SYSTEM AND METHOD FOR POSITIONING MODULAR BUILDING UNITS

Abstract

Methods and systems for moving and installing modular building units or pods are provided. A positioning device and method of using the same comprises a base member pivotally connected to a frame member by a plurality of linkages. The mechanism and method provides for a vertical lifting motion and a horizontal translational movement of a unit or pod that is connected to the mechanism. In one embodiment, the frame member includes a plurality of hooks configured to selectively engage the unit or pod. Placement and installation of cumbersome building units is simplified compared to prior art methods and devices of moving a unit or pod.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 62/423,051 filed Nov. 16, 2016, which is incorporated herein in its entirety by reference.

FIELD

The present disclosure generally relates to modular building units such as prefabricated rooms adapted for quick on-site installation and construction. More specifically, the present disclosure relates to systems and methods for manipulating, positioning, and installing prefabricated building units or “pods”.

BACKGROUND

Onsite labor is a major cost associated with constructing buildings, particularly when such labor is conducted at higher elevations such as in high-rise construction. Labor rates are known to increase with height for a number of reasons including the necessity of moving project materials by crane or elevator. At higher elevations, movement of materials and pace of labor slows down, increasing construction schedule times and adding to the overall construction cost.

Modern methods of constructing buildings including high-rise structures include the provision and use of modular elements or “pods”, wherein a room or portion of a final structure is prefabricated as a unit, delivered to a site as a substantially finished unit, and installed into the larger structure. For example, one or more bathrooms intended to be provided as individual rooms in a finished building structure may be assembled off-site, shipped to the construction site, and installed as units.

U.S. Patent Application Publication No. 2008/0236056 to Hourihan, which is hereby incorporated by reference in its entirety, discloses a modular building structure. Although some features of modular units of Hourihan are contemplated for use with embodiments of the present disclosure, Hourihan fails to disclose various features of the present invention including, but not limited to, methods and devices for moving and installing modular rooms and pods.

U.S. Patent Application Publication No. 2007/0294954 by Barrett et al. generally describes a prefabricated bathroom assembly as well as methods of manufacturing and installing prefabricated bathroom assemblies. The bathroom assembly of Barrett et al. can be used with the methods and devices of the present disclosure. However, Barrett et al., which is incorporated herein in its entirety by reference, does not disclose various features of the present disclosure, including at least the methods and devices for manipulating, positioning, and installing prefabricated building units described herein.

U.S. Patent Application Publication No. 2011/0056147 to Beaudet, which is hereby incorporated by reference in its entirety, discloses a construction pod or module and methods of installing the same. The installation methods and devices of Beaudet, however, generally comprise conventional cranes and similar equipment. Beaudet fails to disclose various features of the present invention including, for example, methods and devices for fine-tuning the placement and final positioning of a module or pod.

U.S. Patent Application Publication No. 2013/0086849 to Clouser et al., which is hereby incorporated by reference in its entirety, discloses a modular bathroom pod. Clouser et al., however, fail to disclose devices and methods for positioning and installing such a pod, at least as provided by embodiments of the present disclosure.

U.S. Patent Application Publication No. 2013/0152485 to Austin et al., which is hereby incorporated by reference in its entirety, discloses modular building units that are adapted for installation on-site. Various features and methods of constructing building units and pods as disclosed in Austin et al. are contemplated for use in embodiments of the present disclosure. Austin et al., however, fails to disclose various features, methods and devices of the present disclosure including methods and devices for fine-tuning the positioning and final installation location of a pod.

Existing modular building units are typically constructed with a relatively thick structural floor, commonly made of steel or concrete. Known flooring systems for existing pods typically comprise six-inch elevated floors. Alternatively, existing units or pods may be delivered to a location or installation site without a floor. The pod is then finished in the field.

When a modular building unit or pod is delivered to a construction site for installation in a building structure, the pod must typically be moved into alignment with walls of the building. The pod may also be aligned with utility connections. However, existing methods and devices for positioning pods with respect to walls and utility connections present a number of challenges and serve to increase labor costs and risks to workers on-site.

Accordingly, there is a need for improved systems and methods for manipulating, positioning, and installing prefabricated building units or pods within a building structure.

SUMMARY

In one aspect of the present disclosure, a system and device for positioning a modular building unit is provided. In certain embodiments, modular building units and pods are provided with a honeycomb composite floor member. Optionally, the floor member is between about 0.4 and about 0.6 inches thick. The provision of floor units in accordance with the embodiments of the present invention provides a solution to existing problems related to door thresholds. Accepted building methods in the United States do not allow four or six-inch pod depressions or excessive slab toppings. Accordingly, embodiments of the present disclosure provide a thin floor member to accommodate building methods of the United States and wherein the floor of a pod unit can be provided substantially flush with an associated building upon installation.

Embodiments of the present disclosure contemplate providing a thin floor member, which reduces overall weight of a pod or unit and provides various enhancements in construction efficiency. However, the thinner floor also comprises less structural integrity than a thicker, conventional floor. Thinner floors may be subject to bending stresses and damage, particularly during shipping and installation of a pod. In order to accommodate for the reduced structural integrity of a thinner floor, methods and devices of the present invention contemplate providing one or more pods on a pallet or similar support. Embodiments of the present disclosure further contemplate the provision of lifting and supporting devices to enable removal of a pallet or similar device, particularly in confined spaces and/or corner-installations.

