Field of the invention

The present invention relates to a modular building unit, a modular building formed from a plurality of modular building units, and a method of constructing the modular building.

Background

By constructing a building formed from modular building units, it is possible to prefabricate discrete modules of the building and install them on-site separately. This can save on time and costs associated with transport, logistics and construction.

However, existing building module units are typically not very customizable, can be relatively labour-intensive to install, and once the modular building is constructed, it can be difficult to alter the building with additional or alternative modules, not least because amenities such as services such as wastewater infrastructure require reconfiguring.

There is a need to address the above, and/or at least provide a useful alternative.

Summary

According to a first aspect of the present invention, there is provided a modular building unit for use in forming a modular building, the unit comprising:

(a) a first framework defining a wall and floor structure of the unit which, viewed from above, has a convex polygonal footprint such that two or more units may be positioned adjacent one another to define a continuous internal living space of the modular building; and

(b) a second framework defining a corresponding convex polygonal roof structure of the unit, wherein the second framework is separately attachable to the first framework in a number of positions by rotating the second framework relative to the first framework prior to attachment such that the orientation of the roof structure relative to the wall and floor structure of each unit can be varied.

According to embodiments of the invention, the first and second frameworks comprise attachment features to enable the frameworks to be secured to one another in X different positions, X being the number of sides defining the convex polygonal footprint.

According to embodiments of the invention, the attachment features are configured to:

(a) enable a pinned connection between the two frameworks; and

(b) provide lifting points via which the frameworks may be lifted, for example by a crane, and positioned for transport and/or installation.

According to embodiments of the invention, the second framework supports a sloped roof structure configured such that rainfall thereon flows towards a lower end of the sloped roof, into a gutter and through one or more downpipes of the unit.

According to embodiments of the invention, the first framework supports walling of the unit, and wherein at corners where external walling defining one side of the unit meets external walling defining an adjacent side of the polygonal unit, the external walling is scalloped for receipt of downpipes.

According to embodiments of the invention, the first framework comprises vertically extending hollow sections for supporting walling of the unit, the unit further comprising legs configured to be adjustably extendable relative to respective hollow sections to enable level installation of the unit on varying or uneven ground.

According to embodiments of the invention, the legs are telescopically extendable relative to respective hollow sections. According to embodiments of the invention, the first framework is adapted to be attachable to or stacked on top of another first framework to provide an internal living space of increased height and/or an additional floor of the resulting modular building.

According to embodiments of the invention, the footprint is substantially that of a regular polygon such that the units can tesselate with one another to form the modular building.

According to embodiments of the invention, the footprint is substantially that of a hexagon.

According to a second aspect of the invention, there is provided a modular building formed from a plurality of modular building units according to the first aspect of the invention.

According to a third aspect of the invention, there is provided a method of constructing a modular building according to the second aspect of the invention, comprising:

(a) lowering a first framework onto the ground at a desired location and in a desired orientation;

(b) hoisting a second framework, rotating it to a desired orientation relative to the first framework and securing the two frameworks to form a first modular building unit of the modular building; and

(c) repeating steps (a) and (b) with additional first and second frameworks to form one or more additional modular building units, wherein each modular building unit is adjacent one or more other modular building units so as to define a continuous internal living space of the modular building.

Brief description of the drawings In order that the invention may be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a front perspective view of a modular building unit of a modular building according to embodiments of the invention;

Figures 2(a) to 2(o) are schematic side views of a modular building unit of different configurations;

Figure 3 includes plan schematic views of a modular building unit in various orientations;

Figure 4 are schematic plan views of different modular buildings that can be constructed from the modular building unit

Figure 5 is a front view of a modular building unit according to embodiments of the invention;

Figure 6 is a front view of a framework of a modular building unit according to embodiments of the invention;

Figure 7 is a close-up front perspective view of a connection point between a roof framework and a wall framework of the framework of Figure 3;

Figure 8 is a close-up top schematic plan view of scalloped external walling of a modular building unit according to embodiments of the invention.

Figure 9 is a perspective view of an adjustable support of an embodiment of the invention;

Figures 10(a) to 10(c) and side views of the modular building unit in different orientations;

Figure 11 is a side view of a support and vertical structural members of the frame and their connection; and

Figure 12 is a front view of a support and vertical structural members of the frame and their connection.

Detailed description A modular building unit 4 according to a preferred embodiment of the present invention is shown in Figure 1. A plurality of units 4 can be used to form a modular building 2.

As shown in other Figures, when viewed from above, the footprint of each unit 4 is substantially that of a regular hexagon. This allows individual units 4 to be positioned adjacent other hexagonal units 4 and joined in a tessellating manner to form a modular building 2.

As illustrated in Figure 2, each of the six sides of the hexagonal unit 4 can be customised with different enclosing features such as wall panels 11 and windows 7, 8 9. Additionally, the wall panels 11 themselves may be configured with large windows 7, medium windows 6, small windows 9, doors 8 and the like (see Figures 1 and 6 for example). Of course, one or more of the six sides can be substantially open to enable the unit 4 to join with another open side of another unit 4 to define a continuous internal living space of the modular building 2.

