MODULAR BUILDING CAPABLE OF BEING READILY ASSEMBLED

Abstract

A modular building capable of being readily assembled and disassembled comprising rectangular base and roof frames each formed by two longitudinal beams and two lateral beams, the roof frame having a smaller periphery than the base frame. Four columns extend between corners of the base and roof frames, these columns being set back within the periphery of the base frame while having a periphery matching that of the roof frame. The building includes a floor panel having an outer periphery matching the periphery of the roof frame and being dimensioned to rest on inner edge portions of the base frame beams, a roof panel for resting on the roof frame and having an outer periphery at least as large as that of the base frame, and side and end wall panels dimensioned to fit between the base frame beams and the roof panel.

Description

FIELD OF THE INVENTION

The present invention relates to a modular building, and provides a series of components which can readily be assembled into a temporary structure, and readily disassembled and moved.

BACKGROUND OF THE INVENTION

Building sites often have need of a temporary building which can serve as an office or as shelter for workers. Often such a building is in the form of a trailer. It is also known to provide buildings in modular, knock-down form.

SUMMARY OF THE INVENTION

The present invention provides a temporary building of modular type which can be delivered to a site, such as a building site, in disassembled, generally flat form, and in which the components can readily be bolted together to provide a somewhat insulated and weather-proof structure. The building can be, generally from 20 to 60 feet in length, and generally from 8 to 14 feet in width, the buildings being connectable to other building to provide larger buildings as needed or desired.

In accordance with the present invention, a modular building capable of being readily assembled and disassembled comprises, a rectangular base frame formed by two longitudinal base beams and two lateral base beams connected at their ends, so that said base beams define a first rectangular periphery; a rectangular roof frame formed of two longitudinal roof beams and two lateral roof beams connected at their ends so that said roof beams define a second rectangular periphery which is less in width and length than said first rectangular periphery; four columns adapted to extend between corners of the base and roof frames and attachable thereto, said four columns, when positioned, having outer surfaces defining a rectangular outer periphery which substantially matches said second rectangular periphery of the roof frame, said columns being set back within the corners of said the first rectangular periphery of the base frame; a floor panel having an outer periphery substantially matching said second periphery, said floor panel being dimensioned to rest on inner edge portions of the base beams; a roof panel for resting on the roof frame and having an outer periphery at least as large in length and width as said first rectangular periphery; and side and end wall panels dimensioned to fit between said base beams and said roof panel with said wall panels resting on outer edge portions of said base beams, said wall panels enclosing outer peripheries both of said four columns and of the roof frame.

Preferably, the base beams and roof beams are I beams. Also, the columns are preferably I beams having upper and lower end plates at their respective upper and lower ends, these end plates having apertures for bolting to apertures in the roof and base beams.

The lower end plates of the columns preferably may each have four rectangularly positioned bolt apertures, an outer three of these apertures being suitable for bolting to apertures in inner edge portions of the base beams at a respective corner. The base beams also have a reinforcing corner element attached to the inside of each corner of the base frame, which reinforcing corner element has an additional aperture end positioned to be bolted to the fourth, inside, aperture of the lower end plate of a column. The reinforcing corner element for each corner of the base frame may be in the form of a tube having sides welded to inner sides of the base beams and having an upper end plate provided with said additional aperture. The corner elements may extend below the base beams to provide legs for resting on the ground.

The roof frame may have apertured lifting lugs fixed to the top thereof, each lug positioned above one of said columns, the roof panel having apertures to accommodate the lifting lugs.

The roof beams may each have, attached thereto in parallel relationship, an additional elongated roof member, such as a channel member, which provides flanges at the second rectangular periphery, so that these flanges provide locating means for the side and end wall panels. Similarly, the base beams may each have, attached thereto in parallel relationship, an additional elongated base member having an upstanding flange suitable for locating the outer periphery of the floor panel on the inside of the flange, and also suitable for locating lower edge margins of the wall panels on the outside of the flange.

In longer versions of the building, the base frame and roof frame may each have one or more additional, intermediate lateral members which meet the longitudinal members at intermediate areas. These intermediate areas of the base and roof frames are connectable by additional intermediate columns which have bolt connections to the base and roof beams. In this construction, the lifting lugs are preferably provided at the upper ends of the intermediate columns, rather than at the corners of the roof frame.