Embodiments of the present disclosure contemplate providing or positioning a modular building unit in a corner such that at least two walls or panels of the unit are provided substantially adjacent to walls of larger buildling structure. Two other walls of the unit are configured to face away from the walls of the building structure. Such positioning necessarily requires that the unit be held, supported, or otherwise manipulated on the two free walls or panels that are not intended to be placed in a corner. This positioning provides various challenges, as will be recognized by one of ordinary skill in the art, and serves to increase labor costs and risks to workers. Methods and devices as shown and described herein provide for a more efficient means of positioning a modular building unit, including removing the unit from a pallet or similar shipping device, and efficiently positioning the unit without complex attachment of heavy equipment, counterweights, etc.

In one aspect of the present disclosure, a lifting and moving assembly for modular building units is provided. The assembly comprises a base member comprising a plurality of rollers. The base member is moveable with respect to the modular building unit. The lifting and moving assembly can optionally include a track member for placement on a ground or surface. The rollers of the base member can be aligned with the track member.

The base member is pivotally interconnected to a frame member. In one embodiment, a plurality of linkages are rotatably connected to the base member and to the frame member.

The frame member includes a support member. In one embodiment, the support member extends substantially horizontally. A plurality of load-bearing hooks are provided on the support member. The support member and the load-bearing hooks are operable to receive and support the weight of a modular building unit. The support member is in force-transmitting communication with the plurality of linkages, and a displacement of the linkages about the connection between the linkages and the base member causes a corresponding arcing displacement of the support member.

Another aspect of the present disclosure includes methods of moving, lifting, and installing modular building units. In one embodiment, a method is provided comprising: (1) providing a lifting and moving assembly which includes at least a support member and a plurality of linkages; (2) providing a modular building unit on the lifting and moving assembly such that the modular building unit is in communication with the support member; (3) inducing a movement of the plurality of linkages and the support member to move the modular building unit, the movement providing the modular building unit in a desired location; and (4) removing the lifting and moving assembly from the modular building unit. In one embodiment, inducing a movement of the plurality of linkages can include moving the modular building unit vertically. Additionally, the lifting and moving assembly can move the modular building unit in a direction substantially parallel to at least one wall of the modular building unit.

One aspect of the present disclosure is an assembly for lifting and moving objects. The assembly includes one or more of, but is not limited to: (1) a track member for placement on a surface that is generally horizontal; (2) a base member that is movable along a length of the track member; (3) a plurality of linkages, each linkage being rotatably connected to the base member; (4) a support member in force-transmitting communication with the plurality of linkages, the support member extending substantially parallel to the track member; and (5) a plurality of load-bearing hooks provided on the support member, the support member and the load-bearing hooks operable to receive and support the weight of an object, wherein a displacement of the linkages about connections between the linkages and the base member causes a corresponding displacement of the support member in a direction generally parallel to the track member. The displacement of the linkages also causes an arcing displacement of the support member which alters a distance between the surface and the support member. In this manner, in one embodiment, the displacement of the linkages about the connections causes a vertical and a horizontal displacement of the support member. In one embodiment, the object is modular building unit. Optionally, the modular building unit is a prefabricated room for a building.

In one embodiment, the base member includes a plurality of rollers. Optionally, the rollers have a notch configured to engage a protrusion of the track.

In one embodiment, the assembly further includes a frame member rotatably connected to each linkage. In another embodiment, the assembly includes a drive member interconnected to the base member and the frame member, the drive member configured to displace the linkages about the connections. Optionally, each linkage can rotate between approximately 0° and approximately 100° relative to the base member. Altering an angle of the linkages alters a position of the frame member relative to a length of the base member.

The support member is associated with the frame member. In one embodiment, the support member is configured to rotate such that a free end of each of the load-bearing hooks is rotatable into a position to engage the object. In another embodiment, at least a portion of each of the load-bearing hooks extends beyond a plane defined by the frame member when the hooks are in the position to engage the object. Optionally, the load-bearing hooks can be repositioned along a length of the support member.

Another aspect is a positioning device to lift and move a building pod. The device comprises one or more of: (1) a base member configured to move on a surface; (2) two or more linkages, each linkage including a first end and a second end, the first end being pivotably interconnected to the base member; (3) a frame member pivotably interconnected to the second end of each linkage; (4) a support member rotatably interconnected to the frame member; and (5) a plurality of hooks positioned on the support member and configured to selectively engage the building pod, wherein altering an angle of the two or more linkages relative to the base member alters a distance between the hooks and the surface. Altering the angle of the two or more linkages also alters a position of the hooks relative to a length of the base member. More specifically, in one embodiment, altering the angle of the two or more linkages alters a position of the frame member relative to the length of the base member. In one embodiment, the building pod is a prefabricated room for a building. In another embodiment, the building pod is a prefabricated bathroom.

Optionally, the device includes a drive member. The drive member is configured to alter the angle of the two or more linkages relative to the base member. In one embodiment, the drive member is threadably interconnected to one of the base member and the frame member.

In one embodiment, rotating the support member in a first direction moves each of the plurality of hooks to a support position to engage the building pod. In another embodiment, at least a portion of each of the plurality of hooks extends beyond a plane defined by the frame member when the hooks are in the support position. Optionally, each of the plurality of hooks can be selectively repositioned along a length of the support member.

The base member may optionally include at least two wheels. In one embodiment, the at least two wheels are configured to engage an optional track positioned on the surface. In another embodiment, the at least two wheels include a circumferential recess to engage a protrusion of the optional track. The circumferential recess has a “V” shape in one embodiment. Optionally, the track has a corresponding “V” shape with an apex positioned distal to the surface.

Yet another aspect of the present disclosure is a method of lifting and moving an object, such as a modular building unit. The method includes, but is not limited to: (1) aligning a first positioning device with a first side of the object; (2) aligning a second positioning device with a second side of the object; (3) moving hooks of the first and second positioning devices to engage the object; (4) inducing a movement of a plurality of linkages of the first and second positioning devices to move the object into a desired location; and (5) moving the hooks of the first and second positioning devices to disengage the object. In one embodiment, the object is a modular building unit. Accordingly, in one embodiment, the first side of the object is a first wall and the second side of the object is a second wall.

