Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
FOLDING BEAM SYSTEMS
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
63/136,268
filed January 12, 2021 and U.S. Provisional Application No. 63/188,101 filed
May 13,
2021.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The inventions herein relate to structures, such as dwellings and other
buildings for
residential occupancy, commercial occupancy and/or material storage, and to
components
for such structures.
Description of the Related Art
[0003] In the field of residential housing, the traditional technique for
building homes is
referred to as "stick-built" construction, where a builder constructs housing
at the intended
location using in substantial part raw materials such as wooden boards,
plywood panels, and
steel columns. The materials are assembled piece by piece over a previously
prepared
portion of ground, for example, a poured concrete slab or a poured concrete or
cinder block
foundation.
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[0004] There have been a variety of efforts to depart from the conventional
construction
techniques used to create dwellings, as well as commercial spaces and like.
One of the
alternatives to stick-built construction is very generally referred to as
modular housing. As
opposed to stick-built construction, where the structure is built on-site, a
modular house is
constructed in a factory and then shipped to the site, often by means of a
tractor-trailer.
[0005] Such modular housing often exceeds in size normally-permitted legal
limits for road
transport. For example, in the United States the maximum permitted dimensions
for road
transport are in general 102 inches (259.1 cm) in width, 13.5 feet (4.11 m) in
height and 65
to 75 feet (19.81 to 22.86 m) in length. Thus, in many cases transporting a
modular house
from factory to site requires oversize load permits, which may impose
restrictions on when
transport can be undertaken and what routes can be utilized. Oversize road
regulations may
also require the use of an escort car and a trailing car as well. All of these
requirements and
restrictions inevitably increase the cost of the modular housing.
[0006] Significant advancements in the construction of dwellings and
commercial space are
described in U.S. Patent Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029 and
10,926,689. In one aspect, these patents pertain to fabricating wall, floor
and roof
components in a factory that are folded together into a compact shipping
module, and which
are then transported to the intended location and unfolded to yield a fully
formed structure.
SUMMARY OF THE INVENTION
[0007] The present inventions constitute advancements in transferring vertical
loads, such
as personnel weight, furniture, equipment and the like, to the edges of
horizontally oriented
enclosure components, particularly floor components and roof components. These
inventions include structural members that can be folded, to permit the
creation of a
compact shipping module, yet can be unfolded and locked in the unfolded
position to
provide a rigid structure for resisting the stress arising from vertical loads
and transferring
them to lower levels and ultimately the building foundation. These inventions
also facilitate
defining a basic structural section that can be utilized to construct
foldable, transportable
buildings of varying size, and simplify their manufacturing.
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[0008] In one aspect, the present inventions are directed to a hinge assembly
rotatable
between an open first position and a closed second position comprising (a) a
first hinge
portion and a second hinge portion, where each such hinge portion comprises
(i) a base
plate with an obverse face, a reverse face, an upper edge, an opposed lower
edge and a base
plate vertical centerline; (ii) a hinge section with a hinge section vertical
centerline, the
hinge section extending from the obverse face and comprising a plurality of
spaced-apart
hinge leaves symmetrically positioned about the hinge section vertical
centerline, with the
hinge section vertical centerline being offset from the base plate vertical
centerline, each of
the plurality of hinge leaves defining a hinge leaf aperture, and with the
hinge leaf apertures
positioned in horizontal alignment with each other along a hinge aperture
centerline; (iii) a
locking pin barrel extending from the obverse face and positioned to a first
side of the base
plate vertical centerline, the locking pin barrel defining a bore; (iv) a
plurality of locking
pin leaves extending from the obverse face and positioned to the first side of
the base plate
vertical centerline, each locking pin leaf defining a locking pin aperture,
the locking pin
apertures positioned in vertical alignment with each other, and with the bore
of the locking
pin barrel; and (v) a plurality of free interlock leaves extending from the
obverse face, each
free interlock leaf defining an interlock aperture, with the interlock
apertures in vertical
alignment with each other, and the free interlock leaves positioned to a
second side of the
base plate vertical centerline at a position so that, when the hinge assembly
is in the second
position, the free interlock leaves of each of the first and second hinge
portions interleave
with the locking pin leaves of the other of the first and second hinge
portions. The hinge
leaves of the first hinge portion are interleaved with the hinge leaves of the
second hinge
portion, with a hinge pin positioned in the hinge leaf apertures of the
interleaved hinge
leaves of the first and second hinge portions to pivotally join the first
hinge portion and the
second hinge portion and permit the second hinge portion to rotate relative to
the first hinge
portion from the first position to the second position. There is also provided
a first locking
pin adapted to be inserted into the bore defined in the locking pin barrel of
the first hinge
portion and received in (i) the locking pin apertures of the first hinge
portion and (ii) the
interlock apertures of the second hinge portion, when the hinge assembly is in
the second
position.
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[0009] In another aspect, the present inventions are directed to a foldable
enclosure
component having a folded position and an unfolded position comprising (a) a
planar first
component portion having a planar laminate construction and a first edge; and
(b) a planar
second component portion having a planar laminate construction and a second
edge, with
the first edge of the first component portion positioned proximate to the
second edge of the
second component portion. The planar laminate construction of each of the
first and second
component portions comprises: (i) a planar foam panel layer having a first
face and an
opposed second face, (ii) a planar first metal layer having a first face and
an opposed second
face bonded to the first face of the planar foam panel layer, (iii) a planar
second metal layer
having a first face bonded to the second face of the planar foam panel layer
and an opposed
second face; and (iv) a protective layer having an inorganic composition, a
first face bonded
to the second face of the second metal layer, and an opposed second face. A
first hinge
assembly joins the planar first component portion and the planar second
component portion
along their respective first and second edges and is adapted to permit the
foldable enclosure
component to rotate the second component portion relative to the first
component portion
from a folded position to an unfolded position, with the protective layers of
the first and
second component portions positioned adjacent to each other when the second
component
portion is in the unfolded position.
[0010] These and other aspects of the present inventions are described in the
drawings
annexed hereto, and in the description of the preferred embodiments and claims
set forth
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 is a perspective view of finished structures prepared in
accordance with the
present inventions.
[0012] Figure 2 is a top schematic view of a finished structure prepared in
accordance with
the present inventions.
[0013] Figure 3 is an end view of a shipping module from which is formed the
finished
structure respectively shown in Figure 1.
[0014] Figures 4 and 5 are partial cutaway views of a finished structure in
accordance with
the present inventions, depicting in greater detail aspects of the roof and
floor components.
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[0015] Figure 6 is a schematic perspective view depicting the exterior edge
reinforcement
for a wall component in accordance with the present inventions.
[0016] Figure 7 is an exploded cross-sectional view of a multi-layered,
laminate
construction for use in the enclosure components of the present inventions.
[0017] Figures SA is a perspective view of a foldable 1-beam for a floor
component in
accordance with the present inventions, in the beam unfolded position, and
Figure 8B is a
side view of a foldable 1-beam for a floor component in accordance with the
present
inventions, in the beam folded position.
[0018] Figure 9 is a perspective view showing the obverse face of one
embodiment of a
hinge assembly portion in accordance with the present inventions.
[0019] Figure 10 is a front view of the embodiment of the hinge assembly
portion shown in
Figure 9.
[0020] Figure 11 is a side view of the embodiment of the hinge assembly
portion shown in
Figure 9.
[0021] Figure 12 is a perspective view showing the reverse face of the
embodiment of the
hinge assembly portion shown in Figure 9.
[0022] Figure 13A is a cutaway perspective view showing the embodiment of the
hinge
assembly portion shown in Figure 9 incorporated into the structure of a floor
component in
accordance with the present inventions, Figure 13B is a cutaway perspective
view showing
the placement of floor end hinge assemblies in the structure of a floor
component in
accordance with the present inventions, Figure 13C is a perspective view of a
locking pin,
and Figures 13D and 13E are sectioned side and perspective views of the
locking pins as
received in hinge assemblies that utilize the hinge assembly portions shown in
Figures 9-12.
[0023] Figure 14A is a perspective view of a floor end hinge in accordance
with the present
inventions, and Figure 14B is a front view of a floor end hinge in accordance
with the
present inventions.
[0024] Figures 15A is a perspective view of a foldable 1-beam for a roof
component in
accordance with the present inventions, in the beam unfolded position, and
Figure 15B is a
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side view of a foldable 1-beam for a roof component in accordance with the
present
inventions, in the beam folded position.
[0025] Figure 16 is a perspective view showing the obverse face of another
embodiment of
a hinge assembly portion in accordance with the present inventions.
[0026] Figure 17 is a front view of the embodiment of the hinge assembly
portion shown in
Figure 16.
[0027] Figure 18 is a side view of the embodiment of the hinge assembly
portion shown in
Figure 16.
[0028] Figure 19 is a perspective view showing the reverse face of the
embodiment of the
hinge assembly portion shown in Figure 16.
[0029] Figure 20 is a perspective view showing the obverse face of a further
embodiment
of a hinge assembly portion in accordance with the present inventions.
[0030] Figure 21 is a front view of the embodiment of the hinge assembly
portion shown in
Figure 20.
[0031] Figure 22 is a side view of the embodiment of the hinge assembly
portion shown in
Figure 20.
[0032] Figure 23 is a perspective view showing the reverse face of the
embodiment of the
hinge assembly portion shown in Figure 20.
[0033] Figure 24A is a cutaway perspective view showing the embodiment of the
hinge
assembly portion shown in Figure 16 incorporated into the structure of a roof
component in
accordance with the present inventions, and Figure 24B is a cutaway
perspective view
showing the placement of roof end hinge assemblies in the structure of a roof
component in
accordance with the present inventions,
[0034] Figures 25A, 25B and 25C respectively are perspective, front and side
views of one
embodiment of a roof end hinge in accordance with the present inventions, and
Figure 25D
is a perspective view of another embodiment of a roof end hinge in accordance
with the
present inventions.
[0035] Figure 26 is a perspective view of an enclosure component fabrication
facility in
accordance with the present inventions.
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[0036] Figure 27 is a perspective view of a rectangular roof component
containing two
foldable I-beam assemblies in accordance with the present inventions.
[0037] Figures 28A and 28B respectively depict perspective and side views of
an I-beam
cover in accordance with the present inventions, and Figure 28C depicts in
side view the
arrangement of I-beam cover arrangement positioned as placed over the flanges
of an I-
beam.
