GB2513939A

GB2513939A - A modular building unit

Info

Publication number: GB2513939A
Application number: GB1322116.3A
Authority: GB
Inventors: Douglas Rose; Darren Simpson
Original assignee: Portakabin Ltd
Current assignee: Portakabin Ltd
Priority date: 2013-12-13
Filing date: 2013-12-13
Publication date: 2014-11-12
Anticipated expiration: 2033-12-13
Also published as: GB201322116D0; GB2513939B

Abstract

The modular building unit 100 comprises an upright column 113 which includes an interior space. A connecting apparatus 135 is located within the interior space and deployable from a retracted to a deployed position. In the deployed position attachment to a second modular unit using the connector is possible. A mechanism for controlling the connector from within the unit may also be provided. The mechanism may use a flexible member such as a cord, wire or chain to control the connecting apparatus. A fastener may be used to secure the connecting apparatus to the second unit. The modular building unit may be rectangular in plan and have four upright columns in the corners of the unit, wherein at least two of which comprise the connecting apparatus. Also claimed are a method of joining two modules together and a kit comprising the connector.

Description

A modular building unit

FIELD OF THE INVENTION

The present invention relates to modular building units, particularly but not exclusively those used in temporary building constructions.

BACKGROUND OF THE INVENTION

Modular huilding units are prefahricated in a factory and transported on lorries to the installation site where one or more modular building units are assembled into buildings. The buildings can be single storey or multi-storey. Multi-storey buildings include two or more building units stacked verticafly. The buildings maybe temporary (e.g. a site ofhce cii a building site) or substantiafly permanent (e.g. offices, classrooms, hospital buildings and the like).

When two or more modular building units are stacked a joining plate is typically bolted to adjoining parts ol the two units to secure them together. A prohlem with this arrangement is that installation personnel require ladders or lifting platforms to reach the attachment points and secure the units together, particularly when the building is three or more storeys. Ladders are generally considered undesirable under current safety regulations, and provision of lifting platforms adds to the cost of installation.

Further problems include the fact that that the plates may get lost when they are not being used for connecting, or damaged due to their exposed position.

The present invention seeks to overcome or at east mitigate the problems of the prior art.

SUMMARY OF THE NVENTION

A first aspect of the invention provides a modular building unit for vertical attachment to a second modular building unit, comprising; an upright column defining an interior space thereof: a connecting apparatus located within the interior space and deployable from a retracted to a deployed position. such that in the deployed position attachment to the second modular building unit may be achieved.

Advantageously this allows for the releasable securerncnt of a first modular building unit vertically to a second modular building unit via a self contained mechanism that is protected from damage by being housed with a co'umn ol the unit.

Prelerably a mechanism is lurther provided for controlling the deployment of (lie connecting apparatus between the retracted position and a deployed position which may be advantageous as it simplifies the connecting process.

More preferably the mechanism for controlling the deployment of the connecting apparatus is accessihle from inside the modular building unit which may he advantageous as it avoids the use of ladders/li Ring platforms.

Still more preferably the connecting apparatus is configured so as to he completely inside the column of the modular building unit when retracted and able to fit into a colTesponding colunm of the second modular building unit when deployed which may be advantageous as it protects the connecting apparatus.

In one embodiment the connecting apparatus is located in an upper section of the upright column when retracted and extends into a lower section of a corresponding column of the second modular building unit when deployed.

In another embodiment the connecting apparatus is located in a lower section of the upright column when retracted and extends into an upper section of a corresponding column of the second modular building unit when extended.

Preferably, securement of the connecting apparatus to the second modular building unit is achieved from inside the first or second modular building unit which is advantageous as it avoids the use of ladders/lifting platforms.

More preferably the connecting apparatus comprises a stop to limit movement thereof in at least one direction which is advantageous as it makes vertical alignment easier.

In one embodiment at least one fastener is arranged to hold the connecting apparatus in at least one of its retracted and deployed positions which is advantageous as it provides a simple way of securing connecting apparatus.

Optionally at least one fastener is arranged to secure the connecting apparatus to the second modular building unit in the deployed position which is advantageous as it provides a simple and secure way of making (lie connection.

In one embodiment the mechanism for controfling the deployment of the connecting apparatus comprises an ethngate flexible member such as a wire, cord or chain which is advantageous as it provides a simple and reliable mechanism.

Preferably the mechanism for controlling the deployment of the connecting apparatus is selectively restrained with respect to the upright column which is advantageous as it provides a simple way olholding it in p'ace.