In one embodiment, the movement of the plurality of linkages alters an angle of the linkages with respect to lengths of the first and second positioning devices. In this manner, the movement of the plurality of linkages causes a movement of the object along a horizontal axis and a movement along a vertical axis.

In one embodiment, aligning the first and second positioning devices further comprises positioning the first positioning devices substantially parallel to the second positioning device. In another embodiment, the first and second positioning devices can be interconnected.

In another embodiment, inducing a movement of the plurality of linkages causes both a vertical movement and a horizontal movement of the object, the horizontal movement being substantially parallel to lengths of the first and second positioning devices.

Optionally, the method may further include inducing a longitudinal movement of the first and second positioning devices along a horizontal surface. In one embodiment, the longitudinal movement is along optional first and second tracks positioned on the horizontal surface. In another embodiment, the method includes aligning the first track with the first wall and aligning the second track with the second wall. The method may also include engaging wheels of the first positioning device with the first track and engaging wheels of the second positioning device with the second track.

In one embodiment, moving the hooks of the positioning devices includes rotating first and second support members of the first and second positioning devices. In one embodiment, moving the hooks to engage the object comprises rotating a least a portion of each of the hooks to extend beyond plane defined by the respective first and second positioning devices.

In another embodiment, inducing a movement of the plurality of linkages comprises changing an angle of the linkages with respect to a horizontal surface. In one embodiment, the linkages can rotate between approximately and approximately 100° relative to the horizontal surface. In another embodiment, inducing the movement of the plurality of linkages includes activating first and second drive members associated with the respective first and second positioning devices. In one embodiment, activating the first and second drive members comprises rotating the drive members.

It will be expressly recognized that certain devices and features shown and described herein are not limited to the embodiment or embodiments with which they are described or shown in combination with. Various combinations of features shown herein are contemplated, even if such combinations are not shown in the drawings or specifically described in the Specification. One of skill in the art will recognize that various features of the present disclosure, which generally relate to lifting and moving assemblies, may be combined. Furthermore, one of ordinary skill in the art would understand how such combinations could be achieved. For example, it is contemplated that a lifting device of the present disclosure may comprise a combination of various features shown in the Figures of the present disclosure, even if such a combination is not specifically shown in a single Figure. It will therefore be recognized that the various features and improvements shown herein are not mutually exclusive features.

The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more clear from the Detailed Description, particularly when taken together with the drawings.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about” or “approximately.” The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the Summary, Brief Description of the Drawings, Detailed Description, Abstract, and Claims themselves.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosed system and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosed system(s) and device(s).

FIG. 1 is a top perspective view of a modular building unit in a surrounding environment, such as a building under construction, according to one embodiment of the present disclosure.

FIG. 2 is a top perspective view of a modular building unit in a surrounding environment according another embodiment of the present disclosure.

FIG. 3 is a perspective view of a modular building unit and a related adjustment and lifting member according to one embodiment of the present disclosure.

FIG. 4 is a perspective view of a modular building unit prepared for installation according to one embodiment of the present disclosure.

FIG. 5 is a perspective view of a modular building unit and an associated positioning device according to one embodiment of the present disclosure.

FIG. 6 is another a perspective view of the modular building unit and the positioning device according to the embodiment of FIG. 5 and illustrating the modular building unit positioned proximate to a corner by the positioning device.

FIG. 7A is a front elevation view of a positioning device according to one embodiment of the present disclosure, the positioning device illustrated in an elevated state.

FIG. 7B is a right side elevation view of the positioning device according to the embodiment of FIG. 7A.

FIG. 7C is another front elevation view of the positioning device of FIG. 7A and showing the positioning device in a lowered state.

FIG. 7D is a front elevation view of a hook member of the present disclosure.

FIG. 7E is a right side elevation view of the hook member of FIG. 7D.

FIG. 7F is another right side elevation view of the positioning device of FIG. 7A and illustrating a hook member in an engaged position relative to the positioning device.

FIG. 7G is a cross-sectional elevation view of the positioning device taken along line 7G-7G of FIG. 7A.

The drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the embodiments illustrated herein.

The following is a listing of components according to various embodiments of the present disclosure, and as shown in the drawings:

• • 2 Modular building unit or pod
  • 4 Building structure
  • 5 Final location
  • 7 Corner
  • 8 First wall of building structure
  • 10 Second wall of building structure
  • 11 Corner of building structure
  • 12 Utility connections
  • 14 Pallet
  • 16 Lifting member
  • 18 Free wall of pod
  • 20 Free wall of pod
  • 22 First wall of pod
  • 24 Second wall of pod
  • 26 Free corner of pod
  • 30 Anchor member
  • 31 Adjustable anchor point
  • 32 Ballast
  • 33 Skid
  • 34 Arm
  • 35 Wheels
  • 36 Tensioning device
  • 38 Tension member
  • 50 Positioning device
  • 52 Frame member
  • 54 Vertical member
  • 56 Transverse member
  • 58 Support member or torsion bar
  • 60 Handle associated with support member
  • 62 Hook member
  • 64 Lock
  • 66 Eyelet
  • 68 Hook opening
  • 70 Bottom portion of hook
  • 72 Linkage
  • 74 Base member
  • 76 Moving member
  • 76 Wheel
  • 80 Protrusion
  • 82 Drive member
  • 84 Shaft
  • 86 First pivot
  • 88 Second pivot
  • 90 Optional track
  • 92 Track stop

DETAILED DESCRIPTION

FIG. 1 is a top perspective view of a modular building unit 2 or “pod” in accordance with one embodiment of the present disclosure. The pod 2 is provided in an initial location within a building structure 4. The building structure 4 may comprise a partially-constructed building unit. The building structure may have multiple levels or floors, such as a high-rise construction. The pod 2 can be provided in the initial location by, for example, a crane or similar lifting and moving device.

