Erectable housing structure with a shipping container configuration

[0001] This application claims the benefits of U.S. provisional patent application Ser. No. 61/731,379, filed on Nov. 29, 2012, the entire contents of which is expressly incorporated herein by reference.

[0002] Not Applicable

[0003] The present invention relates to a housing structure that is erectable from a shipping container configuration to a two-story housing structure.

[0004] When natural disaster strikes, the residents are displaced and may be without shelter for extended periods of time until permanent shelter can be built for the displaced residents. Other types of situations may occur that cause residents to be displaced and without shelter. By way of example and not limitation, military conflict, economic conditions, disease, etc. may cause large numbers of residents to move to a different location. When large numbers of people suddenly move from one location to another, it is difficult, if not impossible to provide shelter for all of these displaced refugees.

[0005] Accordingly, there is a need in the art for providing shelter.

[0006] The portable two story housing structure disclosed herein provides a convenient and easy device and method for quickly transporting a housing structure to a site. When collapsed, the portable two story housing structure may be transported through a standard intermodal transportation system including but not limited to trucking, shipping and railway. The structure when collapsed utilizes standard corner castings to ship the structure to a site. At the site, the structure unfolds into a two story housing structure capable of providing shelter to people and things. The structure has a plurality of panels that are stored in the collapsed structure and are later pivoted into position to form the floors, sidewalls, and roof of the two story housing structure. In this manner, when needed, the portable two story housing structure can be quickly deployed and erected at a site.

[0007] More particularly, a portable two story housing structure is disclosed. The structure may comprise a pair of first vertical end frames, a pair of second vertical end frames, corner castings, a top panel and opposed side panels. The pair of first vertical end frames may be sufficiently strong to support a second story of the portable two story housing structure and to stack one or more portable two story housing structures upon each other during transportation. The pair of second vertical end frames may be sufficiently strong to support the second story of the portable two story housing structure and to stack one or more portable two story housing structures upon each other during transportation. The corner castings may be fitted on opposed distal ends of the first and second vertical end frames wherein the corner castings are positioned so that the portable two story housing structure may be transported through a standard intermodal transportation system. The top panel may be disposed adjacent to the upper ends of the first and second vertical frame members. The top panel may be traversed upward so as to form a roof of the portable housing structure. The opposed side panels may be disposed adjacent to respective ones of the pair of first and second vertical end frames. The opposed side panels may be rotated into position to form side walls of the second story of the structure.

[0008] The structure may have additional panels disposed interior to the top panel and the opposed side panels. The side panels and the additional panels may be vertically oriented when the structure is in the collapsed state. The additional panels may be rotated into position to form the floor of the second story of the structure and the side walls and floor of the first story of the structure.

[0009] Level mechanisms may be disposed below the panels forming the first floor for leveling the first floor of the two story housing structure when erected.

[0010] The structure may also have pairs of upper and lower longitudinal members and pairs of upper and lower lateral members. The pairs of upper and lower longitudinal members may be attached to respective upper and lower distal end portions of the pairs of first and second vertical end frames. The pairs of upper and lower lateral members may be attached to respective upper and lower distal end portions of the pairs of first and second vertical end frames. The panels may be rotatably attached to the pairs of upper longitudinal members, pairs of lower longitudinal members and the pairs of first and second vertical end frames.

[0011] In another aspect, a method of erecting a portable two story housing structure is disclosed. The method may comprise the steps of traversing a top panel upward one story to form a roof of the structure; rotating side panels into position to form side walls of the second story of the structure; locking the side panels and the top panel; and forming a hermetic seal at all rotatable joints and edges of the side panels.

[0012] The method may further comprise the steps of rotating panels into position to form a first floor of the two story housing structure; and leveling the rotated panels forming the first floor of the two story housing structure.

[0013] In the method, the forming the hermetic seal step may include the step of extending a roof panel over the side panel so that rain cascades off of the roof and onto a ground.

[0014] In the method, the traversing step may include the step of extending a telescoping member attached to the top panel and locking the telescoping member to support the roof. Alternatively, the traversing step may include the step of rotating a pivoting mechanism to raise the roof panel and locking the pivoting mechanism when the roof panel is in position to support the roof panel.

