AU2013100588A4 - Veranda roof and decking system - Google Patents

Abstract

Abstract The present invention provides a stowable veranda system, including a roofing panel and a decking panel, wherein the veranda system is able to be folded against an outer wall of a dwelling.

Description

P/00/01I Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: PIOTRAN PTY LTD Actual Inventor(s): AL HOCKLEY PETER LENNOX GRAEME SMITH Address for Service: Houlihan 2 , Level 1 / 70 Doncaster Road Balwyn North VIC 3104, Australia Invention Title: VERANDA ROOF AND DECKING SYSTEM The following statement is a full description of this invention, including the best method of performing it known to the Applicant:- 2 VERANDA ROOF AND DECKING SYSTEM Field of the Invention The present invention relates to a veranda system, which is suitable for use on a dwelling, 5 preferably a transportable accommodation module. Specifically, the present invention relates to a veranda roof and decking system that allows the veranda roof and deck to be stowed safely for transportation of a transportable accommodation module. Background to the Invention 10 Pre-fabricated housing and commercial building units are built and assembled at factories and then transported to a site for use. Such units may also be referred to a transportable accommodation module (TAM). At the site of use, the TAM may be used as a permanent or a temporary structure, in that it might require relocating at some time in the future. In addition, a number of TAMs might be joined to form a larger structure or dwelling. 15 A principal constraint in the design of TAMs, is the size restrictions set out by road transport authorities. Under Australian regulations, road freight is limited to a maximum width of 3.5 metres and a maximum height of 4.8 metres. Furthermore, the maximum length allowed for the prime mover and trailer is 19.5 metres. If these dimensions are 20 exceeded, considerable expense is incurred since the regulations require permits, escorts and set routes as well as restrictions on time of travel for such large loads. These costs and inconveniences can be avoided if the load has a maximum width of 3.5 metres, a height of no more than 4.8 metres and the overall length of 19.5 metres. Taking into account the length of a prime mover used for transporting the TAM, the effective maximum length of 25 the transportable load is 13.4 metres. In order to remain within the above dimensions, a variety of design approaches and features have been proposed to suit the requirements of the customer. For example, Australian Patent No. 539799 and UK Patent Application No. GB2257170 disclose 30 manufactured housing with a hinged or an extendable roof, veranda or alcove elements. Australian Patent Application No. 71019/87 discloses a demountable building assembly which is adaptable to form one or more transportable containers, within which building panels are stored. U.S. Patent No. 4,635,412 discloses an assembly which folds to shipping container dimensions and includes multiple hinged panels to form, for example, an 3 enlarged floor area. Extension floor panels fold down on each side of the assembly and the frame assemblies fold up from the outer edges of the extension floor panels. U.S. Patent No. 5,237,784 discloses a transportable container in the form of a shipping container and includes foldable walls which are designed to form an enlarged floor and ceiling. 5 Australian Patent No. 720059 discloses an arrangement in which the core of the house is transportable as a shipping container. As can be seen from the above, TAMs have been produced previously, however, there are certain design limitations on such modules that make them less than desirable in many 10 instances. The present invention seeks to address at least some of the shortcomings of previously known TAMs. Summary of the Invention The present invention provides a stowable veranda system, including a roofing panel and a 15 decking panel, that is foldable against an outer wall of a dwelling. The skilled person will readily appreciate the broad applicability of the present invention to many types of dwelling. In particular, the invention has been developed for use with TAMs but is suitable for use with other forms of dwelling, including other transportable dwellings 20 and non-transportable dwellings such as, but not limited to, houses. It is to be understood that the use of the word "dwelling" encompasses not only structures intended for accommodation, but also structures intended for business or storage, etc. These additional applications are equally encompassed by the present invention. 25 The veranda system of present invention includes: a roofing panel, hingedly connected to a roofing rafter or an upper region of a wall panel of a dwelling; a decking panel, hingedly connected to a floor joist or a lower region of the wall panel; and a cable system including a cable and a winch. The winch may be a hand operated winch or a powered winch, such as, but not limited to, an electric winch, a mechanical winch or a hydraulic winch. The 30 veranda system is movable between a stowed condition and an open condition. In the stowed condition, the roofing panel and the decking panel are arranged such that they are lying parallel and adjacent to the wall panel. In a preferred embodiment, the roofing panel lies between the wall panel and the decking panel in the stowed condition.