In one embodiment the connecting apparatus comprises a connection plate which is advantageous as it a simple apparatus.

Preferably a retention arrangement is provided to slideably hold the plate in a substantially face contacting relationship with a wall of the column.

The modular building unit may be substantially rectangular in plan and may contain four upright columns located in the corners of the modular building unit, at least two of which may comprise a connecting apparatus.

Preferably the upright column further comprises a formation for releasably securing a further connecting apparatus thereto.

A second aspect of the invention provides a method of joining a first and second vertically stacked modular building units comprising the steps of: deploying a connecting apparatus from a within an upright column of a first modular building unit; and releasably securing the first modular building unit to an upright column of a second modular building unit utilising the connecting apparatus.

Advantageously this allows for the releasable securement of a first modular building unit vertically to a second modular building unit via a self contained mechanism that is protected from damage by being housed with a column of the unit.

Preferably the step of releasably securing the first modular building unit to the second modular building unit comprises releasably securing the connecting apparatus to the first modular building unit and rclcasably securing the connecting apparatus to the second modular building unit which is advantageous as it provides a secure connection.

Optionally, the step of deploying the connecting apparatus comprises deploying the connecting apparatus suhstantialy upwardly from an upper portion of the upright column into the second modular building unit.

In another embodiment the step of deploying the connecting apparatus involves extending the connecting apparatus substantially downward from a lower portion of the upright column into the second modular building unit.

Preferably the step of releasably securing the connecting apparatus to the modular building units is carried out using at least one fastener.

A third aspect of the invention provides a kit of parts for fitting to a modular building unit to enable the vertical attachment of a first modular building unit having an upright column defining an interior space thereof to a second modular building unit having a corresponding upright column, the kit comprising; a connecting apparatus to be housed within the interior space, the connecting apparatus being arranged to be moveable between a retracted position and a deployed position, such that in the deployed position attachment to the second modular building unit may be achieved.

Advantageously this allows for the releasable securement of a first modular building unit vertically to a second modular building unit via a self contained mechanism that is protected from damage by being housed with a colunm of the unit.

Preferably, the kit further comprises a mechanism for controlling the vertical movement of the connecting apparatus between a retracted position and a deployed position.

More preferably the connecting apparatus comprises a stop to Hniit the movement thereof in at east one direction.

S

Yet more preferably, the mechanism for controlling the vertical movement of the connecting apparatus comprises an elongate flexible member such as a wire, a cord or a chain.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention vil1 now he described with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a modular building unit according to an embodiment of the present invention; Figure 2 is a perspective view of a building formed from four modular building units of Figure 1; Figures 3A and 3B are an end and side view of the frame of the modular building unit of Figure 1 respectively illustrating assembly of the connecting apparatus; Figures 4A and 4B are an end and side view of the frame of the modular building unit of Figure 1 respectively illustrating a connecting apparatus in a fully retracted state; Figure 5A is a vertical cross section view of the section 3-3' from Figure 3B; Figures SB and SC are detail views of the encircled sections B I and CI of Figure 5A respectively; Figure 6 is a vertical cross section view of the section 4-4' from Figure 4B; Figure 7A is a vertical cross section view of the connecting apparatus in a deployed position, housed inside two vertically stacked modular building units; Figure 7B is a view of the same portion of the modu'ar building units of Figure 7A hut at 90° to the cross-section of 7A: Figure 8 is an isometric view of a connecting apparatus according to a second embodiment of the present invention; and Figure 9 is an isometric, partially cutaway view of a connecting apparatus according to a third embodiment of the present invention within columns of upper and lower modular building units.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Figure 1 illustrates a modular building unit 100 according to an embodiment of the present invention comprising a roof 102, a floor 108. and two side walls 104 and 106.

The modular building unit 100 has a rear wall 110. but no front wall, so that the modular building unit 100 is open from the front. In other embodiments, various other wall formats maybe used, dependent upon whether the unit 100 is designed to he self-contained or part of a larger building.

The structure of the unit 100 is formed from four steel box section upright corner columns 113, joined by four C-section floor beams 111 and four C-section roof beams 112. The roof 102 of the modular building unit 100 is supported by the roof beams 112.

Figure 2 shows how four modular building units 100, shown in Figure 1, are combined to form a building 101 on two storeys with two units having their open fronts facing each other on each storey to form a large open-plan interior space.

As can be seen most clearly in Figure 1, the upright columns 113 are secured to the four C-section floor beams 111 and the four C-section roof beams 112 of the modular building unit 100 proximate to each corner. The upright columns 113 are box sections with a rectangular profile.

