A system for installing a modular building pod

Abstract

A trolley for a system for installing a modular building pod in a building, the system comprising a modular building pod having a base, an interior and an exterior and at least two trolleys. The modular building pod further comprising two or more spaced apart brackets arranged on the exterior of the modular building pod. The system further having two or more trolleys each trolley comprising a bracket-engaging means for engaging with one of the brackets. The bracket-engaging means is engageable with the bracket in a first engagement position and a second engagement position, wherein the second engagement position is lower than the first engagement position. The trolley can lower the modular building pod into a recessed installation site. The trolley has a threaded bar jacking mechanism and the bracket engagement means and bracket engage via a pin and aperture engagement.

Description

Field of the Invention

[0001] The invention relates to a system for installing a modular building pod. In particular, the invention relates to a system for installing a modular building pod including a trolley for manoeuvring the modular building pod. Background

[0002] Modular building pods, such as modular bathroom pods, have gained popularity in the construction industry. Modular bathroom pods are particularly popular for buildings of multiple occupancy. The pods are designed as fully contained bathrooms that are produced in a factory environment utilising the most modern construction methods. The pods are constructed as a series of interconnected panels fabricated from steel profiles. The panels once constructed are bonded and covered on one side with fibre board panels to add rigidity to the panel. Panels are then assembled in the required shape to meet the architectural drawings. Once assembled pods are then tiled, all sanitaryware installed along with plumbing and electrical infrastructure. This finished product can be then installed as buildings are constructed and need only be connected to relevant water, foul and electrical systems.

[0003] An issue on large construction projects lies in the construction of a pod that will, in its finished form, will have a finished floor level that matches the finished floor level within the building without leaving a step or trip hazard. In some cases, a finishing floor screed or concrete pour can take place, but this is costly and increases costs for the construction company as well as increasing the overall size of the building or reducing the internal dimensions of the structure. In recent years there has also been a progression to use less concrete due to environmental factors.

[0004] The present invention seeks to obviate or mitigate the problem of aligning the floor of a modular building pod with the floor level of the overall building during instalation of the modular building pod. Summary of the Invention

[0005] According to a first aspect of the invention there is provided a system for installing a modular building pod in a building, the system comprising: a modular building pod having a base, an interior and an exterior, the modular building pod further comprising two or more spaced apart brackets arranged on the exterior of the modular building pod; two or more trolleys each trolley comprising: one or more wheels to enable movement of the trolley on a surface, an upright support member supported by the one or more wheels, a bracket-engaging means for engaging with one of the brackets, the bracketengaging means being movably connected to the upright support member, and a means for moving the bracket-engaging means along the upright support member, wherein the bracket-engaging means is engageable with the bracket in a first engagement position and a second engagement position, wherein in the first engagement position the base of the modular building pod is at the same height as the one or more wheels of the trolley and wherein in the second engagement position the base of the modular building pod is at a lower height than the one or more wheels of the trolley, and wherein the means for moving the bracket-engaging means along the upright support member can be operated to move between the first engagement position and the second engagement position.

[0006] Optionally, in the second engagement position, the bracket-engaging means is level with or is below the height of the one or more wheels of the trolley.

[0007] Optionally, the trolley is manually operated. This simplifies construction and use relative to automated trolleys or motorised trolleys.

[0008] Optionally, the one or more wheels of the trolley are not motorised.

[0009] Optionally, the means for moving the bracket-engaging means along the upright support member is manually operated.

[0010] Optionally, the means for moving the bracket-engaging means along the upright support member comprises a crank handle, and wherein rotation of the crank handle results in movement of the bracket-engaging means along the upright support member.

[0011] Optionally, the crank handle is engaged with a rotatable threaded bar, and wherein the bracket-engaging means is engaged with the rotatable threaded bar, and wherein rotation of the crank handle results in rotation of the threaded bar which further results in movement of the bracket-engaging means along the rotatable threaded bar.

[0012] Optionally, the rotatable threaded bar is disposed within the upright support member.

