Field of the Invention

The present invention relates to rapid deployment modular structures and, in particular, to the sealing of various components of the modules used to create the rapid deployment structures.

Background Art

International Patent Application No. PCT/AU2011/000334 (Published under No. WO2011/120075) discloses a module having a pitched roof, a floor, four hinged columns arranged at the corners of the module, two side walls and two end walls . Each of the walls is able to be pivoted from a stowed substantially horizontal position to a deployed substantially vertical position. The creation of such modules, and structures formed using the modules, requires that in order the structures be waterproof, there be various seals created. One form of seal is a seal required at the location of the hinges of the columns. Another type of seal is the seal between the walls and the columns, and the third type of seal is the seal between adjacent modules in a multi-module structure.

Genesis of the Invention

The genesis of the present invention is a desire to improve such rapid deployment structures including the seals thereof and preferably also the columns thereof and the alignment of adjacent modules. In particular, it is desired to improve the overall rigidity of such structures.

Summary of the Invention

In accordance with a first aspect of the present invention there is disclosed a sealing arrangement for a stationary column against which an edge of a pivotable wall mates, said wall being pivotable between a substantially horizontal stowed position and a substantially vertical deployed position, said arrangement comprising a hollow resilient strip seal extending along a leading surface of said wall edge, and an abutment strip protruding from said column and against which said hollow seal abuts with the wall in said deployed position to thereby resiliency deform said strip seal.

Preferably the wall includes a resilient blade seal extending along a trailing surface of said wall edge, said blade being spaced from said resilient strip seal and resiliently wiped against said column with said wall in said deployed position.

In accordance with a second aspect of the present invention there is disclosed a module to module seal for adjacent modules of a rapid deployment modular structure having at least one hinged column having first and second elongate portions which are hinged together and are pivotable between a stowed position in which said portions lie alongside each other and a deployed position in which said portions are aligned, said seal comprising:

a first elongate seal extending along said first portion;

a second elongate seal extending along said second portion;

with said column in said stowed position said first seal abutting said second portion, said second seal abutting said first portion, and said first and second seals lying alongside each other; and

said first seal and said second seal are transversely displaced whereby with said column in said deployed position, said column can abut a like deployed column such that the seals of said like column lie alongside said first and second seals but with a substantially equal, but opposite, transverse displacement .

In accordance with a third aspect of the present invention there is disclosed a sealing arrangement for a hollow column of rectangular transverse cross-section having first and second portions which are hinged together, said arrangement comprising a hinge located within the interior of said hollow column, said first portion and said second portion having complementary inter-engaging profiles, one of said profiles comprising an inner rectangular rim surrounded by an outer shelf, and the other of said profiles comprising an outer rectangular rim having an inner shelf.

In accordance with a fourth aspect of the present invention there is disclosed a column for rapid deployment structures, said column having three pivoted portions which are hingedly connected, and comprising:

an upper portion hingedly connected by a first hinge to a roof member, an intermediate portion hingedly connected by a second hinge to said upper portion, and

a lower portion hingedly connected by a third hinge to a floor member, said first and third hinges being able to pivot through approximately 90°, and said second hinge being able to pivot through approximately 180°.

In accordance with a fifth aspect of the present invention there is disclosed a alignment mechanism for a pair of modules of a rapid deployment structure which are intended to have two opposed surfaces abutted, said mechanism comprising a pair of equally spaced apart lugs located on each said opposed surface, each of said lugs having a ramped surface, for the pair of lugs on each said module the ramped surfaces facing in opposite directions and for opposed lugs on opposed modules the ramped surfaces facing in opposite directions, whereby as said modules are abutted, the ramped surfaces of said opposed modules slidingly engage to align said modules.

