"Prefabricated and transportable building"

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention is directed to the field of building construction and, in particular, about a prefabricated and transportable building.

2. Description of Related Art Prefabricated and transportable buildings are well known. Temporary or transportable housing is needed in a number of different situations. For example, during natural disasters people are often displaced from their homes.

ISO shipping containers are used as transportable buildings in these situations.

However, it will be readily understood that these structures are unsuitable to house individuals or families for a prolonged period of time. They do not provide the comforts of living, mainly because of the restricted width.

With the aim of achieving more comfortable accommodation it has been attempted, for example, to combine or join two or more containers, removing one of the two longitudinal walls, in order to obtain a unit of twice the former width, a living space of double width, doubling, at the same time, the transport cost.

Another attempt to achieve a better accommodation is to pre-build a bigger house, divide it into two or more parts and transport it on the site. This solution is very complex and expensive.

Moreover, such mobile homes are typically not suitable to be conveniently transported by rail, air, or ship.

A solution for lower transport costs is to build a house or an office that can be supplied flatpacked, known as "Transpack". However, it needs to be assembled on site. Shipping containers have a very rigid structure. All parts of it, including floor, ceiling and side walls, shape a crushproof box structure.

Containers employed as transportable buildings preserve this kind of structure, therefore the side (longitudinal) walls have an important structural function. In transportable buildings these walls have some small "holes", the windows and the doors. These small "holes" do not weaken the crushproof box structure, so the container is sufficiently rigid during transportation.

These known transportable buildings maintain the "idea" of the ISO shipping containers because of the following: the box shape; the external walls made in corrugated metal; the comer fittings for the lifting of the containers usually remain in sight in the transportable buildings. In order to achieve an aesthetically attractive building, large windows are often required. However, these "holes" could cause the weakening of the structure, which then is no more sufficiently rigid for transportation.

The present invention describes a transportable building which provides a solution to the above-mentioned problems, as well as having other related advantages.

SUMMARY OF THE INVENTION

Object of the present invention is a prefabricated and transportable building comprising: two of more shipping containers next to each other of which each container is composed of:

- a fixed and partially closed box part, composed of a floor deck, a roof deck, fixed walls of both external side and front walls, and fixed inside walls.

- structural side parts and non-structural side parts, foldable and hinged or fixed to the outer edge parts of aforementioned floor and roof decks, aforementioned structural side part and non-structural side part which can be rotated to form an extension of the flooring and the ceiling of the building in order for both side parts of close containers to be close and at the same level;

- head removable structures with corner fittings for transportation and lifting, removable and connected to the aforementioned structural side parts to the fixed walls, aforementioned corner fittings intended to anchor and lift the container.

In particular, object of this invention is a prefabricated and transportable building, as further described in claims, which are part and parcel of the present description. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate an implementation of the invention (and some variants) and, together with the description, serve to explain the advantages and principles of the invention.

This apparatus and the method of construction/assembly represent a presently preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

Figure 1 schematically illustrates a plan and a cross section of the transportable building structure when closed in two shipping containers;

Figure 2 schematically illustrates a plan and a cross section of the transportable building structure when unfolded;

Figure 3 schematically illustrates an elevation and an axonometric view of the head structures with corner fittings; 80 Figure 4 schematically illustrates a plan and an axonometric view of the head structures with corner fittings when removed, which, as shown, can be used as structural walls of a garage;

Figure 5 schematically illustrates an axonometric view of the structure of the transportable building while figure 5 ^* schematically illustrates an axonometric view 85 of the only structural side parts;

Figure 6 schematically illustrates a plan and a cross section of the foundation of the building;

Figures 7, 8, 9 e 10 schematically illustrate cross sections of the hinge structures of the side parts; 90 Figures 11 and 12 schematically illustrate perspective views of the transportable building during the assembly/opening on the construction site and as finished;

Figure 13 schematically illustrates cross sections of a variant of the hinge structures of the side parts;

Figure 14 schematically illustrates the self-powered plant of the house. 95 Identical reference numbers in the drawings identify the same elements or parts.

BEST MODE FOR CARRYING OUT THE INVENTION

The structure of the prefabricated and transportable building, in accordance with the invention, is preferably assembled from two container units, but of course a oo different number is possible.

Every container is composed by a fixed and partially closed box part, composed of a floor deck (27), a roof deck (26) and fixed walls (21) of both external and inside walls.

This box part does not have foldable parts and it is intended to house parts such

105 as bathrooms, kitchen, fireplaces preassembled with wiring, plumbing, heating, air conditioning, etc.