DETAILED DESCRIPTION OF TIIE PREFERRED EMBODIMENTS
[0038] An embodiment of the foldable, transportable structure 150 in which the
inventions
disclosed herein can be implemented is depicted in Figures 1 through 5. When
fully
unfolded, as exemplified by Figure 1, structure 150 has a rectangular shape
made of three
types of generally planar and rectangular enclosure components 155, the three
types of
enclosure components 155 consisting of a wall component 200, a floor component
300, and
a roof component 400. As shown in Figures 1 and 2, the perimeter of structure
150 is
defined by first longitudinal edge 106, first transverse edge 108, second
longitudinal edge
116 and second transverse edge 110. For convenience, a direction parallel to
first
longitudinal edge 106 and second longitudinal edge 116 may be referred to as
the
"longitudinal- direction, a direction parallel to first transverse edge 108
and second
transverse edge 110 may be referred to as the "transverse" direction, and a
direction parallel
to the vertical direction in Figure 1 may be referred to as the "vertical"
direction. Structure
150 as shown has one floor component 300, one roof component 400 and four wall
components 200; although it should be understood that the present inventions
are applicable
to structures having other configurations as well.
[0039] Enclosure components 155 (wall component 200, floor component 300 and
roof
component 400) can be fabricated and dimensioned as described herein and
positioned
together to form a shipping module 100, shown end-on in Figure 3. The
enclosure
components 155 are dimensioned so that the shipping module 100 is within U.S.
federal
highway dimensional restrictions. As a result, shipping module 100 can be
transported over
a limited access highway more easily, and with appropriate trailering
equipment,
transported without the need for oversize permits. Thus, the basic components
of structure
150 can be manufactured in a factory, positioned together to form the shipping
module 100,
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and the modules 100 can be transported to the desired site for the structure,
where they can
be readily assembled, as described herein.
Enclosure Component (155): General Description
[0040] The enclosure components 155 of the present invention include a number
of shared
design features that are described below.
A. Laminate Structure Design
[0041] Enclosure components 155 can be fabricated using a multi-layered,
laminate design.
A particular laminate design that can be used to fabricate enclosure
components 155
comprises a first structural layer 210, a foam panel layer 213, a second
structural layer 215
and a protective layer 218, as shown in Figure 7 and described further below.
[0042] In particular, first structural layer 210 is provided in the embodiment
of enclosure
component 155 that is depicted in Figure 7. First structural layer 210 in the
embodiment
shown comprises a sheet metal layer 205, which can be for example galvanized
steel or
aluminum. Sheet metal layer 205 is made from a plurality of generally planar
rectangular
metal sheets 206 positioned adjacent to each other to generally cover the full
area of the
intended enclosure component 155.
[0043] Referring again to Figure 7, there is next provided in the depicted
embodiment of
enclosure component 155 a foam panel layer 213, comprising a plurality of
generally planar
rectangular foam panels 214 collectively presenting a first face 211 and a
second opposing
face 212. Foam panels 214 are made for example of expanded polystyrene (EPS)
foam. A
number of these foam panels 214 are positioned adjacent to each other and
superposed first
face-down on first structural layer 210 to generally cover the full area of
the intended
enclosure component 155. The foam panels 214 of foam panel layer 213
preferably are
fastened to the metal sheets 206 of first structural layer 210 using a
suitable adhesive,
preferably a polyurethane based construction adhesive. Foam panel layer 213
can include
exterior edge reinforcement and interior edge reinforcement, as described
further below
[0044] In the embodiment of the enclosure component 155 depicted in Figure 7,
there is
next provided a second structural layer 215, having a first face that is
positioned on the
second opposing face 212 of foam panels 214 (the face distal from first
structural layer
210). and also having a second opposing face. Second structural layer 215 in
the
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embodiment shown comprises a sheet metal layer 216, which can be for example
galvanized steel or aluminum. Sheet metal layer 216 is made from a plurality
of generally
planar rectangular metal sheets 217 positioned adjacent to each other and
superposed first
face-down on the second opposing face of foam panel layer 213 to generally
cover the full
area of the intended enclosure component 155. The metal sheets 217 of second
structural
layer 215 preferably are fastened to foam panel layer 213 using a suitable
adhesive,
preferably a polyurethane based construction adhesive.
[0045] In the embodiment of the enclosure component 155 depicted in Figure 7,
there is
optionally next provided a protective layer 218, having a first face that is
positioned on the
second opposing face of second structural layer 215 (the face distal from foam
panel layer
213), and also having a second opposing face. Optional protective layer 218 in
the
embodiment shown comprises a plurality of rectangular structural building
panels 219
principally comprising an inorganic composition of relatively high strength,
such as
magnesium oxide (MgO). The structural building panels 219 are positioned
adjacent to
each other and superposed first face-down on the second opposing face of
second structural
layer 215 to generally cover the full area of the intended enclosure component
155. The
building panels 219 of protective layer 218 preferably are fastened to second
structural layer
215 using a suitable adhesive, preferably a polyurethane based construction
adhesive.
Protective layer 218 can be used if desired to impart a degree of fire
resistance to the
enclosure component 155, as well as to provide a pleasing texture and/or feel.
[0046] Other embodiments of multi-layered, laminate designs, which can be used
to
fabricate the enclosure components 155 of the present invention, are described
in U.S.
Nonprovisional Patent Application No. 16/786,130, entitled "Foldable Building
Structures
with Utility Channels and Laminate Enclosures," filed on February 10, 2020 and
now issued
as U.S. Patent No. 11,118,344. The contents of that U.S. Nonprovisional Patent
Application No. 16/786,130, entitled "Foldable Building Structures with
Utility Channels
and Laminate Enclosures" and filed on February 10, 2020 are incorporated by
reference as
if fully set forth herein, particularly including the multi-layered, laminate
designs described
for example at paragraphs 0034-57 and depicted in Figures 4A-4D thereof.
B. Enclosure Component Exterior Edge Reinforcement
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[0047] The exterior edges of each enclosure component 155 (i.e., the edges
that define the
perimeter of enclosure component 155) can be provided with exterior edge
reinforcement,
as desired. Exterior edge reinforcement generally comprises an elongate rigid
member
which can protect the foam panel material of foam panel layer 213 that would
otherwise be
exposed at the exterior edges of enclosure components 155. Exterior edge
reinforcement
can be fabricated from one or more of laminated strand lumber board, wooden
board, C-
channel extruded aluminum or steel, or the like, and is generally secured to
the exterior
edges of enclosure component 155 with fasteners, such as screw or nail
fasteners, and/or
adhesive.
C. Enclosure Component Partitioning
[0048] Enclosure components 155 in certain instances are partitioned into
enclosure
component portions to facilitate forming a compact shipping module 100. In
those
instances where an enclosure component 155 is partitioned into enclosure
component
portions, any exterior edge reinforcement on the exterior edges defining the
perimeter of the
enclosure component is segmented as necessary between or among the portions.
[0049] The enclosure component portions can he joined by hinge stnictures or
mechanisms
to permit the enclosure component portions to be "folded" and thereby
contribute to
forming a compact shipping module 100.
D. Enclosure Component Interior Edge Reinforcement
[0050] An enclosure component 155 partitioned into enclosure component
portions will
have interior edges. There will be two adjacent interior edges for each
adjacent pair of
enclosure component portions. Such interior edges can be provided with
interior edge
reinforcement. Similar to exterior edge reinforcement, such interior edge
reinforcement
generally comprises an elongate, rigid member which can protect the foam panel
material of
foam panel layer 213 which that would otherwise be exposed at the interior
edges of
enclosure components 155. Interior edge reinforcement can be fabricated from
one or more
of laminated strand lumber board, wooden board, C-channel extruded aluminum or
steel, or
the like, and is generally secured to the interior edges of enclosure
component 155 with
fasteners, such as screw or nail fasteners, and/or adhesive.
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E. Enclosure Component Load Transfer
[0051] In the case of enclosure components 155, it is necessary to transfer
the loads
imposed on their surfaces to their exterior edges, where those loads can be
transferred either
to or through adjoining walls, or to the building foundation. For enclosure
components 155
that are horizontally oriented when in use (floor component 300 and roof
component 400),
such loads include the weight of equipment, furniture and people borne by
their surfaces, as
well as vertical seismic loads. For enclosure components that are vertically
oriented when
in use (wall component 200), such loads include those arising from
meteorological
conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other
object impacts).
[0052] For this purpose, multi-layered, laminate designs as shown in Figure 7
will function
to transfer the loads described above. To add additional load transfer
capability, structural
members, such as beams and/or joists, can be utilized within the perimeter of
the enclosure
components 155, as is deemed appropriate to the specific design of structure
150 and the
particular enclosure component 155, to assist in the transfer of loads to the
exterior edges.
Particular beam assemblies for floor component 300 and roof component 400 are
described
below.
F. Enclosure Component Sealing Systems
[0053] Structure 150 comprises a number of wall, floor and roof components
with abutting
or exposed exterior edges, as well as a number of partitioned wall, floor and
roof
components with interior edges. In this regard, sealing structures can be
utilized, with the
objective to limit or prevent the ingress of rain water, noise and outside air
across these
exterior and interior edges into the interior of structure 150.
[0054] Particular sealing structures for accomplishing the foregoing objective
are described
in PCT Patent Application No. PCT/US21/56415, entitled "Enclosure Component
Sealing
Systems," filed on October 25. 2021 and having the same inventors as the
present
application. The contents of that PCT Patent Application No. PCT/US21/56415,
entitled
"Enclosure Component Sealing Systems," filed on October 25, 2021 and having
the same
inventors as the present application, are incorporated by reference as if
fully set forth herein,
particularly including the sealing systems described for example at paragraphs
0080-0167
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and depicted in Figures 9-20 thereof, and also including the exemplary
placements for such
sealing systems described in paragraphs 0168-0174 and depicted in Figures 8A-
8B thereof
[0055] Further design details of wall component 200, floor component 300, and
roof
component 400 are provided in the sections following.
Wall Component (200)
[0056] Typically, a structure 150 will utilize four wall components 200, with
each wall
component 200 corresponding to an entire wall of structure 150.
A. General Description
[0057] Wall component 200 has a generally rectangular perimeter. As shown in
Figure 1,
wall components 200 have plural apertures, specifically a door aperture 202,
which has a
door frame and door assembly, and plural window apertures 204, each of which
has a
window frame and a window assembly. The height and length of wall components
200 can
vary in accordance with design preference, subject as desired to the
dimensional restrictions
applicable to transport, described above. In this disclosure, structure 150 is
fashioned with
all sides of equal length; accordingly, its first and second longitudinal
edges 106 and 116,
and its first and second transverse edges 108 and 110, are all of equal
length. It should be
understood however, that the inventions described herein are applicable to
structures having
other dimensions, such as where two opposing wall components 200 are longer
than the
other two opposing wall components 200.