Brief Description of the Drawings

Embodiment of the present invention will now be described, with reference to the accompanying drawings in which:

Fig. 1 is a perspective view of a module with pitched roof and four columns but no walls;

Fig. 2 is a similar perspective view of a module but illustrating the provision of side and end walls;

Fig. 3 is a perspective view of one of the columns of Figs. 1 and 2 in its folded stowed configuration;

Fig. 4 is a perspective view of a column of Fig. 3 being partially deployed;

Fig. 5 is a perspective view showing the column of Figs. 3 and 4 in its fully deployed, substantially vertical configuration;

Fig. 6 is a perspective view showing a three storey rapid deployment structure in the process of being erected in which the upper module has a pitched roof but the lowermost and intermediate modules do not have a pitched roof; Fig. 7 is an enlarged perspective view of the upper semi-deployed hinge joint illustrated in Fig. 6;

Fig. 8 is an enlarged perspective view of the lower semi-deployed hinge joint illustrated in Fig. 6;

Fig. 9 is a view similar to Fig. 7 but illustrating one method of securing the hinge joint of Figs. 7 and 9 when fully deployed;

Fig. 10 is a view similar to Fig. 9 but illustrating how the hinge joint of Figs. 8 and 10 can be secured when fully deployed;

Fig. 11 is a view of a fully deployed hinge joint in the final stages of securement;

Fig. 12 is a perspective view of the hinge joint of Fig. 11 fully secured;

Fig. 13 is a schematic illustration of a prior art hinge joint in its pivoted configuration;

Fig. 14 is a view of two of the prior art hinge joints of Fig. 13 attempting to be edge abutted;

Fig. 15 is a view similar to Fig. 13 but illustrating an interior hinge;

Fig. 16 is a view of the interior hinge of Fig. 15 in the deployed position

Fig. 17 is a perspective view of a rapid deployment module showing the deployment of the end walls;

Fig. 18 is a cross-sectional view along the line 18- 18 of Fig. 17 showing the right hand end of the end wall sealing against the adjacent column;

Fig. 19 is a view of the left hand end of the wall of Fig. 18;

Fig.20 is a view similar to Fig. 18 but illustrating the sealing of the left hand end of the wall of Figs. 18-20;

Fig. 21 is a perspective view of a module being deployed and showing enlarged views of the sealing arrangements of the side walls;

Fig. 22 is a schematic perspective view showing two modular structures being brought together at the same level and illustrating the requirement for sealing;

Fig. 23 is a perspective view of a column showing two longitudinal seals;

Fig. 24 is a perspective view of two columns showing the equal and opposite transverse displacement of the seals;

Fig. 25 is a perspective view showing the column of Figs. 23 and 24 in the stowed position showing the seals located alongside each other; Fig. 26 is a truncated plan view illustrating locating lugs on adjacent modules of Fig. 22 prior to them being edge abutted;

Fig. 27 is a view similar to Fig. 26 but illustrating the conclusion of the abutment process

Fig. 28 is shows two modules which have been end abutted;

Fig. 29 is an enlarged view of a portion of Fig. 28 showing one mechanism of securing adjacent columns;

Fig. 30 is an enlarged view similar to Fig. 29 and illustrating the conclusion of the process illustrated in Fig. 29;

Fig. 31 is a perspective view of abutted columns illustrating an alternative embodiment for securing the columns;

Fig. 32 is a perspective view of a multiple storey rapid deployment structure illustrating the nature of the sealing of adjacent modules and including enlarged views; and

Fig. 33 is a perspective view of a three storey rapid deployment modular structure in substantially completed form.

Detailed Description

As seen in the drawings, in Fig. 1 a module I is illustrated having a pitched roof 2 and a base 3. The roof 2 is supported by four columns 4. As seen in Fig. 2, if desired, two side walls 5 can be provided (only one of which is illustrated). Each of the side walls 5 is formed in two pieces. Each piece is connected between a corresponding pair of columns 4. The lower piece is pivoted to the base 3 and the upper piece is pivoted to the roof 2. The two pieces of the side walls 5 meet at a horizontal line 6. Two end walls 7 can be provided (only one of which is illustrated in Fig. 2). The side walls 5 and end walls 7 are not load bearing since all the vertical load of the roof 2 (and any upper storeys) is carried by the columns 4.

As seen in Figs. 3 to 5, each of the columns 4 has a top portion 41, a middle portion 42 and a base portion 43. Between the base portion 43 and the middle portion 42 is a hinge 45. A similar hinge 44 is provided at the top of the top portion 41 and connects the top of the column 4 to the pitched roof 2. The hinges 44 and 45 are required only to pivot through 90°. However, between the top portion 41 and the middle portion 42 is a hinge 46 which is required to pivot through 180 °. Turning now to Fig. 6, illustrated therein is a three storey structure 10 in the process of deployment The columns 4 of the upper storey are fully deployed, the columns 4 of the middle storey are in the process of being deployed, and the columns 4 of the lower storey are in the fully stowed position. The upper module 11 is illustrated with side and end walls 5, 7 whilst the middle module 12 is illustrated without side or end walls, and the lower module 13 is illustrated with only end walls 7.