Furthermore, both the base frame and the roof frame may have one or more additional longitudinal beams fixed at their ends to the lateral base and roof beams and to the lateral intermediate beams.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which;

FIG. 1 is an isometric view of a first building in accordance with one embodiment of the present invention, before the addition of its roof panel;

FIG. 2 is a similar view but with the frames disassembled, and in which the floor panel covers the base frame and a roof panel covers the roof frame;

FIG. 3 is a partially assembled view of the base frame and roof frame of one embodiment of the present invention, and also showing columns attached to the roof frame;

FIG. 3a is a detail view of the part C of FIG. 3, showing the corner construction of the base frame;

FIG. 3b is a detail plan view of a corner of the base frame;

FIG. 3c is a detailed view of the portion D of FIG. 3, showing the lower end of a column;

FIG. 4 is an isometric view of the base and roof frames and the columns assembled together, and also shows lifting lugs attached to the roof frame;

FIG. 4a is a detailed view of the portion A of FIG. 4, showing the attachment of the lower end of a column to a corner of the base frame;

FIG. 4b is a detailed view of the portion B of FIG. 4, showing the lifting lug connected to the corner of the roof frame;

FIG. 5 shows a cross-sectional view through a completed building;

FIG. 5a is a detailed view of the connection of the lower portion of the enhanced wall of one embodiment of the present invention;

FIG. 5b is a detailed view of the connection of the upper portion of the enhanced wall of one embodiment of the present invention;

FIG. 6 is an isometric view of the base and roof frames of a second embodiment of the building, which is longer and which has additional beams and columns;

FIG. 6a is a detail view of the lifting lug as positioned in the FIG. 6 construction, and

FIG. 6b is a detailed top plan view of a lifting lug as positioned in said second embodiment;

FIG. 7a is a cross-sectional view, of an enhanced end wall panel installed on an end wall in one embodiment of the present invention viewed from within the building unit looking toward the enhanced end wall panel;

FIG. 7b is a cross-sectional view of an enhanced wall panel of one embodiment of the present invention;

FIG. 7c is a detail cross-sectional view of the lower end portion C of the enhanced wall panel illustrated FIG. 7b;

FIG. 7d is a detail cross-sectional view of the mid-portion D of the enhanced wall panel illustrated FIG. 7b;

FIG. 7e is a detail cross-sectional view of the upper end portion B of the enhanced wall panel illustrated FIG. 7b;

FIG. 8a is an illustration of the attachment of two buildings in one embodiment of the present invention;

FIG. 8b is a detailed view of the lower connection element for the attachment of two buildings in one embodiment of the present invention;

FIG. 8c is a is a detailed view of the upper connection element for the attachment of two buildings in one embodiment of the present invention;

FIG. 8d is a perspective view of the connection element illustrated in FIGS. 8b and 8c.

DETAILED DESCRIPTION

FIG. 1 shows the first embodiment 10 of a modular building, with the roof panel removed. The building has a base frame 12, a roof frame 14 connected to the base frame by columns which are not shown in this view, being concealed by inner corner plates 16. The building has a floor panel 18, front and back sidewall panels 20 and 22, and end wall panels 24. In one embodiment of the present invention, the front wall panel 20 has an opening for a door D and a window W, and one end wall panel has, for example, another window opening W. Lifting lugs 26 are shown at the corners of the roof frame 14.

FIG. 2 shows a disassembled view of the same parts, with the addition of roof panel 28 which rests on roof frame 14. This view also shows columns 30 at the ends of the side wall panels 20 and 22.

FIG. 3 shows a partially disassembled view of the base frame 12, the roof frame 14, and the four columns 30 which connect corners of the base frame 12 to the corners of the roof frame 14. FIG. 4 shows an isometric view of these frames as assembled, and also shows the lifting lugs 26.

As shown in FIGS. 3 and 4, the base frame comprises two longitudinal I beams 12a and two lateral I beams 12b connected together at their ends to form a frame having a first rectangular periphery. The corners are formed by having the upper and lower flanges of the lateral beams 12b cut back and welded at their ends to the sides of end portions of the longitudinal beams 12a while the webs of the beams 12b are welded at their ends to the web of the beam 12a. The outermost parts of the ends of the longitudinal beams 12a are closed by small end plates 32, also shown in FIG. 3A, 4, 5 and 5a.

As shown in FIG. 4, The roof frame 14 is formed in generally similar manner, with longitudinal beams 14a having end portions welded to ends of the flanges and webs of lateral beams 14b, and having an outermost portion of the ends of the longitudinal beams 14a closed by small end plates 34, also shown in FIG. 4b, 5 and 5b. The beams 14a and 14b define a rectangular periphery which is slightly smaller in both width and length than the first periphery of the base frame.