[0058] As indicated above, wall components 200 of the present inventions can
utilize a
multi-layered, laminate design. In the embodiment depicted in Figures 1
through 6, wall
component 200 utilizes the multi-layered, laminate design shown in Figure 7
employing
these particular elements: sheet metal layer 205 of first structural layer 210
is 24 gauge
galvanized steel approximately 0.022 ¨ 0.028 inch thick, the foam panels 214
of foam panel
layer 213 are EPS foam approximately 5.68 inches thick, the sheet metal layer
216 of
second structural layer 215 is 24 gauge galvanized steel approximately 0.022 ¨
0.028 inch
thick, and the building panels 219 of protective layer 218 are MgO board
approximately
0.25 inch (6 mm) thick.
[0059] The perimeter of each wall component 200 is generally provided with
exterior edge
reinforcement. As exemplified by wall component 200 shown in Figure 6, the
exterior edge
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reinforcement for wall component 200 is a floor plate 220 along the bottom
horizontal edge,
a ceiling plate 240 along the top horizontal edge and two end pieces 270
respectively
fastened at each vertical edge of wall component 200. In the case of a wall
component 200,
exterior edge reinforcement provides regions for fastening like regions of
abutting wall
components 200, roof component 400 and floor component 300, in addition to
protecting
the exterior edges of foam panel material. In the embodiment shown in Figures
1 through 6,
the exterior edge reinforcement for wall component 200 provided by floor plate
220, ceiling
plate 240, and end pieces 270 is fabricated from laminated strand lumber board
5.625" deep
and 1.5" thick.
B. Partitioned Wall Components
[0060] Referring to Figure 2, structure 150 has two opposing wall components
200, where
one of the two opposing wall components 200 comprises first wall portion 200s-
1 and
second wall portion 200s-2, and the other of the two opposing wall components
200
comprises third wall portion 200s-3 and fourth wall portion 200s-4. Each of
wall portions
200s-1, 200s-2, 200s-3 and 200s-4 has a generally rectangular planar
structure. As shown
in Figure 2, the interior vertical edge 192-1 of wall portion 200s-1 is
proximate to a
respective interior vertical edge 192-2 of wall portion 200s-2, and the
interior vertical edge
194-3 of wall portion 200s-3 is proximate a respective interior vertical wall
edge 194-4 of
wall portion 200s-4. Interior edge reinforcement can be provided at any one or
more of
vertical edges 192-1, 192-2, 194-3 and 194-4. In the embodiment shown in
Figures 1
through 6, the interior edge reinforcement provided at vertical edges 192-1,
192-2, 194-3
and 194-4, is fabricated from laminated strand lumber board 5.625" deep and
1.5" thick.
[0061] Referring again to Figure 2, first wall portion 200s-1 is fixed in
position on floor
portion 300a proximate to first transverse edge 108, and third wall portion
200s-3 is fixed in
position on floor portion 300a, opposite first wall portion 200s-1 and
proximate to second
transverse edge 110. First wall portion 200s-1 is joined to second wall
portion 200s-2 with
a hinge structure that permits wall portion 200s-2 to pivot about vertical
axis 192 between a
folded position and an unfolded position, and third wall portion 200s-3 is
joined to fourth
wall portion 200s-4 with a hinge structure to permit fourth wall portion 200s-
4 to pivot
about vertical axis 194 between a folded position and an unfolded position.
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[0062] Notably, first wall portion 200s-1 is longer than third wall portion
200s-3 by a
distance approximately equal to the thickness of wall component 200, and
second wall
portion 200s-2 is shorter than third wall portion 200s-3 by a distance
approximately equal to
the thickness of wall component 200. Furthermore, wall portion 200s-1 and wall
portion
200s-3 are each shorter in length (the dimension in the transverse direction)
than the
dimension of floor portion 300a in the transverse direction. Dimensioning the
lengths of
wall portions 200s-1, 200s-2, 200s-3 and 200s-4 in this manner permits wall
portions
200s-2 and 200s-4 to nest against each other in an overlapping relationship
when in an
inwardly folded position. In this regard, Figure 2 depicts wall portions 200s-
2 and 200s-4
both in their unfolded positions, where they are labelled 200s-2u and 200s4-u
respectively,
and Figure 2 also depicts wall portions 200s-2 and 200s-4 both in their
inwardly folded
positions, where they are labelled 200s-2f and 200s4-f respectively. When wall
portions
200s-2 and 200s-4 are in their inwardly folded positions (200s-2f and 200s-
4f), they
facilitate forming a compact shipping module. When wall portion 200s-2 is in
its unfolded
position (200s-2u), it forms with wall portion 200s-1 a wall component 200
proximate first
transverse edge 108, and when wall portion 200s-4 is in its unfolded position
(200s-4u), it
forms with wall portion 200s-3 a wall component 200 proximate second
transverse edge
110.
[0063] The hinge structures referenced above, for securing first wall portion
200s-1 to
second wall portion 200s-2, and third wall portion 200s-3 to fourth wall
portion 200s-4, can
be surface mounted or recessed, and of a temporary or permanent nature. The
provision of
interior edge reinforcement, as described above, can provide a region for
securing such
hinge structures_ Suitable hinge structures can he fabricated for example of
ferrous or non-
ferrous metal, plastic or leather material.
C. Unpartitioned Wall Components
[0064] As compared to the two wall components 200 proximate first and second
transverse
edges 108 and 110, which are partitioned into wall portions, the remaining two
wall
components 200 proximate first and second longitudinal edges 106 and 116 do
not comprise
plural wall portions, but rather each is a single piece structure. However,
one of these wall
components 200, which is sometimes denominated 200P in this disclosure, and
which is
located on floor portion 300b proximate first longitudinal edge 106, is
pivotally secured to
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floor portion 300b by means of hinge structures to permit wall component 200P
to pivot
about horizontal axis 105 shown in Figure 3 from a folded position to an
unfolded position.
Pivotally securing wall component 200P also facilitates forming a compact
shipping module
100. The remaining wall component 200, sometimes denominated 200R in this
disclosure,
is rigidly secured on floor portion 300a proximate second longitudinal edge
116 and
abutting the vertical edges of first wall portion 200s-1 and third wall
portion 200s-3
proximate to second longitudinal edge 116, as shown in Figure 2.
[0065] The hinge structures referenced above, for securing wall component 200P
to floor
portion 300b, can be surface mounted or recessed, and of a temporary or
permanent nature.
The provision of exterior edge reinforcement, as described above, can provide
a region for
securing such hinge structures. Suitable hinge structures can be fabricated
for example of
ferrous or non-ferrous metal, plastic or leather material.
Floor Component (300)
[0066] Typically, a structure 150 will utilize one floor component 300; thus
floor
component 300 generally is the full floor of structure 150.
A. General Description
[0067] Floor component 300 has a generally rectangular perimeter. Figures 4
and 5 depict
floor component 300 in accordance with the present inventions. The perimeter
of floor
component 300 is defined by first longitudinal floor edge 117, first
transverse floor edge
120, second longitudinal floor edge 119 and second transverse floor edge 118.
In particular,
(a) first longitudinal floor edge 117, (b) first transverse floor edge 120,
(c) second
longitudinal floor edge 119 and (d) second transverse floor edge 118 generally
coincide
with (i.e., underlie) (w) first longitudinal edge 106, (x) first transverse
edge 108, (y) second
longitudinal edge 116 and (z) second transverse edge 110, respectively, of
structure 150.
[0068] The length and width of floor component 300 can vary in accordance with
design
preference. In the particular embodiment of structure 150 depicted in Figures
2, 4 and 5,
floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).
[0069] Floor component 300 and its constituent elements are generally designed
and
dimensioned in thickness and in other respects to accommodate the particular
loads to
which floor component 300 may be subject. It is preferred that floor component
300 utilize
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a multi-layered, laminate design, such as that described in connection with
Figure 7. In the
embodiment shown in Figures 4 and 5, the bottom-most surface of floor
component 300
comprises sheet metal layer 205 of first structural layer 210. with sheet
metal layer 205
being 24 gauge galvanized steel approximately 0.022 ¨ 0.028 inch thick. Above
sheet metal
layer 205 there are provided foam panels 214 of foam panel layer 213. In the
embodiment
shown in Figures 4 and 5, foam panels 214 are EPS foam approximately 7.125
inches thick.
Above foam panel layer 213 there is provided sheet metal layer 216 of second
structural
layer 215, with sheet metal layer 216 being 24 gauge galvanized steel
approximately 0.022
¨ 0.028 inch thick. Above sheet metal layer 216 of second structural layer
215, there are
provided building panels 219 of protective layer 218, with building panels 219
being MgO
board approximately 0.25 inch (6 mm) thick.
[0070] The perimeter of each floor component 300 is generally provided with
exterior edge
reinforcement. As exterior edge reinforcement for the embodiments of floor
component
300 shown in Figures 4 and 5, a first footing beam 320 (visible edge-on in
Figure 4) is
positioned at the first longitudinal floor edge 117 of floor component 300, a
second footing
beam 320 (visible edge-on in Figure 5) is positioned at the second transverse
floor edge 118
of floor component 300, a third footing beam 320 (visible edge-on in Figure 5)
is positioned
at the first transverse floor edge 120 of floor component 300, and a fourth
footing beam 320
(visible edge-on in Figure 4) is positioned at the second longitudinal floor
edge 119 of floor
component 300. In the case of floor component 300, the exterior edge
reinforcement
provided by footing beams 320 assists in resisting vertical loads and
transferring such loads
to any roof component 400 thereunder and then to underlying wall components
200, and/or
to the foundation of the finished structure 150, in addition to protecting the
edges of foam
panel material of the foam panel layer 213. In the embodiment shown in Figures
1 through
6, the exterior edge reinforcement provided by footing beams 420 of floor
component 300 is
fabricated from laminated strand lumber board 7.125" deep and 1.5" thick.
B. Floor Partitioning
[0071] The floor component 300 is partitioned into floor portion 300a and
floor portion
300b. Figure 2 shows flow portions 300a and 300b in plan view, and Figure 4
shows floor
portions 300a and 300b in section view, edge-on.
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[0072] Each of the floor portions 300a and 300b is a planar generally
rectangular structure,
with floor portion 300a adjoining floor portion 300b. Interior edge 301a of
floor portion
300a abuts interior edge 301b of floor portion 300b, as shown in Figure 4. As
interior edge
reinforcement, a reinforcing hoard 307 is positioned in floor portion 300a
adjacent interior
edge 301a, and a reinforcing board is positioned in floor portion 300b
adjacent interior edge
301b. In the embodiment shown in Figures 1 through 6, the interior edge
reinforcement
provided by reinforcing boards 307 is laminated strand lumber board 7.125"
deep and 1.5"
thick.