In Fig. 3 the structure 10 is shown being deployed by means of a crane (not illustrated) which is lifting the upper module 11. It will be appreciated by those skilled in the building arts that more than three levels can be provided, however, most building regulations require the provision of a lift or elevator (not illustrated) if a building has more than three storeys. So for this reason there is not much demand for rapid deployment structures having in excess of three storeys. Turning now to Figs. 7 and 9, it will be seen that the hinge 46 has an internal SOSS (Trade Mark) hinge which is located within the hollow top and middle portions 41 and 42. The middle portion 42 has a rectangular internal rim 15 which is surrounded by a shelf 16 whereas the top portion 41 has an exterior rectangular rim 17 which has an interior shelf 18.

It will be apparent that the rim 15 mates with the shelf 18 and the shelf 16 mates with the rim 17 so as to form a complementary inter-engaging arrangement which enables the column portions 41 and 42 to be moved into the aligned positions illustrated in Figs. 11 and 12. Turning now Figs. 8 and 10, it will be seen that the hinge 45 which interconnects the middle portion 42 and base portion 43 of the columns 4 is similarly provided with rims 15, 17 and shelves 16, 18. As seen in Figs. 9 to 12, the column portions can be secured in the aligned position by means of a long screw 22, and preferably also two short screws 21. It will be apparent that the overlapping relationship between the rims 15, 17 and the shelves 16, 18 provides an adequate seal in which gravity prevents moisture penetrating into the interior of the hollow column 4. Turning now to Figs. 13 to 16, if a column 4 is provided with a conventional hinge 146 as illustrated in Fig. 13, then two such columns cannot be edge abutted because, as illustrated in Fig. 1 , the protruding hinges 146 prevent the columns being edge abutted. For this reason, it is necessary, as illustrated in Fig. 15, to provide a hinge which is entirely contained within the column 4 so that when the column portions are straightened as illustrated in Fig .16, the hinge is entirely contained within the column. This produces the entirely self-contained arrangement as illustrated in Figs. 7 to 12. Turning now to Figs. 17 to 20, it will be seen that after the columns 4 are straightened, the end walls 7 are raised as indicated by arrows A from a substantially horizontal stowed position to a substantially vertical deployed position.

As illustrated in Fig. 18, the right hand end of the end walls 7 is provided with a hollow resilient seal 24 extruded from rubber or other elastomeric material. The seal 24 is provided with feet 25 (Fig. 19) which are retained in a groove 26 formed in an aluminium extrusion 27. The aluminium extrusion 27 also contains a second groove 28 within which is located a wiper blade seal 29. It will be apparent that the aluminium extrusion 27 can be pushed onto the end edges of the end walls 7. In addition, the column 4 is provided with a kinked abutment strip 48.

It will be apparent from Figs. 18 and 20 that as each end wall 7 is raised into the deployed position by moving in the direction of arrow A, the hollow seal 24 comes into contact with the abutment strip 48 and thereby resiliently deforms as illustrated in

Figs. 18 and 19. Simultaneously, the wiper blade seal 29 also makes contact with the column 4 at the conclusion of the pivoting of the end walls 7, thereby forming a stagnant air seal between the end walls 7 and the column 4, the edges of which are bounded by the two seals 24, 29. In this way, an effective seal is made between the end walls 7 and the columns 4 which is both weatherproof and insulating. Since the side walls 5 are directly connected with the columns 4, there is a permanent and fixed seal between the side wall pieces and the corresponding panel portions.

However, as illustrated in Fig. 21, it is necessary to seal the side walls 5 along the horizontal line 6. This is achieved by complementary aluminium extrusions 36 and 37 which push onto the panels of the side walls 5. The extrusion 37 carries two strip seals 38 of semi-circular transverse cross-section. These are compressed against the crest of the extrusion 36 to form a stagnant air insulative seal when the side wall 5 is vertical. In addition, where the side walls 5 pivot relative to the roof 2 and the base 3, the hinge 40 incorporates two push on extrusions 58 and 59. The extrusion 58 includes one of the strip seals 38. When the hinge 40 is in the closed position, which corresponds to the side wall 5 being vertical, the seal 38 is compressed against the extrusion 59. Turning now to Fig. 22, it will be seen that at any given level or storey, two modules I can be abutted so as to form a larger room. Therefore it is necessary to provide sealing to waterproof the join between the module 1 and also provide a degree of insulation. Preferably this is achieved by means of pairs of longitudinal seals 31, 32 which are arranged to lie alongside each other when the two modules 1 are. abutted.