As shown in FIGS. 3 and 4, the columns 30 are connected at upper ends to the corners of the roof frame 14, and have outer surfaces defining the same periphery as the roof frame. The connection is made as shown in FIG. 5 by having the upper end of column 30 closed by a rectangular plate 30a welded perpendicularly across its end, the plate 30a having four apertures which can be bolted to apertures in the underside of an end portion of a beam 14a.

As stated, the periphery of the roof frame 14 and of the columns is less than that of the base frame; in effect the roof frame and columns are set back about ½ the width of the base beams 12a and 12b. This means that the columns 30 cannot be bolted to the base frame in quite the same manner as they are to the roof frame. Details of a corner of the base frame are shown in FIGS. 3a and 3b, and the actual attachment between a column and a corner of the base frame is shown in FIG. 4a.

As seen in FIGS. 3a, 3b and 5, the inside of a corner formed by the longitudinal and lateral base beams 12a and 12b is provided with a reinforcing corner element 36 preferably in the form of a square tube having two sides welded to surfaces or edges of the beams 12a and 12b. As shown in FIGS. 3a and 3b, the upper end of this tube 36 is preferably closed by transverse plate 38 having an aperture 38a, and the underside of this plate 38 has preferably welded to it a nut 38b for receiving a bolt 38h passing through the aperture 38a. As will be seen in FIG. 3b, this aperture 38a is one of four apertures provided at the corner of the base frame, the other three apertures 40 being provided in inner flanges of the beams 12a and 12b. These three apertures 40 and the additional aperture 38a are rectangularly positioned, specifically being located as at the corners of a square.

FIG. 3c shows the formation at the lower end of a column 30, and shows the lower end plate 30b, similar to plate 30a, which closes the lower end of the column 30, and which has four apertures for bolts which can pass through the apertures 38a and 40 to connect the column to the corner of the base frame. Two of these bolts 42 are shown in FIG. 4a. As also seen in FIG. 3a, the upper surface of plate 38 is level with the upper surfaces of the beams 12a and 12b.

FIG. 4b shows details of a lifting lug 26, one of four provided at the corners of the roof frame. This consists of a short square tube 46 having its lower end welded to the top of roof beams 14a, and having a plate 48 with its sides welded to opposite inside corners of the tube 46 so as to extend diagonally across the tube. The plate 48 is provided with an aperture 48a which is suitable for engagement by a hook, so that the parts provide a lifting lug whereby during assembly or disassembly of the building, the roof may be lifted as needed, and once fully assembled, the building can be lifted by a crane attached to the four lugs.

FIG. 5a shows some additional members which help to locate the floor and wall panels and which are fixed in parallel relationship to the beams of the base and roof frames. These include angle members 50 having a lower flange 50a welded to the inner side portions of the base beams 12a and 12b, and, as illustrated in FIG. 5b, channel members 52 welded to outer or lower edge portions of the roof frame beams 14a and 14b. The members 50 and 52 terminate at the columns 30. The angle member 50 is positioned so that its outer flange 50b has the same periphery as the roof frame and the columns 30. The channel member 52 has a periphery matching that of the roof frame and the columns.

As also shown in FIG. 5a, inner surfaces of flanges 50b of angle members 50 locate the outer edges of the floor panel 18, and their outer surfaces locate the lower edges of wall panels provide means for securing these panels to the base frame. Floor panel 18 has notches cut in its corners to accommodate the columns 30, as shown in FIG. 2. As illustrated in FIG. 5b, the outer surfaces of the channel members 52 locate the upper margins of the wall panels and provide means for securing these panels to the roof frame.

As will be seen in FIG. 5 and FIG. 5a, lower edges of the wall panels preferably rest on outer portions of the base beams 12a and 12b. The amount by which the columns, and roof frame, are set back from the periphery of the base frame is typically 3 inches. In the preferred embodiment the wall panels 20, 22 and 24 are each two inches thick, while the floor and roof panels 18 and 28 are three inches thick. Preferably both types of panels are formed of closed cell insulating foam, encased on inner and outer sides by sheet steel. Suitable panel material is sold under the trademark “Accuwall” by Vicwest of Oakville, Ontario, Canada. When the wall panels have been put in place, and attached to the members 50 and 52, the junctions between the panels can be concealed by corner plates 16 as shown in FIG. 1.