Outside the external fixed walls 21 there are the hinged, foldable side walls 22, 23, 24, 25. Referring to Figure 2 of the drawings, side walls 22, 23, 24 and 25 are centred no with hinges (36) to the outer edge parts of the aforementioned fixed box part (26, 27, 21). In this way, the side walls can be rotated as you can see when comparing figure 1 and 2. Structural side parts 23 and 25 are composed of a truss structure with vertical, horizontal and diagonal beams (see also Fig. 5'), having the aforementioned truss the same height of the side part (part 25), or having a lower us height (part 23).

Generally speaking, structural side parts (23 and 25) that are floor parts, and nonstructural side parts (22 and 24) that are roof parts, can also be made up of corrugated metal, cellular deck, sandwich panels, fibreglass, etc. Side parts 23 can be rotated by 90 degrees in order to form the floor of the

120 external veranda.

Side parts 22 can be rotated by 90 degrees in order to form the roof of the external veranda.

Side parts 24 are, in the example, subdivided into 3 panels. The central panel, of the side part 24, can be rotated by 115 degrees in order to form the central

125 skylight in the living room (Fig. 12).The other two panels, of side part 24, can be

rotated by 90 degrees in order to form the roof of the house in the space between the two containers.

The head structures (20) of the containers, as shown in Figure 3, contain ISO corner fittings (50), and they also prevent cross deformation of the shipping

130 containers during transportation. Steel ISO corner fittings, with ISO holes (51) are intended to lift and lock the containers during transportation by truck, train, etc. During transportation the head structures (20) are firmly joint together with side parts 22, 23, 24 and 25 by bolts 55 (Fig 5). After resting the containers in the correct position, the bolts (55) are unscrewed and the head structures removed.

135 The head structures, when removed, can be used as structural walls of a garage (size 1-2) built near the house (Fig 4).

After the head structures (20) are removed, the triangular trusses (60) can be locked on between the roofs of the two closed containers (Fig 11). These triangular trusses can house the winches for the opening of the structural side

140 parts (23 and 25) and the non-structural side parts (22 and 24). During transportation the triangular trusses can be put inside or below the shipping containers.

The transportable building can rest on several kinds of well known foundation.

The building is rigid during transportation, even if every container is positioned on

145 the only four outer corners (50), thanks to the load-bearing, structural side parts 23 and 25.

When the building is installed on the construction site, side parts 23 and 25 of each container lose their load-bearing function, because they are put in a horizontal position. The diagonal beams of the truss structure of side parts 23 and

150 25, in open position, lose their load-bearing function.

That is why, when the house is installed, it needs to rest on a number of points that ensure an acceptable deflection of the floor deck. For example, 25 resting points can be applied for two containers of 45 x 8 ft.

Moreover, the installation of the building needs standard electricity/water 155 connection.

Figure 6 schematically illustrates a plan and a cross section of the foundation of the building.

It is possible to use supports (02) in order to separate the building from the soil

(because of moisture). 160 This kind of support is placed on the foundation (made up of several isolated footing or pile foundation, or floating foundation) and is composed of 03, 04, 06 parts. Circular plates 06 are the supports for beams 10 that allow to separate

MORE the building from the soil and to give firm support to the floor parts 23.

Part 03 is a cylinder threaded on the outside part, part 04 is a hollow cylinder (an 165 upside down cup) threaded on the inside part. Due to the bars 05 it is possible to screw or to unscrew part 04 in order to take down or lift the circular plates 06, which are the supports for the building's load-bearing beams 10.

The 25 foundation circular plates (06) are placed, in this way, at the same level.

The deflection of the floor deck (of little height), due to the little gap between the no foundation points, is acceptable.

The 25 supports (02) are linked with beams (10), which have also the task of underpinning a waterproof wrap against the moisture, and of underpinning additional insulating material if needed (depending on construction site climate).

This insulating material is put right under the house, separated from the ground.

175 Basically, if the site climate were very hot or very cold, it would add insulation material both beneath the house, lean on these beams, and on the roof of the building. The insulation material on the roof is hidden from the roof fascias (70). After the opening of the building, the structural side part (25) of one of the container remains slightly separated form the structural side part (25) of the other

180 container, and these parts 25 (now floor) remain slightly separated form the floor deck 27, and this floor deck 27 remains slightly separated form the external parts 23. These gaps between the parts are covered by a "strip" of floor (43) (Fig 7), for example some wood boards, installated when the house is opened. Moreover, after the opening of the building, the non-structural side part (24) of one

185 of the containers remains slightly separated form the non-structural side part (24) of the other container, and these parts 24 (now roof) remain slightly separated form the roof deck 26, and this roof deck 26 remains slightly separated form the external parts 22. The gaps between the parts are covered (Fig 7) by for example some wood or gypsum boards, installated when the house is opened.