[0013] Optionally, the trolley comprises a chassis and wherein the one or more wheels are connected to the chassis and the upright support member is supported on the chassis.

[0014] Optionally, the upright support member can rotate about its longitudinal axis relative to the one or more wheels.

[0015] Optionally, the upright support member can rotate about its longitudinal axis relative to the chassis.

[0016] Optionally, the trolley further comprises a handle, and wherein the handle is hingedly connected to the chassis.

[0017] Optionally, the bracket comprises an aperture and wherein the bracketengaging means comprises a protrusion, and wherein the bracket-engaging means can engage the bracket by the protrusion extending through the aperture.

[0018] Optionally, the bracket-engaging means comprises an aperture and wherein the bracket comprises a protrusion, and wherein the bracket can engage the bracketengaging means by the protrusion extending through the aperture.

[0019] Optionally, both the bracket-engaging means and the bracket comprise alignable apertures, wherein the alignable apertures are aligned when the bracketengaging means engages the bracket, and wherein the alignable apertures can receive a locking pin when they are aligned.

[0020] Optionally, the bracket engaging means comprises a structural support, the structural support being connected to the upright support member.

[0021] Optionally, the interior of the modular building pod is defined by a plurality of interior walls, and the exterior is defined by a plurality of exterior walls, wherein the exterior walls surround the interior.

[0022] Optionally, there are four brackets and four trolleys.

[0023] Optionally, the modular building pod has a square or rectangular base, and wherein each bracket is arranged at or proximal to the corners of the base.

[0024] According to a second aspect of the invention there is provided a method for installing a modular building pod using the system of claim 1, the method involving the steps of: positioning the trolleys proximal the brackets and engaging the brackets with the bracket-engaging means; operating the means for moving the bracket-engaging means along the upright support member to raise the modular building pod; moving the trolleys to position the modular building pod such that the modular building pod is vertically above the desired installation location of the modular building pod; operating the means for moving the bracket-engaging means along the upright support member to lower the modular building pod into the installation location; and, disengaging the bracket-engaging means from the brackets.

[0025] Optionally, the step of engaging the brackets with the bracket-engaging means comprises inserting a locking pin through the bracket-engaging means and through the bracket.

[0026] Optionally, the step of disengaging the bracket-engaging means form the brackets involves removing the locking pin.

[0027] According to a third aspect of the invention there is provided a trolley for engaging with and moving a modular building pod, the trolley comprising: one or more wheels to enable movement of the trolley on a surface, wherein the one or more wheels are not motorised, an upright support member supported by the one or more wheels, a bracket-engaging means for engaging with a bracket on a modular building pod, the bracket-engaging means being movably connected to the upright support member, and a means for moving the bracket-engaging means along the upright support member, wherein the means for moving the bracket-engaging means along the upright support member is manually operated and comprises a crank handle, wherein rotation of the crank handle results in movement of the bracket-engaging means along the upright support member.

[0028] The trolley may be referred to as a modular building pod installation trolley.

[0029] Optionally, the bracket-engaging means comprises a protrusion for engaging an aperture on a bracket.

[0030] Optionally, the bracket-engaging means comprises an aperture for receiving a locking pin.

[0031] Optionally, the trolley comprises a chassis and wherein the one or more wheels are connected to the chassis and the upright support member is supported on the chassis,

[0032] Optionally, the trolley further comprises a handle, and wherein the handle is hingedly connected to the chassis. List of Figures

[0033] Specific implementations of the present disclosure will now be described, by way of example only, and with reference to the accompanying drawings in which:

[0034] Figure 1 shows a perspective view of a trolley of the present disclosure.

[0035] Figure 2 shows an alternative perspective view of the trolley of Figure 1.

[0036] Figure 3 shows a perspective view of a modular building pod and trolleys engaged with the brackets of the modular building pod. The walls of the modular building pod are omitted from this view to enable visibility of the trolleys.