In one embodiment of the present invention, enhanced wall panels may be utilized as illustrated in FIGS. 7a, 7b, 7c, 7d and 7e. As illustrated in FIGS. 7a, 7b, 7c, 7d and 7e, preferably having one or more sheets 111 of closed cell insulating foam 112, encased on the inner side and outer side by sheet steel 114 as previously described, and additionally having a preferably aluminum or steel sheet 122 securely attached to and covering a substantial portion of the inward surface thereof (the aluminum sheet being preferably screwed or otherwise securely fastened to the sheet steel in a manner known to a person skilled in the art). In one embodiment, an inverted “U” shaped length 134 of extruded aluminum is screwed or otherwise securely fastened along the top of the enhanced wall panel as illustrated in FIG. 7e, and a “J” shaped length 120 of extruded aluminum is screwed or otherwise securely fastened along the bottom of the enhanced wall panel as illustrated in FIG. 7c, the upper inverted “U” shaped length 134 of extruded aluminum having recesses 132 or grooves therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art. Additionally, upper inverted “U” shaped length 134 of extruded aluminum preferably having a recess 130 or groove therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art so that when the enhanced wall panel is installed, the lengths of rubber or other weatherproofing materials will provide a water and weather-tight seal between the inverted “U” shaped length 134 of extruded aluminum and the underside of the roof panel 28 as illustrated in FIGS. 5 and 5b. Similarly, the lower “J” shaped length 120 of extruded aluminum preferably has recesses 116 or grooves therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art. Additionally, lower “J” shaped length 120 of extruded aluminum preferably has a recess 118 or groove therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art so that when the enhanced wall panel is installed, the lengths of rubber or other weatherproofing materials will provide a water and weather-tight seal between the “J” shaped length 120 of extruded aluminum and angle surface 50b. The enhanced wall panel may be installed by passing screws through the channel member 52 into the enhanced wall panel as illustrated in FIG. 5B, and through the angle members 50 and the lower “J” shaped length 120 of extruded aluminum as illustrated in FIG. 5A or in such other manner known to a person skilled in the art. In a further embodiment of the present invention, as illustrated in FIGS. 7a, 7b and 7d, a length of aluminum 108, preferably in square tubular form, is welded or otherwise securely fastened to the inward-facing surface of the aluminum sheet, to thereby increase the structural integrity of the enhanced wall panel, the aluminum tube being securely fastened at both ends, to the vertical columns 30 in a manner known to a person skilled in the art.

The interiors of the wall panels can be provided with bus bars 60, fuse boxes 62, etc. as shown in FIG. 1, for bringing electrical supplies into the building.

FIG. 6 shows the framework of a similar modular building which differs from that so far described in being longer, having a length of 40 feet as compared to a typical length of 20 feet for the first embodiment. The base frame 112 has outer longitudinal I beams 112a and lateral outer I beams 112b connected at their ends in similar manner to the base beams of the first embodiment. Here, however, two intermediate lateral beams 113 are provided, having ends welded to the longitudinal beams 112. Also, there are provided two intermediate longitudinal beams 116 which having separate segments 116a, 116b, and 116c, these segments being welded respectively between a first end lateral beam 112b and a first intermediate lateral beam 113, between the first intermediate beam 113 and the second intermediate beam 113, and between the latter beam and the second end lateral beam 112b. The lateral beams 113 have the same cross-sectional dimensions as the beams 112a and 112b, while the intermediate longitudinal beams 116 are of lesser height than the other beams but have their upper surfaces co-planar therewith so as to give level support for a floor panel.

In this embodiment, the roof frame 114 has longitudinal beams 114a and 114b, and also has two intermediate lateral beams 118 which overlie the beams 113. The roof panel also has an additional, central longitudinal intermediate beam 120, having three segments 120a, 120b and 120c extending respectively between a first end beam 114b and a first lateral beam 118, between this beam 118 and the second beam 118, and between the second beam 118 and the second end beam 114b. Again, the lateral beams 118 have the same cross-sectional dimensions as the outer beams 114a and 114b, while the intermediate longitudinal beam 120 has a less depth but has a top co-planar with the other beams to give support for the roof panel.

As with columns 130, the columns 131 are set back from the outer periphery of the base frame and have the same periphery as the corner columns. At each junction of base beam 112a and each intermediate base beam 113 each of these two connected beams provides two apertures for attachment to four bolts securing the base plate of an intermediate column 131 to the junction. The base plates of the columns are similar to that shown in FIG. 3c, having a square arrangement of apertures matching the apertures in beams 112a and 113. At upper ends of these intermediate columns 131 the roof beams 114a provide apertures for connection to top plates of the columns, adjacent the attachment points of intermediate beams 118.

