Abstract:
A modular building capable of being readily assembled and disassembled comprising rectangular base and roof frames each formed by two longitudinal beams and two lateral beams, the roof frame having a smaller periphery than the base frame. Four columns extend between corners of the base and roof frames, these columns being set back within the periphery of the base frame while having a periphery matching that of the roof frame. The building includes a floor panel having an outer periphery matching the periphery of the roof frame and being dimensioned to rest on inner edge portions of the base frame beams, a roof panel for resting on the roof frame and having an outer periphery at least as large as that of the base frame, and side and end wall panels dimensioned to fit between the base frame beams and the roof panel.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a modular building, and provides a series of components which can readily be assembled into a temporary structure, and readily disassembled and moved. 
       BACKGROUND OF THE INVENTION 
       [0002]    Building sites often have need of a temporary building which can serve as an office or as shelter for workers. Often such a building is in the form of a trailer. It is also known to provide buildings in modular, knock-down form. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention provides a temporary building of modular type which can be delivered to a site, such as a building site, in disassembled, generally flat form, and in which the components can readily be bolted together to provide a somewhat insulated and weather-proof structure. The building can be, generally from 20 to 60 feet in length, and generally from 8 to 14 feet in width, the buildings being connectable to other building to provide larger buildings as needed or desired. 
         [0004]    In accordance with the present invention, a modular building capable of being readily assembled and disassembled comprises, a rectangular base frame formed by two longitudinal base beams and two lateral base beams connected at their ends, so that said base beams define a first rectangular periphery; a rectangular roof frame formed of two longitudinal roof beams and two lateral roof beams connected at their ends so that said roof beams define a second rectangular periphery which is less in width and length than said first rectangular periphery; four columns adapted to extend between corners of the base and roof frames and attachable thereto, said four columns, when positioned, having outer surfaces defining a rectangular outer periphery which substantially matches said second rectangular periphery of the roof frame, said columns being set back within the corners of said the first rectangular periphery of the base frame; a floor panel having an outer periphery substantially matching said second periphery, said floor panel being dimensioned to rest on inner edge portions of the base beams; a roof panel for resting on the roof frame and having an outer periphery at least as large in length and width as said first rectangular periphery; and side and end wall panels dimensioned to fit between said base beams and said roof panel with said wall panels resting on outer edge portions of said base beams, said wall panels enclosing outer peripheries both of said four columns and of the roof frame. 
         [0005]    Preferably, the base beams and roof beams are I beams. Also, the columns are preferably I beams having upper and lower end plates at their respective upper and lower ends, these end plates having apertures for bolting to apertures in the roof and base beams. 
         [0006]    The lower end plates of the columns preferably may each have four rectangularly positioned bolt apertures, an outer three of these apertures being suitable for bolting to apertures in inner edge portions of the base beams at a respective corner. The base beams also have a reinforcing corner element attached to the inside of each corner of the base frame, which reinforcing corner element has an additional aperture end positioned to be bolted to the fourth, inside, aperture of the lower end plate of a column. The reinforcing corner element for each corner of the base frame may be in the form of a tube having sides welded to inner sides of the base beams and having an upper end plate provided with said additional aperture. The corner elements may extend below the base beams to provide legs for resting on the ground. 
         [0007]    The roof frame may have apertured lifting lugs fixed to the top thereof, each lug positioned above one of said columns, the roof panel having apertures to accommodate the lifting lugs. 
         [0008]    The roof beams may each have, attached thereto in parallel relationship, an additional elongated roof member, such as a channel member, which provides flanges at the second rectangular periphery, so that these flanges provide locating means for the side and end wall panels. Similarly, the base beams may each have, attached thereto in parallel relationship, an additional elongated base member having an upstanding flange suitable for locating the outer periphery of the floor panel on the inside of the flange, and also suitable for locating lower edge margins of the wall panels on the outside of the flange. 
         [0009]    In longer versions of the building, the base frame and roof frame may each have one or more additional, intermediate lateral members which meet the longitudinal members at intermediate areas. These intermediate areas of the base and roof frames are connectable by additional intermediate columns which have bolt connections to the base and roof beams. In this construction, the lifting lugs are preferably provided at the upper ends of the intermediate columns, rather than at the corners of the roof frame. 
