Note: Descriptions are shown in the official language in which they were submitted.
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BUILDINGS FORMED FROM COMPLEMENTARY BUILDING MODULES, AND
METHODS FOR BUILDING SAME
RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No.
61/388,673, filed
October 1, 2010. The entire teachings of the above application are
incorporated herein by
reference.
BACKGROUND OF THE INVENTION
Foldable houses have been described in the literature; however, very few have
been built.
Reasons that have hindered commercialization of foldable houses include the
large extent of
work that needs to be performed at the building site, the presumed limited
design capabilities and
difficulty of designing houses that have sufficiently large and interesting
floor plans while
having corresponding compact and easily transportable folded configurations.
There is, therefore, a need for foldable houses and buildings that exhibit
more design
flexibility, are fonned from easily transported folding building modules, and
allow buildings that
are substantially in finished condition.
SUMMARY OF THE INVENTION
A first embodiment of the present invention is a building formed at least in
part from a
first unfolded building module connected to a complementary building module.
A second embodiment of the present invention is a house. The house is formed
at least in
part from a first unfolded building module and a connected complementary
second unfolded
building module, wherein the first unfolded building module and the second
unfolded building
module, each independently, have a core part and an unfolded part attached to
the respective core
part; i) the unfolded part of the first unfolded building module is connected
to a complementary
core part of the second unfolded building module, ii) the unfolded part of the
first unfolded
building module is connected to the complementary unfolded part of the second
unfolded
building module, or iii) the core part of the first unfolded building module
is connected to a
1125054.1
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complementary core part of the second unfolded building module; and the first
unfolded building
module and/or the second unfolded building module contain kitchen elements
and/or bathroom
elements in one or both of the respective core structures that were present in
the respective
folded building modules.
A third embodiment of the present invention is a method of forming a building.
The
method includes (a) setting a first folded building module on a foundation,
the folded building
module having a core structure and an unfoldable structure attached to the
core structure, the
unfoldable structure including a plurality of foldably connected panels, (b)
unfolding part or all
of the unfoldable structure of the first folded building module to form an
unfolded structure, (c)
setting a complementary building module on the foundation and positioned such
that panels of
the complementary building module complement respective panels of the unfolded
structure, (d)
connecting the panels of the complementary building module and respective
panels of the
unfolded structure, and (e) connecting one or more roof elements to the
building modules.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular description
of
example embodiments of the invention, as illustrated in the accompanying
drawings in which
like reference characters refer to the same parts throughout the different
views. The drawings
are not necessarily to scale, emphasis instead being placed upon illustrating
embodiments of the
present invention.
FIG. 1 is a schematic axonometric view of the structural frame of a house
according to an
exemplary embodiment of the present invention, substantially provided by two
connected
complementary structural frames of two respective unfolded building modules.
FIG. 2 is a perspective view of an exemplary unfolding sequence according to
an
embodiment of the present invention starting from two separate folded
structural frames of
respective two separate folded building modules to the structural frame
described in FIG. 1.
FIG. 3 is a schematic floor plan of a completed house according to an
exemplary
embodiment of the present invention, based on the structural frame of FIG. 1.
FIG. 4 provides schematic views from four sides of a completed house according
to an
exemplary embodiment of the present invention, based on the structural frame
of FIG. 1.
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FIG. 5 is a schematic view of a frame element according to an exemplary
embodiment of
the present invention.
FIG. 6 is a schematic view of a frame element according to an exemplary
embodiment of
the present invention.
FIG. 7 is a schematic view of a frame element according to an exemplary
embodiment of
the present invention.
FIG. 8 is a schematic view of a frame element according to an exemplary
embodiment of
the present invention.
FIG. 9 is a schematic view of a frame element according to an exemplary
embodiment of
the present invention.
FIG. 10 is a schematic cross-sectional view illustrating an exemplary
connection
assembly connecting a fixed floor panel of one building module with a folding
floor panel in
unfolded configuration of another complementary unfolded building module.
FIG. 11 is a schematic cross-sectional view illustrating an exemplary
connection
assembly connecting a fixed back wall panel of one building module with a
removable side wall
panel of another complementary unfolded building module.
FIG. 12 provides a schematic perspective and plan view illustrating an
exemplary
connection assembly connecting a fixed back wall frame element and a fixed
floor frame
element of one building module with a folding floor frame element and side
wall frame element
of a complementary unfolded building module.
FIG. 13 is a schematic cross-sectional view illustrating an exemplary
connection
assembly connecting a fixed interior wall panel and a fixed interior side
panel of one building
module with an exterior flip (i.e., folding) wall panel of another
complementary unfolded
building module.
FIG. 14 provides a schematic perspective view illustrating an exemplary
connection
assembly of a folding floor frame element and exterior flip wall frame element
of one building
module with a fixed floor frame element, fixed interior wall frame element,
and fixed side wall
frame element of a complementary unfolded building module.
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FIG. 15 is a schematic axonometric view of the structural frame of a house
according to
an exemplary embodiment of the present invention, substantially provided by
three connected
complementary structural frames of three respective unfolded building modules.
FIG. 16 is a schematic axonometric view of the structural frame of a house
according to
an exemplary embodiment of the present invention, substantially provided by
two connected
complementary structural frames of two respective unfolded building modules.
FIG. 17 provides schematic views of a house that can be built with a
structural frame
such as the one shown in FIG. 15.
FIG. 18 provides schematic views of a house that can be built with a
structural frame
such as the one shown in FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
The buildings and, particularly, houses of the present invention are formed at
least in part
from an unfolded building module connected to a complementary building module.
The
combination of foldable building technology in conjunction with complementary
design as
described herein allows fabrication of substantially finished houses and
buildings that exhibit
more design flexibility, are formed from easily transported building modules,
and require little
finishing at the building site. It further allows to reduce the weight of the
structural frame,
allows large spaces with high ceilings extending from one complementary
building module to
another, allows single and therefore thin panels between complementary
building modules, and
allows overall reduction of material, labor and transport costs.