FIGS. 6a and 6b show details of the lifting lugs 126 for this embodiment. The lugs are the same as those of the first embodiment, but are attached to portions of the roof beams 114a which overlie the intermediate columns.

As previously described, two or more building units may be connected together to form larger building units, such as, for example, as illustrated in FIG. 8a, where a first building unit 150 is connected to a second building unit 152, by way of connection elements 160 and 162 as more fully hereinafter described. In the preferred embodiment, as illustrated in FIGS. 8b and 8c, a lower connection element 160 and an identical upper connection element 166 having bolt holes 162 there through as illustrated in FIG. 8d, may be securely fastened by way of bolts (not shown) to adjacent columns 130 of the adjacent building unit, which columns 130 have corresponding bolt holes 164 there through in alignment with the connection element bolt holes 162, so that when the building units are positioned adjacent one another, lower connection elements 160 and identical upper connection elements 166 may be bolted to adjacent columns 130 of the adjacent building units to thereby temporarily and securely connect the adjacent building units to former a larger building unit, it being understood that alternative methods may be utilized, as would be known to a person skilled in the art, to temporarily and securely connect the adjacent building units to former larger building unit.

The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.

Claims

1. A modular building capable of being readily assembled and disassembled comprising:

a. a rectangular base frame formed by two longitudinal base beams and two lateral base beams connected at their ends, so that said base beams define a first rectangular periphery;

b. a rectangular roof frame formed of two longitudinal roof beams and two lateral roof beams connected at their ends so that said roof beams define a second rectangular periphery which is less in width and length than said first rectangular periphery;

c. four columns adapted to extend between corners of the base and roof frames and attachable thereto, said four columns, when positioned, having outer surfaces defining a rectangular outer periphery which substantially matches said second rectangular periphery of the roof frame, said columns being set back within the corners of said the first rectangular periphery of the base frame;

d. a floor panel having an outer periphery substantially matching said second periphery, said floor panel being dimensioned to rest on inner edge portions of the base beams;

e. a roof panel for resting on the roof frame and having an outer periphery at least as large in length and width as said first rectangular periphery; and

f. side and end wall panels dimensioned to fit between said base beams and said roof panel with said wall panels resting on outer edge portions of said base beams, said wall panels enclosing outer peripheries both of said four columns and of the roof frame.

2. A modular building according to claim 1, wherein said base beams and roof beams are I beams.

3. A modular building according to claim 1, wherein said columns are I beams having upper and lower end plates at their respective upper and lower ends, said end plates having apertures for bolting to apertures in the roof and base beams.

4. A modular building according to claim 3, wherein said lower end plates of the columns each have four rectangularly positioned bolt apertures, an outer three of said lower end plate apertures being suitable for bolting to apertures in the base beams at a respective corner, and wherein said base beams have a reinforcing corner element attached to the inside of each corner, which reinforcing element has an additional aperture positioned to be bolted to a fourth, inside, aperture of the lower end plate.

5. A modular building according to claim 4, wherein said reinforcing corner element for each corner of the base component is in the form of a tube having sides welded to inner sides of said base beams and having an upper end plate providing said additional aperture.

6. A modular building according to claim 5, wherein said tubes extend down below lower surfaces of said base beams to provide legs for supporting the building.

7. A modular building according to claim 1, wherein said roof frame has apertured lifting lugs fixed to its top surface, each lifting lug being positioned above one of said columns, wherein said roof panel is apertured to accommodate said lifting lugs.

8. A modular building according to claim 2, wherein said roof beams each have, attached thereto, an additional elongated roof member which provides flanges at said second rectangular periphery, which flanges provide locating means for the side and end wall panels.

9. A modular building according to claim 8, wherein said additional elongated roof members are channel members fixed to lower surfaces of said roof beams.

10. A modular building according to claim 2, wherein said base beams each have, attached thereto, an additional elongated base member having a flange suitable for locating the outer periphery of said floor panel.

11. A modular building according to claim 1, wherein said base frame and said roof frame each have one or more additional, intermediate lateral members which meet said longitudinal members at intermediate, reinforced areas, and wherein said intermediate areas of the base and roof frames are connectable by additional columns which have bolt connections to said base and roof beams.

12. A modular building according to claim 1, wherein said base frame has one or more additional longitudinal beams fixed at their ends to said lateral base beams.

13. A modular building according to claim 1, wherein said roof frame has one or more additional longitudinal beams fixed at their ends to said lateral roof beams.