[0073] Referring to structure 150 shown in Figures 2 and 4, floor portion 300a
is fixed in
position relative to first wall portion 200s-1, third wall portion 200s-3 and
wall component
200s-R. Floor portion 300a is joined with hinge structures to floor portion
300b, so as to
permit floor portion 300b to pivot through approximately ninety degrees (90 )
of arc about a
horizontal axis 305, located proximate the top surface of floor component 300,
between a
fully folded position, where floor portion 300b is vertically oriented as
shown in Figure 3,
and a fully unfolded position, shown in Figures 2 and 4, where floor portion
300b is
horizontally oriented and co-planar with floor portion 300a. Particular
embodiments of
suitable hinge structures for joining floor portion 300a to floor portion 300b
are described
below.
C. Hinged Vertical Load Transfer Components
[0074] Figure 8A shows a beam assembly 325 that can be placed within floor
component
300 to provide reinforcement in the direction along the beam and assist in
transferring
vertical loads borne by floor component 300 to its edges. Beam assembly 325
includes two
Lbeams 326a and 326b. I-beam 326a is positioned approximately in the middle of
floor
portion 300a, I-beam 326b is positioned approximately in the middle of floor
portion 300b,
and each of I-beams 326a and 326b is oriented in the transverse direction. A
hinge
assembly 329A joins I-beam 326a to I-beam 326b. The hinge assembly 329A
permits beam
assembly 325 to be folded to a beam folded position shown in Figure 8B and
unfolded to a
beam unfolded position shown in Figure 8A. Further, the hinge assembly 329A
can be
locked when beam assembly 325 is in the beam unfolded position, which
transforms beam
assembly 325 into a rigid structure that will reinforce floor component 300 in
the direction
perpendicular to its axis of folding_
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[0075] Hinge Assembly 329A. Hinge assembly 329A comprises two identical hinge
assembly portions 330A partnered together to form a pivoted junction. The
inter-
positioning of the parts of two partnered hinge assembly portions 330A is
described below,
and can also be seen in Figures 13D and 13E, which depict the two partnered
hinge
assembly portions 330 of a hinge assembly 329A that joins floor portion 300a
and floor
portion 30011. Figures 13D and 13E are section views, sectioned in the
transverse and
longitudinal directions respectively.
[0076] Hinge assembly portion 330A, shown in Figure 9, in principal part
includes a hinge
base plate 331 having a generally planar, rectangular or, as shown in Figures
9, 10 and 12, a
square configuration, with an obverse face 318 and a reverse face 319 (visible
in Figure 12).
A hinge section 332, a pin interlock section 334, a free interlock section 338
and a locking
pin barrel 340 are secured to the obverse face 318 of hinge base plate 331.
Hinge assembly
portion 330A can be manufactured from steel that is cast as a single piece
that includes
sections 332, 334 and 338, and barrel 340.
[0077] Hinge section 332 shown in Figure 9 has four hinge leaves 333, each of
which
extends away in a perpendicular direction from hinge base plate 331 and
defines a hinge pin
hole 327 in the region distal from hinge base plate 331. The centerline of
each hinge pin
hole 327 is horizontally oriented and aligned with the centerline of the hinge
pin holes 327
in the other three hinge leaves 333 of hinge section 332. Hinge leaves 333
each has the
same thickness and are spaced apart a distance equal to the thickness of a
hinge leaf 333, so
as to permit interleaving the corresponding hinge leaves 333 of a partnering
hinge assembly
portion 330A.
[0078] Pin interlock section 334 shown in Figure 9 has two pin interlock
leaves 336. Each
pin interlock leaf 336 extends away in a perpendicular direction from hinge
base plate 331
and defines a lock pin hole 347 in the region distal from base plate 331. The
centerline of
each lock pin hole 347 is vertically oriented and in alignment with the
centerline of the lock
pin hole 347 of the adjacent pin interlock leaf 336. The two pin interlock
leaves 336 each
has the same thickness as the other, and are spaced apart a distance equal to
the thickness of
a pin interlock leaf 336.
[0079] Free interlock section 338 shown in Figure 9 has two free interlock
leaves 339.
Each free interlock leaf 339 extends away in a perpendicular direction from
hinge base plate
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331 and defines a lock pin hole 347 in the region distal from base plate 331.
The centerline
of each lock pin hole 347 is vertically oriented and in alignment with the
lock pin hole 347
of the adjacent free interlock leaf 339. The two free interlock leaves 336
each has the same
thickness as the other, and both free interlock leaves 339 have the same
thickness as pin
interlock leaves 336. The free interlock leaves 339 are spaced apart a
distance equal to the
thickness of a free interlock leaf 339 (which is equal to the thickness of a
pin interlock leaf
336).
[0080] Locking pin barrel 340 shown in Figure 9 extends away in a
perpendicular direction
from hinge base plate 331 and defines a locking pin bore 341. The centerline
of bore 341 is
vertically oriented and co-linear with the centerline of lock pin holes 347 of
pin interlock
leaves 336.
[0081] As can be seen in Figure 10, the vertical centerline 343 of hinge
section 332 is not
coincident with the vertical centerline 342 of hinge base plate 331. Rather,
it is offset, in
the view shown in Figure 10, leftward an offset distance 344, which is one-
half the
thickness of a hinge leaf 333. This permits utilizing two hinge assembly
portions 330A
with identical designs in a partnering relationship to form the hinge assembly
329A and the
desired pivoting junction. Hinge assembly 329A is assembled by interleaving
the hinge
leaves 333 of two hinge assembly portions 330A and inserting a hinge pin 364
through their
hinge pin holes 327, which can be secured in place using for example an
external retaining
ring clip. Hinge assembly 329A can pivot 90 from a first, hinge open
position, where I-
beam 325 is in the beam folded position shown in Figure 8B, to a second, hinge
closed
position, where I-beam 325 is in the beam unfolded position shown in Figure
8A.
[0082] As shown in Figure 10, the free interlock leaves 339 of free interlock
section 338
are offset in the vertical direction from the position of the pin interlock
leaves 336 of the pin
interlock section 334 by an offset distance 346, which is equal to the
thickness of a free
interlock leaf 339 (which is equal to the thickness of a pin interlock leaf
336). In the hinge
closed position (the beam unfolded position), the free interlock leaves 339 of
the free
interlock section 338 of a first of the two hinge assembly portions 330A will
interleave with
the pin interlock leaves 336 of the pin interlock section 334 of the second of
the two hinge
assembly portions 330A, as generally indicated in Figure 13E. Correspondingly
in the
hinge closed position (the beam unfolded position), the free interlock leaves
339 of the free
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interlock section 338 of the second of the two hinge assembly portions 330A
will interleave
with the pin interlock leaves 336 of the pin interlock section 334 of the
first of the two hinge
assembly portions 330A, again as generally indicated in Figure 13E. The
centerline of lock
pin holes 347 of the free interlock leaves 339 of each hinge assembly portion
330A is
positioned so that, when a hinge assembly 329A is in the hinge closed position
(the beam
unfolded position), that lock pin hole centerline will be co-linear with the
centerline of the
lock pin holes 347 in the pin interlock section 334 of the other hinge
assembly portion 330A
of the hinge assembly 329A.
[0083] As can be appreciated, when hinge assembly 329A is in the hinge closed
position
(the beam unfolded position), there is on each side of the vertical centerline
of the assembly
a locking pin barrel 340 positioned over a set of interleaved leaves 336, 339.
The hinge
assembly 329A is accordingly locked into the hinge closed position by
inserting a locking
pin 349 into the locking pin bore 341 provided in the locking pin barrel 340
of each of its
two hinge assembly portions 330A, as shown in Figures 13D and 13E.
[0084] Locking pin 349, which is shown in Figure 13C, has a length sufficient
to be
received in the lock pin holes 347 of the interleaved leaves of 336, 339
positioned below it
and thus lock beam assembly 325 in the beam unfolded position. It is
preferable for locking
pin 349 to be cylindrical in cross-section. Also, locking pin 349 can be
tapered along its
length, so that the widest cross section is at the upper face of locking pin
barrel 340. In that
case, the diameter of locking pin bore 341 can be tapered, and the diameters
of lock pin
holes 347 in leaves 336, 339 can be correspondingly reduced, the further they
are located
from locking pin barrel 340. Alternatively, and as shown in Figure 13C, only
the portion
349a of locking pin 349, which is received in lock pin holes 347 of leaves
336, 339, can be
made tapered (with the diameters of lock pin holes 347 in leaves 336, 339
being
correspondingly reduced, the further they are located from locking pin barrel
340), while
locking pin bore 341, and the portion 349b of locking pin 349 not received in
lock pin holes
347 of leaves 336, 339, each can be given a uniform diameter. In this latter
case, the
portion 349c of locking pin 349 (the upper section of portion 349b), which is
received in
locking pin bore 341, as well as locking pin bore 341 itself, can be provided
with
complimentary screw threads, as shown in Figures 13C-13E, to permit securing
locking pin
349 in place.
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[0085] To facilitate the rotation of hinge assembly 329A so that beam assembly
325 can
smoothly move into the beam unfolded position shown in Figure 8A, it is
preferred that the
upper and lower faces of leaves 336, 339 not be planar, but rather curved.
Referring to
Figure 11, there is shown interlock leaves 336 in profile. As compared to
planar surfaces
348, which originate at hinge base plate 331 and extend out in a direction
perpendicular to
the plane of hinge base plate 331, the upper and lower faces of free interlock
leaves 339 can
be seen to be curved, about a point proximate to hinge pin hole 327.