A description of example embodiments of the invention follows.
Several houses using the building technology described herein have been built
and are
described in the following FIGS. 1 to 16.
FIG. 1 is a schematic axonometric view of the structural frame 100 of a house
according
to an exemplary embodiment of the present invention. In this embodiment, the
structural frame
is a structural steel frame, and is substantially provided by two connected
complementary
structural frames of two respective unfolded building modules. The first
unfolded structural
frame is made from a number of frame elements, specifically, a fixed floor
frame element 110 in
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fixed connection with a fixed back wall frame element 112, a fixed side wall
frame element 114,
and a further fixed side wall frame element 116. Frame element 112 is also in
fixed connection
with frame elements 114 and 116. In combination, the frame elements 110, 112,
114 and 116
form a core structure of the first unfolded building module. Fixed floor frame
element110 is
foldably connected to a folding floor frame element 118, and fixed side wall
frame element 116
is foldably connected to a folding side wall frame element 120 which itself is
foldably connected
to a further folding side wall frame element 122. The folding floor frame
element is further
foldably connected to an exterior flip (i.e., folding) wall frame element 124,
which itself is
further foldably connected to another exterior flip (i.e., folding) wall frame
element 126.
Analogously to fixed side wall frame element 116, fixed side wall frame
element 114 can be
connected to foldable side wall frame elements (similar to frame elements 120
and 122).
Alternatively, as is the case here, a removable side wall frame element 128
can be installed. The
foldably connected frame elements provide the unfolded structure of the first
building module,
and any removable frame element can be installed (i.e. connected) separately
to respective
adjacent frame elements. In fully folded configuration the foldably connected
frame elements
arrange compactly as shown in step (1) of FIG. 2 and leave substantially all
of the core structure
volume available for other parts to be prefabricated and finished in the core
volume. It is noted
that the fully folded structural frame 210 of the first building module
includes two foldable side
wall frame elements (similar to frame elements 120 and 122) connected to fixed
side wall frame
element 114. However, except for this difference, the folded and unfolded
configurations
associated with the first structural frame are the same. With respect to FIG.
1, additionally, in
fully folded configuration, the foldable floor frame element 118 provides a
wall of the folded
module, which increases structural stability of the building module in folded
configuration,
protects prefabricated and finished parts in the core volume, and thereby
facilitates transportation
of the respective building module.
The second unfolded structural frame is also made from a number of frame
elements,
specifically, a fixed floor frame element 130 in fixed connection with a fixed
side wall frame
element 132, a further fixed side wall frame element 134, a fixed back wall
frame element 140,
and a further fixed back wall frame element 142. Frame element 140 is also in
fixed connection
with frame element 134, and frame element 142 is also in fixed connection with
frame element
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132. In combination, the frame elements 130, 132, 134, 140 and 142 form a core
structure of the
second unfolded building module. Fixed floor frame element 130 is foldably
connected to a
folding floor frame element 144, which in turn is foldable connected to a flip
wall 145. Fixed
side wall frame element 132 is foldably connected to a folding side wall frame
element 146
which itself is foldably connected to a further folding side wall frame
element 148. The fixed
back wall frame element 140 and 142 are further foldably connected with a
folding clerestory
frame element 150. Side frame elements 136 and 138 are in fixed connection
with respective
fixed side wall frame elements 132 and 134, and are not part of the structural
frame in folded
configuration. Analogously to fixed side wall frame element 132, fixed side
wall frame element
134 can be connected to foldable side wall frame elements (similar to frame
elements 146 and
148). Alternatively, as is the case here, a removable side wall frame element
152 can be
installed. The foldably connected frame elements provide the unfolded
structure of the second
building module, and any removable frame element can be installed (i.e.
connected) separately to
respective adjacent frame elements. In fully folded configuration the foldably
connected frame
elements arrange compactly as shown in step (7) of FIG. 2 and leave
substantially all of the core
structure volume available for other parts to be prefabricated and finished in
the core volume. It
is noted that the fully folded structural frame 220 of the second building
module includes two
foldable side wall frame elements (similar to frame elements 146 and 148)
connected to fixed
side wall frame element 134; however, except for this difference, the folded
and unfolded
configurations associated with the second structural frame are the same. With
respect to FIG. 1,
additionally, in fully folded configuration, the foldable floor frame element
144 provides an
exterior wall of the folded building module and the foldable clerestory frame
element 150
provides a further exterior wall of the folded building module, which
increases structural
stability of the building module in folded configuration, protects
prefabricated and finished parts
in the core volume, and thereby facilitates transportation of the respective
building module.
As described above, FIG. 1 shows the structural frame of a house made from two
complementary structural frames, a first unfolded structural frame and a
second unfolded
structural frame. Although only frame elements and respective structural load
carrying members
are shown it is to be understood that typically the house is not only formed
from two
complementary folded structural frames, but from two folded building modules
that when
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unfolded complement each other and form a substantially finished house
including even kitchen
elements including but not limited to cabinets, appliances, and sink(s),
and/or bathroom elements
including but not limited to cabinets, shower, bathtub, toilet, and sink.
As described above, the structural frame shown in FIG. 1 is made from a number
of
frame elements. Examplary connection assemblies are also indicated in 151-164,
170 and 180.