         [0010]    Furthermore, both the base frame and the roof frame may have one or more additional longitudinal beams fixed at their ends to the lateral base and roof beams and to the lateral intermediate beams. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which; 
           [0012]      FIG. 1  is an isometric view of a first building in accordance with one embodiment of the present invention, before the addition of its roof panel; 
           [0013]      FIG. 2  is a similar view but with the frames disassembled, and in which the floor panel covers the base frame and a roof panel covers the roof frame; 
           [0014]      FIG. 3  is a partially assembled view of the base frame and roof frame of one embodiment of the present invention, and also showing columns attached to the roof frame; 
           [0015]      FIG. 3   a  is a detail view of the part C of  FIG. 3 , showing the corner construction of the base frame; 
           [0016]      FIG. 3   b  is a detail plan view of a corner of the base frame; 
           [0017]      FIG. 3   c  is a detailed view of the portion D of  FIG. 3 , showing the lower end of a column; 
           [0018]      FIG. 4  is an isometric view of the base and roof frames and the columns assembled together, and also shows lifting lugs attached to the roof frame; 
           [0019]      FIG. 4   a  is a detailed view of the portion A of  FIG. 4 , showing the attachment of the lower end of a column to a corner of the base frame; 
           [0020]      FIG. 4   b  is a detailed view of the portion B of  FIG. 4 , showing the lifting lug connected to the corner of the roof frame; 
           [0021]      FIG. 5  shows a cross-sectional view through a completed building; 
           [0022]      FIG. 5   a  is a detailed view of the connection of the lower portion of the enhanced wall of one embodiment of the present invention; 
           [0023]      FIG. 5   b  is a detailed view of the connection of the upper portion of the enhanced wall of one embodiment of the present invention; 
           [0024]      FIG. 6  is an isometric view of the base and roof frames of a second embodiment of the building, which is longer and which has additional beams and columns; 
           [0025]      FIG. 6   a  is a detail view of the lifting lug as positioned in the  FIG. 6  construction, and 
           [0026]      FIG. 6   b  is a detailed top plan view of a lifting lug as positioned in said second embodiment; 
           [0027]      FIG. 7   a  is a cross-sectional view, of an enhanced end wall panel installed on an end wall in one embodiment of the present invention viewed from within the building unit looking toward the enhanced end wall panel; 
           [0028]      FIG. 7   b  is a cross-sectional view of an enhanced wall panel of one embodiment of the present invention; 
           [0029]      FIG. 7   c  is a detail cross-sectional view of the lower end portion C of the enhanced wall panel illustrated  FIG. 7   b;    
           [0030]      FIG. 7   d  is a detail cross-sectional view of the mid-portion D of the enhanced wall panel illustrated  FIG. 7   b;    
           [0031]      FIG. 7   e  is a detail cross-sectional view of the upper end portion B of the enhanced wall panel illustrated  FIG. 7   b;    
           [0032]      FIG. 8   a  is an illustration of the attachment of two buildings in one embodiment of the present invention; 
           [0033]      FIG. 8   b  is a detailed view of the lower connection element for the attachment of two buildings in one embodiment of the present invention; 
           [0034]      FIG. 8   c  is a is a detailed view of the upper connection element for the attachment of two buildings in one embodiment of the present invention; 
           [0035]      FIG. 8   d  is a perspective view of the connection element illustrated in  FIGS. 8   b  and  8   c.    
       
    
    
     DETAILED DESCRIPTION 
       [0036]      FIG. 1  shows the first embodiment  10  of a modular building, with the roof panel removed. The building has a base frame  12 , a roof frame  14  connected to the base frame by columns which are not shown in this view, being concealed by inner corner plates  16 . The building has a floor panel  18 , front and back sidewall panels  20  and  22 , and end wall panels  24 . In one embodiment of the present invention, the front wall panel  20  has an opening for a door D and a window W, and one end wall panel has, for example, another window opening W. Lifting lugs  26  are shown at the corners of the roof frame  14 . 
         [0037]      FIG. 2  shows a disassembled view of the same parts, with the addition of roof panel  28  which rests on roof frame  14 . This view also shows columns  30  at the ends of the side wall panels  20  and  22 . 