The pod 2 is any pre-fabricated structure intended to be installed in the building structure 4. In one embodiment, the pod 2 comprises a bathroom pod shipped to a site of the building structure 4. However, the pod 2 can be any structure that needs to be positioned and aligned within the building structure. An interior of the pod 2 may be partially or completely constructed. Regardless of the type of pod, the purpose of the pod, and the amount of materials or work required to finish construction of the pod, the pod 2 is ready for installation in the building structure.

The pod 2 is configured to be installed into a final location 6. More specifically, the pod 2 may be configured to align with features of the building structure, such as one or more walls and utility connections. Optionally, the final location 6 is proximate to a corner 7 of the building structure 4. Although positioning devices of the present disclosure can be used to position pods 2 in various final locations, FIG. 1 illustrates a situation in which the pod 2 is intended to be provided in a corner 7 of the existing room or structure 4. First and second walls 22, 24 of the pod 2 are intended to be provided in a predetermined alignment with a first wall 8 and a second wall 10 of the existing structure 4. In one embodiment, the walls 22, 24 of the pod 2 are configured to be flush with (or adjacent to) the first and second walls 8, 10.

One of skill in the art will recognize the various issues and challenges associated with placing the pod 2 in a corner location 7 which includes adjacent walls 8, 10. Methods and devices of the present disclosure are provided to simplify the installation procedures associated with moving a pod 2 to a final location 6. Further, the methods and devices of the present disclosure can be used to align the pod 2 with respect to existing utilities 12 (e.g. plumbing and electrical) of the building structure 4. More specifically, connections for the utilities 12 may be provided in one or more of the floor associated with the final location 6, walls 8, 10, and a ceiling of the building structure 4. The pod 2 can include connections that must tie into the existing utilities 12 of the building structure 4. Accordingly, the pod 2 must be moved from the initial location to the final location 6 and aligned with respect to the corner 7 and subsequently tied into connections for the utilities 12.

Referring now to FIG. 2, a top perspective view of an installation procedure and associated equipment related to a pod 2 and in accordance with one aspect of the present disclosure is provided. The pod 2 is illustrated in an initial position which comprises a non-final or uninstalled position. A final position 6 for the pod is shown. The final position 6 corresponds to a corner location 7 formed by at least two walls 8, 10 of the existing building structure 4.

A pallet 14 is shown as being separated from the pod 2 such that the pod is ready for installation in the final location 6. The pallet 14 is generally provided underneath the pod 2 during shipping and transit such that the pod 2 may be manipulated and moved using various known methods and devices (forklifts, straps, cranes, etc.). The pallet 14 comprises a contact point with the ground such that the pod 2 is elevated from the ground at least until it is ready for installation.

As one of skill in the art will appreciate, pallets 14 are frequently bulky and heavy. Further, as generally illustrated in FIG. 2, a pallet 14 may cover a significant amount of floor space within the building structure. Because of the size and weight of the pallet 14, it is difficult to separate the pallet 14 from a pod 2 and then remove the pallet from the building structure 4 with known lifting apparatus and methods.

In one embodiment of the present disclosure, lifting members 16 are provided in order to elevate the pod 2 above the pallet 14, remove the pallet 14, and generally render the pod 2 mobile. The lifting members 16 can be used to align the pod 2 with, and optionally, move the pod 2 into the final location 6. The lifting members 16 can be positioned on at least two free walls 18, 20 of the pod 2. The lifting members 16 may comprise various features for lifting the pod 2 and/or attaching wheels to the pod 2. U.S. patent application Ser. No. 15/236,184 to Nyce, filed on Aug. 12, 2016, and U.S. patent application Ser. No. 15/699,583 also by Nyce, filed Sep. 8, 2017, disclose various attachment and support devices for modular building structures, and are hereby incorporated by reference in their entirety. The lifting, moving, and supporting devices shown and described in U.S. patent application Ser. Nos. 15/236,184 and 15/699,583 are specifically contemplated for use with the systems and methods of the present disclosure.

FIG. 2 depicts a pod 2 that is prepared for installation. Once the pallet 14 has been removed from the pod 2, the pallet 14 may be removed completely from the work area and discarded or reused. The pod 2, which is now supported by at least one lifting member 16 on each of the two free walls 18, 20 of the pod 2, is ready for movement into the final position 6. The first and second walls 22, 24 of the pod 2 are ready for installation in alignment with walls 8, 10 of the building 4. The pod walls 22, 24 can be configured to be one or more of against, flush with, and adjacent to the building walls 8, 10.

Referring now to FIG. 3, a perspective view of a method and system for positioning and installing pods according to another embodiment of the present disclosure is provided. As shown, a pod 2 is provided in an uninstalled state thus requiring manipulation and movement prior to final placement and installation. An anchor member 30 of an embodiment of the present disclosure may be releasably interconnected to the pod 2 during the manipulation and movement of the pod. The anchor member 30 comprises a means for tilting and moving an associated pod 2. More specifically, the anchor member 30 can be used to facilitate lifting of the pod 2 one wall 20 such that a rear corner opposite to the free corner 26 does not drag on the ground during movement of the pod 2. Optionally, the anchor member 30 may be interconnected to one or more of walls 18, 20 of the pod 2.