FIG. 2 is a perspective view of an exemplary unfolding sequence according to
an
embodiment of the present invention starting from two separate folded
structural frames of
respective two separate folded building modules to the structural frame
described in FIG. 1. For
ease of visualization, only the structural frames are shown and not the
complete building
modules, however, the respective building modules include the structural
frames and, thus, the
unfolding sequence is the same for the structural frame and the respective
building module. A
first folded structural frame of 210 of a first folded building module is
unfolded to form an
unfolded structural frame 215 of the unfolded building module. Firstly, as
shown in (1), the first
folded structural frame 210 is set on a foundation (not shown). Then, the
folding floor frame
element 118 folds down to the configuration shown in (2). In the next step,
the exterior flip wall
frame element 124 folds up to the configuration shown in (3). In a further
step, a further exterior
flip wall 126 folds up to the configuration shown in (4). Then, the accordion
walls 218 and 219
fold out as shown in (5) to yield the unfolded structural frame 215. The
unfolded structural
frame 215 and corresponding unfolded building module exhibit an opening 216,
here on the front
side of the unfolded structure of the unfolded structural frame 215. Accordion
wall 218 is made
from two folding side walls, as described above as alternative for the
removable side wall 128 in
FIG. 1. Accordion wall 219 is made from folding side walls 120 and 122 (shown
in FIG. 1).
Subsequently, a second complementary folded structural frame 220 is set on the
foundation and
connected to the first unfolded structural frame 215 and corresponding
building module. The
second building module and structural frame 220 are adapted to complement the
first building
module and structural frame 215. Specifically, in this embodiment, the
interior wall frame
element 142 and part of the folding clerestory frame element 150 of the second
structural frame
220 complement the front side of the first unfolded structural frame 215 by
providing interior
wall frame elements for the first unfolded structural frame 215. Here, the
opening 216 is
reduced in area by fixed interior wall frame element142. In the context of the
unfolding of
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folded building modules, the second building module having the second
structural frame,
typically, includes substantially finished panels corresponding to the frame
elements, and panels
corresponding to frame elements such as 142 can have interior finishing
material on both sides.
After the second complementary folded building module is set (only structural
frame 220 is
shown), the folding floor frame element 144 folds down to the configuration
shown in (8). Then,
the flip wall frame element 145 folds up to the configuration shown in (9).
Then, the accordion
walls 225 and 230 fold out as shown in (10) to the configuration shown in
(11). Accordion wall
225 is made from two folding side walls, as described above as alternative for
the removable side
wall 152 in FIG. 1. Accordion wall 219 is made from folding side walls 146 and
148 (shown in
FIG. 1). Finally, the folding clerestory frame element 150 is folded up to
yield the structural
frame 200 of a house according to an exemplary embodiment of the present
invention. Likewise
, the unfolding of the corresponding building modules that include the first
and second structural
frames, results in part of a house, and, at this stage, further elements such
as some interior walls
and/or roof elements are connected to the structural frame to form the
completed house.
Typically, kitchen and bathroom elements are already included in the folded
building modules.
FIG. 3 is a schematic floor plan 300 of a completed house according to an
exemplary
embodiment of the present invention, based on the structural frame 100 of FIG.
1. The house is
formed in part from two complementary unfolded building modules that are the
basis for the
completed respective parts 210 and 220 of the house. Substantial parts of the
plumbing, heating,
cooling and electrical system (not shown) can be installed in the core
structure of the building
modules. This includes kitchen elements such as 322 and bath elements such as
324. Interior
walls such as 326 can be foldably attached to the structural frames of the
building modules, or
they are separate and are connected to the structural frame at the building
site. Typically, the
structural frame can be adapted for attachment of these interior walls. The
house includes
several rooms, including a kitchen area 330, a first bathroom 335, a first
bedroom 340, a seconf
bathroom 345, a second bedroom 350, an office room 355 and a living room 357.
The house
features a plurality of windows 360, which typically are included in the
folded building modules.
FIG. 4 provides schematic views from four sides (a), (b), (c) and (d) of a
completed
house according to an exemplary embodiment of the present invention. The house
is based on
the structural frame of FIG. 1, and can have the floor plan shown in FIG. 3.
The house has two
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parts 310 and 320. Part 210 is substantially provided by an unfolded building
module having the
unfolded structural frame 215 (see FIG. 2) and part 210 is substantially
provided by an unfolded
building module having the unfolded structural frame 235 (see FIG. 2). The
views further show
the roof elements 410 and 420.
FIG. 5 is a schematic view of an exemplary fixed back wall frame element 140
in FIG. 1
with exemplary dimensions. It can, for example, be made from four structural
steel load
carrying members that have the following exemplary dimensional
characteristics:
Member Tag Length
510 C 6 x 13 12'
520 W 4.125 x 13 12 ' 2"
530 W 6.25 x 16 8' 9" 7/8
540 HSS 4 x 2 x 0.25 8' 9" 7/8
In the "Tag" column of the Table above and the ones below, W stands for "W-
Section"
or a "Wide Flange" member, C for a "C-Channel", and HSS for "Hollow Structural
Steel
Member". For Cs and Ws, the first number is the depth of the member and the
second number is
the weight per lineal foot. So, in the case of "C 6 x 13", it is a C-channel
member with a depth
of 6" and a weight of 13 pounds/ft.
