place, and stair
modules may be hinged up into the second floor module for shipment.
The utility module may be a self-contained separate structure
containing the chilled water pumps, controls, bore and power panels
and a fuel oil tank, if utilized, may be placed on a common base
with the utility module. Erection of a typical building will
consist of simply placing a first floor module in position,
leveling it, standing up and locking the hinged walls, installing
the second floor on the first floor walls and placing the roof
structure. Adjacent modules are self-aligning and the process is
repeated.
Referring now to FIG. 1 of the drawing, there can be seen an
assembled building 10 having a plurality of first floor modules 11
and second floor modules 12 assembled together. The modules are
aligned side by side and have end walls 13 attached thereto along
with plurality of doors 14 and upper level canopy attachments 15
and lower level canopy attachments 16. Each module wall is
illustrated as having one window 17 therein but it could of course
have several windows or no windows as desired. The building has a
roof 18 and a floor ceiling combination 20 between the lower unit
11 and the upper unit 12.
Referring now to FIG. 2, there can be seen that the modular unit 11
may be set on a grade beam 21 having grouting spaces 22 for
placement of flat portion 23 of leveling jacks 24 which are
attached to elongated structural members 25, which leveling jack
may be threaded for raising or lowering to align each corner of the
module 11 during assembly and also to adjustments for settling of
the building. The flat bottom portion 23 of the leveling jack when
placed in the grouting space 22 may be grouted therearound for
anchoring it to the grade beam 21. The elongated members 25 are
interconnected by a plurality of structural box members 26 which
are interconnected with members 27, having structural metal deck 28
attached thereto which in turn has the floor panels 30 which may be
cemented asbestos board, or the like, attached thereover and which
may have carpet 31 placed thereover to provide the floor section of
the lower module. The elongated box member 25 has lifting pins 32
therein for lifting the individual unit, such as with a crane, for
placement on the graded beams 21 and also has tapered alignment
pins 33 fixedly attached thereto for aligning pairs of modules, as
will be described in more detail in connection with FIG. 6. The end
walls 34 of the building have base structural box members 35 and
upright extending box structural members 36 along with upper
structural members 37 welded together into a rigid wall structure
which is hinged to the elongated structural members 25 by pins, or
the like, 38, as will be described in more detail in connection
with FIG. 4. Walls 34 may be folded on hinge pins 38 to lay flat on
the floor and then be extended into their upright position for
assembly, in which position they can be locked. The wall structural
members have exterior wall panels 40 along with window units which
can be aluminum frame sliding glass window units, as illustrated,
or any other type as desired, but attached to the exterior siding
40. Metal flashing 42 has been attached to the top portion of the
wall structure and the exterior unit can be separately insulated
and can have panels 40 of insulating exterior wall material. The
frame members 36 provide attaching holes 43 for engaging similar
holes 44 on an overhang canopy 45 which canopy provides exterior
shelter from rain, or snow, or the like, for people entering or
leaving the buildings. Inasmuch as the modules illustrated in this
figure are for a unit such as in FIG. 1, there would be a plurality
of modules interconnected with only end walls at each end of the
plurality of modules which are then attached upon completion of the
end modules. The upper module 12 has structural box members 46 with
interconnecting structural members 47 and 48. The structural
members 46 similarly have lifting pins 50, tapering alignment pins
51, and hinge pins 52 therein. The end wall structure 53 is similar
to that taught for the lower unit and hinges on the pins 52 to
allow a folded unit foldable onto the floor unit. This unit
similarly has a structural metal deck 54 similar to the metal deck
28 and floor boarding 55 thereon but has been covered with tile 56,
such as vinyl asbestos tile rather than the carpet 31. Brackets 58
allow for the alignment and attachment of the upper and lower units
and the end walls of the upper unit have exterior wall panels 59
along with window units 60 and upper metal flashing 61. Brackets 57
are used to connect modules together. The floor of the second level
unit has a utility duct 62 attached thereto having the heating and
air conditioning conduits 63 with grills 64 therein along with
separate power line tubing 69. A roof section 65 has elongated
structural box member 66 having tapering pins 67, lifting pins 68
and brackets 70 for attaching to structural members 53 of the upper
level module 12. The roof unit has interconnecting box structural
member 71 with utility conduits passing therein along with roofing
panel 72 which can be nylon liquid roofing with a fiberglass mesh
at the panel joints and may contain rigid insulation board 73 on
the structural metal deck 74. The upper module similarly has an
overhang 75 which may have a welded steel beam 76 welded to
removable steel plate 77 along with bracket 78 for attaching to the
building structure and is typically the same as the overhang 45 of
the lower module.
As can be seen at this point, the lower module can be lifted in
place with a crane, or the like, connecting to lifting pins 32 to
place the leveling jacks 24 into grouting spaces 22 of the grade
beam 21. The lower unit can then be leveled utilizing standard
carpenter's levels for leveling the four corners of the module.