[0037] Figure 4 is a side elevation view of a trolley with a bracket-engagement means engaged with a bracket in a first position.

[0038] Figure 5 is a side elevation view of a trolley with a bracket-engagement means engaged with a bracket in a second position.

[0039] Figure 6 is a top view the modular building pod and trolleys of Figure 3.

[0040] Figure 7 is a further top view of the modular building pod and trolleys of Figure 3 but wherein the trolleys are in a different position.

[0041] Figure 8 is a further top view of the modular building pod and trolleys of Figure 3 but wherein the trolleys are in a different position.

[0042] Figure 9 is a further top view of the modular building pod and trolleys of Figure 8 but wherein the handles of the trolleys are in a different position.

[0043] Figure 10 is a side elevation view of the modular building pod and trolleys of Figure 9.

[0044] Figure 11 is a perspective view of the modular building pod, wherein the walls are not omitted. Detailed Description

[0045] In the figures there is shown a system, indicated generally by reference numeral 1, for installing a modular building pod in a building. The system 1 comprises a modular building pod 2 having a base 3, an interior and an exterior. The interior of the modular building pod 2 is defined by a plurality of interior walls, and the exterior is defined by a plurality of exterior walls, wherein the exterior walls surround the interior. In the figures, the walls are purposefully not shown to provide visibility of the functional parts of the system.

[0046] The modular building pod 2 further has four spaced apart brackets 4a-d. In other embodiments, the modular building pod may have less than four brackets, or more than four brackets. The four spaced apart brackets 4a-d are arranged on the exterior of the modular building pod 2.

[0047] The system 1 further comprises four trolleys 5a-d. In other embodiments, not shown, the system may have less than four trolleys or more than four trolleys. Each trolley 5a-d has four wheels 6 which enable movement of the trolley on a surface. Each trolley further has an upright support member 7 supported by the wheels 6. Each trolley further has a bracket-engaging means 8 for engaging with one of the brackets 4a-d. The bracket-engaging means 8 is movably connected to the upright support member 7.

[0048] Each trolley further has a means 9 for moving the bracket-engaging means 8 along the upright support member 7. The bracket-engaging means 8 is engageable with the bracket 4a-d in a first engagement position and a second engagement position (as shown in Figure 5), wherein in the first engagement position the base 3 of the modular building pod 2 is at the same height as the wheels 6 of the trolley 5a-d and wherein in the second engagement position the base 3 of the modular building pod 2 is at a lower height than the wheels 6 of the trolley 5a-d. The means 9 for moving the bracket-engaging means 8 along the upright support member 7 can be operated to move between the first engagement position and the second engagement position. References to “height”, “lower”, “higher”, “above” or “below” as used herein refer to the relative height between objects when the trolley wheels and base of the modular building pod are level with a horizontal plane.

[0049] In the second engagement position, the base 3 of the modular building pod 2 is lower than the wheels 6 of the trolley 5a-d. As such, it is possible that the trolley wheels 6 can be resting on a surface surrounding the installation location of the modular building pod 2. Such a surface will be elevated relative to the installation location, as the installation location must be recessed to accommodate the thickness of the base 3 of the modular building pod 2. Thus, in use the trolleys 5a-d and the modular building pod 2 can be moved into position, when the bracket-engaging means 8 is engaged with the bracket 4a-d in the first engagement position, so that the modular building pod 2 is vertically above the installation location. The means 9 for moving the bracket-engaging means 8 along the upright support member 7 can then be operated to move the bracket-engaging means 8 and bracket 4a-d into the second position. In the second position, the base 3 is lower than the wheels 6 and also lower than the surrounding surface upon which the trolley 5a-d rests. The operator can adjust the height of the modular building pod 2 by operating the means 9 for moving the bracketengaging means 8 along the upright support member 7 until the desired height is achieved. The trolley 5a-d can thereafter be removed by disengaging the bracketengaging means 8 from the bracket 4a-d.