The anchor member 30 generally comprises a skid 33 that is configured to receive ballast 32. Optionally, the skid 33 can include wheels (not illustrated). In one embodiment, the ballast 32 comprises commercially available metal plates. It will be recognized, however, that various devices or weights may be provided as ballast members for the anchor member 30.

The anchor member 30 comprises an anchor point 31. In one embodiment, the position of the anchor point 31 is adjustable vertically with respect to the skid 33. More specifically, in one embodiment, the anchor point 31 comprises a securing feature that is adjustable in at least a vertical direction.

The anchor point 31 comprises a connection point for at least one of a tension member 38 and an arm 34. Collectively, the arm 34 and the tension member 38 comprise a means to tip the pod 2, wherein a point of rotation of the pod 2 is centered about a connection between the adjustable arm(s) 34 and the pod 2. The anchor member 30 can be used to move a center of mass and a balance point of the pod 2 toward the anchor member.

The arm 34 extends between the anchor member 30 and the pod 2. In one embodiment, a pair of arms 34 are provided with the anchor member. Optionally, the arms 34 comprise an adjustability such that a length of the arms 34 may be selectively altered. In certain embodiments, the arms 34 comprise telescoping members that can be secured at a plurality of different lengths. Optionally, an arm 34 may engage a lifting member 16 associated with the pod 2. In one embodiment, the arms 34 include a hook to engage the pod 2 or a lifting member 16. Additionally, or alternatively, the arms 34 can engage a positioning device 50 described herein. The arms 34 are operable to receive one or more of compression and tension forces between the anchor member 30 and the pod 2.

The tension member 38 extends between the anchor member 30 and a portion of the pod 2. The tension member 38 is operable to receive a tension force. The tension member 38 can be connected to the pod 2 to provide leverage. The tension member 38 may be connected to any surface of the pod 2. Optionally, the tension member can be connected to a wall and proximate to the roof of the pod to maximize leverage. In one embodiment, the tension member 38 comprises one or more of a strap, a rope, a cable, and the like.

Optionally, an end of the tension member 38 associated with the pod branches into two tension portions. Each tension portion can be separately secured to the pod 2. Alternatively, two individual tension members 38 are interconnected to the anchor member 30 and the pod 2. The tension member 38 can optionally include a hook or clamp configured to interconnect the tension member to a pod.

The tension member 38 also comprises a tensioning device 36. The tensioning device 36 is operable to alter the length of the tension member 38 to adjust tension of the tension member 38. The tensioning device 36 can be used to level of a pod 2 to which the tensioning device is affixed by increasing or decreasing the length of the tension member 38.

The tensioning device 36 may be one or more of a hand-winch, a come-along cable puller, or a similar tension-applicator. The tension member 38 may be connected to the pod in a slack state, and tension may subsequently be applied to the tension member to tilt the pod 2. Once tilted, the pod may be moved and positioned.

Wheels 35 can be positioned on at least one side 18, 20 of the pod 2 to enable movement of the pod 2. The wheels 35 may be associated with a lifting member 16.

Referring now to FIG. 4, a perspective view of a pod 2 provided within a building structure 4 is generally provided. The pod 2 is prepared for positioning in a final location 6, substantially adjacent to at least two walls 8, 10. In certain embodiments, the final location 6 is a corner area 7.

The pod 2 is positioned on a pallet 14. A side wall 22 of the pod may be placed flush with or adjacent to a first wall 8 of the building structure 4. The pod is thus prepared for final positioning as shown and described herein. It is contemplated that the final location 6 may comprise an adhesive treatment or mat to facilitate securing of the pod in the final location 6. Accordingly, the systems and methods of the present disclosure can be used to position the pod 2 in the final location 6 without disturbing the adhesive. In one embodiment, the systems and methods described herein can be used to move the pod 2 into position above the final location without contacting an adhesive applied to the final location 6. The pod 2 may then be lowered onto the adhesive.

Referring now to FIG. 5, a perspective view of the pod 2 according to FIG. 4 is illustrated. The pallet 14 and pod 2 are provided with a positioning device 50 according to one embodiment of the present disclosure. As shown, a first positioning device 50a can be associated with a free wall 18 of the pod and a second positioning device second 50b can be associated with a first wall 22 of the pod. The positioning devices 50a, 50b are configured to lift and move the pod 2.

The first and second positioning devices 50a, 50b are aligned substantially parallel. In one embodiment, a distance between the positioning devices 50a, 50b is fixed. Optionally, the first positioning device 50a may be interconnected to the second positioning device 50b. For example, in one embodiment, at least one transverse member (not illustrated) can be attached to each of the first and second positioning devices 50a, 50b. The at least one transverse member may be substantially rigid. In this manner, the distance between the first and second positioning devices can be kept substantially constant during movement and positioning of a pod 2.

FIG. 6 is another perspective view of the pod 2 and positioning device 50 according to the embodiment of FIG. 5. The positioning device 50 has been manipulated to lift the pod 2 off of the pallet 14. The pod 2 has been moved such that the pallet 14 may be removed. More specifically, the positioning device 50 has been moved from a first position (illustrated in FIG. 5) to a second position (illustrated in FIG. 6) to enable installation of the pod 2 proximate to a corner 7 between walls 8, 10. As shown in FIGS. 5-6, the positioning device 50 enables a movement of the pod 2 in a translational manner and in a direction generally parallel to the first wall 8 of the building structure 4.

FIGS. 7A-7G provide various detailed views of the positioning device 50 shown in FIGS. 5-6. The positioning device 50 generally comprises a frame member 52 and a base member 74. The positioning device 50 is illustrated in a raised position in FIG. 7A. In contrast, FIG. 7C illustrates the positioning device 50 in a lowered position in which the frame member 52 is closer to the base member 74 compared to FIG. 7A.

