Foldable Living Compartment

The present invention relates to a foldable living compartment. More particularly, the present invention relates to a foldable living compartment with improved insulation.

Foldable living compartments are known to be a quick solution to meet the need for temporary accommodation. Such a living compartment can be folded into a compact structure for easy storage and transport. When in use, it can be unfolded to form a reasonably sized enclosed space that serves as a reusable sheltered living area.

Currently, most foldable living compartments on the market consist of holes cut into metal panels to form side walls, pre-prefabricated windows and doors installed, and an exterior coating of thermal insulation. However, the metal panels do not provide sufficient insulation, particularly thermal insulation, which can lead to uncomfortable living conditions in extreme weather conditions. In addition, the metal panels of modular houses do not provide adequate sound insulation, which means that external noises such as raindrops hitting the roof and blowing of wind can be very disturbing to the occupants.

Poor soundproofing may also compromise privacy, as any noise or conversation made by the occupants can be heard by neighbours. It is thus crucial to address these issues to ensure a comfortable and private living space.

The invention seeks to eliminate or at least mitigate such shortcomings by providing a foldable living compartment with improved insulation.

According to a first aspect of the present invention, there is provided a foldable living compartment comprising a ceiling, a floor and a sidewall disposed between the ceiling and the floor, wherein the sidewall comprises two or more panels engaged with each other to enable the living compartment to transit between an expanded state and a collapsed state, each of the sidewall panels comprising: (i) a first subpanel, and (ii) a second subpanel opposing the first subpanel, wherein the first subpanel is spaced apart from the second subpanel defining a chamber trapping a layer of air therebetween.

In an embodiment, the living compartment is configured to have a maximum volume in the expanded state and a minimum volume in the collapsed state. and a minimum volume in the collapsed state, the maximum volume to minimum volume ratio is about 2.8 to 1.66

In an embodiment, the chamber is fillable with materials selected from a fire-resistant material, a heat insulating material, a sound insulating material, or a combination thereof.

In an embodiment, the first subpanel and the second subpanel are spaced apart at a distance adjustable to provide a predetermined insulation effect.

In an embodiment, the ceiling comprises one or more ceiling panels, wherein each of the ceiling panels comprising: (i) a first ceiling subpanel, and (ii) a second ceiling subpanel opposing the first ceiling subpanel, wherein the first ceiling subpanel is spaced apart from the second ceiling subpanel defining a chamber trapping a layer of air therebetween.

In an embodiment, the floor comprises one or more floor panels, wherein each of the floor panels comprising: (i) a first floor subpanel, and (ii) a second floor subpanel opposing the first floor subpanel, wherein the first floor subpanel is spaced apart from the second floor subpanel defining a chamber trapping a layer of air therebetween.

In an embodiment, the foldable living compartment further comprising a main frame for accommodating at least the ceiling, the floor and the sidewall, and configured to permit relative movement between the ceiling and the floor relative to the sidewall.

In an embodiment, an outer surface of the main frame is covered with an insulating material.

In an embodiment, the main frame further comprising supplementary frame members, configured to provide mechanical reinforcement to the ceiling, the floor and the sidewall.

In an embodiment, the supplementary frame members are positioned within the chamber of each of the panels.

In an embodiment, the sidewall includes a door, a window or a combination thereof.

In an embodiment, the chamber includes a first chamber and a second chamber, the first chamber of the first panel is in fluid communication with the second chamber of the second panel.

In an embodiment, the first and second chambers are connected by a passageway configured to accommodate network wires, electrical cables, pipes or a combination thereof.

In an embodiment, the ceiling comprises a first ceiling panel and a second ceiling panel.

In an embodiment, the first ceiling panel is in engagement with the sidewall, and the second ceiling panel is movably connected with the first ceiling panel to enable the second ceiling panel to move relative to the first ceiling panel.

In an embodiment, the second ceiling panel is connected to the sidewall via a hydraulic arm or a powered rod.

In an embodiment, the floor comprises a first floor panel and a second floor panel.

In an embodiment, the first floor panel is in engagement with a second edge of the sidewall, and the second floor panel is movably connected with the first floor panel to enable relative movement there between.

In an embodiment, the sidewall comprises a plurality of sidewall panels movably engaged with each other, enabling the sidewall to move between an expanded state, and a collapsed state.

