Rapidly deployable modular building and methods
A modular building comprises a sled comprising a rectangular box frame. A shed comprising a steel framework of spaced apart columns that are linked to one another by overhead ceiling beams to provide a rigid structural frame. A sliding expansion modules is attached to the shed.
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This application claims priority to U.S. Provisional Patent Application Ser. No. 60/784,520, filed on Mar. 20, 2006, which is incorporated in its entirety by reference herein.
BACKGROUNDEmbodiments of the present invention relate to a modular building and related methods.
Modular buildings are pre-fabricated portable structures that are developed to facilitate shipment of building structures to building sites. The modular buildings are typically transported in large pre-assembled sections and then connected at the building site. Modular buildings can reduce the fabrication and assembly costs of building structures and can also be rapidly deployed to replace damaged or demolished buildings and houses, after natural disasters, such as hurricanes and earthquakes. Such replacement housing has to be constructed to be stored and readily deployable on short notice and tight planning cycles. To achieve such needs, it is desirable for the components and structures of the modular building to be standardized for mass production and storage. The standardization reduces fabrication costs and the warehouse storage space required to keep a large number of prefabricated components, and also allows for a wide variety of end use customization through user-selected components.
Modular buildings also have unique design requirements which are different from conventional building structures. For example, modular building should be designed to allow flexible configurations and ease of assembly on a building site. Labor resources in disaster zones are often very limited as most of the local labor resources are employed at repairing existing damaged structures to prevent further damage to these structures. Thus, it is desirable for replacement housing to be designed for easy set up and assembly by unskilled or low skill personnel. It is further desirable to have a replacement housing that is a customizable to allow configuration of the modular building at a building site to achieve unique requirements.
It is also desirable for the modular building to be structurally sound to withstand earthquakes and extreme storms such as hurricanes. When modular buildings are transported and set up in post-storm or earthquake disaster zones, such regions are often subject to other hurricanes in the same season or earthquakes aftershocks. Thus, replacement housing located in the same region should provide a seismically and hurricane resistant structural frame. This becomes even more difficult when considering that the rapidly deployable housing has to be built from modular and transportable components and often has to be assembled on-site or is constrained by the limitations of transportation by truck along local roads. Thus, it is desirable to have modular deployable housing that can be assembled on site with a minimum of labor and heavy equipment and still be structurally strong to resist to earthquakes and storms.
Modular buildings can also be designed to be constructed for specific applications, for example, rapidly deployable schoolrooms that can be easily transported and set up to respond to emerging demographic requirements for temporary educational space without compromising standards. Such educational housing units have specific requirements for space, lighting, and to provide a good educational environment. Also, often entire schoolhouses are destroyed in the disaster zones, and the schoolchildren have no place to go to school. It is desirable to have rapidly deployable schoolroom that can meet urgent schooling needs on short notice. Such temporary school housing standards are not necessarily met by the ‘one-size-fits-all’ constraints of mobile trailer home manufacturing. Thus it is desirable to have rapidly deployable structures which provide a flexible, mobile and modular solution for learning environments such as classrooms, labs, offices and studios. It is also desirable to provide a rapidly deployed modular building designed for emergency response rooms for police and fire services.
Thus it is desirable to have modular building that can be easily stored, transported, and assembled on-site to different design configurations. It is further desirable for the modular building to be designed to meet specific applications, such as schoolrooms and emergency response rooms.
These features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings, which illustrate examples of the invention. However, it is to be understood that each of the features can be used in the invention in general, not merely in the context of the particular drawings, and the invention includes any combination of these features, where:
A modular building 100 that is designed to be rapidly deployable, easily transportable, and minimize on-site assembly, comprises a structure that includes a supporting sled 102, a shed 104, and one or more optional expansion modules 106, as shown diagrammatically in
An assembly comprising a sled 102, a shed 104, and an expansion module 106 that serves as a power pack module 108, is shown in
Various embodiments of the components of the modular building 100 will now be described. In one version, as shown in
Floor joists 140 extend across the upper surface of the sled 102 and overlap every 8 feet to provide a floor having structural rigidity and without seams. The floor joists 140 can comprise conventional tubular sections or beams. A raised floor is formed from floor panels 142 placed between the framework of the floor joists 140 to provide the necessary structural diaphragm for the base of the shed 104. As one example, the floor panels 142 can be made from structural metal decking. As another example, the floor panels 142 can be composed of concrete filled metal pans that sit on pedestals so that the underlying cavity can house electrical and mechanical services. The floor panels 142 can also be rearranged to move outlets, ports, and air diffusers providing the user with maximum flexibility. The under floor distribution of mechanical services for the overlying shed 104 can include HVAC (heating, ventilation and cooling) hollow tubes 144 are joined together in an integrated framework in the spaces between the beams and tubes that form the rectangular box frame 116 of the sled 102. The hollow tubes 144 have duct connector openings 146 for connecting to ventilation ducts to be positioned in the overlying shed 104. Electrical junction boxes 148a with. preassembled wiring can also be located at desired positions along the sled 102 to provide electrical and data services to the shed 104. Additional mechanical junction boxes for connecting mechanical services can also be provided. Locating electrical and mechanical services within a rectangular box frame of the sled 102 provides an integrated infrastructure for such services and can be tailored without extensive pre-wiring and ventilation planning for the overlying shed 104.