190 Referring to figures 7, 8, 9 and 10, some details are enumerated and then described, as follows: 39 load-bearing beam; 30 waterproofing membrane; 31 panel; 32 insulating material; 33 panel; 34 wood or gypsum board; 35 installated gypsum board; 37 and 38, 47 and 48 flashings; 40 installed sealing material; 46 gasket; 45 angle iron; 44 pipes; 41 pivot bolt; 42 floor;

195 Referring to figures 3: 54 reinforcement plates; 52 and 53 linking beams.

Figure 9 schematically illustrates the hinges used for open the side parts (that can be opened), to shape the internal and external roof and floor of the finished building. Every hinge 36 is composed by at least two plates (for example in stainless steel) and the pivot bolt 41.

200 There are two holes on every plate, one for the pivot bolt insertion, the other for blocking the hinge in open position. In fact, when the hinges are in open position, the remaining holes on the two plates of every hinge are lined up, and the hinge can be blocked by insertion through these holes by blockage bars 41' (which have a diameter slightly inferior to that of the holes). The blockage of the hinges in open

205 (horizontal) position blocks the side parts (22 and 24) in open (horizontal) position (to shape roof and floor).

Blockage bar 41' could be very long and be inserted through the remaining holes of several hinges of the same side part (that can be opened). In this way, with just one bar, several hinges can be easily blocked. For example all hinges of one side

2io part can be easily blocked in horizontal position with just two bars, of half container length, inserted from the two heads of the container. Figure 8 schematically illustrates the detail (cross section views) of the hinge system between side part 22-24, and fixed parts 26. Exterior container parts are covered by waterproofing membrane 30 and flashing

215 37 and 38.

The wavy, flexible flashing 38 (the wavy shape adds to its flexibility), together with flashing 37, avoid that water and dust filter into the building when the containers are closed or opened. The flashings can be made in stainless steel, for example. These flashings are the same length as the container, reaching the two the head

220 structures with corner fittings (20).

Under flashing 37, gasket 49 is inserted and touches beams 39 and panel 31. In the course of the opening of parts 22 and 24, flexible flashing 38 is driven between flashing 37 and beam 39.

In open position, i.e. when parts 22 and 24 are in horizontal position, the flexible

225 flashing 38 is completely inserted under the flashing 37, pushing against gasket 49. In this way, waterproofing is guaranteed.

The wavy shape of the flashing 38, as matter of fact, has a "height" of about the same distance between flashing 37 and beam 39. Thus, the elasticity of the wavy flashing and of the gasket, pushing against each other, guarantee waterproofing.

230 In this position there is a little gap between the fold at the end of flashing 37 and the bend of flashing 38 in contact with the beams 39. This gap is filled by a sealing material 40, which add waterproofing to the roof.

This joint could be covered by another waterproofing layer, installed when the building is opened.

235 Figure 10 schematically illustrates the detail of the hinge system of the central part of parts 24 (the skylight). In this case flat flexible flashings 47 and 48 are used. In the course of the opening, flexible flashing 48 is driven under flashing 47, between the plates of the hinges 36, meanwhile the ending of flashing 47 is driven into the recess 56. Thus, both when the containers are open and closed, they are

240 waterproof.

As an alternative to the aforementioned hinge system, the structural and nonstructural side parts can be linked to the fixed parts via bolts or framing (Fig 13). When the container is closed, the structural and non-structural side parts are linked (for example by bolts) to the longitudinal outer edge parts of the floor and

245 roof decks in "closed" position. When the container is on site, the side parts are separated and re-linked (for example by bolts) to the longitudinal outer edge parts of the floor and roof decks in

"open" position, for example perpendicular to the previous position, in order to shape floor and deck of the finished building. 250 Strips are installed to cover the gap between the floor and the roof parts.

Figure 13 schematically illustrates an example of the bolt link between the roof deck (26) and the non-structural side parts (22, 24). The same principle can be used for the bolt link between the floor deck (27) and the structural side parts (23,

25). 255 The entire roof could be protected by another waterproof layer, installed when the house is open. For example, it could be a waterproof membrane tense in order to obtain the right slop for the water flowing. The membrane could have some roof drains linked to the downspouts, which could be hidden, for example, inside the fixed walls 21. The membrane could 260 have the roof drains at the same level of the roof, whereas the outer edges of the membrane could be linked to the higher part of the roof fascias (70), which is at a higher level as the roof of the open building. In this way, the membrane could be sloped enough to drain the water.