In an embodiment, the panels are connected with each other in a manner to enable the transition between the expanded and collapsed states to proceed in a continuous motion.

According to a second aspect of the present invention, there is a panel applicable as a ceiling, a floor or a sidewall of a foldable living compartment, wherein the panel comprising: (i) a first subpanel, and (ii) a second subpanel opposing the first subpanel, wherein the first subpanel is spaced apart from the second subpanel defining a chamber trapping a layer of air therebetween.

shows a foldable living compartmentaccording to the present invention. For ease of transport, the compartmentis kept in a folded state to save space. It is then assembled and expanded to its fully expanded state, as shown in, on arrival at the site of use so as to provide a living compartment of a reasonable size for habitation. The area within the living compartmentreaches its maximum in the expanded state, and reduces the its minimum in the folded state.

The foldable living compartmentcomprises a main framefor supporting the mechanical structure of the compartment. The main frameincludes joints and articulations to allow movement of the living compartmentbetween an expanded state and a folded/collapsed state. The main frameis configured to enable ceiling panels, floor panels, a plurality of sidewall panelsand a door, windowsto mount thereon.

To enable smooth movement between the panels, movement rodssuch as hydraulic arms or powered rods are deployed between the movable connections, which in the present embodiment are between the ceiling panelsand a central portion of the sidewall, to assist the expanding and folding movement of the ceiling panelsagainst the sidewall and also to provide structural reinforcement.demonstrates the dimensions of an embodiment of the foldable living compartment according to the present invention. The dimensions of the foldable living compartment in the expanded state and the folded state (collapsed state) are shown in table 1 and table 2.

The ratio of size of the foldable living compartment in the expanded state to the size of the foldable living compartment in the folded state is about 1.66. The preferred expanded size of the foldable compartment is 6000 mm×6000 mm×2986 mm and the preferred folded size of the foldable compartment is 6000 mm×3609 mm×2986 mm. The preferred interior height is 2400 mm. The height of the indoor of the foldable living compartment is 213 cm in the exhibition version, and 213 cm in the production version. The roof slope is 0 degree in the exhibition version and 2.5 degrees in the production version.

andshow a main frameas such and a frame structure. The frame structurecomprises the main framein combination with members of an insulated frame cover made of insulating material which covers part of the main frame.

In a preferred embodiment, the main frameis made of lightweight steel which provides adequate mechanical support for the living compartment while remaining lightweight for efficient transport. However, the metal frame, which is of higher thermal conductivity than the surrounding material, creates a path of least resistance for heat transfer also known as thermal bridge.

Thermal bridges in the building structure can have a significant impact on the heat transfer into and out of the living compartment, and therefore increases the amount of energy required to heat and cool a compartment (provided by an air-conditioner and a heater for example), as well as causing condensation within the compartment causing discomfort in the living environment.

This is especially problematic when the cross beamsand columns, which are made of metal, are exposed to the external environment. To address this problem, members of the insulating frame cover which are made of insulating materials, such as polyvinyl chloride (PVC) and other plastics, are used to cover at least a portion of the main frame. This reduces the overall thermal conductivity of the frame structure, thereby minimizing heat transfer into and out of the living compartment via thermal bridges.

As shown in, the main framecomprises a ceiling frame structure, a sidewall frame structureand a floor frame structurefor supporting a ceiling, a sidewall and a floor respectively. To allow the living compartment to transit between an expanded state and a collapsed state, the ceiling frame structureand/or the floor frame structureare movably interconnected with the sidewall frame structureto enable movement. In a preferred embodiment, the frame members are hingedly engaged with each other.

In the present embodiment, the ceiling frame structurecomprises three ceiling frame members, the first and second ceiling frame membersandare hinged to either side of a third ceiling frame member, forming a triple-fold frame structure. Likewise, the floor frame structureconsists of three floor frame members,, and. A triple-fold frame structure is formed by hinging a first and second floor frame member,andrespectively, to either side of a third floor frame member. Each of the floor frame members,,further comprises supplementary frame membersfor mechanical reinforcement.