         [0038]      FIG. 3  shows a partially disassembled view of the base frame  12 , the roof frame  14 , and the four columns  30  which connect corners of the base frame  12  to the corners of the roof frame  14 .  FIG. 4  shows an isometric view of these frames as assembled, and also shows the lifting lugs  26 . 
         [0039]    As shown in  FIGS. 3 and 4 , the base frame comprises two longitudinal I beams  12   a  and two lateral I beams  12   b  connected together at their ends to form a frame having a first rectangular periphery. The corners are formed by having the upper and lower flanges of the lateral beams  12   b  cut back and welded at their ends to the sides of end portions of the longitudinal beams  12   a  while the webs of the beams  12   b  are welded at their ends to the web of the beam  12   a . The outermost parts of the ends of the longitudinal beams  12   a  are closed by small end plates  32 , also shown in  FIG. 3A ,  4 ,  5  and  5   a.    
         [0040]    As shown in  FIG. 4 , The roof frame  14  is formed in generally similar manner, with longitudinal beams  14   a  having end portions welded to ends of the flanges and webs of lateral beams  14   b , and having an outermost portion of the ends of the longitudinal beams  14   a  closed by small end plates  34 , also shown in  FIG. 4   b ,  5  and  5   b . The beams  14   a  and  14   b  define a rectangular periphery which is slightly smaller in both width and length than the first periphery of the base frame. 
         [0041]    As shown in  FIGS. 3 and 4 , the columns  30  are connected at upper ends to the corners of the roof frame  14 , and have outer surfaces defining the same periphery as the roof frame. The connection is made as shown in  FIG. 5  by having the upper end of column  30  closed by a rectangular plate  30   a  welded perpendicularly across its end, the plate  30   a  having four apertures which can be bolted to apertures in the underside of an end portion of a beam  14   a.    
         [0042]    As stated, the periphery of the roof frame  14  and of the columns is less than that of the base frame; in effect the roof frame and columns are set back about ½ the width of the base beams  12   a  and  12   b . This means that the columns  30  cannot be bolted to the base frame in quite the same manner as they are to the roof frame. Details of a corner of the base frame are shown in  FIGS. 3   a  and  3   b , and the actual attachment between a column and a corner of the base frame is shown in  FIG. 4   a.    
         [0043]    As seen in  FIGS. 3   a ,  3   b  and  5 , the inside of a corner formed by the longitudinal and lateral base beams  12   a  and  12   b  is provided with a reinforcing corner element  36  preferably in the form of a square tube having two sides welded to surfaces or edges of the beams  12   a  and  12   b . As shown in  FIGS. 3   a  and  3   b , the upper end of this tube  36  is preferably closed by transverse plate  38  having an aperture  38   a , and the underside of this plate  38  has preferably welded to it a nut  38   b  for receiving a bolt  38   h  passing through the aperture  38   a . As will be seen in  FIG. 3   b , this aperture  38   a  is one of four apertures provided at the corner of the base frame, the other three apertures  40  being provided in inner flanges of the beams  12   a  and  12   b . These three apertures  40  and the additional aperture  38   a  are rectangularly positioned, specifically being located as at the corners of a square. 
         [0044]      FIG. 3   c  shows the formation at the lower end of a column  30 , and shows the lower end plate  30   b , similar to plate  30   a , which closes the lower end of the column  30 , and which has four apertures for bolts which can pass through the apertures  38   a  and  40  to connect the column to the corner of the base frame. Two of these bolts  42  are shown in  FIG. 4   a . As also seen in  FIG. 3   a , the upper surface of plate  38  is level with the upper surfaces of the beams  12   a  and  12   b.    
         [0045]      FIG. 4   b  shows details of a lifting lug  26 , one of four provided at the corners of the roof frame. This consists of a short square tube  46  having its lower end welded to the top of roof beams  14   a , and having a plate  48  with its sides welded to opposite inside corners of the tube  46  so as to extend diagonally across the tube. The plate  48  is provided with an aperture  48   a  which is suitable for engagement by a hook, so that the parts provide a lifting lug whereby during assembly or disassembly of the building, the roof may be lifted as needed, and once fully assembled, the building can be lifted by a crane attached to the four lugs. 