FIG. 6 is a schematic view of an exemplary interior wall frame element 142 in
FIG. 1
with exemplary dimensions. It can, for example, be made from four structural
steel load
carrying members that have the following exemplary dimensional characteristics
Member Tag Length
610 PLATE 4 x 0.25 12'2"
620 W 4.125 x 13 12'2"
630 HSS 4 x 2 x 0.25 8' 9" 5/8
640 W 6.25 x 16 8' 9" 5/8
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FIG. 7 is a schematic view of an exemplary clerestory frame element 150 in
FIG. 1 with
exemplary dimensions. It can, for example, be made from twelve structural
steel load carrying
members that have the following exemplary dimensional characteristics:
Member Tag Length
701 C 6 x 10.5 23 ' 10'
702 W 6.25 x 16 48'
703 HSS2x4x 0.25 12'2"
704 W 4 x 13 11' 5" 3/4
705 HSS2x4x 0.25 12'2"
706 HSS 4x 2x 0.25 6' 2" 1/4
707 W 6 x 16 6' 2" 1/4
708 W 6 x 16 6' 2" 1/4
709 HSS 4x 2x 0.25 6' 2" 1/4
710 W 4 x 13 2' 2" 3/4
711 W4 x13 2' 2" 3/4
712 W 4 x 13 2' 2" 3/4
FIG. 8 is a schematic view of an exemplary exterior flip (i.e., folding) wall
frame element
124 in FIG. 1 with exemplary dimensions. It can, for example, be made from
four structural
steel load carrying members that have the following exemplary dimensional
characteristics:
Member Tag Length
810 C6x13 12'
820 W 4.125 x 13 12'
830 HSS4x2x 0.25 8' 9" 7/8
840 HSS 4 x 2 x 0.25 8' 9" 7/8
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FIG. 9 is a schematic view of an exemplary exterior flip (i.e., folding) wall
frame element
126 in FIG. 1 with exemplary dimensions. It can, for example, be made from
four structural
steel load carrying members that have the following exemplary dimensional
characteristics:
Member Tag Length
910 HSS 2 x 4 x 0.25 12'
920 W 6.25 x 16 12'
930 HSS 4 x 2 x 0.25 3' 5" 1/4
940 HSS 4 x 2 x 0.25 3' 5" 1/4
FIG. 10 is a schematic cross-sectional view illustrating an exemplary
connection
assembly 1000 connecting a fixed floor panel 1010 (based on the fixed floor
frame element 130
of FIG. 1) of one building module with a folding floor panel (in unfolded
configuration and
based on the folding floor frame element 118 of FIG. 1) of another
complementary unfolded
building module. Cross-sectional view (a) of FIG. 10 shows the panels 1010 and
1020 in
connected and finished configuration. Cross-sectional view (b) of FIG. 10
shows the cross-
sectional outlines 1011 and 1012 of respective panels 1010 and 1020. Cross-
sectional view (c)
of FIG. 10 shows how the two panels are connected with suitable fasteners 1070
(e.g., HILTI
Kwik-Flex screws) by fastening the steel plate 1042 of panel 1020 with the C-
channel 1035 of
panel 1010, and by fastening the steel plate 1040 of panel 1010 with the C-
channel 1037 of panel
1020. Panels 1010 and 1020 are substantially in finished condition, however,
to allow fastening
the C-channels, a section 1031 above the C-channels is unfinished (or the part
1031can be
included in the folded building module, and disassembled before the respective
panel is moved
into unfolded configuration) to allow access to the channels for fastening
purposes (as shown in
view (b) of FIG. 10). After, the panels 1010 and 1020 are connected, the
unfinished area 1031
can be finished with finishing material (e.g., flooring) 1030 (or, the part
1031 can be returned
into position) . Each panel includes blocking members 1055 connected to the
interior surface
areas of the respective C-channels, and further blocking members 1050
connected to the
respective blocking members 1055. The blocking members are adapted to
facilitate connection
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of subflooring 1060 (e.g., plywood, oriented strand board, or other pre-finish
surfacing) and
finish floor 1065 to the frame element. As illustrated in FIG. 10 the
structural load carrying
members, C-channels 1035 and 1037, of the two panels complement each other to
form a
combined structural load carrying member of approximately I-beam shape
indicated in FIG. 1 as
element 153. Additionally, the panels 1010 and 1020 complement each other to
form a
continuous floor area from one unfolded building module to the connected
unfolded building
module.
FIG. 11 is a schematic cross-sectional view illustrating an exemplary
connection
assembly 1100 connecting a fixed back wall panel 1120 (based on the fixed back
wall frame
element 140 of FIG. 1) of one building module with a removable side wall panel
1110 (based on
the removable side wall frame element 128 of FIG. 1) of another complementary
unfolded
building module. FIG. 11 shows the panel 1110 and 1120 in connected and
finished
configuration. Panel 1110 includes a hollow structural steel member 1114, a
blocking member
1112 fastened to the member 1114, and interior wall board (e.g., gypsum board)
1116 and
sheathing 1118 (e.g., plywood, oriented strand board, etc.). Panel 1120
includes a steel I-beam
member 1124, a blocking member 1122 fastened to the member 1124, and interior
wall board
1126 and sheathing 1128 fastened to the blocking member. After the panels 1120
and 1124 are
fastened to each other, a further blocking member 1122 and interior wall board
1123 are used to
finish the connection assembly. As illustrated in FIG. lithe structural load
carrying members,
I-beam 1124 and 1114, of the two panels complement each other to form a
combined structural
load carrying member indicated in FIG. 1 as element 163. Additionally, the
panels 1110 and
1120 complement each other to form a continuously finished wall through the
connection corner
1150.
FIG. 12 provides a schematic perspective (a) and plan view (b) illustrating an
exemplary
connection assembly 1200 similar to 170 in FIG. 1 of structural load carrying
members 1210 of a
fixed back wall frame element (only shown in part) and structural load
carrying members 1220
of a fixed floor frame element (only shown in part) of one complementary
building module with
structural load carrying members 1230 of a side wall frame element (only shown
in part) and
structural load carrying members 1240 of a folding floor frame element (only
shown in part) of
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another complementary unfolded building module. The bolt holes 1250 can be
drilled on site to
ensure alignment and the structural load carrying members bolted with bolts
(not shown).