As seen in Fig. 23, each of the columns 4 is preferably provided with two seals 34, 35 which are transversely displaced on the middle portion 42 relative to the top portion

41. This equal and opposite transverse displacement of the seals 34, 35 has two effects. First of all, when opposing columns 4 are abutted as indicated in Fig. 24, the seals 34 of the top portion 41 lie alongside each other and the seals 35 of the middle portion 42 also lie alongside each other, thereby forming a double seal which is not only waterproof but which includes a stagnant air insulative barrier. In addition, as foreshadowed in Fig. 23, and illustrated in Fig. 25, when the top portion 41 and middle portion 42 lie alongside each other in the column stowed position, then the seals 34 and 35 lie alongside each other and therefore do not come into contact with each other. If the seals 34 and 35 were aligned, then they would lie one above the other with the column 4 in the stowed position. This would have two consequences.

Firstly, the seals would tend to flatten and lose their resilience if stowed like that for long periods of time. Secondly, the top portion 41 and middle portion 42 would not be truly parallel in the stowed position. Turning now to Figs. 26 and 27, when two modules 1 are end abutted as illustrated schematically in Fig. 21, it is desirable to provide a locating mechanism which preferably takes the form of a wedge 50 located on each of the columns 4 as illustrated in Figs. 26 and 27. Each wedge 50 has a ramp 21 having an inclined surface. As the two modules approach each other as seen in Fig. 22, the columns 4 are only roughly aligned by the crane operator using the crane to move one of the modules 1 relative to the other of the modules 1. However, as the columns 4 approach each other, the ramps 51 engage and slide relative to each other, thereby automatically aligning and centring the modules 1 into the finished configuration illustrated in Fig. 28.

Once the two modules 1 are aligned and abutted as illustrated in Fig. 28, it is then necessary to secure the abutting columns 4. As indicated in Figs. 29 and 30, this may be accomplished by means of several threaded fasteners 53 each with a corresponding nut 54. Alternatively, as illustrated in Fig. 31, two toggle latches 56 can be used to secure the adjacent columns 4.

As seen in Fig. 32, a two storey module 60 can be provided with an upper module 61 and a lower module 62. The lower module 62 is preferably provided with four upstands 63 which are of a height sufficient to project above the pitched roof 2 when both modules 61, 62 are in the stowed position. This enables two of the two storey modules 60 to be stacked one on top of the other without the base 3 of the upper module 60 coming into contact with the pitched roof 2 of the lower module 60. A similar arrangement can be provided for two of the three storey structures 10 of Fig. 6.

Also illustrated in the enlarged views of Fig. 32 is the location of the hinges 44, 45 and 46 in both their bent open positions and their straight closed positions. In the straight closed positions the hinges and columns are locked by the fasteners 21, 22. As a consequence, both the columns and the modules are braced and made more rigid. Finally, as illustrated in Fig. 33, a three storey structure 70 can be created using two of the structures 10 of Fig. 6. The absence or presence of side walls 5 and end walls 7 can be used to create a structure 70 of any desired configuration, for example including verandas 71. The abovementioned bracing effect achieved by the fasteners 21 , 22 is particularly important for modules having a veranda 71 since the normal cross bracing effect produced by the walls, is absent. The foregoing describes only some embodiments of the present invention and modifications, obvious to those skilled in the rapid deployment arts, can be made thereto without departing from the scope of the present invention.

For example, it will be apparent that the columns 4 can be inverted so that instead of the portions 1 and 43 being hinged to a roof member 2 and a floor member 3 respectively, the column as illustrated in Figs. 3 to 5 can be inverted so that the portions 1 and 43 are hinged to a floor member 3 and a roof member 2 respectively. The term "comprising" (and its grammatical variations) as used herein is used in the inclusive sense of "including" or "having" and not in the exclusive sense of

"consisting only of.