Field of the Invention

The present invention relates to rapid on-site assembly portable buildings and to a method of forming filled hollow Fibreglass panels and to panels so- formed.

Background to the Invention

Temporary building installations are required for a large range of applications, most commonly in the building trade to provide offices and shelter for the work force of construction work in progress. Other applications include military headquarters and hospitals, temporary emergency rescue headquarters, temporary factories and classrooms and temporary exhibition buildings.

For small scale temporary building structures numerous rapid assembly modular cabin systems have been developed. However, larger scale temporary buildings cannot be readily constructed from the modular cabin system and the predominant form of large scale temporary construction relied upon remains the tent structure.

Whereas tents are low cost in terms of materials and provide natural ventilation they suffer in terms of labour intensiveness of construction and their inherent low structural integrity.

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According to a second aspect of the present invention there is provided a Fibregiass panel comprising an outer shell of resin filled with a plurality of filler blocks of foam, there being Fibregiass matting between each adjacent block of foam structurally linking the front and rear faces of the panel and thereby providing intermediate strengthening of the panel.

According to a third aspect of the present invention there is provided a rapid on-site assembly portable building which comprises: a primary framework having a floor, a roof and two opposing side walls and two opposing end walls, the floor, roof and end walls each having a fold out extension panel which is hinged to the primary framework during folding out thereof to assemble the building, the primary framework being adapted to be transpoπed on a wheeled trailer with the extension panels folded there against; each of the extension panels being formed according to the method of the first aspect of the invention.

Preferably a respective track is provided, in use, along each end wall extension panel and at least one of said side walls has a runner means at each vertical edge thereof, each of which runs along a respective said track, in use, to enable the end wall to be moved out to its operative position.

Preferably each said track comprises a metal channel embedded in the respective end wall extension panel. The runner means is suitably a roller that is dimensioned to be constrained to run along the track.

Preferably each track is located at or adjacent the top edge, in use, of the end wall extension panel, parallel to that edge and parallel to the opposing track of the opposing end wall extension panel.

In a method of assembly of the rapid on-site assembly portable building of the first aspect of the present invention the preferred sequence of the assembly comprises the steps of: raising the roof extension panel; folding out the end wall extension panels to extend the end walls: running the side wall out along the end wall extension panels; lowering the floor; and lowering the roof extension panel into position.

blocks of filler foam substantially fill the cavity within the shell, the blocks of foam being overlaid with Fibregiass matting that extends from one face of the block adjacent the first part of the shell, between opposing end edges of adjacent blocks of foam and then along the opposing face of the block of foam or the adjacent block of foam, the fibreglass matting being impregnated or coated with wet resin; and

iii) allowing the fibreglass matting to dry to form a rigid support web from the first part of the shell to the second part of the shell between each block of filler foam within the internal cavity of the panel.

This construction greatly strengthens the panel against longitudinal and lateral compressive or torsional forces, thereby enabling a panel to be constructed to dimensions of the order of ten foot square and larger while maintaining adequate load bearing properties to enable it to be used on its own or in combination with only one or two other panels to form a complete wall, roof or floor of a portable building.

Preferably the fibreglass matting forming the rigid support web is placed so that a part of the matting adjacent the first part of the shell lies thereagainst and bonds thereto and a part of the matting along the opposing face of the block of foam lies against and bonds to the second part of the shell.

Suitably the resin shell is formed of Gelcote (/JELCOTE/ Gelcoat), which is a proprietary product well known in the Fibreglass industry that is commonly formed of polyester resin in styrene monomer including methylmethacraylate and suitable colour pigmentation.

The foam blocks are suitably of polyurethane or of expanded polystyrene.

The preferred size of the foam blocks is of the order of one foot in width (not thickness).

Advantageously where the roof is mounted to the top of the primary framework, it is drawn in and out by winch means mounted to beams.

The roof may comprise rigid sections, similar to the floor, at least one of which is hinged to the primary framework during folding out of the roof.