FIG. 13 is a schematic cross-sectional view illustrating an exemplary
connection
assembly 1300 connecting a fixed interior wall panel 1301 (based on the fixed
interior wall
frame element 142 of FIG. 1) and a fixed interior side panel 1302 (based on
the fixed side wall
frame element 132 of FIG. 1) of one building module with an exterior flip
(i.e., folding) wall
panel 1303 (based on the exterior flip (i.e., folding) wall frame element 124
of FIG. 1) of another
complementary unfolded building module. FIG. 13 shows the panels 1301, 1302
and 1303 in
connected and finished configuration except for one area which is adapted to
receive a non-
structural interior wall panel 1304 which includes blocking members 1385 and
interior wall
board 1380. Panel 1303 includes a hollow structural steel member 1305, a
blocking member
1310 fastened to the member 1305, and sheathing1315 and interior wall board
1320 fastened to
the blocking member 1310. Panel 1302 includes a steel I-beam member 1325, a
blocking
member 1330 fastened to the member 1325, a blocking member 1335 fastended to
the member
1325, and sheathing 1340 and interior wall board 1345 fastened to the blocking
members. Panel
1301 includes a hollow structural steel member 1350, a blocking member 1355
fastened to the
member 1350, two blocking members 1360 and 1365 fastened to the blocking
member 1355, and
interior wall board 1370 and interior wall board 1375 fastened to the blocking
members. The
folded up exterior flip wall panel 1303 of the first building module is
complementary to the fixed
panels 1301 and 1302 of the second building module. The structural load
carrying members, I-
beam 1325, hollow structural steel sections 1360 and 1305 of the three panels
complement each
other to form a combined structural load carrying member (also, indicated in
FIG. 1 as element
164), and the three panels upon connection provide continuous finishing
through the connection
corners 1390.
FIG. 14 provides a schematic perspective view illustrating an exemplary
connection
assembly 1300 similar to 180 in FIG. 1 of structural load carrying members
1310 of a folding
floor frame element and structural load carrying members 1320 of an exterior
flip wall frame
element of one building module with structural load carrying members 1330 of a
fixed floor
frame element, fixed interior wall frame element (not shown), and structural
load carrying
members 1340 of a fixed side wall frame element of a complementary unfolded
building module.
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FIG. 15 is a schematic axonometric view of the structural frame 1500 of a
house
according to an exemplary embodiment of the present invention, substantially
provided by three
connected complementary structural frames 1510, 1520 and 1530 of three
respective unfolded
building.
FIG. 16 is a schematic axonometric view of the structural frame of a house
1600
according to an exemplary embodiment of the present invention, substantially
provided by two
connected complementary structural frames 1610 and 1620 of two respective
unfolded building
modules.
FIG. 17 provides schematic views of a house that can be built with a
structural frame
such as the one shown in FIG. 15. FIG. 17 provides a front view (a) showing
three connected
complementary building modules 1710, 1720 and 1730, a back view (b), a view on
the outside of
a unfolded building module 1710 (c), a back view on the outside unfolded
building module 1730
(d), a view from inbetween module 1710 and 1730 on module 1710 (e), and a view
from
inbetween module 1710 and 1730 on module 1730 (e).
FIG. 18 provides schematic views of a house that can be built with a
structural frame
such as the one shown in FIG. 16. FIG. 18 provides a back view (a) showing two
connected
complementary building modules 1810 and 1820, a front view (b), a first side
view (c) and a
second side view (c).
Building modules of the present invention can be formed from fixed panels and
folding
panels that are foldably connected to other folding panels or fixed panels.
Accordingly, building
modules can include folding panels or are entirely formed from fixed panels.
Typically, the
building modules include folding panels in an arrangement that allows the
building modules to
be folded into a folded configuration (typically, of box shape) that takes up
a smaller volume,
primarily, for transport purposes. Such a folding building module can be
unfolded to result in an
unfolded building module.
The panels that can form an unfolded building module have frame elements (see,
e.g.
FIGS. 5-9) which typically are made from a number of structural load carrying
members in fixed
connection. The structural load carrying members of different panels can be
connected to
provide a fixed connection of the panels in both folded and unfolded
configuration of the folding
building module, or can be foldably connected to provide a foldable connection
of the panels and
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thereby allow folding and unfolding of the folding building module. After
unfolding and
affixing of the frame elements of the panels through connection of respective
structural load
carrying members, the frame elements form at least part of the structural
frame of building or
house.
The buildings (typically, houses) of the present invention are formed at least
in part from
a first unfolded building module connected to a complementary building module.
The
complementary building module can be a folding building module, but can also
be a fixed
building module, that is, a building module that does not have a structure
that can be unfolded.
Typically, buildings, and particularly, houses are formed at least in part
from a first unfolded
building module connected to a complementary second unfolded building module.
The complementary building modules of the present invention are not merely
building
modules that can be placed structurally independently side by side, stacked,
or otherwise
positioned next to the each other, but are adapted to complement each other.
Typically, this is
achieved without substantial structural redundancy. In comparison, when
conventional building
modules are connected, substantial structural redundancy results, for example,
a marriage wall
for building modules placed side by side, or a ceiling of a first building
module connected to the
floor of a second building module stacked on top of the first building module.
As a contrasting
example, the complementary building module of the present invention can
include a panel
having a first side and an opposing second side, and the first side provides
an interior surface in
the complementary building module and the second side provides and interior
surface in the
connected first unfolded building module.
The unfolded building module and the complementary building module typically
are
connected through structural load carrying members. Typically, these members
are dimensioned
and shaped to form a combined structural load carrying member, which has a
load carrying
capacity suitable for the part of the structural frame of the building that it
provides. Connecting
structural load carrying members in connection assemblies such as illustrated
in FIGS. 10-14
minimizes structural redundancy. Further, typically, the structural load
carrying members
considered separately (unconnected) do not have a load carrying capacity
suitable for the part of
the structural frame of the building that it provides. More generally,
typically, the
complementary building modules are structurally interdependent.
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The complementary folding building modules of the present invention can
further be
dimensioned and shaped to fold compactly and/or arrange compactly with other
folded building
modules.
The buildings of the present invention can be formed, in part or substantially
completely,
from a plurality of complementary unfolding building modules. The number of
complementary
unfolding building modules that can be connected to form the buildings of the
present invention
is not limited in principal; however, typically, the buildings include up to
one hundred
complementary unfolding building modules, more typically, up to ten, even more
typically, two
or three complementary unfolding building modules.