The frame member 52 comprises an upstanding support member that serves to contain or engage an associated pod 2. The frame member 52 also operates as a structural support to provide enhanced structural stability to the positioning device 50, including a support member 58.

The frame member 52 may be provided in various configurations to resistance to bending and torsional stresses that may be applied to the lifting member 50. In one embodiment, the frame member 52 comprises a truss or truss-like member. Optionally, the frame member 52 comprises a plurality of vertical members 54 interconnected to transverse members 56. In one embodiment, the vertical members 54 have one or more different lengths. Alternatively, in another embodiment, the vertical members 54 may have a substantially uniform length.

The frame member 52 can be of any size. In one embodiment, the frame member has a length that is about equal to at least one wall 20-24 of a pod 2 to which the positioning device 50 will be engaged. In another embodiment, the frame member has a length that is greater than the at least one wall 20-24.

The support member 58 is interconnected to the frame member 52. In one embodiment, the support member 58 comprises a substantially horizontal bar or cylinder. Optionally, the support member 58 is interconnected to one or more of the vertical members 54. For example, the support member 58 may extend through apertures formed in the vertical members 54.

A plurality of hook members 62 are positioned along the support member 58. The hook members 62 are configured to be repositionable along a length of the support member 58. In one embodiment, the hook members 62 can slide with respect to a length of the support member.

The positioning device 50 comprises a handle 60 to manipulate the support member 58. The handle 60 is accessible to a user, and allows the support member 58 and any associated hook members 62 to be moved between at least two positions. A first position comprises a position of non-use. In one embodiment, in the first position, the hooks 62 are generally positioned in a plane defined by the positioning device 50, as generally illustrated in FIG. 7B. More specifically, in one embodiment, the hooks 62 do not project beyond the positioning device 50 in the first position. The first hook position may be needed or desirable for removing the positioning device 50 from a pod 2 or for positioning the positioning device 50 adjacent to a pod and prior to connection with the pod.

A second position of the handle 60 comprises a support position for the hooks 62. In the second position, the hooks 62 are moved away from the first position. The hooks 62 are configured to support or engage a pod 2 or similar device when in the second position. Optionally, the second position may move the hooks 62 transverse to the plane define by the positioning device 50, for example, as illustrated in FIG. 7F.

In one embodiment, the support member 58 is interconnected to the frame member 52 such that the hooks 62 are positioned proximate to a lower portion of the frame member. Optionally, when a hook 62 is positioned on the support member, at least a bottom portion 70 of the hook is positioned below a middle of the frame member 52 to provide stability.

The frame member 52, is moveably interconnected to the base member 74. The base member 74 comprises a moving member 76. The moving member 76 is operable to translate the base member 74 and the frame member 52 longitudinally. More specifically, the moving member 76 comprises bearings or wheels 78 such that the moving member 76 is slidable or rollable with respect to the ground even when the weight of a building pod 2 or similar structure is provided in communication with the frame member 52.

Optionally, a track 90 may be provided with the positioning device 50. The moving member 76 can engage the optional track 90. In this manner, the moving member 76 is repositionable along a length of the track 90 when present. The optional track 90 may be of any desired length. Optionally, a stop 92 may be positioned at one or more ends of the track 90.

A plurality of linkages 72 are provided to connect the moving member 76 with the frame member 52. The linkages 72 are configured to rotate or pivot with respect to the moving member 76 and the frame member 52. Accordingly, the linkages 72 provide for the ability of the frame member 52 and an associated pod 2 (or similar device) to move in an arcing manner at least with respect to the moving member 76 and the track 90. In one embodiment, a first end of each of the linkages 72 is pivotally interconnected to a portion of the frame member 52. A second end of each of the linkages is pivotally interconnect to a portion of the moving member 76. The positioning device may include any number of linkages. Optionally, the positioning devices includes from three to eight linkages 72.

The position and angle of the linkages 72 with respect to the base member 74 is controlled with a drive member 82. The drive member 82 may be operable by a user to affect a position of the linkages 72 and the frame member 52 relative to the base member 74. The drive member 82 is adjustably interconnected to each of the frame member 52 and the base member 74. In one embodiment, the drive member 82 is operable to be provided in tension. In another embodiment, the drive member 82 is operable to be in one or more of tension and compression.

The linkages 72 can be configured to pivot by a predetermined amount in relation to the base member 74. In one embodiment, a linkages 7 can rotate from approximately 0° to approximately 180° relative to the base member 74. Accordingly, the linkages can pivot to a position substantially perpendicular to the moving member 76. Additionally, in one embodiment, the linkages 72 can pivot to a position substantially parallel to the moving member. In one embodiment, the linkages 72 are arranged such that a first linkage does not cross a second linkage. More specifically, in one embodiment, the linkages 72 remain generally parallel as they pivot relative to the base member 74. Additionally, or alternatively, in one embodiment, the linkages 72 are configured to rotate in the same direction relative to the base member.

Optionally, the drive member 82 may use a hydraulic force to move the frame member 52 relative to the base member 74. In one embodiment, rotating the drive member alters an angle of the linkages relative to the base member 74. The drive member 82 may be flexible. In another embodiment, the drive member is substantially rigid.

Additionally, or alternatively, the drive member 82 can comprise a shaft 84. In one embodiment, the shaft is configured to extend through a bore of a first pivot 86 associated with the base member 74. The shaft may also extend through a bore of second pivot 88 which is associated with the frame member 52. The drive member 82 is pivotable about at least one of the first and second pivots 86, 88 to allow the frame member 52 to move in the arcing motion.