Similarly, the upper
and lower faces of pin interlock leaves 336 are comparably curved. The
curvature varies
depending on the face location, with faces closer to pin hole 327 being more
deeply curved
than faces further away_
[0086] A stop 324 is optionally provided at the edge of the lower free
interlock leaf 339 of
each hinge portion 330A of hinge assembly 329A to assist in preventing hyper-
extending
beam assembly 325 when unfolded. In the case where hinge assembly 329A is
fabricated as
a single casting, stops 324 of the partnered hinge portions 330A of each hinge
assembly
329A can be more precisely machined or ground down as necessary following the
casting
step to insure that when hinge assembly 329A is in the hinge closed position,
I-beams 326a
and 326B do not extend beyond the desired beam unfolded position. In the beam
unfolded
position (when hinge assembly 329A is in the hinge closed position), while I-
beams 326a
and 326b can be co-linear, it is preferred that I-beams 326a and 326b not be
co-linear. In
particular, in the beam unfolded position it is preferred that hinge assembly
329A, when
joined to I-beams 326a and 326b, causes those I-beams to assume a small
upwardly arched
configuration. This can be realized for example by designing hinge assembly
portion 330A
so that when hinge assembly portion 330A is secured to an end of an I-beam
326a or 326b,
obverse face 318 is canted a select positive angle (i.e., angularly rotated
clockwise about the
centerline of hinge pin holes 327 shown in Figure 11), such as one-half degree
(+0.5 ),
relative to the reverse face 319 of hinge assembly portion 330A. This upward
arching is
intended to reduce or eliminate any sag in floor component 300 when in the
fully unfolded
position.
[0087] The reverse face 319 of hinge assembly portion 330A is adapted to be
secured to an
end of one of I-beams 326a and 326b. The hinge assembly portions 330A that
join I-beam
326a and I-beam 326b are secured to I-beams 326a, 326b with their hinge
sections 332
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oriented upwardly, so that I-beam 326b shown in Figure 8A can fold up relative
to I-beam
326a, as shown in Figure 8B. In particular, as shown in Figure 12 reverse face
319 is
provided with four positioning tabs 321, extending away from reverse face 319
in a
perpendicular direction. Each positioning tab 321 has two flat sections 317
oriented
perpendicular to each other and joined by a rounded section 315. The
positioning tabs 321
form a guide frame, having an "I" shape in profile, for receiving an end of
one of 1-beams
326a and 326b. It is preferred that the I-beams 326a, 326b be secured to the
reverse faces
319 by welding their internal flanges to hinge assembly portions 330a. For
this purpose,
each of the positioning tabs 321 is preferably provided with a serpentine cut-
out 322, to
increase the length of the weld line with the goal of increasing the strength
of the weld_
[0088] Figure 13A, a cutaway view of a portion of floor component 300 in the
floor
component unfolded position, depicts the mounting of hinge assembly 329A
within the
floor component 300, specifically where floor portion 300a abuts floor portion
300b. As
seen in Figure 13A (and also visible in Figure 13E), a bolt plate 314 joins
the reinforcing
board 307 positioned in floor portion 300b, adjacent interior edge 301b, to
the hinge
assembly portion 330A secured to I-beam 326b. A similar bolt plate 314 is
located on the
portion of I-beam 326b not visible in Figure 13A, and similar bolt plates 314
are located on
each side of the partnering hinge assembly portion 330A secured to I-beam 326a
(not
visible).
[0089] In the embodiment of floor component 300 shown in the figures, I-beam
assembly
325 is located at the mid-point between first transverse floor edge 120 and
second
transverse floor edge 118, and no hinge assemblies 329A are utilized elsewhere
within floor
component 300, such as proximate to first transverse floor edge 120 and second
transverse
floor edge 118. Therefore, to assist in smoothly rotating floor portion 300b,
there is
provided adjacent first transverse floor edge 120 a first floor end hinge
assembly 345A
joining floor portions 300a and 300b, and there is provided adjacent second
transverse floor
edge 118 a second floor end hinge assembly 345A joining floor portions 300a
and 300b.
The locations of both first and second floor end hinge assemblies 345A is
indicated in
Figure 13B.
[0090] Floor end hinge assembly 345A. Floor end hinge assembly 345A comprises
two
identical floor end hinge portions 350A. Referring to Figures 14A and 14B,
floor end hinge
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portion 350 in principal part includes a hinge base plate 351 on which is
secured a hinge
section 352. Hinge section 352 has five hinge leaves 353 in the depicted
embodiment, each
of which extends away in a perpendicular direction from hinge base plate 351
and defines a
hinge pin hole 354 in the region distal from hinge base plate 353. The
centerline of each
hinge pin hole 354 is horizontally oriented and aligned with the centerline of
the hinge pin
holes 354 in the other hinge leaves 353 of hinge section 352. Hinge leaves 353
each has the
same thickness and are spaced apart a distance equal to the thickness of a
hinge leaf 353, so
as to permit interleaving the corresponding hinge leaves 353 of the partnering
hinge
assembly portion 350A.
[0091] As can be seen in Figure 14B, the vertical centerline 358 of hinge
section 352 is not
coincident with the vertical centerline 359 of hinge base plate 351. Rather,
it is offset, in
the view shown in Figure 14B, rightward an offset distance 357, which is one-
half the
thickness of a hinge leaf 353. This permits utilizing two hinge assembly
portions 350A
with identical designs in a partnering relationship to form the hinge assembly
345A and the
desired pivoting junction. Floor end hinge assembly 345A can pivot ninety
degrees (90')
from a first, hinge open position, corresponding to where 1-beam 325 is in the
folded
position shown in Figure 8B, to a second, hinge closed position, corresponding
to where I-
beam 325 is in the unfolded position shown in Figure 8A. Floor end hinge
assembly 345A
is assembled by interleaving the hinge leaves 353 of two hinge assembly
portions 350A and
inserting a hinge pin (not visible) through the hinge pin holes 354 of the
interleaved hinge
leaves 353, which can be secured in place using for example an external
retaining ring clip.
[0092] Floor end hinge portion 350 additionally includes two opposed block-out
shields
355a and 355b. Block out shield 355a is positioned adjacent a first vertical
edge of base
plate 351 and extends away from base plate 351 in a perpendicular direction.
Block out
shield 355b is positioned proximate to an opposing second vertical edge of
base plate 351,
but is inset an inset distance 356 equal to at least the thickness of block
out shield 355a, and
extends away from base plate 351 in a perpendicular direction.
[0093] Referring to the floor end hinge assembly 345A shown in Figure 13B
adjacent first
floor transverse edge 120, one of its hinge assembly portions 350A is joined
to the
reinforcing board 307 adjacent edge 301b, and the other of its hinge assembly
portions
350A is joined to the reinforcing board 307 adjacent interior edge 301a. As to
the floor end
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hinge assembly 345A shown in Figure 13B, which is adjacent second transverse
floor edge
118, likewise one of its hinge assembly portions 350A is joined to the
reinforcing board 307
adjacent edge 301a, and the other of its hinge assembly portions 350A is
joined to the
reinforcing board 307 adjacent second interior edge 301b.
[0094] Optionally, an I-beam cover 505, shown in Figures 28A-28C can be
positioned over
the interior flanges (the flanges proximate to the enclosed space of structure
150) of each of
I-beams 326a and 326b. I-beam cover 505 is an elongate member that defines a
deep
channel 506 in cross-section dimensioned to be placed over and snugly fit one
side of an I-
beam flange. As shown in Figure 28C, two 1-beam covers 505 are positioned
abutting each
other in an opposed manner to cover both sides of an I-beam flange. I-beam
flange cover
505 is fabricated from a material that, relative to steel, has a low thermal
conductivity, such
as polyvinyl chloride.
Roof Component (400)
[0095] Typically, a structure 150 will utilize one roof component 400; thus
roof component
400 generally is the full roof of structure 150.
A. General Description
[0096] Roof component 400 has a generally rectangular perimeter. Figures 1, 4
and 5
depict roof component 400 in accordance with the present inventions. The
perimeter of roof
component 400 is defined by first longitudinal roof edge 406, first transverse
roof edge 408,
second longitudinal roof edge 416 and second transverse roof edge 410. In
particular, (a)
first longitudinal roof edge 406, (b) first transverse roof edge 408, (c)
second longitudinal
roof edge 416 and (d) second transverse roof edge 410 of roof component 400
generally
coincide with (i.e., overlie) (w) first longitudinal edge 106, (x) first
transverse edge 108, (y)
second longitudinal edge 116 and (z) second transverse edge 110, respectively,
of structure
150.
[0097] The length and width of roof component 400 can vary in accordance with
design
preference. In the particular embodiment of structure 150 depicted in Figures
1. 4 and 5, the
length and width of roof component 400 approximates the length and width of
floor
component 300.
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[0098] Roof component 400 and its constituent elements are generally designed
and
dimensioned in thickness and in other respects to accommodate the particular
loads to
which roof component 400 may be subject. It is preferred that roof component
400 utilize a
multi-layered, laminate design, such as that described in connection with
Figure 7. In the
embodiment shown in Figures 4 and 5, the top-most surface of roof component
400
comprises sheet metal layer 205 of first structural layer 210, with sheet
metal layer 205
being 24 gauge galvanized steel approximately 0.022 - 0.028 inch thick. Below
sheet metal
layer 205 there are provided foam panels 214 of foam panel layer 213, with
foam panels
214 in the embodiment shown in Figures 4 and 5 being EPS foam for example
approximately 7.125 inches thick. Below foam panel layer 213 there is provided
sheet
metal layer 216 of second structural layer 215, with sheet metal layer 216
being 24 gauge
galvanized steel approximately 0.022 - 0.028 inch thick. Below sheet metal
layer 216 of
second structural layer 215, there are provided building panels 219 of
protective layer 218,
with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.
[0099] The perimeter of roof component 400 is generally provided with exterior
edge
reinforcement. As exterior edge reinforcement for the embodiment of roof
component 400
shown in Figures 4 and 5, a first shoulder beam 435 (visible edge-on in Figure
4) is
positioned at the first longitudinal roof edge 406 of roof component 400, a
second shoulder
beam 435 (visible edge-on in Figure 5) is positioned at the first transverse
roof edge 408 of
roof component 400, a third shoulder beam 435 (visible edge-on in Figure 5) is
positioned
at the second transverse roof edge 410 of roof component 400, and a fourth
shoulder beam
435 (visible edge-on in Figure 4) is positioned at the second longitudinal
roof edge 416 of
roof component 400. In addition to protecting the exterior edges of foam panel
material, the
exterior edge reinforcement provided by shoulder beams 435 assists in
resisting vertical
loads and transferring such loads to lower floors through underlying wall
components 200
supporting roof component 400, and then to the foundation of the finished
structure 150.
Such exterior edge reinforcement can also provide a region for fastening like
regions of
abutting enclosure components 155 (underlying and any overlying). Shoulder
beams 435 of
roof component 400 can be fabricated from laminated strand lumber board 7.125-
deep and
1.5" thick.
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B. Roof Partitioning
[00100] The roof component 400 of structure 150 is partitioned into roof
portions 400a,
400b and 400c. Figure 1 shows roof portions 400a, 400b and 400c in perspective
view, and
Figure 4 shows roof portions 400a, 400b and 400c in section view, edge-on.