Suitably the roof and support columns are sufficiently rigid and strong to support at least one said portable building upon another.

In one paπicularly preferred aspect of the invention the building is adapted to have a shrapnel or bomb proof roof wherein the roof is formed of one or more sheets of elastomeric material. A suitable such material is KEVLAR. The sheets are suitably slung from the framework and suppoπed by outer corner posts such that the sheets are not fully taut, when the building is assembled, to provide a greater degree of resilient movement when struck by incoming projectiles.

Panels of material may be fastened to the underside of the roof such as to be able to drop down and provide partitions within the building. Suitably these panels of material may be fastened at their lowermost end to the floor by catches or other suitable means.

Most desirably three or more floor extension sections are hinged in a sequence extending outwardly from the primary framework. To allow for adequate articulation and nesting together of the innermost linked pair of sections these are suitably hinged together by hinges which have one leaf longer than the other.

Advantageously the hinges between the floor sections which are hinged together are removable therefrom to provide an uninterrupted floor surface.

Suitably at least one wall extension panel is hinged to another wall extension panel to enable the extended wall to change direction. Thus, for example, a first wall extension panel may extend the right hand side wall of the building and a second panel hinged to the outer end of the first extension panel may

Suitably the roof extension panel is provided with peripheral channels to lock over the upper edges of the end wall extension panels and side wall.

The fibre glass panels may suitably be moulded to incoφorate glazing panel mounts integrally and to incoφorate the hinges by means of which the extension panels are hinged to the primary framework integrally also.

In one advantageous arrangement the hinges may be concealed between the abutting edges of the panels hinged to each other in a manner similar to conventional door hinge concealment but with each respective portion of the hinge being mounted to each respective panel having not simply a flat plate configuration but comprising a shoe that fits over the abutting edges and which is secured in place by subsequently applied glass fibre material.

Fuπher inventive features of the design of the poπable assembly building include the incoφoration of stanchions in the end edges of glass fibre panels to enable an upper storey of the portable assembly building to be pinned to a lower storey without use of extraneous components.

Preferably the end wall panels are rigid, and most preferably, of box section.

Preferably the respective upper ends of the opposing end walls of the primary framework are joined by one or more rigid beams to which, suitably, winch means are mounted for winching the one or more hinged sections of the floor down into the folded out state or winching it back into the folded up state.

Preferably the primary framework lies at or near the central region of the assembled building, a respective section of the floor being hinged to each opposing side of the central framework during folding out of the floor.

Preferably the roof is mounted to the top of the framework, fastened thereto at one end of the roof and folded against the primary framework such that the roof may be drawn out and unfolded when required.

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Figure 6 is a part cut-away perspective view of the structure of Figure 5 illustrating it's use as a dormitory;

Figure 7 is a perspective view of a yet further structure during assembly; and

Figure 8 is a perspective view of the yet further structure when assembled and stacked to form a multi-storey structure.

Figure 9 is a perspective view of a further assembled portable assembly building;

Figure 10 is a detailed view showing the track in the end wall along which the side wall is adapted to run;

Figure 11 is a detailed view of the central section of the Figure 10 portable building illustrating the hinged connection between the central end wall of the primary framework and the adjacent end wall extension panel;

Figure 12 is a general internal perspective view of the portable building shown in Figure 9 with the side walls in their operative position and with floor extension panels absent; and Figure 13 is a detailed view of a preferred form of the hinge for the extension panels.

Figure 14 is a transverse sectional view of a panel embodying the first aspect of the invention; and

Figures 15 through to 17 are schematic views of respective stages in the sequence of interleaving foam filler blocks with Fibreglass matting.

Description of the Preferred Embodiments

Referring to figure 1, there are shown the stowed components of the building prior to assembly mounted upon a trailer behind a truck cab.

SUBSTΠTJTE SHEET (RULE 26)

be swung into a position at right angles to the first panel and thereby provide an end wall to the building.