The first and second pivots 86, 88 can be interconnected to portions of the positioning device other than those illustrated in FIG. 7A. For example, in one embodiment, the first pivot 86 is fixed to a portion of the moving member 76. Additionally, or alternatively, the second pivot 88 can be fixed to a vertical member 54 or a transverse member 56. Optionally, one of the first and second pivots 86, 88 can be fixed to one of the linkages 72.

Optionally, the shaft 84 is threaded. In one embodiment, the bore of one of the first and second pivots 86, 88 is threaded. In another embodiment, the bore of the second pivot 88 includes threads engageable by the threaded shaft 84.

The drive member 82 can optionally be driven or powered by various devices including, but not limited to, a hand-operated crank, a motor, and other devices. It is further contemplated that a safety guard may be associated with the drive member 82. For example, in one embodiment, a motor is provided to operate the drive member 82. In one embodiment, operation of the motor requires activation of a safety switch, wherein a user must first disengage a safety switch prior to activating the motor. Accordingly, the safety switch provides an additional step and reduces the risk of accidental operation of the drive member 82.

Embodiments of the present disclosure provide for a positioning device 50 to position a pod 2 (for example) in close proximity to a wall 8, even when the pod is still positioned on the positioning device. In various embodiments, it is contemplated that a clearance of a predetermined width is provided between a pod 2 and an adjacent wall 8. In one embodiment, the clearance width is not more than approximately 2.0 inches. In another embodiment, the clearance width is approximately 1.0 inches.

The positioning device 50 has a width to fit into the clearance width. In one embodiment, the positioning device 50 is provided with compact pivots and narrow rollers 78 as shown and described herein. More specifically, as illustrated in FIGS. 7B and 7G, the positioning device 50 has a width that is less than the clearance width between a pod 2 and an adjacent wall 8. In one embodiment, the width of the positioning device 50 is less than approximately 6.0 inches. In another embodiment, the frame member 52 has a width of between approximately 1.0 inches and approximately 5.0 inches. Optionally, the track 90 has a width of less than approximately 1.5 inches. In one embodiment, the frame member 52 and associated linkages and rollers has a maximum width of approximately 1.438 inches. In another embodiment, the frame member 52, linkages, and the moving member 76 have a width no greater than approximately 1.0 inch.

FIGS. 7D-7E provide detailed front and side elevation views of a hook 62 contemplated for use on the frame member 52. An eyelet 66 or aperture is provided at an upper end of the hook for receiving the support member 58. Accordingly, the hook 62 can be securely provided on the support member but also moveable with respect thereto. Optionally, the hooks 62 comprise a lock 64 for selectively securing the positions of the various hooks relative to the support member 58. A portion of the lock 64 may selectively project at least partially into the eyelet 66. In one embodiment, the lock 64 is a set screw, a lock pin, or a similar member.

In one embodiment, the hook 62 comprises an overall height of between approximately 5.0 inches and approximately 5.5 inches. Optionally, the hook height may be approximately 5.125 inches. In another embodiment, the hook 62 comprises an overall width of approximately 1.50 inches

An opening 68 or gap of the hook is configured to engage a pod 2. In one embodiment, the hook opening 68 is configured to engage a support member of the pod 2. Optionally, the hook 62 can engage a support member extending from at least one stud or vertical structure member of a pod 2. The support member may comprise a bar or beam. In one embodiment, the support member is generally rectangular. Alternatively, the support member can have a shape that is generally cylindrical. Any number of support members can be associated with the pod. The support members may be releasably associated with the pod 2. In this manner, the support members can be removed from the pod once the pod is arranged in the final location 6. The support member may optionally extend generally horizontally from a stud of the pod 2. Optionally, the support member can extend from a first stud to a second stud. A clamp can be used to releasably attach a support member to a stud. In one embodiment, a support member may extend at least partially from an exterior surface of a wall 18, 20, 22, 24 of the pod 2. Additionally, or alternatively, one or more support members can be positioned at least partially within an interior of a wall. For example, in one embodiment, a support member can be positioned between two studs of one or more of the walls. In another embodiment, a support member may engage a hook bracket positioned on a stud. Suitable hook brackets are described in U.S. patent application Ser. No. 15/699,583. Optionally, the hook opening has a width of less than approximately 1.0 inch. In another embodiment, the hook opening 68 is approximately 0.625 inches.

FIG. 7G is a detailed cross-sectional elevation view taken at line 7G-7G of FIG. 7A. The wheels 78 of the moving member 76 may be positioned on a floor of the building structure. Additionally, or alternatively, the wheels 78 can be configured to engage the optional track 90. More specifically, in one embodiment the track 90 and the wheels 78 have corresponding shapes.

Optionally, the wheels 78 include a recess. The recess may be generally centered on a circumference of the cylindrical body of the wheels. The recess is configured to substantially conform to a protrusion formed on the track 90. In one embodiment, the track 90 comprises an inverted “V” shape. In this manner, the track 90 reduces contact surface area and enhances movement of the positioning device 50, such as by ensuring the positioning device moves substantially parallel to the length of the track 90. The rollers or wheels 50 of the moving member 76 comprise a corresponding V-notch that interact with the track 90. The corresponding inverted “V” shapes also reduce the likelihood of a roller or wheel 78 becoming derailed or disconnected from the track 90. Other geometries of the track 90 and wheel 78 are contemplated for use with the positioning device 50 of the present disclosure.

In one embodiment, the moving member 76 includes a protrusion 80 for interconnection to a linkage 72. Optionally, the protrusion may be a hinge or pivot point. The linkage 72 extends from the protrusion 80 and is interconnected to the frame member (illustrated in FIG. 7A).