[0032] Referring now to the drawings, a portable two-story housing structure 10, 100 that can be transported through a standard intermodal transportation system when collapsed (see FIG. 1) and erected (see FIG. 2) at a destination site to provide shelter to people or storage is disclosed. The portable two-story housing structure 10, 100 provides for a quick and convenient way of deploying shelter or storage to the destination site. The portable two-story housing structure 10, 100 is useful for deploying shelter or storage to an area that has been hit by a natural disaster such as a hurricane, tsunami or other natural disasters. Moreover, the portable two-story housing structure 10, 100 is also useful for providing shelter to low income areas as well as Third World countries. In other words, the structure 10, 100 may be transported as a single intermodal container and is capable of being erected to about an 1800 square feet structure 10, 100 with relatively minimal shipping and logistics costs for a structure 10, 100 that large.

[0033] Referring now to FIG. 1, the portable two-story housing structure 10 may have a pair of first vertical end frames 12a, b and a pair of second vertical end frames 12c, 12d. These vertical end frames 12a-d define the external envelope of the portable two-story housing structure 10 when collapsed. The vertical end frames 12a-d are also sufficiently strong and have corner castings 13 (e.g., cast twistlock corners) so that one or more collapsed portable two-story housing structures 10 can be stacked upon each other and transported via shipping, train or other standard intermodal transportation systems. Moreover, the vertical end frames 12a-d support the second story 14 of the portable two-story housing structure 10 when erected, as shown in FIG. 2.

[0034] The portable two-story housing structure 10 may also have a plurality of upper longitudinal members 16a, b to transfer the weight of the second story and its personnel and contents to the vertical end frames 12a-d. The longitudinal member 16a, b may be sufficiently strong and stiff to mitigate excessive bending of the longitudinal members 16a, b during transportation and under the weight of the personnel and contents during use. The upper longitudinal members 16a, b are attached to the upper distal ends of the pairs of first and second vertical end frames 12a-d (as shown) or the upper lateral members 20a, b. The portable two-story housing structure 10 may also have a plurality of lower longitudinal members 18a, b which are attached to the lower distal ends of the pairs of first and second vertical end frames 12a-d which provide structural support during transportation and when the structure 10 is erected.

[0035] The portable two-story housing structure 10 may also have a plurality of upper lateral members 20a, b and a plurality of lower lateral members 22a, b. The upper lateral members 20a, b are attached to the upper distal ends of the pair of first vertical end frames 12a, b and the upper distal ends of the pair of second vertical end frames 12c, d. The lower lateral members 22a, b are attached to the lower distal ends of the pair of first vertical end frames 12a, b and the lower distal ends of the pair of second vertical end frames 12c, d.

[0036] The pairs of first and second vertical end frames 12a, d, the upper longitudinal members 16a, b, the lower longitudinal members 18a, b and the upper and lower lateral members 20a, b, 22a, b define the overall external envelope of the portable two-story housing structure 10 when the structure 10 is collapsed (see FIG. 1). A plurality of panels 24 are stored within the overall external envelope that are later traversed (e.g., rotated or pivoted) to form the floors of the first and second story, side walls and roof of the portable two-story housing structure 10.

[0037] Referring now to FIGS. 3 and 4, three panels 24a, b and c are stacked upon each other and raised upward by way of pivoting structures 26. The panels 24a-c are raised so that a distance 28 between the panels 24a-c and the upper lateral and longitudinal members 20a, b and 16a, b is equal to a height or distance 30 between the upper lateral and longitudinal members 20a, b, 16a, b and the lower lateral and longitudinal members 22a, b, 18a, b. Alternatively, the distance 28 may be reduced to either provide a storage area above the first floor or a minimal height to allow people to work or live on the second story 14.

[0038] The pivoting structures 26 may include first and second pivoting arms 32a, b. The first and second pivoting arms 32a, d pivot about pivot joint 34 with respect to each other. Moreover, the first pivoting arm 32a pivots about panel 24a. The upper distal end of the first pivoting arm 32a is also pivotally attached to one of the four corners of the panel 24a. The lower distal end of the second pivoting arm 32b is secured to the interior of the corner defined by the upper lateral member 20a, first vertical end frame 12b and the upper longitudinal member 16b. The lower distal ends of the other second pivoting arms of the other pivoting structures 26 are attached to the interior of the respective corner defined by the upper lateral member 20, the vertical end frame 12 and the longitudinal member 16. When the pivoting structures 26 are fully extended, as shown in FIG. 4, the pivot joints 34 may be locked with a locking mechanism to prevent collapse of the panels 24a-c. A horizontal panel 24d is stationary and fixed to the upper longitudinal and lateral members 16a, b, 20a, b so as to form the floor of the second story 14 of the portable two-story housing structure 10. The panels 24a-c form the roof of the portable two-story housing structure 10 which are unfolded at a later time.