Turning to Figures 3A, 3B and 5A. a connecting apparatus 130 for joining stacked modular building units 100 is shown prior to being fitted inside the upright column 113 of the modular building unit 100.

The connecting apparatus 130 comprises an dongate member 135 in the form of a steel connecting plate, with three holes 131, 132, and 133. The holes comprise an upper hole 131, a middle hole 132 and lower hole 133 and are threaded for use with fasteners to releasably secure the connecting apparatus to the upright column 113 as described in more detail below. The holes are relatively large. e.g. to receive an M16 fastener The connecting plate 135 further comprises an elongate slot 136 which runs parallel with the long edge of the connection plate along approximately half its length. The length of the slot is equivalent to the spacing between the upper hole 131 and middle hole 132. A further relatively small alignment hole 134 is located immediately above the lower hole 133, to be used for alignment of the connection plate 135. A further hole 138 is located at the top of the connection plate 135 which is used to secure a chain 140 to the connection plate.

A lowerportion of the upright column 113 is provided two holes, a column hole 120 and lower column alignment hole 122 on one face thereof inside the modular building unit 100, having a mutual spacing the same as that between upper hole 131 and middle hole 132 of the plate 135. The hole 120 is not threaded and dimensioned to receive a setscrew 160 as illustrated in Figure 7A.

A further guide pin receiving hole 124 is threaded and provided at the same level as the upper column hole 120, but is somewhat smaller -e.g. 10mm.

The upright column 113 also contains a larger hole 114, through which the chain 140 can be passed. lit other embodiments an alternative flexible member such as a wire or a cord maybe used in place of a chain.

On a second face of the column, at 90° to the first, a retention arrangement is provided which comprises two further threaded guide pin receiving holes offset from the first face by the thickness of the plate 135 and have guide pins 144 received therein.

The upright column 113 has, at its upper end, a top column hole (not visible) to receive a setscrew, and a further alignment hole (not visihk), to aid with alignment of the hole 134 on the connection plate 135.

The chain 140 extends to the interior of upright column 113 through a wall on the inside of the modular building unit 100 via an access hole 114.

A guide pin 142 is secured to hole 124 to project into the intenor of the column 113.

In Figures 4A and 4B the connecting apparatus 130 has been fitted and is completely housed in the upright column of the modular building unit 100.

Turning to Figure SA. SB and SC the connecting apparatus 130 is shown in more detail in a partially assembled state.

Assembly of the connecting system is as follows: The chain 140 is passed down into the upright column 113 of the modiflar building unit 100 through the access 114 and held (e.g. with a larger cnd link) with a portion remaining inside the unit 100. The chain 140 is then fixed to the plate 135 via the hole 138 using a screw. The plate is then lifted into the column 113 and the elongate slot 136 is then fitted over the guide pin 142 as illustrated in Figure 6.

The plate 135 is then fully withdrawn into the upright ccñumn 113 using the chain 140 via the intcrior of the modular building unit 100. The plate 135 is secured in its uppermost position by securing a setscrew 160 through the upper column hole 120 and middle hole 132 in the plate. Finally, the upper and lower retaining pins 144 are screwed through the wall of the column to hold the plate 135 against one face.

This process is then repeated for each of the four upright columns 113 which house a connecting apparatus 130.

When fully assembled, the connecting apparatus 130 is as shown in Figure 6. As can be seen, the apparatus is held completely inside the colunm to avoid damage during transportation.

When two modular building units 100 are vertically stacked, the columns 113 of the respective upper and lower units are aligned, as can be seen in Figure 2. The connecting apparatus 130 is extended from a retracted position in the upper column of Figure 6 to the deployed position of Figures 7A and 7B where it extends into the top of the lower column of the lower modular building unit 100.

Deployment and fixing of the connecting apparatus is carried out as follows: A set of temporary or permanent stairs will then typically be fitted on the exterior of the stacked modular building units to enable access to the interior of the upper modular building unit 100.

An operative will then access die upper modular building unit 100. The setscrew 160 and chain of the 140 of the connecting apparatus 130 can then he accessed via die inside of the upper modular building unit 100.

The operative releases the plate 135 from its uppermost position of Figure 6 by removing the setscrew 160 from the middle hole 132 of the plate and upper hole 120 of the column. The operative pays out die chain 140 to lower the plate 135 until it is fully deployed into the upright column 113 of lower modular building unit 100.

Excess deployment is prevented by the top of the slot 136 hitting the guide pin 142.

The plate is then releasably secured to the column 113 of the upper modular building unit 100 by replacing the setscrew 160 in the lower colunm hole 120 and top hole 131 of the plate 135.