The folding building modules of the present invention can have a core part and
an
unfolded part connected to the core part. Typically, (i) the unfolded part (or
structure) of a first
unfolded building module is connected to a complementary core part (or
structure) of a second
unfolded building module or to a fixed building module, or (ii) the core part
(or structure) of a
first unfolded building module is connected to a complementary core part (or
structure) of the
second unfolded building module or a fixed building module.
Buildings of the present invention can further include non-complementary
building
modules and parts (such as non-structural removable walls, non-structural
interior walls, etc.)
that can be affixed to the parts of the buildings that are formed from
connected complementary
building modules (particularly, complementary unfolded building modules).
The complementary building modules of the present invention can be
prefabricated such
that the buildings, after unfolding on the building site and connecting of
removable sections
(such as roof elements and non-structural interior walls), are substantially
in finished condition.
That is, they do not typically require or at least significantly reduce the
addition of interior and
exterior finish materials with the exception of minor, non-structural
finishing in areas required
for folding movement. Further, typically, the houses of the present invention
include roof
sections that are panelized but can be easily installed at the building site.
The prefabrication
process can be reduced substantially, even to the extent that merely
complementary folding
structural frames of the present invention are prefabricated and unfolded and
connected at the
building site.
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Further, all necessary mechanical and electrical systems for the residential
or commercial
foldable building, for example, all the required appliances and plumbing
fixtures, can be
installed in a core part (or structure) (i.e., a part of the structural frame
of the foldable building
that is made of frame elements that are not unfolded at the building site).
Flexible piping and
wiring can also be chased throughout both fixed and foldably connected panels
of the foldable
building units of the present invention.
Use of structural steel in the form of appropriately dimensioned I-beams, c-
channels,
wide-flange beams, and hollow structural sections allows for large frame
geometries as part of
the structural frame of the foldable building unit, for example, rectangular
frame elements
spanning the entire side of a foldable building, reducing prefabrication cost
and/or simplifying
unfolding at the building site.
Further, foldable structural frames substantially made of metal frame elements
(e.g.,
made from hot-fonned steel such as I-beams, c-channels, wide-flange beams, and
hollow
structural sections) can be prefabricated to superior tolerances such that a
respective folding
building module in substantially finished condition upon unfolding exhibits
reduced or no gaps
in the seam areas between foldably connected frame elements thereby reducing
the work
associated with on-site finishing of these seam areas.
The buildings of the present invention, for example, the building
corresponding to the
structural frame shown in FIG. 1 can further include a number of prefabricated
interior walls
(e.g, as shown in FIG. 3) that can be fixed, foldably connected, or panelized
and form one or
more rooms in the unfolded building.
The buildings of the present invention can be several stories high.
Steel frame elements of the present invention are typically combined with
wooden or
light-gauge metal intermediate elements to form lightweight steel and
wood/light-gauge metal
hybrid structures in which the frame elements provide structural stability and
the wooden or
light-gauge metal intermediate elements provide substantial lateral structural
resistance and/or
are used to attach interior and exterior finishing material using standard
construction approaches,
reducing labor training and associated costs.
In certain embodiments of the present invention, structural load carrying
members
connecting different frame elements of the structural frame allow blocking
material (e.g. wood or
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light-gauge metal studs) to be connected to inside areas of the structural
load carrying members,
and the structural load carrying members are positioned such that the blocking
members face the
outside of the foldable building unit. This allows structural frames that have
a continuous
conventional structural grid (e.g., 16 inch wood lumber grid) through the
edges/corners of the
folding building module, thereby allowing attachment of exterior finishing
material through the
edges/corners using standard construction approaches, reducing labor training
and associated
costs, and work at the building site.
Use of these strong and lightweight structures can also substantially reduce
the amount
of required building material and the weight of the frame elements, which in
turn facilitates the
transport of larger folded building modules for a given maximal allowed weight
according to
given road regulations.
Indirect connections of interior and/or exterior finishing materials to metal
frame
elements (particularly, frame elements made of structural steel sections) are
one aspect of a
"multi-tolerance" building approach that disaggregates and cushions brittle or
otherwise fragile
finish materials from the vibrational, kinetic and settling forces applied to
the structural frame
during shipping, setting, unfolding and settling of the prefabricated foldable
building units. A
second aspect of a multi-tolerance building approach is provided by using
offset hinges (in
particular, L-shaped offset hinges) which are specifically engineered to
safely nest hingedly (i.e.,
foldably connected with one or more hinges) connected frame elements at a
designed distance
away from its neighboring frame element, allowing, for example, for thicker
wall depths and
thus the prefabricated inclusion of finish materials. This is associated with
a significant
reduction in the scope of work to be completed on-site, where costs and
scheduling are far less
manageable. Thus, foldable building units of the present invention can include
final interior
finishing, such as trim, gypsum board, paint or wallpaper.
Structural load carrying members of the present invention can be foldably
connected with
hinges to foldably connect frame elements and respective panels. More
typically, structural load
carrying members of the present invention can be foldably connected with
offset hinges, and
preferably, L-shaped offset hinges adapted and positioned to remain within the
building
envelope. In completely folded configuration of foldably connected panels, L-
shaped offset
hinges provide an offset, which allows sufficient clearance for finish and
other materials.
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Further, the interior finish materials attached to the frame elements can be
sufficiently offset
from each other to avoid direct and potentially damaging contact, for example,
during transport.
A folding building module in "unfolded configuration" is a foldable building
unit in
which the foldably connected frame elements have been unfolded into positions
that can be
maintained in the finished condition of the resulting building. A folding
building module in
"folded configuration" is a folding building module in which foldably
connected frame elements
are folded into positions suitable for uploading, transport, and/or unloading
of the building unit.
A "structural frame" as used herein, refers to the totality of structural load
carrying
members of a building module or building that are primarily responsible for
providing structural
stability of the building module or building by transmitting loads (e.g.,
static, dynamic, and/or
vibrational loads) to the ground. Structural frames can include members that
are made of a
plurality of materials in various forms and dimensions. Suitable materials
that can be used
include but are not limited to metal (e.g., aluminum or steel), wood and
polymers. Typically,
steel is used.