4 In the stowed condition, an end of the cable is engaged with the outermost edge of the decking panel and the winch is used to retract the cable and keep it tight to thereby assist in securing the decking panel in the stowed condition. Optional fastening means may also be employed to secure the decking panel in the stowed condition. 5 In certain embodiments of the present invention, the veranda system is attached to a TAM. In exemplary embodiments of such an arrangement, the decking panel is approximately 2.4 m wide, 13.4 m long and 100mm in thickness and the roofing panel is approximately 2.0 m wide, 13.4 m long and 75mm thick. These measurements may vary between 10 embodiments of the invention, and will be dependent on the requirements and the final configuration of the dwelling with which the veranda system is to be used. The construction of the decking and roofing panels may be as standard in the art or modified to suit the particular requirements of the environment in which the veranda system is to be used. 15 The cable and winch effectively form a crane that remains attached to the dwelling. The winch may be manually, electrically, mechanically or hydraulically operated. The mechanism utilized requires a cable of an engineered strength to pass from the attachment point through a series of pulleys and to be wound around the winch drum on the winch, 20 thus allowing for the controlled raising and lowering of each panel. The cable is of a suitable size and rating to allow for the proposed loads imposed on the cable. The cable is releasably attached to the panels at a fixed point. The cable may be attached to the outer edges of either of the roofing panel or the decking panel by the use of any suitable means, for example an engineer approved "D" shackle or a carabiner shackle. 25 In embodiments having more than one cable, a single winch may be used to operate all cables. In certain embodiments, the winch in located under floor level of the dwelling, near where the decking panel hinges with the wall panel. The cable(s) travel from the winch parallel to and under the wall panel, then go up the wall and out through an outlet, 30 optionally including a pulley, adjacent to and substantially opposite the point at which the cable is to be connected to the decking panel. If there is a plurality of cables, each cable has its own exit point similarly positioned.

5 The present invention also provides a method of allowing for the decking panel and the roofing panel to be lowered and raised in a safe manner. The mechanism may be incorporated within the structure of the dwelling and is operated by a winch, either manually, electrically, mechanically or hydraulically, wherein the winch is sized to suit the 5 weight of the decking panel and roofing panel to be moved. The invention provides a means by which the safe lifting and lowering of each panel, around fixed hinge points, may be effected. The invention also allows for the safe installation of support legs and posts to allow for the resulting structure to be solid and stable. The method of the present invention permits safe operation of the raising and lowering of the panels in order to reduce the risk 10 of injury to an operator in the event of unplanned movement of the panels. In order to move the veranda system from the stowed condition to the open condition, it is necessary to lower the decking panel and raise the roofing panel. It will be appreciated by the skilled person that these panels are of substantial weight and that lowering or raising 15 such panels requires much care to be taken. The present invention provides an elegant means by which these difficult and potentially dangerous tasks may be completed: by the use of the cable and winch. Upon release of the optional fastening means, the decking panel is supported by the cable and winch. The winch may be used to lower the decking panel until it is substantially perpendicular to the wall panel. When in a suitable position, 20 decking support members may be positioned under the decking panel. The decking panel is then lowered fully onto the decking support members which provide a stable foundation for the decking. The cable is then disconnected from the outer edge of the decking panel and then 25 connected to an outer edge of the roofing panel, which may be substantially parallel to the wall panel. In order to allow the cable and winch to pull the roofing panel into its desired position, it preferable to employ a strut to provide the necessary leverage and thereby simplifies set up and places less strain on the winch. Accordingly, when the strut is installed between the cable and the roofing panel, the winch may be used to raise the 30 roofing panel into position. Once in position, suitable roofing support members may be positioned under the outer edge of the roofing panel to provide a stable foundation thereto. The use of the roofing support members means that the roofing panel is not being supported from above, but rather from below, thereby satisfying safety concerns. In 6 particular, there is little chance that the suspended roof might fall or collapse, which event would otherwise result in injury or damage to people or items positioned thereunder. The strut is removable, or at least able to be repositioned or folded, since it is required to 5 be substantially perpendicular to the roofing panel when the roofing panel is being moved into its open condition, but must be removed before the decking panel can be folded over the roofing panel in the stowed condition. Once in the open condition, the veranda system of the present invention provides a 10 covered, outdoor living area. The veranda system of the present invention may also be returned to the stowed condition. The user may wish to do so for any of a number of reasons, including, but not limited to, security of the dwelling to which it is attached, particularly when the dwelling is 15 unattended or during severe weather conditions; and reducing the overall size of the dwelling for transportation. The cable and winch system allows the user to return the veranda system to the stowed condition in a controlled and safe manner that essentially reverses the steps taken 20 previously to place the veranda in the open condition. Initially, the winch is used to take the tension on the cable so that the roofing support members no longer support the roofing panel. The roofing support members are then removed. The winch is then used to loosen the cable and thereby allow the roofing panel to pivot downwardly until it is adjacent and substantially parallel to the wall panel. Further loosening of the cable then allows the strut 25 to be removed. The end of the cable is then attached to the outer edge of the decking panel. Again, the winch is used to take the tension on the cable so that the decking support members no longer support the decking panel. The decking support members are then removed. The winch is then used to pivotally raise the decking panel until it is substantially 30 vertical and adjacent the roofing panel. The optional fastening means may then be used to assist in holding the decking panel and the roofing panel in the stowed condition.