The operative then enters the lower modular hui Iding unit 100, uses hole 134 and the alignment hole on the column 113 of the lower modular building unit 100 to align hole 133 with the top column hole. This enables a setscrew 160 to be secured through these holes to releasably secure the plate to the column 113 of the lower modular building unit 100, resulting in the upper and lower modifiar building units 100 being rcleasably secured together via the connecting apparatus 130.

This process is then repeated for the three remaining colunms 113, to securely hold the two modular building units together.

The two modular building units can be separated by a reversal of the process.

It will be appreciated that the arrangement permits the floor of the upper modular building unit 100 to he the support for the operative whilst releasing and deploying the connecting apparatus, which is compliant with current safety legislation on the one hand, and cheaper than using a mobile lifting platform on the other.

Figure 8 illustrates a second embodiment of the connecting apparatus. Corresponding components of this Figure are labelled 100 higher with respect to the first embodiment. Only differences with respect to die first embodiment are discussed in more detail.

In Figure 8 the connecting apparatus 230 functions using a simfiar principle to the first, but replaces the plate 135 with a box section 235 having a tapered lower end section 228. The box section is configured to be a slideable close lit within the upright columns 213. The box section 235 is provided with the same arrangement of slot 236, chain 240 and holes 231, 232 and 233 to control vertical motion and releasably secure the upper and lower columns 213. However the fact that the box section substantially prevents any horizontal motion negates the need for the retaining pins located in the upright column. Although not shown, the box section 235 may also comprise an equivalent of alignment hcAe 134.

In Figure 9 a third embodiment of the connecting apparatus 330 is shown. Again, like parts arc labelled by like numerals labelled 100 higher. The apparatus of this embodiment comprises vertically arranged rod 335 which has a transverse bar 328 at its lower end to act as one part of a bayonet-style fitting. and is illustrated in a partially lowered state At the upper end, the rod 335 is rotationally fast but axially slideable with respect to a gear 370, The gear 370 is rotationally supported on a horizontal plate 372 towards the lower end of a column 313. The plate 372 has a bore (not visilie) through which the rod extends. The gear 370 is meshed with a bevel gear 374 which rotates about a horizontal axis and has a shaft 375 extending through an interior wall of the colunm 313. The shaft 375 has a suitable drive formation 376 on the end such as a hex head to which a suitable tool may be connected to rotate the gears 370, 374 and therefore the rod 335 and transverse bar 328.

A pair of plates 378 are welded to the interior of the columns 313 near the top. The plates define a slot 379 therebetween to receive the transverse bar 328, and the rod is dimensioned such that when two units 300 are placed on top of each other, the bar 328 when aligned passes through the slot 379 and is positioned just below the plates 378.

Rotation of the drive formation 376 then allows the transverse bar to he secured against vertical movement by the plates, thus securing the two colunms together. This process is repeated for each pair of columns until the units are secured.

In some embodiments the undersides of the plates 378 may have stop foimations (not shown) to block over-rotation and/or ramp formations (not shown) to tighten die connection vertically.

In this embodiment, the rod 335 lowers under gravity when a unit 300 is lifted off the ground and when lowered onto another unit, will lift again until the transverse bar is aligned with the slot, when it will drop again. As in the previous embodiment, the connecting operation is controlled from inside the upper of the two units, but in this embodiment, no additional securenient operations are needed from the lower unit.

It is envisaged that it will be usual for each modular building unit to have both parts of the connecting arrangement -i.e. the part to be deployed and the part to receive or restrain the deployed part, so that each unit is essentially interchangeable. However that need not always be the case.

Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.

In the embodiments described above the connecting apparatus is housed in the lower section of the upright column of the modular building unit intended to he uppermost, and extends into the upper section of the upr ght column of the modular building intended to be lowermost, hi other embodiments, however, the connecting apparatus is housed in the upper section of the upright column of the modular building unit intended to be lowermost and is deployed upwardly using suitable lifting aiTangements which may include resilient elements, pulleys etc. In the third embodiment, the bayonet arrangement may be replaced by a threaded lower end section to the rod to be received in a corresponding internally threaded portion mounted to lower column.

In another embodiment of the present invention the chain passes through an aperture to the exterior of the modular building unit, instead of the inside.

Whilst it is expected that the connecting apparatus will principally be fitted to new modular building units during their assembly, it is also envisaged that existing units may he retrouitted by providing a suitalie kit of components to do so.