Another version of a sled 102 for a modular building 100, as shown in
The shed 104 placed on the sled 102, comprises a steel framework of spaced apart columns 170 that are linked to one another by overhead ceiling beams 172 to provide a rigid structural frame with large spans that has minimal material usage while providing a highly flexible and tailorable interior space, as shown in FIGS. 2C and 3A-3B. Referring to
In one version, the minor columns 170b are spaced apart a sufficient distance to allow the space between the columns to be pre-sized to dimensions suitable to receive wall panels 184 such as light impermeable panes 186, light permeable panes 188 such as windows or translucent screens, or even doors 190. A suitable spacing distance between the columns 170b comprises about four feet, but can also be other distances. Advantageously, positioning the minor columns 170b a predefined spacing distance provides a highly adaptable exterior sidewall for the shed 104, so that each exterior sidewall can be adapted to allow the transmission of light, serve as an opaque wall, or even provide an integrated connection of the interior space of the shed 104 to other structures, such as an expansion module 106.
The structure of the shed 104 also enables the two long exterior sidewalls to be absent structural reinforcements which are conventionally needed to provide strength in seismic or storm locations, consequently enabling the shed 104 to have a variety of different external wall configurations. It also enables the ceiling or roof plane to have variable heights and provide optional clerestory natural lighting. As a result, the shed 104 provides the ability to be tailored to a wide range of interior environments while still providing a quick-to-deploy modular building 100 that is safe and long-lasting—such a structure is without precedent in conventional pre-engineered modular buildings.
The ceiling of the shed 104 is designed as an open area that is suitable for receiving a variety of different ceiling panes 194. For example, the open ceiling can receive light impermeable panes 196 to enclose the structure and provide good heat insulation, solar panels 198 to receive solar energy and convert the energy to electricity or heat, or even light permeable 200 panes to allow outside light to enter the shed. Because the ceiling of the shed 104 is unencumbered by infrastructure, it allows the ceiling skin to be highly flexible in its use and appearance.
In one version, the open ceiling is closed with a roof 202 comprising onsite assembled trusses 204, custom aluminum extrusion rafters 206, and structural metal decking 208. The closed roof 202 is suitable to provide a high strength structure for situations such as storm or high snow environments. It can also be used for buildings needing better heat insulation.
The open ceiling structure also provides clerestory window possibilities that allow natural light to reach deep into buildings used as classrooms or even offices. Further, the ability to position light permeable panes 200, 188 in either the ceiling or between the columns 170, 178 allows the ratio of light permeable versus light impermeable surfaces to be tailored for specific building applications. Further, ratios of glass versus wall surface are now adaptable to building use warrants and applicable code regulations.
The open ceiling can also have flexible applications with both a light permeable skin and a sliding overlay 216 that closes off the light permeable roof when desired, as for example, shown in
The expansion module 106 comprises a steel frame 212 designed to be attached to an open sidewall 214a or end wall 214b of the shed 104 to expand the usable enclosed space provided by the shed 104. For example, as shown in
In one version, the expansion module 106 is sized smaller than the shed 104, so that the entire structure of the expansion module 106 can fit within the volume of the shed 104 during transportation. Advantageously, in this version, the expansion module 106 can be transported fitting as a whole within the enclosed space of the shed 104 so that the entire structure can sit on a single flatbed truck. At the building site, the expansion module 106 is pulled out from within the shed 104, and then bolted to major columns 170 installed in the sidewall of the shed 104. A single wide flange beam 152 bolted to a concrete grade beam 112 can be used to support the outside sidewall of the expansion module 106.
The ceiling 220 of the expansion module 106 can also be an open ceiling similar to the one described for the shed 104 or can be an enclosed ceiling formed by ceiling joists 222 as shown in
Various configurations of the sled 102, shed 104, and one or more expansion modules 106 will now be described. For example, a modular building 100 comprising a shed 104 with two expansion modules 106 attached to the sidewalls of the shed 104 is illustrated in
A modular building 100 with an expansion module 106 that is a power pack module 108 and a roof 226 is illustrated in
Yet another embodiment of a shed 104 of a modular building 100 is illustrated in
The delivery and assembly of an embodiment of a modular building 100 on a building site are shown in
The delivery, assembly, and interior configuration of another embodiment of a modular building 100 on a building site is shown in
A perspective view showing the relative scale of a modular building 100 is shown in
Still another embodiment of a modular building 100, suitable for housing a number of people and having both an end and side expansion module 106a,b, is illustrated in
Diagrams showing different embodiments of modular buildings are shown in
Interior arrangements of a modular building 100 having two wedge shaped side expansion modules 286 and two end modules 106a, suitable for teaching, seminar, library or conference facilities, are shown in
Further configurations of modular buildings having two or more sheds 104 are shown in
Modular buildings having two or more sheds 104 can have different internal configurations, as shown in
Embodiments of modular buildings having three or more sheds 104 are shown in
The assembly of another embodiment of a modular building 100 is shown in
While many different illustrative embodiments of the modular building 100 are described in the present application, it should be understood that other embodiments are also possible. For example, the modular building 100 can have other shapes and structures, and can be made from other materials, as would be apparent to those of ordinary skill in the art. Thus, the scope of the claims should not be limited to the illustrative embodiments described herein
Claims
1. A modular building comprising:
- (a) a sled comprising a rectangular box frame;
- (b) a shed comprising a steel framework of spaced apart columns that are linked to one another by overhead ceiling beams to provide a rigid structural frame; and
- (c) sliding expansion modules attached to the shed.