Where the primary framework is removably mounted upon a wheeled trailer the framework is suitably supported on a bed having hydraulic rams which will enable the bed to be raised from the trailer to enable the trailer to be withdrawn from there beneath once the primary framework has been sited as desired.

Hydraulic rams supporting the bed provide a useful means of raising the whole primary framework or raising the top portion of the framework to thereby enable the elevation of the floor or the elevation of the roof relative to the floor to be varied. By using telescopic hydraulic rams the height of the roof may be extended by between 10 and 18 feet or more.

Brief Description of the Drawings

Preferred embodiments of the present invention will now be more paπicularly described by way of example and with reference to the accompanying drawings wherein:

Figure 1 is a perspective view of a rapid on-site assembly portable building in stowed state installed upon a trailer for transportation;

Figure 2 is a perspective view of the Figure 1 structure in part assembled state:

Figure 3 is a perspective view of the same structure at a later stage in assembly;

Figure 4 is a perspective view of the building once fully assembled;

Figure 5 is a perspective view of a structure having a floor of paired fold out sections in part assembled state;

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The panels 13a, 13c, 13d and 13f which abut the end walls 3,4 of the primary framework 1 are suitably hinged to the edges of those end walls 3,4 which they abut. This enables those extensions to be swung outwardly from a folded state in which they overlie the folded floor panels 8 to the position as shown in figure 4 whereby they define the outer walls of the building once assembled. The end wall extensions 13b, 13e farthest from the primary framework 1 may be hinged to the inner extensions 13a or 13d, respectively. Once in their extended position to form the outer boundaries of the building they may be secured in place to corner pillars 14.

The corner pillars 14 may locate in sockets provided in the corner extremities of the extended floor or may be positioned external to the floor.

It is not essential that the wall extension panels 13a-f are hinged together and to the primary framework 1. They may alternatively be hooked or otherwise fastened together once the floor has been lain and the end pillars fixed in place.

Although, as illustrated, the side wall extension panels 13 are outermost in the stowed state, they may be stowed inwardly of the floor extension panels 8 by adapting the configuration of the hinge attachments to the primary framework 1 or using other means of fastening the panels in place.

The roof 20 of the building may comprise sheets of material which are mounted to the outer periphery of the upper end of the primary framework 1 to be unfolded and extended to fasten over the corner pillars 14. The roof 20 may be stretched taut or may be allowed to sag slightly, especially where the building is to be used for military purposes since this will enhance the resilience of the roof 20 to resist incoming projectiles.

Suitably the roof is provided with more than one layer of material such as to provide a cavity therebetween for insulation or for enabling provision of an air conditioning system. These last provisions are suitably in conjunction with cavities provided in the end wall extension panels to enable the building to be used in a wide range of differing climates. The panels may be

As illustrated, the stowed building comprises a primary, or core, framework 1 having a floor 2 and end walls 3,4. The end walls 3,4 are shown as open frames into which a panel may be fitted which comprises for example a door 5 as illustrated in figure 4.

Extending between the upper ends of the end walls, or end wall frames 3,4 are one or more beams which support a winch mechanism 6 operated by a hydraulic or pneumatic motor 7. This winch mechanism serves to winch out extension sections 8a-f of the floor 2.

The floor extension sections 8a, 8d nearest to the floor 2 of the primary framework 1 are hinged to the floor 2 by removable hinges (not shown).

The winch mechanism 6 is illustrated in figure 3 to be connected to the outer edge of the innermost floor extension panel 8a by belts of webbing 9 which pass through respective removal loops 10 mounted to that edge. By using belt webbing 9 rather than cable and by pivotally mounting the loops 10 to the outer edge of the panel 8a the panel 8a may be raised or lowered without undue risk of jamming of the winch system and with a balanced evenly distributed motion.

Prior to lowering the innermost panel 8a, the outermost panel 8c will have been lowered by means of loops 11 on the outermost edge of that panel 8c.