         [0046]      FIG. 5   a  shows some additional members which help to locate the floor and wall panels and which are fixed in parallel relationship to the beams of the base and roof frames. These include angle members  50  having a lower flange  50   a  welded to the inner side portions of the base beams  12   a  and  12   b , and, as illustrated in  FIG. 5   b , channel members  52  welded to outer or lower edge portions of the roof frame beams  14   a  and  14   b . The members  50  and  52  terminate at the columns  30 . The angle member  50  is positioned so that its outer flange  50   b  has the same periphery as the roof frame and the columns  30 . The channel member  52  has a periphery matching that of the roof frame and the columns. 
         [0047]    As also shown in  FIG. 5   a , inner surfaces of flanges  50   b  of angle members  50  locate the outer edges of the floor panel  18 , and their outer surfaces locate the lower edges of wall panels provide means for securing these panels to the base frame. Floor panel  18  has notches cut in its corners to accommodate the columns  30 , as shown in  FIG. 2 . As illustrated in  FIG. 5   b , the outer surfaces of the channel members  52  locate the upper margins of the wall panels and provide means for securing these panels to the roof frame. 
         [0048]    As will be seen in  FIG. 5  and  FIG. 5   a , lower edges of the wall panels preferably rest on outer portions of the base beams  12   a  and  12   b . The amount by which the columns, and roof frame, are set back from the periphery of the base frame is typically 3 inches. In the preferred embodiment the wall panels  20 ,  22  and  24  are each two inches thick, while the floor and roof panels  18  and  28  are three inches thick. Preferably both types of panels are formed of closed cell insulating foam, encased on inner and outer sides by sheet steel. Suitable panel material is sold under the trademark “Accuwall” by Vicwest of Oakville, Ontario, Canada. When the wall panels have been put in place, and attached to the members  50  and  52 , the junctions between the panels can be concealed by corner plates  16  as shown in  FIG. 1 . 
         [0049]    In one embodiment of the present invention, enhanced wall panels may be utilized as illustrated in  FIGS. 7   a ,  7   b ,  7   c ,  7   d  and  7   e . As illustrated in  FIGS. 7   a ,  7   b ,  7   c ,  7   d  and  7   e , preferably having one or more sheets  111  of closed cell insulating foam  112 , encased on the inner side and outer side by sheet steel  114  as previously described, and additionally having a preferably aluminum or steel sheet  122  securely attached to and covering a substantial portion of the inward surface thereof (the aluminum sheet being preferably screwed or otherwise securely fastened to the sheet steel in a manner known to a person skilled in the art). In one embodiment, an inverted “U” shaped length  134  of extruded aluminum is screwed or otherwise securely fastened along the top of the enhanced wall panel as illustrated in  FIG. 7   e , and a “J” shaped length  120  of extruded aluminum is screwed or otherwise securely fastened along the bottom of the enhanced wall panel as illustrated in  FIG. 7   c , the upper inverted “U” shaped length  134  of extruded aluminum having recesses  132  or grooves therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art. Additionally, upper inverted “U” shaped length  134  of extruded aluminum preferably having a recess  130  or groove therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art so that when the enhanced wall panel is installed, the lengths of rubber or other weatherproofing materials will provide a water and weather-tight seal between the inverted “U” shaped length  134  of extruded aluminum and the underside of the roof panel  28  as illustrated in  FIGS. 5 and 5   b . Similarly, the lower “J” shaped length  120  of extruded aluminum preferably has recesses  116  or grooves therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art. Additionally, lower “J” shaped length  120  of extruded aluminum preferably has a recess  118  or groove therein along the length thereof to receive and secure lengths of rubber or other weatherproofing materials in a manner known to a person skilled in the art so that when the enhanced wall panel is installed, the lengths of rubber or other weatherproofing materials will provide a water and weather-tight seal between the “J” shaped length  120  of extruded aluminum and angle surface  50   b . The enhanced wall panel may be installed by passing screws through the channel member  52  into the enhanced wall panel as illustrated in  FIG. 5B , and through the angle members  50  and the lower “J” shaped length  120  of extruded aluminum as illustrated in  FIG. 5A  or in such other manner known to a person skilled in the art. In a further embodiment of the present invention, as illustrated in  FIGS. 7   a ,  7   b  and  7   d , a length of aluminum  108 , preferably in square tubular form, is welded or otherwise securely fastened to the inward-facing surface of the aluminum sheet, to thereby increase the structural integrity of the enhanced wall panel, the aluminum tube being securely fastened at both ends, to the vertical columns  30  in a manner known to a person skilled in the art. 