7 The veranda system of the present invention is particularly suitable for use with TAMs. In particular, the veranda system of the present invention allows a TAM to include an outdoor living space without having to sacrifice interior living space. 5 Accordingly, the present invention provides a stowable veranda system that is foldable against an outer wall of a TAM whereby the veranda system does not substantially increase the width of the TAM so that the TAM remains within the regulated dimensions for road freight. 10 The present invention also provides a dwelling that includes a stowable veranda system according to the present invention. Preferably, the present invention provides a TAM that includes a stowable veranda system according to the present invention. As noted above, the skilled person will readily appreciate the broad applicability of the 15 present invention to not only TAMs but to any other form of dwelling, including other transportable dwellings. These additional applications are equally encompassed by the present invention. Examples of further applications include, but are not limited to, caravans and houses. One 20 particularly advantageous further application of the present invention is its ability to cover and protect a dwelling, such as a house, from storm damage. For example, a house fitted with a veranda system of the present invention might better withstand destructive winds and associated debris if the veranda system is placed into its stowed condition whereby it covers windows of the dwelling. Once the dangerous conditions have passed, the veranda 25 system can be returned to its open condition. Accordingly, the present invention provides an economical method of raising and lowering decking and roofing structures on TAMs and also, when folded against the TAM, as a storm shutter to protect windows and doors. As the invention simplifies the installation of 30 deck and roof systems due to its ability to pivot along a predefined length of edge and has a controlled method of lowering and rising, less qualified trades-persons are required. Thus, in remote areas, and with minimal supervision, the invention can easily be configured to form the operational or transportable modes where constant relocation is required.

8 The use of a fully incorporated method of raising and lowering the decking and roofing panels in TAMs is a novel method. The mechanism is located is such a manner, that the cable is concealed and protected within the body of the structure and cannot cause harm to the operator or general public. The invention described herein provides a method of 5 locating the components used in the invention. The type of winch required will of necessity require several different types and power configurations to allow for differing weights and to suit specific installations. The integrated crane method utilizing a concealed beam incorporated in the decking and 10 roofing panels with a removable strut is a novel invention. The use of the concealed components, and a removable strut, allows for a narrower building profile, allowing for the widest buildings to be transported on public roads without escorts. The removable strut also allows for the mechanism to be constructed from the ground, eliminating the need to work from heights that may cause injury if a fall occurred. 15 Brief Description of the Figures Figure 1 is an isometric view of an embodiment of a stowable veranda system according to the present invention. 20 Figure 2 shows detail of an embodiment of the plate at the top of the strut according to the present invention. Figure 3 is an isometric view of an embodiment of the crane column according to the present invention. 25 Figure 4 is an end-on view of an embodiment of the crane column according to the present invention, detailing the orientation of the pulleys attached thereto. Figure 5 is an isometric view of an embodiment of a lower pulley according to the present 30 invention. Figure 6 shows a cross-sectional view through the hinges connecting the roofing panel and decking panel to the dwelling, according to an embodiment of the present invention.