[0050] The trolley 5a-d is manually operated. This simplifies construction and use relative to automated trolleys or motorised trolleys. The one or more wheels of the trolley 5a-d are not motorised. The means 9 for moving the bracket-engaging means 8 along the upright support member 7 is manually operated. The means 9 for moving the bracket-engaging means 8 along the upright support member 7 comprises a crank handle 10, and wherein rotation of the crank handle 10 results in movement of the bracket-engaging means 8 along the upright support member 7.

[0051] The crank handle 10 is engaged with a rotatable threaded bar (not shown), and the bracket-engaging means 8 is engaged with the rotatable threaded bar. Rotation of the crank handle 10 results in rotation of the threaded bar which further results in movement of the bracket-engaging means 8 along the rotatable threaded bar. The rotatable threaded bar is disposed within the upright support member 7.

[0052] The trolley 5a-d comprises a chassis 11. The four wheels 6 are each connected to the chassis 11 and rotate relative to the chassis 11. Further, the upright support member 7 is supported on the chassis 11. The upright support member 7 can rotate about its longitudinal axis relative to the wheels 6. This enhances manoeuvrability of the trolley 5a-b and is illustrated in Figures 6-8, wherein the trolleys 5a-d are shown in different positions.

[0053] The trolley 5a-d further comprises a handle 12. The handle 12 is hingedly connected to the chassis 11.

[0054] The bracket 4a-d comprises an aperture 13 and the bracket-engaging means 8 comprises a protrusion 14. The bracket-engaging means 8 can engage the bracket 4a-d by the protrusion 14 extending through the aperture 13. In an alternative embodiment not shown, the bracket-engaging means comprises an aperture and wherein the bracket comprises a protrusion, and wherein the bracket can engage the bracket-engaging means by the protrusion extending through the aperture.

[0055] The protrusion 14 has a shaft and a head, wherein the head has a circumference that is larger than the circumference of the shaft. The aperture 13 comprises a main opening and a slot extending from the main opening. The slot extends upwardly. By “upwardly” we mean upward from the main opening when the modular building pod is resting horizontally. The width of the slot is less than the width of the main opening. The main opening has a width sized to accommodate the entire circumference of the head of the protrusion 14. The slot has a width sized to accommodate the circumference of the shaft, but too narrow to accommodate the circumference of the head. In use, the head of the protrusion 14 is inserted through the main opening of the aperture 13. The bracket-engaging means 8 is then raised, consequently raising the protrusion 14. The shaft of the protrusion rises from the main opening of the aperture 13 into the slot. As the width of the head is greater than the width of the slot, the protrusion 14 cannot be removed laterally from the slot and thus from the aperture 13. To remove the protrusion 14 from the aperture 13, the bracketengaging means 8 must first be lowered, thereby lowering the protrusion 14, until the head is aligned with the main opening. The head can then pass through the main opening, thereby disengaging the protrusion 14 from the bracket 4a-d.

[0056] Both the bracket-engaging means 8 and the bracket 4a-d comprise alignable apertures 15, wherein the alignable apertures 15 are aligned when the bracketengaging means 8 engages the bracket 4a-d, and wherein the alignable apertures 15 can receive a locking pin 16 when they are aligned.

[0057] The bracket 4a-d is disposed on the exterior of the modular building pod 2 and is vertically above the base 3. The bracket 4a-d extends upwardly from the base 3. The bracket 4a-d has a main face 17. The bracket 4a-d further has flanges 18a, 18b at the sides of the main face 17. The flanges 18a, 18b reinforce the bracket 4a-d. The apertures 13, 15 are located on the main face 17 and extend through the main face 17.

[0058] The bracket engaging means 8 comprises a structural support 19. The structural support 19 is connected to the upright support member 7. The bracket engaging means 8 is further connected to the upright support member 7 by a linker 20. The linker 20 is spaced apart from the structural support 19. The linker 20 is above the structural support 19. The structural support 19 extends orthogonally from the longitudinal axis of the upright support member 7.