The floor extensions once lowered slide forward under gravity over girders 12 which are placed upon the ground for that puφose. Where the ground is uneven the girders may be propped by wooden chocks or any other suitable means.

As indicated in ghost lines in figure 2, end wall extension panels 13a-f are suitably provided to extend from the respective sides of the respective end walls 3,4 of the primary framework 1.

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Reveπing again to the general embodiment of Figures 9 to 12, the side walls 35, 36 of the building are. unlike the prior art illustrations of Figures 7 and 8, not hinged to the end wall extension panels 26, 27 respectively but instead are wholly independent of the end wall extension panels 26, 27 except in that they are mounted to run along respective tracks 37, 38 provided on the end wall extension panels 26, 27.

It will also be noted from reference to Figure 12, that the tracks 37, 38 are extended into the end wall 3 of the primary framework to enable the side walls 35, 36 to be nested into the primary framework when the building is in the stowed state.

Figure 10 provides a close illustration of the cooperative engagement of the roller 39 on the vertical edge of the side wall 36 with the track 37 on the end wall extension panel 26. It will further be appreciated that the track 37 comprises a rigid metal channel that constrains the roller 39 to run there along and which provides support to the side wall 36 as it is run out into position.

The sequence of assembly of the portable building as illustrated in Figures 9 to twelve suitably begins with raising of the roof extension panels 20a, 20c which are outermost when the portable building is in the stowed state. The end wall extension panels 26, 27 and opposing panels 28, 29 are then unfolded to extend the respective end walls 3, 4.

The side walls 35, 36 are then slid out along their respective tracks 37 and 38 to the extremity of the end wall extension panels.

Finally, the floor extension panels 8a, 8d are lowered into place within the confines of the extended end walls and the side walls.

Referring to Figure 14, the Fibreglass panel 41 is formed of two parts which, for the sake of convenience. I will refer to as a base part 42 and a lid part 43.

constructed of fibre glass or of any other suitable light weight and strong material and may be of box section with the cavity being filled with glass fibre wool or any other suitable form of insulating material.

Referring to Figures 7 and 8, where it is desired to provide a rigid flat roof 20 having a clearly defined box section 20 a-d this may be achieved by using hinged roof sections which may be winched into position in a manner similar to the floor by the same or preferably another winching mechanism. To this end, rails may be provided along which the outer edges of the roof may be run to extend the roof fully.

Refeπing to Figure 9, this illustrates a constructed prototype of the invention and which comprises single floor extension panels 8a, 8d on each side of the primary framework 1 and corresponding single roof extension panels 20a, 20c. In this embodiment the primary framework 1 incoφorates a floor section 2 and a rigid roof section 25.

As perhaps best illustrated in figures 11 and 12, the end walls 3, 4 of the primary framework are slightly raised relative to the end wall extension panels 8a, 8d hinged thereto. This is to allow for nesting together of the extension panels when the portable building is stowed prior to or after use.

As shown in Figures 11 and 12, each end wall 3, 4 is extended by a respective end wall extension panel 26, 27, each extension panel 26, 27 being hinged to a respective lateral edge of the end wall.

The nature of the hinges illustrated in Figures 11 and 12 is of a prototype form which is suitably to be replaced by a concealed design of hinge as illustrated in Figure 13. The Figure 13 design of hinge comprises a pair of shoes 30, 31 each fitting over a respective abutting edge of the adjacent panels 3, 27 and suitably fastened in place by overmatting with glass fibre and preferably having apertures especially provided in each shoe 30, 31 through which resin, of the type from which the glass fibre panels are formed, may ooze to firmly bond the respective shoe 30, 31 in place.

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46a tucked underneath the filler block 45a in contact with the floor 44, a second part 46b extending up a side edge wall of the filler block 45a, the next part 46c of the Fibreglass mat 46 extending over the top surface of the filler block 45a before the mat 46 down turns into a fourth portion 46d and into a final portion 46e that tucks under the adjacent edge of the next adjacent filler block 45b and again bonds to the floor 44 of the shell base portion 42.