Claims

Claims 1. A modular building unit for vertical attachment to a second modular building unit, comprising: an upright co'umn delining an interior space thereof; S a connecting apparatus located within the interior space and deployable from a retracted to a deployed position, such that in the deployed position attachment to the second modular building unit may he achieved.
2. The modular building unit as claimed in claim 1, wherein a mechanism is further provided for controfling the deployment of the connecting apparatus between the retracted position arid a deployed position.
3. The modular building unit as claimed in claim 2, wherein the mechanism for controlling the deployment of the connecting apparatus is accessible from inside the modular building unit.
4. The modular building unit claimed in any preceding claim, wherein the connecting apparatus is configured so as to be completely inside the colunm of the modular building unit when retracted and able to fit into a colTesponding colunrn of the second modular building unit when deployed.
5. The modular building unit as claimed in any preceding claim, wherein the connecting apparatus is located in an upper section of the upright column when retracted and extends into a lower section of a corresponding column of the second modular building unit when deployed.
6. The modular building unit as claimed in any one of claims 1 to 4. wherein the connecting apparatus is located in a lower section of the upright column when retracted and extends into an upper section of a corresponding column of the second modular building unit when extended.
7. The modular building unit as claimed in any preceding claim, wherein securement of the connecting apparatus to the second modular building unit is achieved from inside the first or second modular building unit.
8. The modular building unit as claimed in any preceding claim, wherein the connecting apparatus comprises a stop to limit movement thereof in at least one direction.
9. The modular building unit as daimed in any preceding claim, wherein at least one fastener is arranged to hold the connecting apparatus in at least one of its retracted and deployed positions.
10. The modular building unit as claimed in claim 9. wherein at least one fastener is arranged to secure die connecting apparatus to the second modular hufiding unit in the deployed position.
11. The modular building unit as daimed in any one of claims 2 to 10, wherein the mechanism for controlling the deployment of the connecting apparatus comprises an elongate flexible member such as a wire, cord or chain.
12. The modular building unit as claimed in any one of claims 2 to 12. wherein the mechanism for controlling the deployment of the connecting apparatus is selectively restrained with respect to the upright column.
13. The modular building unit as claimed in any preceding claim, wherein the connecting apparatus comprises a connection plate.
14. The modular building unit as claimed in claim 13. wherein a retention arrangement is provided to slideably hold the plate in a substantially face contacting relationship with a wall of the column.16. The modular building unit of any preceding claim, wherein the modular building unit is substantially rectangular in plan and four upright columns are located in the corners of the modular building unit, at least two of which comprise a connecting apparatus according to any preceding claim.17 The modular building unit of any preceding claim, wherein the upright column further comprises a formation for releasably securing a further connecting apparatus thereto 18. A method of joining a first and second vertically stacked modular building units comprising the steps of: deploying a connecting apparatus from a within an upright column of a first modular building unit; and releasably securing the first modular building unit to an upright column of a second modular building unit utilising the connecting apparatus.19. The method of claim 18 wherein the step of releasably securing the first modular building unit to the second modular building unit comprises releasably securing the connecting apparatus to the first modifiar building unit and releasably securing the connecting apparatus to the second modular building unit.20. The method of claim 18 or claim 19 wherein the step of deploying the connecting apparatus comprises deploying the connecting apparatus substantially upwardly from an upper portion of the upright column into the second modular building unit.21. The method of claim 18 or claim 19 wherein the step of deploying the connecting apparatus involves extending the connecting apparatus substantially downward from a lower portion of the upright column into the second modular building unit.22. The method of any one of claims 18 to 21 wherein the step of releasaffly securing the connecting apparatus to the modular building units is calTied out using at least one fastener.23. A kit of parts for fitting to a modular building unit to enable the vertical attachment of a first modular building unit having an upright column defining an interior space thereof to a second modular building unit having a corresponding upright colunm. the kit comprising; a connecting apparatus to be housed within the interior space, the connecting apparatus being arranged to he moveable between a retracted position and a deployed position. such that in the deployed position attachment to the second modular building unit may be achieved.24. A kit as claimed in claim 23 further comprising a mechanism for controlling the vertical movement of the connecting apparatus between a retracted position and a deployed position.25. A kit as claimed in claim 23 or claim 24, wherein the connecting apparatus comprises a stop to limit the movement thereol in at least nile direction.26. A kit as claimed in claim 23, wherein the mechanism for controlling the vertical movement of the connecting apparatus comprises an elongate flexible member such as a wire, a cord or a chain.27. A modular building unit, method or kit substantially as hereinbefore described and/or as shown in the Figures.