9 Figure 7 is a schematic diagram showing the cabling arrangement according to an embodiment of the present invention. Figure 8 shows the sequence of events involved with moving the illustrated embodiment of 5 the invention from the stowed condition to the open condition. Detailed Description of the Invention Referring to all the drawings wherein like reference numerals designate like or corresponding parts throughout the several views. The following description refers to the 10 specific, illustrated embodiment of the present invention and is in no way intended to limit the scope of the present invention to the specific, illustrated embodiments. Illustrated in Figure 1 is a stowable veranda system attached to a TAM 1, wherein the veranda system incorporates crane columns 5. The crane columns 5 provide conduits 15 through which cables can pass from a winch to the roofing and decking panels. Configuration of the winch 7 is dependent on specific requirements of the embodiment of veranda system with which it is to be used. In particular, the winch 7 is engineered to suit the lifting capacity required. The cable 17 is attached at the drum of the winch 7 at its proximal end, and to working cables 6, 16 at its distal end. 20 Pulleys 22, 23 are attached to the crane column 5 and the working cables 6, 16 pass through a respective lower pulley 22, rotating 900 and passing up the centre of a respective crane column 5. At the top of the crane column 5 is an upper pulley 23, through which the working cable 6, 16 passes. A roof beam 25 is incorporated within the roof panel 4 at or 25 near the point on the outer edge 27 at which stabilizing wire braces 26 connects to the roof panel 4, and extends laterally across the roof panel 4. The strut 13, when installed, extends substantially perpendicular to the roof beam 25 and is capped by a plate 19. The working cables 6, 16 are releasably attached to the plate 19 and stabilizing wire braces 26 connect the plate 19 to the outer edge 27 of the roofing panel 4. Accordingly, the cable 17 extends 30 from the winch 7 via the working cables 6, 16 to the plate 19 (see Figure 2), located on the uppermost part of the strut 13, and the braces 26 connect the plate 19 to the roof external edge 27. "D" shackles or carabiners are used to connect the ends of the working cables 6, 16 and the braces 26 to the plate 19.