Between the waterproof membrane and the roof it is also possible to put an 265 insulating material (depending on construction site climate). In that case, the waterproof membrane can be shift towards a higher level in order to place the insulating material.

Alternatively, a pitched roof on the flat roof could be installated.

Figures 11 and 12 schematically illustrate an example of prefabricated and 270 transportable building, object of the invention, in two steps of the installation.

Figure 11 shows the two containers positioned on the foundation beams, with the structural side parts of floor 23 and 25, and the non-structural side parts of the

roof 22 and 24 closed, and the two triangular trusses 60 installed. Figure 12 shows the finished building, with the roof and floor parts opened, the central 275 skylight and the other mobile parts installed (sliding windows and mobile walls) which can close the building on the sides still open (73).

Referring to figures 2, 6, 11 and 12, it is shown that the two containers can be shifted with each other, for aesthetic reasons.

For the following reasons, an aesthetically attractive, wide and comfortable 280 building can be achieved, starting from the two shipping containers:

Opening the containers, a covered veranda can be created around the house.

The head structures with corner fittings for the lifting of the containers can be removed during the installation of the house. In this way, the unattractive corner fittings do not jeopardize the house aesthetics. These head structures can be 285 used as structural walls of a garage/laundry.

The closed container is sufficiently rigid during transportation thanks to the hinged structural side parts, which form the internal and external floor of the finished house.

The side parts can be composed, for example, by a structural truss or a cellular 290 deck, because they are load-bearing beams of sufficient height to bear all the weight of the container with an acceptable deflection when the side parts are

"closed" (in perpendicular position with the ground in vertical position),. In the example, these "beams" have at least half the height of the side part, which is more than enough. 295 Every part which could show the foldable structure of the building is hidden/concealed by fascias for the roof and for the veranda platform (70 and 71).

The containers, opened and matched together, and at times shifted long themselves, create a floor plan that definitely hides/ conceals the form of the two box shaped shipping containers.

300 Interior and exterior fixed walls, due to their minimal load-bearing function, can be designed at will to obtain the desired house style. As a matter of fact, these walls do not play a significant role during transportation. Hence, it is possible to open big windows or even to replace all walls with load-bearing windows. The envelope can be a flexible skin so that it is easier to achieve? a more aesthetically attractive

305 building.

The interior is open space without columns, thanks to the two structural triangular trusses (60), which are situated between the ceilings of the two containers, which bear the central part of the roof and the skylight weight. Thanks to the foldable system of the building (first the opening of the roof,

3io followed by the opening of the floor or vice versa) the interior is very wide. From two ISO shipping containers a total floor area of 6.25 times (and not simply double) the size of a conventional container can be achieved. During transportation, all interior and exterior parts in sight of the finished, opened house are well protected. When the house is closed in two shipping containers,

315 only the external part of the roof and the parts beneath the house are in sight. The head parts are protected by the head structures with corner fittings, which also prevent cross deformation during transportation. In this way, style and material choice are not influenced by transportation problems. Because this house could be an off-the-shelf product (for at least 95%),

320 successfully complicated solutions can be achieved and high precision details can be obtained. Installation is restricted to few, simple operations.

It is possible to install a non-traditional plant which allows the building to achieve self-powered status without the use of batteries (expensive, short-lived and pollutant)

325 Figure 14 schematically illustrates the self-powered plant.

It uses photovoltaic panels 80 which transform the sun's radiation into electricity. During the sunny period, when the energy is not completely absorbed by the house occupants, thanks to controller 81 the electricity surplus is sent to the compressor 82 which compresses air (or another gas) into a cistern 83.

330 When the sun sets, the cistern 83 can be used to activate a pneumatic engine (or a turbine) 84 and an alternator 85, which can provide electricity for the house (87), thanks to an DC/AC converter, during the night or when the power provided by panels 80 is not sufficient. This kind of plant provides the house with self-sufficiency, and it is also eco-

335 friendly because no pollution is produced.

Although an embodiment has been described in detail for the purpose of illustration, various modifications can be made without departing from the scope and spirit of the invention. 340 For example, it is possible to achieve a house composed by more than two containers, using technical solutions equivalent to those described in the presently preferred embodiment of the two containers.

From this description an ordinarily skilled building construction technician can understand and realize the object of the invention without adding any further 345 details.