[00101] Each of the roof portions 400a, 40011 and 400c is a planar generally
rectangular
structure, with roof portion 400a adjoining roof portion 400b, and roof
portion 400b
adjoining roof portion 400c. Interior edge 412c of roof component 400c abuts a
first
interior edge 412b of roof component 400b, as shown in Figure 4. For interior
edge
reinforcement, a reinforcing board 437 is positioned adjacent interior edge
412c, and a
reinforcing board 437 is positioned against first interior edge 412b. Interior
edge 412a of
roof portion 400a abuts a second interior edge 412b of roof portion 400b, as
shown in
Figure 4. For interior edge reinforcement, a reinforcing board 437 is
positioned adjacent
interior edge 412a, and a reinforcing board 437 is positioned against second
interior edge
412b. In the embodiment shown in Figures 1 through 6, the interior edge
reinforcement
provided by reinforcing boards 437 of roof component 400 is laminated strand
lumber board
7.125" deep and 1.5" thick.
[00102] Referring to structure 150 shown in Figure 4, roof portion 400a is
fixed in position
relative to first wall portion 200s-1, third wall portion 200s-3 and wall
component 200R.
Roof portion 400a is joined to roof portion 400b with hinge structures
provided between
interior edge 412a of roof portion 400a and second interior edge 412b of roof
portion 400b.
Such hinge structures are adapted to permit roof portion 400b to pivot through
up to one
hundred and eighty degrees (180') of arc about a horizontal axis 405a, located
proximate the
top of roof component 400 and shown in Figure 4, between the roof fully folded
position
shown in Figure 3, where roof portion 400b lies flat against roof portion
400a, and the fully
unfolded position shown in Figure 4.
[00103] In turn, roof portion 400b is joined to roof portion 400c with hinge
structures
provided between first interior edge 412b of roof portion 400b and interior
edge 412c of
roof portion 400c. Such hinge structures are adapted to permit roof portion
400c to pivot
through up to one hundred and eighty degrees (180') of arc about a horizontal
axis 405b,
located proximate the bottom of roof component 400 and shown in Figure 4,
between the
folded position shown in Figure 3, where roof portion 400c lies flat against
roof portion
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portion 400a), and the
fully unfolded position shown in Figure 4. Particular embodiments of suitable
hinge
structures for joining roof portion 400a to roof portion 400b, and for joining
roof portion
400b to roof portion 400c, are described below.
C. Hinged Vertical Load Transfer Components
[00104] Figures 15A and 15B shows a beam assembly 425 that can be placed
within roof
component 400 to provide reinforcement in the direction along the beam and
assist in
transferring vertical loads borne by floor component 300 to its edges. Beam
assembly 425
includes three I-beams 426a, 426b and 426c. I-beam 426a is positioned
approximately in the
middle of roof portion 400a, I-beam 426b is positioned approximately in the
middle of floor
portion 400b, I-beam 426c is positioned approximately in the middle of floor
portion 400c,
and each of I-beams 426a, 426b and 426c is oriented in the transverse
direction. A hinge
assembly 429B joins I-beam 426a to I-beam 426b. In addition, a hinge assembly
429C
joins I-beam 426b to I-beam 426c. The hinge assemblies 429B and 429C permit
beam
assembly 425 to be folded to a beam folded position, shown in Figure 15B, and
unfolded to
a beam unfolded position, shown in Figure 15A. Further, the hinge assemblies
429B and
429C can be locked when beam assembly 425 is in the beam unfolded position,
which
transforms beam assembly 425 into a rigid structure that will reinforce roof
component 400
in the direction perpendicular to its axes of folding.
[00105] Hinge assemblies 429B and 429C are described further below.
[00106] Hinge Assembly 429B. Hinge assembly 429B comprises two identical hinge
assembly portions 430B partnered together to form a pivoted junction. The
inter-
positioning of the parts of the two partnered hinge assembly portions 430B
forming hinge
assembly 429B is substantively the same as illustrated in Figures 13D and 13E
in reference
to the two hinge assembly portions 330A forming hinge assembly 329A.
[00107] Hinge assembly portion 430B is shown in Figure 16. The design of hinge
assembly portion 430B is similar to hinge assembly portion 330A discussed
above.
Accordingly, referring to Figure 16, hinge assembly portion 430B includes a
hinge base
plate 431 having an obverse face 418 and a reverse face 419 (visible in Figure
19). A hinge
section 432, a pin interlock section 434, a free interlock section 438 and a
locking pin barrel
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440 are secured to the obverse face 418 of hinge plate 431. Hinge assembly
portion 430B
can be manufactured from steel that is cast as a single piece that includes
sections 432, 434
and 438, and barrel 440.
[00108] Hinge section 432 shown in Figure 16 has four hinge leaves 433. Each
hinge leaf
433 extends away in a perpendicular direction from hinge base plate 431 and
defines a
hinge pin hole 427 in the region distal from hinge base plate 431. The
centerline of each
hinge pin hole 427 is horizontally oriented and aligned with the centerline of
the hinge pin
holes 427 in the other hinge leaves 433 of hinge section 432. Hinge leaves 433
each has the
same thickness and are spaced apart a distance equal to the thickness of a
hinge leaf 433, so
as to permit interleaving the corresponding hinge leaves 433 of the partnering
hinge
assembly portion 430B.
[00109] Pin interlock section 434 shown in Figure 16 has two pin interlock
leaves 436.
Each pin interlock leaf 436 extends away in a perpendicular direction from
hinge base plate
431 and defines a lock pin hole 447 in the region distal from base plate 431.
The centerline
of each lock pin hole 447 is vertically oriented and in alignment with the
centerline of the
lock pin hole 447 of the adjacent pin interlock leaf 436. The two pin
interlock leaves 436
each has the same thickness as the other, and are spaced apart a distance
equal to the
thickness of a pin interlock leaf 436.
[00110] Free interlock section 438 shown in Figure 16 has two free interlock
leaves 439.
Each free interlock leaf 439 extends away in a perpendicular direction from
hinge base plate
431 and defines a lock pin hole 447 in the region distal from base plate 431.
The centerline
of each lock pin hole 447 is vertically oriented and co-linear with the
centerline of with the
lock pin hole 447 of the adjacent free interlock leaf 439. The two free
interlock leaves 436
each has the same thickness as the other, and both free interlock leaves 439
have the same
thickness as pin interlock leaves 436. The free interlock leaves 439 are
spaced apart a
distance equal to the thickness of a free interlock leaf 439 (which is equal
to the thickness of
a pin interlock leaf 436).
[00111] Locking pin barrel 440 shown in Figure 16 extends away in a
perpendicular
direction from base plate 431 defines a locking pin bore 441. The centerline
of bore 441 is
vertically oriented and co-linear with the centerline of lock pin holes 447 of
pin interlock
leaves 436.
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[00112] As can be seen in Figure 17, the vertical centerline 443 of hinge
section 432 is not
coincident with the vertical centerline 442 of hinge base plate 431. Rather,
it is offset, in
the view shown in Figure 17, leftward an offset distance 444, which is one-
half the
thickness of a hinge leaf 433. This permits utilizing two hinge assembly
portions 430B with
identical designs in a partnering relationship to form the hinge assembly 429B
and the
desired pivoting junction. Hinge assembly 429B is assembled by interleaving
the hinge
leaves 433 of two hinge assembly portions 430B and inserting a hinge pin 464
(shown in
Figure 24A) through their hinge pin holes 427, which can be secured in place
using for
example an external retaining ring clip. Hinge leaves 433, visible in profile
in Figure 18,
extend above hinge base plate 431 so that hinge pin holes 427 are positioned a
vertical
distance 411, the B hinge pin pivot distance, from the lower edge of hinge
assembly portion
430B. B hinge pin pivot distance 411 is sufficient to permit hinge assembly
429B to pivot
one hundred and eighty degrees (1800) from a first, hinge open position, where
I-beam 425
is in the beam folded position shown in Figure 15B, to a second, hinge closed
position,
where I-beam 425 is in the beam unfolded position shown in Figure 15A.
[00113] As shown in Figure 17, the free interlock leaves 439 of free interlock
section 438
are offset in the vertical direction from the position of the pin interlock
leaves 436 of the pin
interlock section 434 by an offset distance 446, which is equal to the
thickness of a free
interlock leaf 439 (which is equal to the thickness of a pin interlock leaf
436). In the hinge
closed position (the beam unfolded position), the free interlock leaves 439 of
the free
interlock section 438 of a first of the two hinge assembly portions 430B will
interleave with
the pin interlock leaves 436 of the pin interlock section 434 of the second of
the two hinge
assembly portions 430B. Correspondingly in the hinge closed position (the beam
unfolded
position), the free interlock leaves 439 of the free interlock section 438 of
the second of the
two hinge assembly portions 430B will interleave with the pin interlock leaves
436 of the
pin interlock section 434 of the first of the two hinge assembly portions
430B. The
centerline of lock pin holes 447 of the free interlock leaves 439 of each
hinge assembly
portion 430B is positioned so that, when a hinge assembly 429B is in the hinge
closed
position (the beam unfolded position), that lock pin hole centerline will be
co-linear with the
centerline of the lock pin holes 447 in the pin interlock section 434 of the
other hinge
assembly portion 430B of the hinge assembly 429B.
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[00114] As can be appreciated, when hinge assembly 429B is in the hinge closed
position
(the beam unfolded position), there is on each side of the vertical centerline
of the assembly
a locking pin barrel 440 positioned over a set of interleaved leaves 436, 439.
The hinge
assembly 429 is accordingly locked into the hinge closed position by inserting
a locking pin
349 (the same as used to lock partnered hinge assembly portions 330A in the
hinge closed
position, and as shown in Figure 13C) into the locking pin bore 441 provided
in the locking
pin barrel 440 of each of its two hinge assembly portions 430B.
[00115] Locking pin 349 has a length sufficient to be received in the lock pin
holes 447 of
the interleaved leaves of 436, 439 positioned below it and thus lock beam
assembly 425 in
the beam unfolded position. As described above, it is preferable for locking
pin 349 to be
cylindrical in cross-section. Also as described above, locking pin 349 can be
tapered along
its length, so that the widest cross section is at the upper face of locking
pin barrel 440. In
that case, the diameter of locking pin bore 441 can be tapered, and the
diameters of lock pin
holes 447 in leaves 436, 439 can be correspondingly reduced, the further they
are located
from locking pin barrel 440. Alternatively, and as shown in Figure 13C, only
the portion
349a of locking pin 349, which is received in lock pin holes 447 of leaves
436, 439, can be
made tapered (with the diameters of lock pin holes 447 in leaves 436, 439
being
correspondingly reduced, the further they are located from locking pin barrel
440), while
locking pin bore 441, and the portion 349b of locking pin 349 not received in
lock pin holes
447 of leaves 436, 439, each can be given a uniform diameter. In this latter
case, the
portion 349c of locking pin 349 (the upper section of portion 349b), which is
received in
locking pin bore 441, as well as locking pin bore 441 itself, can be provided
with
complimentary screw threads (in the manner depicted in Figures 13C-13E), to
permit
securing locking pin 349 in place.