Suitable structural load carrying members include but are not limited to
hollow structural
sections, C-channels (with or without return), I-beams (including S and W
type), T-beams, angle
beams, and wide-flange beams. For example, the structural load carrying
members can be
commercially available American standard structural load carrying members. The
selection of a
material, form and dimension for a given structural part or member of a
structural frame is
interdependent and depends on factors such as the position of the structural
part or member in
the structural frame, and whether the member is part of a frame element that
is foldably
connected.
In the context of the shape of structural load carrying member, "inside",
"inside area",
"interior area", "inside surface" or "interior surface" refers to the areas of
the structural load
carrying member that are inside of a box enveloping the structural load
carrying member. That
is, if a cross-sectional view of the structural load carrying member is
considered any part of the
perimeter of the structural load carrying member that is inside of a rectangle
enveloping (i.e.,
with minimum perimeter length of the rectangle) the structural load carrying
member
corresponds to the "inside", an "inside area", an "interior area", an "inside
surface" or an
"interior surface."
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Interior and exterior finish materials can be attached to the structural
frame, typically, by
attachment with intermediate elements affixed to frame elements of the
structural frame. Interior
and exterior finishing materials are typically attached (e.g., glued, nailed,
screwed, welded
and/or bolted, or otherwise affixed) to intermediate elements. Interior finish
materials include
but are not limited to wall finishing (for example, gypsum board), ceiling
finishing and floor
finishing (for example, sheathing with Bamboo flooring on top). Exterior
finishing elements
include but are not limited to siding and roofing.
For finish materials, and, in particular, interior finish materials, it has
been found that
"indirect connection" to the frame elements to reduce contact, partially or
entirely, of the interior
finish materials with the frame elements is advantageous for one or more of
the following
reasons. Reduced contact can (a) reduce the transfer of structural stresses
from one or more
frame elements of the structural frame to the often fragile and brittle
interior finish materials
thereby reducing or eliminating significant damage (such as dry wall cracking)
of the interior
finish materials, in particular, during folding, uploading, transporting,
unloading and/or
unfolding of the foldable building unit, and settling, (b) reduce or eliminate
the exposure of the
interior finish materials to water, for example, water that can condensate on
metal parts of the
frame elements, and (c) reduce heat transfer between the inside of the
finished building unit to
the outside of the finished building unit.
Thus, generally, it is preferred to use indirect rather than direct
connections of finish
materials, particularly, interior finish materials with respective frame
elements. However, even
though indirect connections are typically preferred, not all connections
between interior finish
material and a respective frame element have to be indirect.
Typically, intermediate elements are made, at least in part, of materials that
have a force
cushioning effect, that is, force cushioning elements such as, for example,
wood, sprayed foam,
and light-gauge metal studs. Typically, an intermediate element is positioned
and dimensioned
such that it can connect or can be connected (e.g., using powder-actuated
fasteners or self-
tapping screws) to the frame element through one area of the intermediate
element (e.g., through
one side of the intermediate element) and that it can be connected to the
finish material,
particularly, the interior finish material (for example, using nails or
screws) through another area
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of the intermediate element (e.g., through another side of the intermediate
element). Even more
preferably, intermediate elements are entirely made of force cushioning
materials such as wood.
Folding building modules of the present invention typically include wall
panels and floor
sections that are in substantially finished condition, that is, with the
exception of unfinished areas
dimensioned to accommodate folding of the frame elements, and unfinished areas
due to wall
connection seams (i.e., seams between walls that are not connected but upon
unfolding jointly
foini a wall), these wall panels, roof and floor panels are finished.
A building or house or part of a building or house that is substantially in
finished
condition after connection of two or more complementary modules of this
invention is a
building, house or part thereof in which more than 75%, preferably 85%, and
more preferably
90% of the construction of the building, house or part thereof is completed
upon connection of
the complementary modules. Thus, the complementary building modules (unfolded
and/or
fixed) can connect to form part of a building or house which is in
substantially finished condition
upon connection of the modules. If substantially all of the building is made
from complementary
building modules, the entire building can be in substantially finished
condition once the
complementary building modules are connected. Examples of when a part of a
building or an
entire building is "substantially finished", is when the interior surfaces of
the part are
substantially finished with finish material, such as a finish floor (e.g.,
tiles, hardwood floor,
laminate, etc.), finish wall (e.g., wall board, wall paper, etc.), electrical
elements (e.g., switches,
lamps, electrical wiring, electrical panel, etc.), and heating and cooling
elements (e.g., heating
system, cooling system, duct work, etc.); typically, this even includes
kitchen elements including
but not limited to cabinets, appliances and sink(s), and/or bathroom elements
including but not
limited to cabinets, shower, bathtub, toilet and sink. However, the
substantially finished
building, house or part thereof typically includes some unfinished elements
upon connection of
the complementary building modules, for example, wall connection seams (i.e.,
seams between
walls that are not connected but upon unfolding jointly form a wall), areas in
connection
assemblies intended for connection of removable substantially finished panels
(e.g., the area in
FIG. 13 to which panel 1304 will be connected).
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"Finished panels" as referred to herein, are panels that include frame
elements and
interior finish materials connected (typically, indirectly) to them, and can
also include elements
such as doors and windows.
The folded building modules of the present invention are typically dimensioned
such that
transport with a transport vehicle is possible, preferably, with a semitrailer
and without requiring
a special transport permit. Regulations pertaining to the operation of trucks
and trailers vary
from country to country, and, in some instances from state to state.
Further, the folded building modules of the present invention can include a
folding floor
panel which provides a wall of the folded building module, which increases
stability of the
building module in folded configuration, protects prefabricated and finished
parts in the core
volume, and thereby facilitates transportation of the building module.