Each unit 4 also comprises a roof structure 10 with a regular hexagonal footprint which is separately attachable to the hexagonal wall and floor structure 12. The roof structure 10 is sloped and the orientation of this slope, relative to the wall and floor structure 12 of the respective unit 4 can be adjusted by rotating the roof structure 10 before securing it to the wall and floor structure 10.

Since the orientation of the roof 10 of any given unit 4 is adjustable, and each of the six sides of a unit 4 is configurable, and each building unit 4 can be positioned in multiple orientations relative to another building unit 4, the present building units 4 allow for the creation of highly customisable modular buildings 2 which can be added to with additional units 4 over time, while simultaneously enabling advantages associated with modular building construction, including the cost, labour, standardised quality and timesavings associated with prefabrication and modular installation and construction. While the present specification primarily discusses units 4 with regular hexagonal footprints, other convex polygons are of course within the scope of the present invention, including triangles, squares, rectangles, pentagons, and octagons.

As illustrated in Figure 1, the unit 4 comprises a first structure 12 which defines the walls, floor and ceiling of the unit 4 and a second structure 10 which defines the roof. When installed on-site, the roof structure 10 has been hoisted above and then connected to the wall and floor structure 12. These two structures 10, 12 can be prefabricated and transported separately, as desired. Advantageously, transporting the two structures separately reduces load, height and transportation restrictions.

Figure 6 shows the metal framework of the unit 4. A first framework 14 comprises interconnected hollow steel sections for supporting the unit’s 4 flooring and walling.

The first framework 14 comprises six vertical uprights 16 in the form of circular hollow sections which define each of the six corners of the hexagonal unit 4. Disposed within each upright 16 is an elongate leg 18 which are telescopically extendable from respective uprights 16 to adjust an effective vertical height thereof. This allows for the level installation of the first framework 14 on ground that is uneven or variable in its structural integrity. Each leg 18 is provided with a bottom foot plate 20 to enhance the stability of the first framework 14 and thus the unit 4. In preferred embodiments of the invention, each elongate leg 18 is rotatable about its axis and relative to the upright in respect of which it is telescopically extendable 16. Additionally, it is envisaged that each foot plate 20 is tiltable in a lockable manner. As such, the versatile and adjustable leg 18 and foot plate 20 combination allows the first framework 14 to be stably erected in a wide variety of ground and site conditions.

Still referring to Figure 6, the upper and lower ends of each upright 16 are welded to horizontally extending rectangular hollow sections 22 which define, respectively, the ceiling and floor sections of each unit 4. As such, two adjacent uprights 16 interconnected by upper and lower rectangular hollow sections 22 define a single side of the hexagonal unit 4 which is configured to receive walling and the like. Given the welded connections, a rigid structure is provided which is stronger than simply bolting and each “side" of the framework 14 does not require additional reinforcements, such as diagonal bracing, which would otherwise limit the configurability of a wall panel receivable at that side. Furthermore, the welded structure can have sufficient strength to resist transportation loads to allow the assembled unit to be transported without damage.

The welding is done in a controlled environment, preferably in jigs, so that the first and second frameworks 14, 24 can be manufactured in a dimensionally consistent manner to facilitate construction of the building 2, and or rotated to ensure full welding cover.

The unit 4 also comprises a second framework 24 which defines and supports the roof structure 10 of the unit 4. The second framework 24 comprises a series of six uprights 26 welded to rectangular hollow sections 28 to define an enclosed hexagonal footprint when viewed from above.

The first and second frameworks 14, 24 are provided with complementary attachment features 30 which allow the roof framework 24 to be attached to the wall and floor framework 14 in six different orientations.

Figure 7 shows a close-up of one such attachment feature 30. In this Figure, an upper end of each upright 16 of the first framework 14 comprises an upwardly extending tab 32 with a through-hole. A lower end of each upright 26 of the second framework 24 comprises two a downwardly extending tabs 34 with through-holes 54. By aligning the respective tabs 32, 34 and through-holes 54, the two frameworks 14, 24 can be secured to one another via pinned connections. Advantageously, these attachment features 30 also serve as lifting points via which the frameworks 14, 24 can be lifted for transport and installation.

It is envisaged that even after installation, the roof structure 10 can be removed (e.g. for repairs or reorientation) without disrupting or remove the associated base structure 12. Referring to Figure 3, it can be seen that upper ends of the roof framework’s 24 uprights 26 also comprise attachment features 30 which and also serve as lifting points.

Figure 5 shows a base structure 12 of the unit 4 and a roof structure above the base structure 12 secured thereto. The roof structure 10 has a parapet wall construction and a single pitch roof 36. As such, rainfall and other debris are biased to travel down the sloped roof 36 and toward the lower end thereof. As such, the sidewall 38 of the parapet wall construction facing the lower end of the sloped roof 10 comprises a horizontal opening or slot 40 through which rainfall can flow out, into a gutter 52 and through stormwater downpipes 42.