[0039] Referring now to FIGS. 5-8, additional panels 24e-l (see FIGS. 6 and 7) may be pivoted into position. Initially, the panels 24e, f and 24i, j may be pivoted upward 35 as shown in FIG. 5. Moreover, the panels 24f and j are pivotally attached to the upper longitudinal members 16a, b or at upper distal end portions of the first and second vertical end frames 12a-d. Thereafter, the panels 24g, h and 24k, l are pivoted downward 37 as shown in FIG. 6. The panels 24h, l are pivotally attached to the lower longitudinal members 18b, a or at lower distal end portions of the first and second vertical end frames 12a-d.

[0040] A plurality of leveling mechanisms 36 (see FIG. 7) may be disposed underneath panels 24h and l to bring them horizontal to a first floor panel 24m or the ground.

[0041] The first floor panel 24m is stationary and fixed to the lower longitudinal and lateral members 18a, b, 22a, b so as to form a part of the floor of the first story 50 of the portable two-story housing structure 10. The panels 24h, l complete the floor of the first story 50 of the portable two-story housing structure 10. Panels 24g and 24k are pivoted upward 39 so that their upper distal edges are under the distal edges of the panels 24f and j. (See FIG. 8A). The panels 24g and h are pivotal with respect to each other about edge 38 on hinges 56. Also, panels 24k and l are also pivotal with respect to each other about edge 40 on hinges 56. The upper distal edges of the panels 24g and k can be secured or attached to the panels 24f and j. Moreover, panels 24e and f are pivotal with respect to each other on hinges 56 so that the panel 24e can be raised or pivoted 52 to the vertical position as shown in FIG. 7. Similarly, panels 24i, j are pivotal with respect to each other on hinges 56. Panel 24i may be pivoted 52 to the vertical position as shown in FIG. 8. After transitioning the panels 24e, i to the vertical position, the panels 24b, c are pivoted 54 outward on hinges 56 so that the upper distal edges of the panels 24e, i reside under the panels 24b, c and provide support for the distal end portions of the panels 24e, i to maintain the panels 24b, c in the horizontal position (see FIG. 8B).

[0042] Referring back to FIG. 2, sheer panels 42 may be attached to the vertical end frame 12b and the edge portion 44 of the panel 24f, edge portion 46 of the panel 24g and the edge portion 48 of the panel 24h. Additional shear panels 42 may also be attached at other locations. By way of example and not limitation, a shear panel 42b may be attached to the vertical end frame 12a, the edge portion 44 of the panel 24j, the edge portion 46 of the panel 24k and the edge portion 48 of the panel 24l. Although not shown, shear panels 42 may be attached to (1) the edge portions of the panels 24c, i, j, (2) edge portions of the panels 24a, d or the upper lateral member 20 and (3) edge portions of the panels 24b, e, f. Shear panels 42 may also be attached to the opposite side (not shown) to enclose the entire second story of the two-story housing structure to protect the contents disposed within the structure 10 and its inhabitants from the environment. The shear panels 42 provide rigidity to the erected structure 10 so that the various panels 24 do not tilt to the left or right and fall over. The shear panels 42 may also be formed with windows so that inhabitants may have an outside view and sunlight may penetrate into the interior of the structure 10.

[0043] The doors 56 may serve as the entrance to the portable two-story housing structure 10 and may be equipped with a traditional doorknob and locking features.

[0044] Additionally, the joints between the panels 24 and the shear panels 42 may be filled with weatherproofing to prevent air from escaping from within the erected structure 10. In doing so, any air conditioning routed to the housing structure 10 and used to heat or cool the inside of the erected structure 10 would be more efficient. Moreover, by weatherproofing the joints, moisture and water are not allowed to enter the erected structure 10.

[0045] The various panels 24 are all vertically disposed within the outer boundaries defined by the upper and lower longitudinal members 16a, b, 18a, b, and the first and second vertical end frame 12a-d. Moreover, space is still left within the collapsed structure 10 to provide for transport of the shear panels 42 and other accessories (e.g. chairs, desks, etc.).

[0046] The panels 24 may be layered to facilitate weatherproofing. For example, the distal end of the roof panels 24b, c may extend over the upper distal end of panels 24e, i, as shown in FIG. 8B. Also, the distal end of the side floor panels 24f, j that make up the floor of the second story may extend past the upper distal end of panels 24g, k, as shown in FIG. 8A. This allows rain water to cascade down the roof panels 24b, c onto the sides of sidewall panels 24e, i and cascade down the sides of sidewall panels 24g, k to help keep the inside of the structure 10 dry.