It is the down turn portion 46d that provides the rigid support web between the base 42 and lid 43 portions of the panel 41. It is this portion 46d of glass fibre matting 46 that is primarily responsible for the greatly enhanced structural integrity of the glass fibre panels of the present invention.

The continuity of the down turned portion 46d with the third and fifth portions 46c and 46e overlying one filler block 45a and underlying the next filler block 45b that spreads any torsional forces across those two surfaces.

By virtue of the fact that the portion 46d of the Fibreglass mat 46 is of substantially the same material as the shell 42, 43 the whole panel once completed dries so that the resin impregnated glass fibre sets to form a substantially integral entity.

The preferred sizes of foam filler block 45a, 45b used are generally of the order of one foot wide but may be a substantial number of feet long. A large panel is simply created by using a greater number of the filler blocks 45 to construct the panel 41.

Referring again to the sequential views of the process in Figures 15 to 17, if it is desired to increase the strength of the down turn portion 46d, further strips of glass fibre mat may be laid over that portion 46d.

SUBSTTTUTE SHEET (RULE 26)

The base part 42 is formed initially following conventional procedure. The first step of the procedure is to polish the mould in which the base part is to be formed, in order to enable the Fibreglass to be readily released from the mould subsequently.

The JELCOTE Fibreglass resin is then applied to the internal surface of the mould either by brush or by spraying.

The JELCOTE resin is allowed to dry and set hard.

Having formed the base part 42, which has a generally tray-shaped form, with upturned side and end walls, the lid portion 43 is then formed as a flat sheet of JELCOTE resin.

The configuration of the base portion 42 and lid 43 is such that when they are brought together they form a panel of a thickness defined by the height of the upturned walls of the base portion 42 and the thickness of the lid 43.

The next stage of the method of the invention involves applying wet resin and a Fibreglass mat 44 to the internal floor of the panel shell base portion 42.

Wet foam filler blocks 45a, 45b and 45c are then sequentially placed within the base portion 42.

Filler blocks 5a-5c are formed of expanded polystyrene or polyurethane foam and are of a thickness to substantially fill the internal cavity of the panel between the floor of the base portion 42 and the internal face of the lid portion 43.

As can be best seen from Figures 15 to 17, each filler block 45a-45c as it is placed within the panel shell base portion 42, has a Fibreglass mat 46 lain over it to bond with the wet Fibreglass 44 covering the floor of the shell base portion 42. The Fibreglass mat 46 is suitably a conventional two ounces per square foot layer of Fibreglass matting. This is draped over the filler block 45a suitably in such a way as to provide a continuous sheet with a first part

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5. A fibreglass panel as claimed in Claim 4 and that is moulded to incoφorate glazing panel mounts integrally.

6. A fibreglass panel as claimed in Claim 4 or Claim 5 which integrally incoφorates a hinge.

7. A fibreglass panel as claimed in any of Claims 4, 5 or 6 incoφorating stanchions in its end edges.

8. A rapid on-site assembly portable building which comprises: a primary framework having a floor, a roof and two opposing side walls and two opposing end walls, the floor, roof and end walls each having a fold out extension panel which is hinged to the primary framework during folding out thereof to assemble the building, the primary framework being adapted to be transported on a wheeled trailer with the extension panels folded there against: each of the extension panels being formed according to the method of Claim 1.

9. A rapid on-site assembly portable building as claimed in Claim 8 wherein a respective track is provided, in use, along each end wall extension panel and at least one of said side walls has a runner means at each vertical edge thereof, each of which runs along a respective said track, in use, to enable the end wall to be moved out to its operative position.

10. A rapid on-site assembly portable building as claimed in Claim 8 or Claim 9 wherein said track comprises a metal channel embedded in the respective end wall extension panel.

11. A rapid on-site assembly portable building as claimed in Claim 10 wherein the roof extension panel is provided with peripheral channels to lock over the upper edges of the end wall extension panels and side wall.