Once leveled, the folded walls 34 can be erected on pins 38 and
locked in place. Then the upper module 12 floor can be lifted in
place by utilizing pins 50 and locked to the lower walls by means
of brackets 58 so that the floor of the upper unit will have a
ceiling 80 thereunder for providing a ceiling for the lower module
and a floor for the upper module. The upper module then has its
walls swing on pins 52 and the side walls are locked in place. The
roof section 65 can then be engaged at pin 65 for lifting by a
crane and putting it in place on top of the upper module walls
which are aligned by the extending portion 81 of the end of the
structural member 66 and with the end portion 82 interconnecting
and locking along with bracket 70 to structural members 53.
Similarly, the upper and lower modules are aligned with brackets 58
to each other. The upper roofing section is then locked in place.
This is followed by a second pair of modules being assembled in the
same manner except for being adapted to slide on the tapered
alignment pins 32 for alignment with the first set of modules. The
overhangs 45 and 75 can be attached at any time during assembly.
Inasmuch as most of the on side assembly is performed by bolting
members together, it should be clear that the units can be easily
disassembled with relatively unskilled labor and crated for
relocation with a minimum amount of labor. This is more clearly
illustrated in connection with FIG. 3.
Turning now to FIG. 3, a shipping crate for shipping the present
relocatable building module in is illustrated at 90 having a
rectangular base with a pair of short base perimeter frame members
91 and a pair of elongated base perimeter members 92 with a
plurality of interconnecting frame members 93 and a center
reinforcing frame member 94. Members 91, 92 and 94 can all be box
or channel members of structural steel welded together. The frame
has four upright channels 95 which can be welded or bolted to the
elongated base members 92 and each upright member 95 has lower
brackets 96 and upper brackets 97 along with a lifting hook 98
thereon. Lifting hook attachment 98 is also utilized for the upper
connections of reinforcing wire cable 100 which is connected
between upright members 95 and between upper lifting hooks 98 and
lower wire holding brackets 101. It should of course be clear that
reinforcing members other than metal cable can be utilized, such as
rigid steel stock. Brackets 96 and 97 have bolt holes therein and
there are also bolt holes 102 in the upright member 95 caps 103.
Caps 103, with bolt holes 102 allow for a first floor shipping
crate to be nested on and bolted to the uprights 95 of the second
floor shipping crate illustrated. The lifting hooks allow a crane,
or the like, to lift a single crated module sitting on and anchored
to the base with a pair of wooden crates 104 and 105 which can
typically be 1-foot deep wooden crates to ship interior wall
partition parts, foam filler gaskets, battens, canopy overhangs,
miscellaneous bolts and nuts, and light fixtures, and the like.
These crates may be lined with and items wrapped with polyethylene
and sealed water-tight. An upper level roof unit 106 having
structural members 107 and a utility and air conditioning conduit
108 thereon, and a pair of protruding bolts 109 attached thereto
would typically be wrapped in polyethylene and sealed water-tight
for shipment and the unit placed on brackets 96 on the uprights 95
with the bolts 109 going in the bolt holes 110 in the brackets 96
and being bolted thereto, and with the utility passageway 108
fitting between the crates 104 and 105 in a space of predetermined
size. The floor and wall unit 111 has a floor 112, a utility
conduit 113, walls that fold up as previously described, which
hinged walls have window units 115 therein. The folded walls which
are hinged at one end to the structural members 116 have been
anchored to the floor by metal strap 117 which is wrapped around
corner pieces 118 to protect surfaces of the walls and floor unit.
This second floor unit would typically have plywood and polystyrene
pads to protect the glass window 115 and would be wrapped with
polyethylene and sealed water-tight for shipment and then would be
placed on the brackets 97 with bolts 120 of structural members 116
fitting into anchor bolt holes 121 on brackets 97 for being bolted
thereto and held in place. Sufficient room is provided between
brackets 97 and 96 for the conduit 113. This crate provides for
lifting these units on cranes, or the like, especially for shipment
in cargo-type ships and provides for the easy stacking of the
crates on the uprights 95 and for bolting pairs of upper and lower
unit crates together. It should be noted that the crates are packed
so that the flooring unit comes off first for placement, followed
by the roof unit and then the crates 104 and 105 can be opened for
removal of the remainder of materials and hardware. The crates can
then be safely stored for shipping the relocatable unit should this
later become necessary. It should also be noted that the brackets
97 are removably connected to the uprights 95 so they can be
removed out of the way for inserting and removing the roof unit 106
and these units can be bolted with bolts 122, if desired, or
removably connected with any other type fasteners desired.
Referring now to FIG. 4, a first floor beam column foundation
connection is illustrated having elongated box beams 125, short
spanning box beams 126 along with the column or upright beams 127.
The long span beams 125 have a threaded anchor or leveling bolt 128
attached thereto by nut 130 threaded on a threaded end 131 of the
bolt 128. The other end has a flat surface 132 which has been set
into a grouting space 133 of a grade beam 134 and grouted with
grout 135 for anchoring to the beam 134. Slotted plates 136 have
been welded to the columns 127 and hinged by threaded bolt 137 to
the long span beam 125. These plates have slots 138 at
predetermined angles therein along with an angled surface 140.