[0047] Referring now to FIGS. 9-14, a second embodiment of a portable two-story housing structure 100 is shown. The structure 100 also includes pairs of first and second vertical end frames 112a-d. The structure 100 also includes upper and lower lateral members 120a, b, 122a, b. The pairs of first and second vertical end frames 112a and the upper and lower lateral members 120a, b, 122a, b are longitudinally spaced apart by upper and lower longitudinal members 16a, b, 18a, b. The pairs of first and second vertical end frames 112a-d, upper and lower lateral members 120a, b, 122a, b and the upper and lower longitudinal members 116a, b, 118a, b define the external envelope of the portable two-story housing structure 10a when collapsed.

[0048] The pairs of first and second vertical end frames 112a-d may have corner castings (e.g., cast twistlock corners) on opposed ends thereof so that one or more collapsed portable two-story housing structures 100 can be stacked upon each other and transported via shipping, train or other standard intermodal transportation systems. Additionally, the vertical end frames 112a-d may also support the second story 114 (see FIG. 14) after the two-story portable housing structure 100 is erected. When the two-story housing structure 100 is erected, the weight of the second story 114 and the weight of the people and things on the second story 114 are transferred to the pairs of vertical end frames 112a-d through the upper longitudinal members 116a, b. The longitudinal members 116a, b may be sufficiently strong and stiff to mitigate excessive bending of the longitudinal members 116a, b during transportation and under the weight of the personnel and contents stored on the second story 114 when erected. The upper longitudinal members 116a, b may be attached to the upper distal ends of the pairs of first and second vertical end frames 112a-d (as shown) or the upper lateral members 120a, b. The lower longitudinal members 118a, d may be attached to the lower distal ends of the pairs of first and second vertical end frames 112a-d which provide structural support during transportation and when the structure 10a is erected.

[0049] A plurality of panels 124 are vertically stored within the overall external envelope of the collapsed structure 10a. These panels 124 are later traversed (e.g. rotated or pivoted) to form the floors of the first and second stories 150, 114, and roof of the portable two-story housing structure 100.

[0050] Referring now to FIG. 10, a roof panel 124a may be raised up to a distance 128 that is preferably equal to or less than a distance 130 of a first story 150. However, it is also contemplated that the roof panel 124a may be raised to a distance 128 that is greater than distance 130. The roof panel 124a may be supported by telescoping columns 160a, b on opposed ends of the panel 124a. The telescoping column 160a, b may have a first part that can slide within a second part. When the telescoping columns 160a, b are extended to the appropriate height, the telescoping columns 160a, b may be locked in place either with a pin or other locking mechanism to prevent the roof panel 124a from collapsing. Instead of telescoping columns 160a, b, it is also contemplated that the roof panel 124a may be supported by pivot joint 34 and pivoting arms 32a, d as described in relation to the embodiments shown in FIGS. 1-8. When the roof panel 124a is raised up and locked in place by the telescoping columns 160a, b, two panels 124b, c and 124d, e on opposed lateral sides of the roof panel 124a are also unfolded. The panels 124b, c and 124d, e were tucked under the roof panel 124a. These panels 124b-e are later raised and pivoted to complete the roof of the two-story housing structure 100.

[0051] Referring now to FIG. 11, the panels 124f, o and 124h, j are pivoted 162 upward. Thereafter, the panels 124m, g and 124i, k are pivoted 164 downward as shown in FIG. 12. The sidewall panels 124o, m, h, i are pivoted 166 upward as shown in FIGS. 13 and 14. The upper distal ends 168 of the panels 124i, e may be secured or attached to a bottom side of the panels 124j, f. In this manner, water cascades off of the sidewall panels 124o, h of the second story 114 and on to the sidewall panels 124m, i of the first story 150 to help with waterproofing the two-story housing structure 100.

[0052] Sheer panels 124 are vertically stored within the collapsed portable housing structure 100. The sheer panels 124 may now be secured to opposed longitudinal edges of the panels 124a-l and to the upper and lower lateral members 120a, b, 122a, b and the pairs of first and second vertical end frames 112a-d. These sheer panels 124 prevent the various panels 124a-l from pivoting during a side wind or lateral forces. By way of example and not limitation, the sheer panels 124 may be placed between the edge portion 170 of the roof panel 124a and the upper lateral member 120a. In this manner, the weight of the panel 124a is transferred to the vertical end frames 112a, b through the sheer panel 124, to the upper lateral member 128 and ultimately to the vertical end frames 112a, b. Another sheer panel may also be placed on the opposed side (not shown). Sheer panels may be attached to (1) the edge portions of panels 124j, i, k and vertical end frame 112a, (2) the edge portions of panels 124g, m, f, (3) the edge portions of panels 124f, o, c, b and (4) edge portions of panels 124j, h, e, d as well as on the opposed sides. The sheer panels 124 help to prevent the panels 124 from tipping over and maintains rigidity of the housing structure 100.