[0059] The bracket 4a-d has a plate 21. The protrusion 14 extends from the plate 21. The aperture 15 extends through the plate 21. The plate 21 has a portion 22. The protrusion 14 extends from the portion 22. The aperture 15 extends through the portion 22. The portion 22 has a planar surface that, wherein the planar surface is parallel with the longitudinal axis of the upright support member 7. The structural support 19 is connected to the portion 22.

[0060] The structural support 22 moves along the upright support member 7 with the bracket-engaging means 8. The upright support member 7 sits on a base plate 25. The structural support 22 is prevented from further downward movement when it connects with the base plate 25. At least part of the bracket-engaging means 8 extends below the structural support 19. At least part of the portion 22 extends below the structural support 19. This thereby means that the bracket 4a-d can be lowered below the position of the structural support 19, or the base plate 25, or to the same level as or below the wheels 6, when engaged with the bracket-engaging means 8.

[0061] The plate 21 further has a second portion 23. The linker 20 is connected to the second portion 23. The second portion 23 has a planar surface and the planar surface is parallel with the longitudinal axis of the upright portion. The plate 21 further has a third portion 24. The third portion 24 extends between the portion 22 and the second portion 23. The third portion 24 slopes from the portion 22 towards the upright support member 7 and towards the second portion 23. The bracket-engaging means 8 has a supporting flange 26. The structural support 19 is connected to the supporting flange 26. The supporting flange 26 is connected to the portion 22 and third portion 23. The supporting flange 26 is arranged orthogonally to the portion 22.

[0062] The modular building pod 2 has rectangular base 3. The shape of the base may be varied as desired and may for example be square or any geometric shape as required. For example, the base may be L-shaped. Each bracket 4a-d is arranged at or proximal to the corners of the base 3.

[0063] Figure 11 shows a perspective view of the modular building pod 2. In this view, the walls 30 and a ceiling structure 31 are shown. Further shown is a lifting frame 32 that is temporarily fixed to the modular building pod 2 for installation. The lifting frame 32 has attachment points 33 to receive lifting equipment 34, such as a chain, to enable the lifting frame and thus the modular building pod 2 to be lifted by a crane, for example. The lifting frame 32 connects to the same brackets 4a-d that are used as connection points for the trolleys 5a-d. As shown in Figure 11, both the lifting frame 32 and trolleys 5a-d may be connected at the same time.

[0064] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently described subject matter pertains.

[0065] Where a range of values is provided, for example, concentration ranges, percentage ranges, or ratio ranges, it is understood that each intervening value, to the tenth of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the described subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and such embodiments are also encompassed within the described subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the described subject matter.

[0066] It should be understood that the terms "a" and "an" as used above and elsewhere herein refer to "one or more" of the enumerated components. It will be clear to one of ordinary skill in the art that the use of the singular includes the plural unless specifically stated otherwise. Therefore, the terms “a,” “an” and “at least one” are used interchangeably in this application.

[0067] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as size, weight, reaction conditions and so forth used in the 5 specification and claims are to the understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present subject matter. At the very least, and not as an attempt to limit 10 the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0068] Throughout the application, descriptions of various embodiments use "comprising" language; however, it will be understood by one of skill in the art, that in 15 some instances, an embodiment can alternatively be described using the language "consisting essentially of or "consisting of."

Claims

1. A modular building pod installation trolley for engaging with and moving a modular building pod, the trolley comprising:one or more wheels to enable movement of the trolley on a surface, wherein the one or more wheels are not motorised,an upright support member supported by the one or more wheels,a bracket-engaging means for engaging with a bracket on a modular building pod, the bracket-engaging means being movably connected to the upright support member,a means for moving the bracket-engaging means along the upright support member, wherein the means for moving the bracket-engaging means along the upright support member is manually operated and comprises a crank handle, wherein rotation of the crank handle results in movement of the bracket-engaging means along the upright support member, andwherein the bracket-engaging means is engageable with the bracket in a first engagement position and a second engagement position, wherein in the first engagement position the base of the modular building pod is at the same height as the one or more wheels of the trolley and wherein in the second engagement position the base of the modular building pod is at a lower height than the one or more wheels of the trolley, and wherein the means for moving the bracket-engaging means along the upright support member can be operated to move between the first engagement position and the second engagement position.