Threaded bolts 141 are welded to the long span beam and have
washers 142 and nuts 143 thereon so that the wall unit having
structural members 126 and 127 can be folded on the hinge bolt 137
resulting in the nuts 141 engaging in the slots 138 of the plates
136. The nuts 143 and washers 142 would typically already be
loosely fitted onto the bolts 141 and can be tightened in position
in an upright and level position and the hinge bolts 137 can be
tightened to provide additional frictional engagement of the wall
structural members with the floor structural member 125. As can be
seen, this provides a simple structural folding corner which can be
assembled or disassembled rapidly by relatively unskilled labor and
also provides an easy and rapid means for leveling the relocatable
unit without having to have external jacks on hand for placing the
unit in proper position. It also provides for adjustments in the
event of settling of the building. It should be noted that beam 125
has a rectangular removed portion 145 for allowing entrance into
the box channel 125 in order to tighten all of the nuts onto the
bolts and for leveling the anchor leveling bolt 128.
FIG. 5 illustrates a means for connecting upper and lower modules
together and has upper level long span beams 145 and short span
beams 147 along with a column 148 welded to the short span beam
147. Column 148 has slotted plates 150 welded thereto and hinged on
pins or bolts 151 and anchored as previously described in
connection with FIG. 4. The bottom portion of the beams 146 and
147, however, do not have the leveling bolts of the lower module
unit, but rather have a pair of brackets 152 and 153 welded to
beams 146 and 147 respectively, having slots 154 and 155 therein.
The lower level column 156 is illustrated having its short span
beam 157 connected thereto and the column 156 has a bolt 159 welded
thereto on one side and a bolt 160 welded thereto on another side,
adapted for fitting in the slots 154 and 155 respectively of
brackets 152 and 153. Threaded bolts 158 and 160 have a pair of
lock washers 161 and nuts 162 for anchoring the brackets 152 and
153 to the column 156. This simple locking means provides for easy
assembly and disassembly while aligning the upper module to the
lower module.
FIG. 6 shows a typical alignment between a pair of side by side
modules, has a corner of one module having a long span beam 170, a
column beam 171, a short span beam 172 along with slotted plates
173 hinged at 174 and locked with bolts at 175. The long span beam
170 has a circular opening 176 for receiving a tapered pin spacer
177 which has been welded at 178 to the long span beam 180 of a
second module in predetermined locations. The second module also
has a short beam 181, an upright column 182, along with slotted
plates 183. The tapered pin spacer 177 may have a 2-inch tapered
surface and a base portion 185 with an annular ledge 186 for
aligning a pair of modules a predetermined space apart. The modules
can then be bolted together with brackets 157 of FIG. 2 or
connected by any means desired, preferably by means which can be
easily disconnected for disassembling the modules for
relocation.
It should be clear at this time that a prefabricated modular
relocatable building structure has been provided but it should also
be clear that variations and equivalents are anticipated without
departing from the spirit and scope of the invention and that while
no particular materials are anticipated, the structural system
could consist of cold rolled structural steel box members in which
the module frames are welded with column and wall members folded
down for packaging. The frames are thus rigid or semi-rigid in both
directions for strength and to carry wind loads in any direction.
Each module is structurally independent during erection and
permanently independent when adjacent upper modules are in place.
The rigidity of the hinged joiits is assured by the use of high
strength bolts with self locking nuts tightened by the turn of the
nut method to produce a friction connection. The bolts and the
hinged joints are shipped hand tightened and tightened for joint
rigidity after adjustment of the walls. The erection alignment is
achieved by mating the 2-inch diameter male and female tapered pins
which are designed to give positive alignment and module spacing in
the most difficult of working conditions. The foundation and
anchoring system is designed for grade beam application which
allows a building to be erected virtually on any hard span surface.
Anchoring and permanent bearing is assured by field grouting the
foot of the leveling jack after erection is completed, but it of
course should be clear that the present application is not
anticipated as being limited to grade beam applications even though
this allows non-reinforcing concrete grade beam foundation
continuously around the periphery of the building. It is also
anticipated that quick fitting and attaching end wall panels can be
applied along with doors and any type of plumbing connections
desired eben though modular piping innerconnections generally
include flexible unions allowing sufficient variation for rapid
connection and adjustment. The same applies to the electrical
wiring and lighting for the modules. It should also be understood
that it is anticipated that the units can be assembled with only
semi-skilled labor, but does require a crane, such as a 20-ton
capacity crane along with crane rigging spreaders, ladders and low
scaffolding equipment in which a skilled operator would be required
for the crane for setting the units in place.
Accordingly, this invention is not to be construed as limited to
the particular forms disclosed herein since these are to be
regarded as illustrative rather than restrictive.
* * * * *