[00116] To facilitate the rotation of hinge assembly 429B so that beam
assembly 425 can
smoothly move into the fully unfolded position shown in Figure 15A, it is
preferred that the
upper and lower faces of leaves 436, 439 not be planar, but rather curved.
Referring to
Figure 18, there is shown interlock leaves 436 in profile. As compared to
planar surfaces
448, which originate at hinge base plate 431 and extend out in an orientation
normal to the
plane of hinge base plate 431, the upper and lower faces of free interlock
leaves 439 can be
seen to be curved, about a point proximate to hinge pin hole 427. Similarly,
the upper and
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lower faces of pill interlock leaf 436 immediately below it are comparably
curved. The
curvature varies depending on the face location, with faces closer to pin hole
427 being
more deeply curved than faces further away.
[00117] A stop 424 is optionally provided at the edge of the lower free
interlock leaf 439 of
each hinge portion 430B of hinge assembly 429B to assist in preventing hyper-
extending
beam assembly 425 when unfolded. In the case where hinge assembly 429B is
fabricated as
a single casting, stops 424 of the partnered hinge portions 430B of each hinge
assembly
429B can be more precisely machined or ground down as necessary following the
casting
step to insure that when hinge assembly 429B is in the hinge closed position,
1-beams 426a
and 426b do not extend beyond the desired beam unfolded position. In the beam
unfolded
position (when hinge assembly 429B is in the hinge closed position), while I-
beams 426a
and 426b can be co-linear, it is preferred that I-beams 426a and 426b not be
co-linear. In
particular, in the beam unfolded position it is preferred that hinge assembly
429B, when
joined to 1-beams 426a and 426b, causes those 1-beams to assume a small
upwardly arched
configuration. This configuration can be realized for example by designing
hinge assembly
portion 430B so that when hinge assembly portion 430B is secured to an end of
an I-beam
426a or 426b, obverse face 418 is canted a select positive angle (i.e.,
angularly rotated
clockwise about hinge pin hole 427 in Figure 18), such as one-half degree
(+0.50), relative
to the reverse face 419 of hinge assembly portion 430B. This upward arching is
intended to
reduce or eliminate any sag in floor component 400 when in the fully unfolded
position.
[00118] The reverse face 419 of hinge assembly portion 430B is adapted to be
secured to
an end of one of I-beams 426a and 426b. The hinge assembly portions 430B that
join I-
beam 426a and I-beam 426b are secured to I-beams 426a, 426b with their hinge
sections
432 oriented upwardly, so that I-beam 426b shown in Figure 15A can fold up
relative to I-
beam 426a to the beam folded position shown in Figure 15B. In particular, as
shown in
Figure 19 reverse face 419 is provided with four positioning tabs 421
extending away from
reverse face 419 in a perpendicular direction. Each positioning tab 421 has
two flat sections
417 oriented perpendicular to each other and joined by a rounded section 415.
The
positioning tabs 421 secured to reverse face 419 form a guide frame, having an
"I" shape in
profile, for receiving an end of one of I-beams 426a and 426b. It is preferred
that the I-
beams 426a, 426b be secured to the reverse faces 419 by welding their flanges
to hinge
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assembly portions 430a. For this purpose, each of the positioning tabs 421 is
preferably
provided with a serpentine cut-out 422, to increase the length of the weld
line with the goal
of increasing the strength of the weld.
[00119] Hinge Assembly 429C. Hinge assembly 429C comprises two identical hinge
assembly portions 430C partnered together to form a pivoted junction. The
inter-
positioning of the parts of the two partnered hinge assembly portions 430C
forming hinge
assembly 429C is substantively the same as illustrated in Figures 13D and 13E
in reference
to the two hinge assembly portions 330A forming hinge assembly 329A.
[00120] Hinge assembly portion 430C is shown in Figures 20-23. The design of
hinge
assembly portion 430C is the same as hinge assembly portion 430B, discussed
above, with
three exceptions.
[00121] The first exception is that the lower pin interlock leaf 436 of the
hinge assembly
portion 430C is extended toward free interlock section 438 to provide a
platform tab 407,
which is shown in Figures 20 and 21. When hinge assembly 429C is in its fully
open
position in a structure 150, the two platform tabs 407 of the partnered hinge
assembly
portions 430C forming hinge assembly 429C provide a foot-supporting area for
construction personnel, while protecting the hinge structure.
[00122] The second exception is shown in Figure 22, in which hinge leaves 453
extend
above hinge base plate 431 so that hinge pin holes 427 are positioned a
vertical distance
409, the C hinge pin pivot distance, from the lower edge of hinge assembly
portion 430C.
The C hinge pin pivot distance 409 is sufficient to permit hinge assembly 429C
to pivot one
hundred and eighty degrees (180') from a first, open position, where I-beam
425 is in the
beam folded position shown in Figure 15B, to a second, closed position, where
I-beam 425
is in the beam unfolded position shown in Figure 15A, without crimping or
interfering with
such protective layer 218 (shown in Figure 22) as may be positioned on second
structural
layer 215.
[00123] The third exception relates to the fact that hinge assemblies 429B and
429C are
mounted in opposite orientations. Referring to hinge assembly 429B, the
reverse face 419
of each of its two hinge assembly portions 430B is adapted to be secured to a
respective end
of the two I-beams 426a and 426b adjacent to each other, and referring to
hinge assembly
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429C the reverse face 419 of each of the two hinge assembly portions 430C is
adapted to be
secured to a respective end of the two I-beams 426b and 426c adjacent to each
other. As
was discussed above, the hinge assembly portions 430B that join I-beam 426a
and I-beam
426b are secured to those I-beams 426a, 426b with their hinge sections 332
oriented
upwardly, so that I-beam 426b shown in Figure 15A can fold up relative to I-
beam 426a. In
contrast, hinge assembly portions 430C that join I-beam 326b and I-beam 326c
are secured
to I-beams 426b, 426c with their hinge sections 332 oppositely oriented; i.e.,
oriented
downwardly, so that I-beam 426c shown in Figure 15A can fold down relative to
I-beam
426b. These orientations permit I-beam 425 to be folded in an accordion
pattern, as shown
in Figure 15B. With these orientations, the three roof components 400a, 400b
and 400c can
be accordion folded (stacked), as shown in Figure 3, with roof component 40011
stacked on
top of roof component 400a, and roof component 400c stacked on top of the roof
component 400b.
[00124] Similar to the beam unfolded position of 1-beams 426a and 426b, while
1-beams
426b and 426c can be co-linear in their beam unfolded position (when hinge
assembly 429C
is in the hinge closed position), it is preferred that I-beams 426b and 426c
not be co-linear
in that beam unfolded position. In particular, in the beam unfolded position
it is preferred
that hinge assembly 429C, when joined to I-beams 426b and 426c, causes those I-
beams to
assume a small upwardly arched configuration. This can be realized for example
by
designing hinge assembly portion 430C so that when hinge assembly portion 430C
is
secured to an end of an I-beam 426b or 426c, obverse face 418 is canted in the
opposite
direction as preferably found in hinge assembly 430B; in other words, it is
preferred that
obverse face 418 of hinge assembly portion 430C be canted a select negative
angle (i.e.,
angularly rotated counterclockwise about hinge pin hole 427 in Figure 22),
such as minus
one-half degree (-0.5 ), relative to the reverse face 419 of hinge assembly
portion 430C. As
stated previously, this upward arching is intended to reduce or eliminate any
sag in floor
component 400 when in the fully unfolded position.
[00125] Figure 24A, a cutaway view of a section of roof component 400 in the
roof
component unfolded position, depicts the mounting of hinge assembly 429B
within the
floor component 400, specifically between floor portion 400a and floor portion
400b. Bolt
plate 414 joins the reinforcing board 437 positioned in roof portion 400b
adjacent second
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interior edge 412b to the hinge assembly portion 430B secured to I-beam 426b.
A similar
bolt plate 414 is located on the portion of I-beam 426b not visible in Figure
24A, and
similar bolt plates 414 are located on each side of the partnering hinge
assembly portion
430B secured to I-beam 426a. Hinge assembly 429C is mounted within floor
component
400 at the junction of roof portions 400b and 400c in a similar manner.
[00126] In the embodiment of roof component 400 shown in the figures, I-beam
assembly
425 is located at the mid-point between first transverse roof edge 408 and
second transverse
roof edge 410, and no hinge assemblies 429B or 429C are utilized elsewhere
within roof
component 400, such as proximate to first transverse roof edge 408 or second
transverse
roof edge 410. Therefore, to assist in smoothly rotating roof portion 400b
relative to roof
portion 400a, there is provided adjacent first transverse roof edge 408 a
first roof end hinge
assembly 445B joining roof portions 400a and 400b, and there is provided
adjacent second
transverse roof edge 410 a second roof end hinge assembly 445B joining roof
portions 400a
and 400b. Additionally, to assist in smoothly rotating roof portion 400c
relative to roof
portion 400b, there is provided adjacent first transverse roof edge 408 a
first roof end hinge
assembly 445C joining roof portions 400b and 400c, and there is provided
adjacent second
transverse roof edge 410 a second roof end hinge assembly 445C joining roof
portions 400b
and 400c. The locations of first and second roof end hinge assemblies 445B are
indicated in
Figure 24B, and the locations of first and second roof end hinge assemblies
445C are
indicated in Figure 24B. The designs of roof end hinge assemblies 445B and
445C are
described below.
[00127] Roof End Hinge assembly 445B. Roof end hinge assembly 445B comprises
two
identical roof end hinge portions 450B. Referring to Figure 25A, roof end
hinge portion
450B in principal part includes a hinge base plate 451 on which is secured a
hinge section
452. Hinge section 452 has five hinge leaves 453 in the depicted embodiment,
each of
which extends in a perpendicular direction away from hinge base plate 451 and
defines a
hinge pin hole 454 in the region distal from hinge base plate 453. The
centerline of each
hinge pin hole 454 is horizontally oriented and aligned with the centerline of
the hinge pin
holes 454 in the other hinge leaves 453 of hinge section 452. Hinge leaves 453
each has the
same thickness and are spaced apart a distance equal to the thickness of a
hinge leaf 453, so
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as to permit interleaving the corresponding hinge leaves 453 of the partnering
hinge
assembly portion 450B.