10 Figure 3 details the crane post and connection of the working cable 6 to the plate 19 and the outer edge 27 of the veranda roofing panel 4. A steel rectangular hollow section is used as the crane column 5. At either end of the crane column 5 are pulleys 22 and 23, oriented at 90 degrees to each other. Figure 4 shows the arrangement of pulleys 22 and 23 by 5 viewing the crane column 5 from above. Figure 5 shows the detail of a pulley 22, 23 comprising a base 31, side members 32, disc member 35 and spindle 34. A steel rectangular hollow section is utilized as the roof beam 25 that is constructed within the body of the roofing panel 4. The roof beam 25 is welded into place. A steel rectangular hollow section is used as strut 13 and it is attached to roof beam 25. On the top of the strut 10 post 13, a 6mm steel, substantially triangular shaped plate 19, with a 18 mm hole each corner, is fixed (see Figure 2). On one side of the plate 19 the working cables 6, 16 are attached. On each of the other corners, the stabilizing wire braces 26 are attached. Each stabilizing wire brace 26 is attached at the outer edge 27 of the roofing panel 4. 15 As illustrated in Figure 6, the roof panel 4 is attached to the TAM 1 with one or more hinges 20. Similarly, the decking panel 3 is attached to the TAM with one or more hinges 21. The hinges 20, 21 are sized to suit the loads imposed upon them, as determined by an engineer. 20 Figure 7 is a schematic illustration of the routes of the various cables of the illustrated embodiment of the invention. From the winch 7, the cable 17 is led under the TAM 1, and the cable is joined under the TAM 1 to working cables 6, 16. Working cables 6 and 16 are then fed (i) around pulleys 38 and 39, respectively; (ii) into a neighbouring lower pulley 22; (iii) up through a respective crane column 5; (iv) through the upper pulley 23 attached 25 to the crane column 5; and (iv) to the connection plate 19 attached to the top of the strut 13. As described above, brace wires 26 are attached to plate 19 at top of the strut 13. Figure 8 shows the sequence for the lowering and raising of the panels between the stowed and open conditions. In Figure 8A, the veranda assembly is in the stowed condition, in 30 which the decking panel 3 and the roofing panel 4 are housed against the TAM 1. The upper section of the crane post 5 is shown as extending above the roof of the TAM 1. The cable 17 is unwound from the winch 7, the working cable 6, 16 passes through the lower pulley 22, through the crane column 5, over the upper pulley 23 and is attached to the decking panel 3 at the attachment point 24 (see Figures 1 and 3). In Figure 8B, the decking 11 panel 3 in its lowered position, and supported by one or more decking support members 11. The decking support member 11 is fixed to the decking panel 3 by a hinge 37 which allows the decking support member 11 to swing through 900 from being parallel to the decking panel 3 to being substantially perpendicular thereto. In Figure 8C, the roofing 5 panel 4 is being raised into position. Working cables 6, 16 are disconnected from the floor section 3 once it has been lowered, the strut 19 has been installed and the working cables 6, 16 are attached to the plate 19 at the top of the strut 13. The stabilizing wires 26 are attached to the outer edge of the roofing panel 4 at attachment point 27 (see Figures 1 and 3) and to the plate 19. In Figure 8D, the roofing panel 4 in its final location. The working 10 cables 6, 16 are attached to the roofing panel 4 as per the method described above. The winch 7 is activated and draws in the cable 17. The roofing panel 4 is moved about the hinge 20 incorporated in the roof section 4 and swings through about 90. Once the roofing panel 4 is at the required height, approximately 850 from its start point, roofing support members 28 are fitted to the roofing panels at 40 and connected to the decking panel 3 at 15 substantially directly below point 40 at point 36. The 850 places the roofing panel 4 in such a position that an approximately 50 roof pitch is achieved, thereby allowing rain to run freely from the roof of the veranda. Figure 8E shows the decking 3 and roofing 4 panels in their open condition in conjunction with the TAM 1. The decking panel 3 is supported by the support leg 11 and the roofing panel 4 is supported by the roof support column 28. To 20 return the veranda arrangement to its stowed condition, the entire process is reversed. Where the terms "include", "includes", "included" or "including" are used in this specification, they are to be interpreted as specifying the presence of the stated features, integers, steps or components referred to, but not to preclude the presence or addition of 25 one or more other feature, integer, step, component or group thereof. Further, any prior art reference or statement provided in the specification is not to be taken as an admission that such art constitutes, or is to be understood as constituting, part of the common general knowledge in Australia. 30

Claims (5)

1. A stowable veranda system, including a roofing panel and a decking panel, wherein the veranda system is foldable against an outer wall of a dwelling. 5

2. The veranda system of claim 1, wherein: (i) the roofing panel is hingedly connected to a roofing rafter or an upper region of a wall panel of a dwelling; (ii) a decking panel, hingedly connected to a floor joist or a lower region of a wall 10 panel; and (iii) a cable system including a cable and a winch; wherein the cable system is adapted to connect separately to the roofing panel and the decking panel and the cable system is used to separately move both the roofing panel and the decking panel. 15

3. The veranda system of claim 1 or 2, wherein the system is movable between a stowed condition and an open condition, wherein, in the stowed condition, the roofing panel and the decking panel are arranged such that they are lying parallel and adjacent to the wall panel. 20

4. A dwelling comprising a stowable veranda system according to any one of claims 1 to 3.

5. The veranda system of any one of claims 1 to 3 or the dwelling of claim 4, wherein 25 the dwelling is a transportable accommodation module.