         [0050]    The interiors of the wall panels can be provided with bus bars  60 , fuse boxes  62 , etc. as shown in  FIG. 1 , for bringing electrical supplies into the building. 
         [0051]      FIG. 6  shows the framework of a similar modular building which differs from that so far described in being longer, having a length of 40 feet as compared to a typical length of 20 feet for the first embodiment. The base frame  112  has outer longitudinal I beams  112   a  and lateral outer I beams  112   b  connected at their ends in similar manner to the base beams of the first embodiment. Here, however, two intermediate lateral beams  113  are provided, having ends welded to the longitudinal beams  112 . Also, there are provided two intermediate longitudinal beams  116  which having separate segments  116   a ,  116   b , and  116   c , these segments being welded respectively between a first end lateral beam  112   b  and a first intermediate lateral beam  113 , between the first intermediate beam  113  and the second intermediate beam  113 , and between the latter beam and the second end lateral beam  112   b . The lateral beams  113  have the same cross-sectional dimensions as the beams  112   a  and  112   b , while the intermediate longitudinal beams  116  are of lesser height than the other beams but have their upper surfaces co-planar therewith so as to give level support for a floor panel. 
         [0052]    In this embodiment, the roof frame  114  has longitudinal beams  114   a  and  114   b , and also has two intermediate lateral beams  118  which overlie the beams  113 . The roof panel also has an additional, central longitudinal intermediate beam  120 , having three segments  120   a ,  120   b  and  120   c  extending respectively between a first end beam  114   b  and a first lateral beam  118 , between this beam  118  and the second beam  118 , and between the second beam  118  and the second end beam  114   b . Again, the lateral beams  118  have the same cross-sectional dimensions as the outer beams  114   a  and  114   b , while the intermediate longitudinal beam  120  has a less depth but has a top co-planar with the other beams to give support for the roof panel. 
         [0053]    As with columns  130 , the columns  131  are set back from the outer periphery of the base frame and have the same periphery as the corner columns. At each junction of base beam  112   a  and each intermediate base beam  113  each of these two connected beams provides two apertures for attachment to four bolts securing the base plate of an intermediate column  131  to the junction. The base plates of the columns are similar to that shown in  FIG. 3   c,  having a square arrangement of apertures matching the apertures in beams  112   a  and  113 . At upper ends of these intermediate columns  131  the roof beams  114   a  provide apertures for connection to top plates of the columns, adjacent the attachment points of intermediate beams  118 . 
         [0054]      FIGS. 6   a  and  6   b  show details of the lifting lugs  126  for this embodiment. The lugs are the same as those of the first embodiment, but are attached to portions of the roof beams  114   a  which overlie the intermediate columns. 
         [0055]    As previously described, two or more building units may be connected together to form larger building units, such as, for example, as illustrated in  FIG. 8   a , where a first building unit  150  is connected to a second building unit  152 , by way of connection elements  160  and  162  as more fully hereinafter described. In the preferred embodiment, as illustrated in  FIGS. 8   b  and  8   c , a lower connection element  160  and an identical upper connection element  166  having bolt holes  162  there through as illustrated in  FIG. 8   d , may be securely fastened by way of bolts (not shown) to adjacent columns  130  of the adjacent building unit, which columns  130  have corresponding bolt holes  164  there through in alignment with the connection element bolt holes  162 , so that when the building units are positioned adjacent one another, lower connection elements  160  and identical upper connection elements  166  may be bolted to adjacent columns  130  of the adjacent building units to thereby temporarily and securely connect the adjacent building units to former a larger building unit, it being understood that alternative methods may be utilized, as would be known to a person skilled in the art, to temporarily and securely connect the adjacent building units to former larger building unit. 
         [0056]    The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.