[0053] The various panels 24 and 124 are described as being pivotal with respect to other panels 24, 124. In this instance, the panels 24, 124 may be attached to each other with hinges 56. These hinges 56 may be stainless steel to mitigate rusting while the collapsed portable housing structure 10, 100 is being transported to a site. The hinges 56 may be heavy duty hinges to hold up to the harsh environment in which these housing structures 10, 100 will be installed.

[0054] The housing structure 10, 100 after being erected may be sealed with weatherproofing to prevent moisture from entering the erected housing structure 10, 100. By way of example and not limitation, the sealant may be caulking, silicone, coating, vinyl or rubber weather stripping, etc.

[0055] The first floor of the housing structure 10 is defined by panels 24h, l, m. Panel 24m may be lower than panel 24h, l. In this instance, filler material may be placed on the panel 24m to raise the level of the middle section to be level with the panels 24l, h. The second floor of the housing structure 10 is defined by panels 24j, d, f. The upper longitudinal members 16a, b may separate the panels 24j, d, f. Filler material may be placed on the panels 24j, d, f and to cover the upper longitudinal members 16a, b so that the floor of the second story 14 is level. The same may be applied to panels 124k, l and g. The filler material may be light weight so that excessive weight is not placed on the structure 10. The filler material is also durable to withstand daily use. The portable housing structure 10, 100 has two stories. The first stories of the housing structures 10, 100 may have a spiral staircase 58, 158 so that personnel may travel between the first and second stories. The staircase 58, 158 are shown in FIGS. 6 and 12 but not in the other figures for the purposes of clarity. The staircase 58, 158 would access the second story of the housing structure 10, 100 through a hole in the panels 24d (see FIG. 8) and 124n (see FIG. 14).

[0056] The structure 10, 100 may be fabricated from various materials to achieve the objective discussed herein. The upper and lower longitudinal members 16a, b, 18a, b and the upper and lower lateral members 20a, b, 22a, b and the first and second pairs of end frames 12a-d may be fabricated from a material sufficiently strong and stiff to act as a frame for the structure 10, 100 during transportation and after the structure 10, 100 is erected. By way of example and not limitation, the upper and lower longitudinal members 16a, b, 18a, b and the upper and lower lateral members 20a, b, 22a, b and the first and second pairs of end frames 12a-d may be fabricated from steel, aluminum, steel or aluminum tubing, or other similar materials. The panels 24, 124 may be fabricated from a weather resistant material that can withstand sustained light impact. By way of example and not limitation, the panels 24, 124 may be fabricated from materials such as steel, aluminum, sheet metal (e.g., steel), galvanized sheet metal, composite material, carbon fiber composite material, carbon fiber, plastic, thermo plastic, composite wood and the like.

[0057] The various panels 24, 124 has been illustrated as being solid. However, it is also contemplated that one or more of the panels 24, 124 may be fabricated in a honey comb structure with external sheets adhered to the honeycomb structure to prevent water and air from passing through the panel 24, 124. The panels 24, 124 may be fabricated from any of the materials discussed above. Alternatively, it is also contemplated that the panels 24, 124 forming the sidewalls of the structure 10, 100 after erected may provide a framework for the sidewalls of the structure 10, 100. After these sidewall panels 24, 124 are set in place, a thin flexible covering may be used to cover the framework to provide protection from the environment.

[0058] The structure 10, 100 disclosed herein may be utilized for the following purposes including but not limited to: mobile housing, mobile hospital, mobile barracks, mobile command center, construction office with the first floor being an equipment storage area, mobile media room such as a mobile newsroom or production studio, mobile retail venue, mobile marking venue, mobile restaurant, semipermanent structure as remote locations, mobile laboratory, mobile communications center, temporary office space or any place where an enclosed space is needed and shipping costs are at a premium.

[0059] The structure 10, 100 may also include an HVAC system, electrical wiring connections and lighting which are routed through the non pivoting parts of the structure 10, 100.

[0060] The structure 10, 100 may be scalable to any length such as 20 feet, 40 feet for international shipping and 53 feet for domestic shipping.

[0061] The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of rotatably connecting adjacent panels 24, 124. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.