In an exploded view as shown in, a ceiling frame membercomprises of four ceiling structural tubes,,,interconnected with each other at the end portions to form a rectangular structure. In a preferred embodiment, the ceiling structural tubes,,,include a coupling elementat each end portion, allowing them to be easily connected with each other. Alternatively, the ceiling structural tubes are spot-weld together. Similarly, the floor frame memberconsists of four structural tubes,,,that are preferably spot-weldedtogether. Coupling elements may also be included at the end portions of the tubes for interconnection via coupling. Preferably, each of the structural tubes have the thickness between 3 mm and 5 mm.

shows the frame structureprovided with members of an insulating frame cover made of insulating materials. Same as the main frame, the frame structurecomprises a ceiling frame structure, a sidewall frame structureand a floor frame structure. A beam holderincluding multiple beam memberswhich covers the steel ceiling frame to enhance insulation and also act as the supplementary frame members to reinforce the mechanical structure. Said beam holderis preferably formed from acrylonitrile butadiene styrene (ABS). Alternatively, it can also be formed from other tough and durable insulating materials.

The frame structurefurther includes a window frame, a door frame, a vertical sidewall frame, a fixing plate for vertical wall enclosure, a ground fixed border stopand an interior fixing plate. These frame members are preferably formed from PVC, PVC foams, or other plastics.

The majority of foldable living compartments on the market are constructed with thin metal plates for their sidewalls and ceiling panels. This is because thin metal plates are easily accessible as building materials and are lightweight, making them easy to transport. Alternative materials include thin PVC panel boards which serve as a skin to the exterior of the sidewall. However, such PVC skin usually has negligible thickness that it is thus unable to provide adequate insulation, both thermally and acoustically, to the foldable living compartment.

Referring now towhich depicts a sectional view of a sidewall panelof a foldable living compartment according to the present invention. The sidewall panelcomprises an inner subpaneland an outer subpanelspaced apart from each other by a distance a. The peripheries of both the inner subpaneland the outer subpanelare sealed with sealing components, thereby defining an enclosed chamberin between which traps a layer of air. Such chamberis well insulated such that both the thermal and acoustic conductivity thereof is lower than that of the materials of the inner and outer subpanels,and the sealing components. This can reduce thermal and acoustic transfer into and out of the living compartment via the sidewall panels, providing a more comfortable living environment to the habitants.

The inner and outer subpanels,are preferably made of PVC with glass fibre sheet attached on both sides. The insulated chambermay be filled with gas, or is fillable with different materials to achieve varying performances, for example in order to enhance the fire-resistance properties of the living compartment, the chamberis filled with phenolic foam, whereas if it is desired to further improve insulation, PU foam can be used as the filing material instead.

To meet the building code requirements for thermal resistance, thicknesses a of the insulated chamber can be adjusted to achieve the desired insulation effect.

shows an exploded view of the sidewall panelof. As is shown, the sidewall panelcomprises an inner subpaneland an outer subpanel, each with a significant thickness aiming to provide adequate insulation. In a preferred embodiment, both the inner and outer subpanels,are of 35 mm thickness, and are made of a sheet moulding compound (SMC) which are also known as a ready-to-mould glass-fibre reinforced polyester material. Alternatively, the inner and outer subpanels,are made from other insulating materials. The inner and outer subpanels,are spaced apart from each other defining an insulated chambertherebetween, wherein the thermal conductivity of the insulated chamberis lower than that of the inner and outer subpanels. Preferably, the thickness of the chamber is at least 30 mm.

When in use, the upper edge of the sidewall panelis in contact with the ceiling of the living compartment whereas the lower edge of the sidewall panelis in contact with the floor. The upper and lower edges of both the inner and outer subpanels,are sealed with inner peripheral frames. Together with the side sealing panels, an insulated chamberis defined between the inner and outer subpanels,.

The inner peripheral framesalso serve to engage with the main frame of the foldable living compartment.

The outer peripheral framesare attached to an outer surface of the side sealing panelsfor engagement with another sidewall panel. Both the inner and outer peripheral frames,include coupling elements for engagement. The coupling elements may be threads or other patterns complementary in shape to the edges of the main frame and another panel. In particular, the side edges of the sidewall panelfurther include a connecting elementwhich, in a preferred embodiment, is a hinge such that two sidewall panels are articulated to each other. This allows the two sidewall panels to move relative to each other in a sideway folding movement.

show an exploded view of the panel structure of the foldable living compartment. The living compartmentincludes a ceiling panel assembly, a first side wall panel assembly, a second sidewall panel assembly, and a floor panel assembly.