2. The modular building of claim 1 wherein the sled comprises a rectangular box frame composed of open web beams.
3. The modular building of claim 2 wherein the open web beams are oriented in a rectangular configuration to form a three-dimensional box.
4. The modular building of claim 2 wherein the sled comprises a plurality of sidewalls formed by vertical rectangle frames of beams.
5. The modular building of claim 1 wherein the sled further comprises an axle housing for receiving an axel for the attachment of wheels that allow the sled to be moved.
6. The modular building of claim 1 comprising floor joists extending across the upper surface of the sled.
7. The modular building of claim 1 wherein the sled comprises an under floor distribution of electrical and mechanical services.
8. The modular building of claim 1 wherein the sled comprises a rectangular box frame that includes a plurality of parallel and spaced apart wide flange beams.
9. The modular building of claim 8 wherein the beams comprise end portions that are located along the external perimeter of the sled and which have welded-on flat plates with bolt holes.
10. The modular building of claim 1 comprising an array of tubular joists are placed on top of the beams and spaced apart from one another to serve as floor joists.
11. The modular building of claim 1 wherein columns of the shed includes major and minor columns, the major columns having a larger cross-sectional area than the minor columns.
12. The modular building of claim 11 wherein the minor columns are spaced apart a sufficient distance to allow the space between the columns to be pre-sized to dimensions suitable to receive wall panels or doors.
13. The modular building of claim 12 wherein the wall panels are light impermeable or light permeable panes.
14. The modular building of claim 12 wherein the shed comprises long exterior sidewalls that are absent structural reinforcements.
15. The modular building of claim 1 wherein the shed comprises a ceiling that is an open area.
16. The modular building of claim 1 wherein the expansion module comprise a steel frame that is attached to an open sidewall or end wall of the shed to expand the usable enclosed space provided by the shed.
17. The modular building of claim 1 wherein the expansion module comprises major columns that form the corners of its structural frame with at least two of the columns being external to the shed, and the two other columns being integrated into a sidewall of the shed.
18. The modular building of claim 1 wherein the expansion module is sized smaller than the shed.
19. A modular building comprising:
- (a) a sled;
- (b) first and second expansion modules supported by the sled, each expansion module comprising a structural frame with an external sidewall, and the expansion modules being linked to one another by a plurality of ceiling beams to define an open interior space; and
- (c) a clerestory roof mounted over the ceiling beams.
20. The modular building of claim 19 wherein the external sidewall of the expansion modules comprises major columns located at corners, and minor columns located between the major columns, the major columns having a larger cross-sectional area than the minor columns.
21. The modular building of claim 20 further comprising diagonal columns to increase lateral and shear strength.
22. The modular building of claim 20 wherein the major columns form corners of the structural frame, and at least two of the major columns are integrated into each external sidewall.
23. The modular building of claim 20 wherein the major and minor columns comprise tubes of structural steel which are linked together with tube steel headers and bolts.
24. The modular building of claim 20 wherein the minor columns are spaced apart a sufficient distance to allow the distance between the minor columns to be pre-sized to dimensions suitable to receive wall panels or doors.
25. The modular building of claim 25 wherein the wall panels are light impermeable panes.
26. The modular building of claim 25 wherein the wall panels are light permeable panes.
27. The modular building of claim 19 wherein the first and second expansion modules are supported by a sled, the sled comprising a rectangular box frame.
28. The modular building of claim 19 wherein the structural frame comprises a preassembled structure having completed welding, drilling and cutting.
29. The modular building of claim 19 further comprising a shed having a steel framework of spaced apart columns that is between the expansion modules.
30. The modular building of claim 19 wherein the expansion modules are rectangular structures.
31. The modular building of claim 19 wherein the clerestory roof is capable of receiving ceiling panes that include light permeable panes, light impermeable panes, or solar panels.
32. The modular building of claim 31 wherein the clerestory roof comprises onsite assembled trusses, custom aluminum extrusion rafters, and structural metal decking.
33. The modular building of claim 19 further comprising an external awning that serves as a sunshade, and is made from solar panels.
Type: Application
Filed: Mar 20, 2007
Publication Date: Aug 28, 2008
Applicant:
Inventors: Mark Miller (San Francisco, CA), Natan Goore (San Francisco, CA), Steven Kelley (Orinda, CA)
Application Number: 11/726,380
International Classification: E04B 1/19 (20060101); E04C 3/00 (20060101); E04C 2/00 (20060101);