Since the roof structure 10 and framework 24 can secure to the wall framework 14 in one of six different positions, the orientation of the sloped roof 36 and thus the stormwater infrastructure can be varied as desired, thereby increasing the freedom and flexibility with which units 4 can be positioned relative to one another to form the resulting modular building 2. Advantageously, if solar panels are to be installed on the roof 10, the orientation of the roofs slope 36 can be oriented to increase the amount of sunlight the solar panels receive throughout the day. Another advantage is that second hand and/or repurposed base units 12 can be accommodated in a build independent of roof orientation since the roof structure 10 can be adjusted as needed, thereby increasing the flexibility and customizability of a build.

Figure 8 shows the metal external framework 14 and internal wall panels 44 secured thereto. The exterior may be formed from timber ply, cement sheet, profiled sheet metal or solid natural timber to suit a variety of individual site conditions and requirements. External cladding material (not shown) or walling of the units 4 can be formed from desired materials to give the unit 4 a specific appearance.

Wall construction is similar to conventional buildings, with internal walling, such as plaster panelling for example, being secured to wall studs which may be formed from wood or steel. A waterproof layer is provided between the internal and external walling. In use, a user will be able to select from a number of standard wall panels of different configuration according to their preference and the final desired configuration of the building 2. Each wall panel may have windows, a door or be solid. Wall panels adjacent wet areas may additionally be provided with small vent windows. The selected wall panels will be assembled off-site and fitted to the unit 4 prior to transportation. Assembling the wall panels off-site allows a complete unit 4 to be assembled and transported to a building site ready for final assembly and commissioning. This is particularly useful in remote locations where the availability of tradesmen is limited.

Figure 8 also shows a close-up top schematic view of one of the corners 46 of the base structure 12. The external cladding or walling 48 are dimensioned and positioned such that adjacent walling 48 does not contact one another at the corners 46. Instead, the walling 48 at these corner locations 46 is scalloped 50 to optionally receive downpipes 42. As viewed from the top, this concave recess 50 between external walling 48 also allows adjacent units 4 to be positioned adjacent one another without needing to interrupt or remove installed downpipes and other stormwater infrastructure since they can nest within the concave recesses 50 formed between adjacent building units 4.

Figure 9 illustrates an adjustable footing 60 for use with building 4. Footing 60 includes at an upper end telescopic cylinders 62, 64 that allow for relatively large height adjustment by the installation of pins (not shown) in apertures 66. Fine adjustment is performed using threaded portion 68 that extends through nut 70, by rotating cylindrical portion 72. At a lower end of the footing 60 is a base plate 74 for securing to a ground surface or foundation. Apertures 76 are provided to facilitate this securement. Pinned connection 78 allows for the base plate 74 to be angled to suit site conditions.

Figures 10a to 10c illustrate the installation of building 2 in different site conditions and using footings 60. As shown in Figure 10a, the building 2 can be installed on a sloping surface. This can be achieved by use of adjustable footings 60. External panelling 13 may be provided to close off the open space under the building 2. With a level ground surface as shown in Figure 10b, footing 60 may be omitted entirely and each building 2 securing directly to a foundation or footing installed in the ground.

Figure 10c illustrates a double story building 4 which includes two building units 2 stacked on top of each other. As external staircase (not shown) may be provided or access from an elevated ground surface 15.

With reference to Figures 11 and 12, there is shown details of the pin connection system used in unit 2. Starting at base plate 74, the structure is secured to a footing of a ground surface. Pinned joint 78 allows for the plate to be angled relative to a horizontal level. Upright 16 extends from joint 78 and forms part of the frame of the floor structure 12. A pinned connection is formed between attachment features 30 formed on the floor structure 12 and roof structure 10 to facilitate rapid connection therebetween. Uprights 26 extend upwardly and are also formed with an upper attachment feature 30 to facilitate lifting. To ensure interchangeability, attachment features 30 are identical.

Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. For example, while the Figures show a roof structure 10 which can be secured to a base structure 12, it is envisaged that the base structures 12 can be configured so as to stack on another base structure 12 to create modular buildings 2 of different heights and/or with different numbers of floors or combined with corresponding and complementary geometric decks and/or covered open sided shelters. For example, the foot plates 20 may be mounted to respective elongate legs 18 via similar attachment features to those which enable the pinned connection between the roof structure 10 and the base structure 12. Accordingly, these attachment features could similarly form pinned connections with the tabs 32 at upper ends of respective uprights 16 of the base structure 12. In preferred embodiments of the invention, each unit 4 comprises a central and single point of wastewater discharge. In this way, wastewater infrastructure of each unit 4 is self-contained and does not impose structural limitations on adjacent units 4 or rotational location of units 4, thereby enhancing the flexibility of customizability of the resulting modular building 2.

It is also envisaged that base structures 12 can be preconfigured with various standard fit-outs, such as fittings for laundries, bathrooms and kitchens, renewable energy infrastructure, and plug-in to on-site utilities including water, power, stormwater and waste provisions.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise", and variations such as “comprises" and “comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.