2. The modular building pod installation trolley of claim 1 wherein the bracketengaging means comprises a protrusion for engaging an aperture on a bracket.

3. The modular building pod installation trolley of claim 1 or claim 2 wherein the bracket-engaging means comprises an aperture for receiving a locking pin.

4. The modular building pod installation trolley of any one of claims 1 to 3 of wherein the trolley comprises a chassis and wherein the one or more wheels are connected to the chassis and the upright support member is supported on the chassis.

5. The modular building pod installation trolley of claim 4 wherein the trolley further comprises a handle, and wherein the handle is hingedly connected to the chassis.

6. The modular building pod installation trolley of any preceding claim wherein the crank handle is engaged with a rotatable threaded bar, and wherein the bracket-engaging means is engaged with the rotatable threaded bar, and wherein rotation of the crank handle results in rotation of the threaded bar which further results in movement of the bracket-engaging means along the rotatable threaded bar.

7. The modular building pod installation trolley of claim 6 wherein the rotatable threaded bar is disposed within the upright support member.

8. The modular building pod installation trolley of any preceding claim wherein the trolley comprises a chassis and wherein the one or more wheels are connected to the chassis and the upright support member is supported on the chassis.

9. The modular building pod installation trolley of claim 8 wherein the trolley further comprises a handle, and wherein the handle is hingedly connected to the chassis.

10. The modular building pod installation trolley of any preceding claim wherein the bracket comprises an aperture and wherein the bracket-engaging means comprises a protrusion, and wherein the bracket-engaging means can engage the bracket by the protrusion extending through the aperture.

11. The modular building pod installation trolley of any preceding claim wherein the bracket-engaging means comprises an aperture and wherein the bracketcomprises a protrusion, and wherein the bracket can engage the bracketengaging means by the protrusion extending through the aperture.

12. The modular building pod installation trolley of any preceding claim wherein both the bracket-engaging means and the bracket comprise alignable apertures, wherein the alignable apertures are aligned when the bracketengaging means engages the bracket, and wherein the alignable apertures can receive a locking pin when they are aligned.

13. The modular building pod installation trolley of any preceding claim wherein the bracket engaging means comprises a structural support, the structural support being connected to the upright support member.

14. A method for installing a modular building pod using two or more trolleys of any preceding claim, the method involving the steps of:positioning the trolleys proximal the brackets and engaging the brackets with the bracket-engaging means;operating the means for moving the bracket-engaging means along the upright support member to raise the modular building pod;moving the trolleys to position the modular building pod such that the modular building pod is vertically above the desired installation location of the modular building pod;operating the means for moving the bracket-engaging means along the upright support member to lower the modular building pod into the installation location; and,disengaging the bracket-engaging means from the brackets.

15. The method of claim 14 wherein the step of engaging the brackets with the bracket-engaging means comprises inserting a locking pin through the bracketengaging means and through the bracket.

16. The method of claim 15 wherein the step of disengaging the bracket-engaging means form the brackets involves removing the locking pin.

17. A system for installing a modular building pod in a building, the system comprising:a modular building pod having a base, an interior and an exterior, the modular building pod further comprising two or more spaced apart brackets arranged on the exterior of the modular building pod;two or more trolleys according to any one of claims 1 to 13.

18. The system of claim 17 wherein the interior of the modular building pod is defined by a plurality of interior walls, and the exterior is defined by a plurality of exterior walls, wherein the exterior walls surround the interior.

19. The system of claim 17 wherein there are four brackets and four trolleys.

20. The system of claim 17 wherein the modular building pod has a square or rectangular base, and wherein each bracket is arranged at or proximal to the corners of the base.17

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