A fourth embodiment of the present invention is a building built in a process
including
the following steps: (a) setting a first folded building module on a
foundation, the folded
building module having a core structure and an unfoldable structure attached
to the core
structure, the unfoldable structure including a plurality of foldably
connected panels; (b)
unfolding part or all of the unfoldable structure of the first folded building
module to form an
unfolded structure; (c) setting a complementary building module on the
foundation and
positioned such that panels of the complementary building module complement
respective panels
of the unfolded structure; (d) connecting the panels of the complementary
building module and
respective panels of the unfolded structure; and (e) connecting one or more
roof elements to the
building modules.
A fifth embodiment of the present invention is a building comprising a first
unfolded
building module connected to a complementary building module.
A sixth embodiment of the present invention is a house comprising a first
unfolded
building module connected to a complementary second unfolded building module,
wherein the
first unfolded building module and the second unfolded building module, each
independently,
have a core part and an unfolded part attached to the respective core part; i)
the core part of the
first unfolded building module is connected to a complementary unfolded part
of the second
unfolded building module, or ii) the core part of the first unfolded building
module is connected
to a complementary core part of the second unfolded building module; and the
first unfolded
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building module and/or the second unfolded building module contained kitchen
elements and/or
bathroom elements in one or both of the respective core structures that were
present in the
respective folded building module.
A first specific embodiment is a building or house as described in the first,
second,
fourth, fifth or sixth embodiment of the present invention, wherein the first
unfolded building
module includes a structural load carrying member through which the unfolded
building module
is connected to a structural load carrying member of the complementary
building module without
substantial structural redundancy.
More particularly, the structural load carrying member of the first unfolded
building
module can form part of a first panel and the structural load carrying member
of the first
unfolded building module can form part of a second panel, and the first panel
and second panel
upon fastening of the structural load carrying members in a connection area
provide substantially
finished exterior and/or interior surfaces continuously throughout the
connection area with the
exception of an area for the fastening of the structural load carrying
members.
A second specific embodiment is a building or house as described in the first,
second,
fourth, fifth or sixth embodiment, wherein the complementary building module
is a second
unfolded building module.
A third specific embodiment is a building or house as described in the first,
second,
fourth, fifth or sixth embodiment, wherein the complementary building module
includes a panel
having a first side and an opposing second side, and the first side provides
an interior surface in
the complementary building module and the second side provides and interior
surface in the first
unfolded building module.
A fourth specific embodiment is a building or house as described in the first,
second,
fourth, fifth or sixth embodiment having a steel structural frame, wherein a
plurality of
connected complementary unfolded building modules provides more than 50% of
the steel
structural frame of the building.
More particularly, the plurality of connected complementary unfolded building
modules
provides more than 75% of the steel structural frame of the building.
Even more particularly, the plurality of connected complementary unfolded
building
modules provides more than 90% of the steel structural frame of the building.
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Yet even more particularly, the plurality of connected complementary unfolded
building
modules provides substantially all of the steel structural frame of the
building.
In a fifth specific embodiment, the first unfolded building module of the
first, second,
fourth, fifth or sixth embodiment has a core part and an unfolded part
connected to the core part.
Particularly, the complementary building module is a second unfolded building
module,
and (i) the unfolded part of the first unfolded building module is connected
to a complementary
core part of the second unfolded building modules, or (ii) the core part of
the first unfolded
building module is connected to a complementary core part of the second
unfolded building
modules.
A sixth specific embodiment is a building or house as described in the first,
second,
fourth, fifth or sixth embodiment of the present invention, wherein the first
unfolded building
module and the complementary building module are connected at one side and
positioned to
share only part of the side.
A seventh specific embodiment is a building or house as described in the
first, second,
fourth, fifth or sixth embodiment of the present invention, wherein the first
unfolded building
module and the complementary building module are connected through a plurality
of connection
assemblies that (i) form from complementary panels of the building modules,
and (ii) are in
substantially finished condition when the panels are connected.
An eighths specific embodiment is a building or house as described in any of
the
preceding embodiments, wherein the first unfolded building module and the
complementary
building module are structurally interdependent.
A ninth specific embodiment is a building or house as described in any of the
preceding
embodiments, wherein the first unfolded building module and the complementary
building
module are connected without substantial structural redundancy.
A tenth specific embodiment is a building or house as described in any of the
preceding
embodiments, wherein the first unfolded building module and the complementary
building
module of are not independently structurally stable when not connected to each
other.
An 11th specific embodiment is a building or house as described in any of the
preceding
embodiments comprising a combined structural load carrying member formed from
one or more
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structural load carrying members of the first unfolded building module and one
or more
structural load carrying members of the second unfolded building module.
A 12th specific embodiment is a building or house as described in any of the
preceding
embodiments, wherein the first and second unfolded building modules in folded
configuration
are dimensioned and shaped such that they fit within a volume spanned by a
length of 70', a
width of 16' and a height of 15', while providing in combination a total floor
area of between
300 and 5000 square feet. Particularly, a total floor are of between 300 and
3000 square feet is
provided.
A 13t1i specific embodiment of the present invention is a building or house
formed by the
method as described in the third embodiment.
A 14t1i specific embodiment of the present invention is a method for forming a
building as
described in the third embodiment, wherein the panels of the complementary
building module
and respective panels of the unfolded structure are connected without
substantial structural
redundancy.
In a more particular embodiment, the method further comprises setting and
connecting
further complementary building modules to the first and/or complementary
building module.
Further teaching of the general folding building technology relevant to the
present
invention is described in International Patent Application No.
PCT/US2010/050041, filed
September 23, 2010, and published as W02011/038145, and in International
Patent Application
No. PCT/US2011/029643, filed March 23, 2011.
The relevant teachings of these patent applications, and all patents,
published published
applications and references cited herein are incorporated by reference in
their entirety.
While this invention has been particularly shown and described with references
to
example embodiments thereof, it will be understood by those skilled in the art
that various
changes in form and details may be made therein without departing from the
scope of the
invention encompassed by the appended claims.