Referring again to FIGS. 7A, 7C, operation of the lifting mechanism 50 comprises lowering the frame member 52 by activating the drive member 82. In this manner, the frame member 52 and hooks 62 are lowered, as generally illustrated in FIG. 7C. In one embodiment, when the lifting mechanism is in the lowered state, the bottom portion 70 of the hooks 62 is a predetermined distance from the ground. The hooks 62 can then be rotated with the handle 60 into alignment with a support member of a pod 2.

Subsequently, the drive member 82 is activated in a reverse direction to lift the frame member 52 and hooks 62, such as generally illustrated in FIG. 7A, until the hooks 62 are engaged with the pod 2 and the pod is lifted from a floor or pallet. In one embodiment, the lifting mechanism is configured to raise a bottom surface of a pod 2 at least 0.4 inches above an upper surface of a pallet 14 when the lifting mechanism is in the raised state. Once the frame member 52 and pod 2 are lifted, the pod is free to roll or translate generally parallel to one or more walls 18, 22 associated with positioning devices 50a, 50b. Optionally, the positioning device 50 may move along the optional track 90, when present. The pallet 14 (if provided) may be easily removed from the workspace.

When the pod 2 is positioned in a desired location, the drive member 82 is operated to lower the frame member 52 and “land” the pod. The hooks 62 or connections to the pod 2 may thereafter be disengaged. The hooks 62 are then retracted such as to the position illustrated in FIG. 7B, by operating handle 60. In this manner, the positioning device 50 is disconnected from the pod 2. The positioning device 50 may then be rolled out or otherwise removed from the pod 2.

Although not shown in FIGS. 7A, 7C, positioning devices 50 of the present disclosure also contemplate the provision of various safeguards to prevent injury, such as that which may occur if a user or bystander were to become entrained in the moving components of the present invention. For example, in certain embodiments, an outer barrier is provided that includes a sheet of material to prevent ingress of body parts and other objects between the linkages 72. In further embodiments, a plurality of strands or strips (e.g. red or yellow tape) hang from a portion of the frame member 52 and provide a visual guide that users should remain clear of moving parts that are under heavy load.

While various embodiments of the system have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.

To provide additional background, context, and to further satisfy the written description requirements of 35 U.S.C. § 112, the following references are incorporated by reference herein in their entireties: U.S. Pat. No. 4,930,598; U.S. Pat. No. 7,093,691; U.S. Pat. No. 9,617,130; and U.S. Patent Pub. 2010/0193290.

Claims

1. A lifting and moving assembly for modular building units, comprising:

a track member for placement on a surface that is generally horizontal;

a base member that is movable along a length of the track member;

a plurality of linkages, each linkage being rotatably connected to the base member;

a support member in force-transmitting communication with the plurality of linkages, the support member extending substantially parallel to the track member; and

a plurality of load-bearing hooks provided on the support member, the support member and the load-bearing hooks operable to receive and support the weight of a modular building unit, wherein a displacement of the linkages about connections between the linkages and the base member causes a corresponding displacement of the support member in a direction generally parallel to the track member.

2. The assembly of claim 1, wherein the base member includes a plurality of rollers.

3. The assembly of claim 2, wherein the rollers have a notch configured to engage a protrusion of the track.

4. The assembly of claim 1, wherein each linkage can rotate between approximately 0° and approximately 100° relative to the base member.

5. The assembly of claim 1, wherein the displacement of the linkages causes an arcing displacement of the support member which alters a distance between the surface and the support member.

6. The assembly of claim 1, further comprising a frame member rotatably connected to each linkage, wherein the support member is associated with the frame member.

7. The assembly of claim 6, further comprising a drive member interconnected to the base member and the frame member, the drive member configured to displace the linkages about the connections.

8. The assembly of claim 1, wherein the support member is configured to rotate such that a free end of each of the load-bearing hooks is rotatable into a position to engage the modular building unit.

9. A positioning device to lift and move a building pod, comprising:

a base member configured to move on a surface;

two or more linkages, each linkage including a first end and a second end, the first end being pivotably interconnected to the base member;

a frame member pivotably interconnected to the second end of each linkage;

a support member rotatably interconnected to the frame member; and

a plurality of hooks positioned on the support member and configured to selectively engage the building pod, wherein altering an angle of the two or more linkages relative to the base member alters a distance between the hooks and the surface.

10. The device of claim 9, further comprising a drive member configured to alter the angle of the two or more linkages relative to the base member.

11. The device of claim 10, wherein the drive member is threadably interconnected to one of the base member and the frame member.

12. The device of claim 9, wherein rotating the support member in a first direction moves each of the plurality of hooks to a support position to engage the building pod.

13. The device of claim 12, wherein at least a portion of each of the plurality of hooks extends beyond a plane defined by the frame member when the hooks are in the support position.

14. The device of claim 9, wherein the base member includes at least two wheels.

15. The device of claim 14, wherein the at least two wheels include a circumferential recess to engage a track positioned on the surface.

16. The device of claim 9, wherein each of the plurality of hooks may be selectively repositioned along a length of the support member.

17. The device of claim 9, wherein altering an angle of the two or more linkages alters a position of the frame member relative to a length of the base member.

18. A method of lifting and moving a modular building unit, comprising:

aligning a first positioning device with a first wall of the modular building unit;

aligning a second positioning device with a second wall of the modular building unit;

moving hooks of the first and second positioning devices to engage the modular building unit;

inducing a movement of a plurality of linkages of the first and second positioning devices to move the modular building unit into a desired location; and

moving the hooks of the first and second positioning devices to disengage the modular building unit.

19. The method of claim 18, wherein the movement of the plurality of linkages causes a movement of the modular building unit along a horizontal axis and a movement along a vertical axis.

20. The method of claim 18, wherein the movement of the plurality of linkages alters an angle of the linkages with respect to lengths of the first and second positioning devices.