[00128] As depicted in Figure 25B, the vertical centerline 458 of hinge
section 452 of roof
end hinge portion 445B is not coincident with the vertical centerline 459 of
hinge base plate
451. Rather, it is offset an offset distance 457, which is one-half the
thickness of a hinge
leaf 453. This permits utilizing two hinge assembly portions 450B with
identical designs in
a partnering relationship to form the hinge assembly 445B and the desired
pivoting junction.
Roof end hinge assembly 445B is assembled by interleaving the hinge leaves 453
of two
hinge assembly portions 450B and inserting a hinge pin (not visible) through
their hinge pin
holes 454, which can be secured in place using for example an external
retaining ring clip.
As shown in Figure 25C, hinge leaves 453 of roof end hinge portion 445B extend
above
hinge base plate 451 so that hinge pin holes 454 are positioned a vertical
distance 461, the B
roof end hinge pivot distance, from the lower edge of hinge assembly portion
450B. B roof
end hinge pivot distance 461 is sufficient to permit hinge assembly 445B to
pivot one
hundred and eighty degrees (1800) from a first, hinge open position,
corresponding to where
I-beam 425 of roof portion 400b is in the beam folded position shown in Figure
15B, to a
second, hinge closed position, corresponding to where I-beam 425 is in the
beam unfolded
position shown in Figure 15A.
[00129] Roof end hinge portion 450B additionally includes two opposed block-
out shields
455a and 455b, which are shown in Figure 25A. Block out shield 455a is
positioned
adjacent a first vertical edge of base plate 451 and extends away from base
plate 451 in a
perpendicular direction. Like the positioning of block out shield 355b of
floor end hinge
portion 351, block out shield 455b is positioned proximate to an opposing
second vertical
edge of base plate 451, but inset an inset distance 456 equal to at least the
thickness of
block-out shield 455a, and extending away from base plate 351 in a
perpendicular direction.
[00130] The roof end hinge assemblies 445B shown in Figure 24B have their
hinge
sections 452 oriented up, so that roof portion 400b can be folded upward
relative to roof
portion 400a. The roof end hinge assembly 445B that is adjacent first roof
transverse edge
408 in Figure 24B is secured in place by joining one of its hinge assembly
portions 450B to
the reinforcing board 437 adjacent edge 412a, and by joining the other of its
hinge assembly
portions 450B to the reinforcing board 437 adjacent second interior edge 412b.
As to the
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roof end hinge assembly 445B shown in Figure 24B, which is adjacent second
roof
transverse edge 408, likewise one of its hinge assembly portions 450B is
joined to the
reinforcing board 437 adjacent edge 412a, and the other of its hinge assembly
portions 450B
is joined to the reinforcing board 437 adjacent second interior edge 412b.
[00131] Roof End Hinge assembly 445C. Roof end hinge assembly 445C comprises
two
identical roof end hinge portions 450C, one of which is shown in Figure 25D.
The principal
elements and geometry of roof end hinge portion 450C are the same as roof end
hinge
portion 450B, except that hinge leaves 453 of roof end hinge portion 445C
extend above
hinge base plate 451 so that hinge pin holes 454 are positioned a vertical
distance 462, the C
roof end hinge pivot distance, from the lower edge of hinge assembly portion
450C. C roof
end hinge pivot distance 462 is sufficient to permit hinge assembly 445C to
pivot one
hundred and eighty degrees (180') from a first, hinge open position,
corresponding to where
I-beam 425 of roof portion 400b is in the beam folded position shown in Figure
15B, to a
second, hinge closed position, corresponding to where 1-beam 425 is in the
beam unfolded
position shown in Figure 15A, without crimping or interfering with such
protective layer
218 as may be positioned on second structural layer 215. Each roof end hinge
assembly
445C is completed by inserting a hinge pin (not visible) in the hinge pin
holes 454 of the
interleaved hinge leaves 453 of the partnered hinge assembly portions 450C,
which can be
secured in place using for example an external retaining ring clip.
[00132] The roof end hinge assemblies 445C shown in Figure 24B have their
hinge
sections 452 oriented down, so that roof portion 400c can be folded downward
relative to
roof portion 400b. The roof end hinge assembly 445C that is adjacent first
roof transverse
edge 408 in Figure 24B is secured in place by joining one of its hinge
assembly portions
450C to the reinforcing board 437 that is adjacent first interior edge 412b,
and by joining
the other of its hinge assembly portions 450C to the reinforcing board 437
adjacent interior
edge 412c. As to the roof end hinge assembly 445C shown in Figure 24B, which
is
adjacent second roof transverse edge 408, likewise one of its hinge assembly
portions 450C
is joined to the reinforcing board 437 that is adjacent first interior edge
412b, and by joining
the other of its hinge assembly portions 450C to the reinforcing board 437
adjacent interior
edge 412c.
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[00133] Optionally, an I-beam cover 505, as shown in Figures 28A-28C and
described
above, can be positioned over the interior flanges (the flanges proximate to
the enclosed
space of structure 150) of each of I-beams 426a, 426b and 326c.
Enclosure Component Manufacture
[00134] For enclosure components 155 having the construction disclosed herein
in
reference to Figure 7, the metal sheets 206 and 217 that can be used to form
first structural
layer 210 and second structural layer 215 respectively can be entirely flat
and juxtaposed in
a simple abutting relationship. Optionally, metal sheets 206 and 217 can be
provided with
edge structures that facilitate placement of sheets and panels during
manufacture.
[00135] Particular edge structure designs for metal sheets 206 and 217 are
described in
U.S. Nonprovisional Patent Application No. 17/504,883 entitled "Sheet/Panel
Design for
Enclosure Component Manufacture." having the same inventors as the inventions
described
herein and filed on October 19, 2021. The contents of U.S. Nonprovisional
Patent
Application No. 17/504,883 entitled "Sheet/Panel Design for Enclosure
Component
Manufacture,- having the same inventors as the inventions described herein and
filed on
October 19,2021. are incorporated by reference as if fully set forth herein,
particularly
including the exterior and interior edge structure designs described for
example at
paragraphs 00187-00205 and 00212 and in Figures 8, 9A-9C, 23A-23J and 24A-24B
thereof.
[00136] Figure 26 depicts a facility 10 for fabricating the enclosure
components 155. The
facility comprises a conveyor table 50, a press table 51, and in the
embodiment shown in
Figure 5, four material turntables 52A, 52B, 52C and 52D and four robotic
assemblers 54A,
54B, 54C and 54D. There is also an adhesive spray gantry 55 straddling the
conveyor table
50. Whether partitioned or not, all of the enclosure components 155 ¨ wall
components
200, floor components 300 and roof components 400 ¨ can be formed on the same
facility
10.
[00137] Conveyor table 50 is provided with a plurality of cylindrical rollers
to facilitate
movement of work pieces from the assembly area 56 into the press table 51. The
enclosure
components 155 are built up, layer upon layer, in the assembly area 56, and
then moved into
the press table 51. Press table 51 preferably employs a vacuum bag system to
press together
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the layers forming enclosure components 155. Spray gantry 55 is movable over
conveyor
table 50 between a first position proximate to press table 51 and a second
position distal
from press table 51. Spray gantry 55 is provided with a number of downward-
directed
spray heads for spraying adhesive, such as polyurethane based construction
adhesive, onto
the work pieces, as directed.
[00138] The facility 10 depicted in Figure 26 can fabricate up to two complete
enclosure
components 155 simultaneously, although it is equally capable of forming
subassemblies
thereof, such as laminated panel sections used to form complete enclosures
components
155. Thus robotic assemblers 54A and 54B are positioned as opposed pairs with
conveyor
table 50 between them, as shown in Figure 26, and are used to move sheets and
panels from
turntables 52A and 52B, respectively, to appropriate locations on conveyor
table 50 to form
a first enclosure component 155, or a first laminated panel section for an
enclosure
component 155. Likewise, robotic assemblers 54C and 54D are positioned as
opposed pairs
with conveyor table 50 between them, as shown in Figure 26, and are used to
move sheets
and panels from turntables 52C and 52D, respectively, to appropriate locations
on conveyor
table 50 to form a second enclosure component 155, or a second laminated panel
section for
an enclosure component 155.
[00139] Additional information concerning the facility 10 shown in Figure 26,
as well as
exemplary manufacturing steps, are also described in U.S. Nonprovisional
Patent
Application No. 17/504,883 entitled "Sheet/Panel Design for Enclosure
Component
Manufacture," having the same inventors as the inventions described herein and
filed on
October 19, 2021. The contents of U.S. Nonprovisional Patent Application No.
17/504,883
entitled "Sheet/Panel Design for Enclosure Component Manufacture," having the
same
inventors as the inventors described herein and filed on October 19, 2021, are
incorporated
by reference as if fully set forth herein, particularly including the facility
suitable for
manufacturing the enclosure components 155 of the present invention, as well
as exemplary
manufacturing steps, described for example at paragraphs 00178-00186 and 00206-
00222,
and in Figures 22, 23A-23J and 24A-24B.
Enclosure Component Relationships and Assembly for Transport
[00140] It is preferred that there be a specific dimensional relationship
among enclosure
components 155. In reference to the embodiment shown in the figures, it is
preferred that
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the height "H" of wall components 200 he the same as the span "Sr." between
the I-beam
assembly 325 of floor component 300 and either its first transverse floor edge
120 or its
second transverse floor edge 118, with I-beam assembly 325 being located at
the middle of
floor component 300. Correspondingly, it is preferred that the height of wall
components
200 be the same as the span "Sr" between the I-beam assembly 425 of roof
component 400
and either its first transverse roof edge 408 or its second transverse roof
edge 410, with I-
beam assembly 425 being located at the middle of roof component 400. Thus it
is preferred
that H = Sf = Sr. Accordingly, Sr and Sr are referred to herein simply as "S",
the panel
section span.
[00141] Making H = S improves the production throughput of manufacturing
facility 10.
Specifically, manufacturing facility 10 can be tasked with making multiple
laminate panel
sections sharing a common dimension based upon the bed width 49 of conveyor
table 50
shown in Figure 26, which can then be used to assemble either floor components
300 or
roof components 400. In an embodiment of manufacturing facility 10 shown in
Figure 26,
the bed width 49 can accommodate work pieces having a dimension up to
approximately
9.5 feet. Correspondingly, in the embodiment shown in the figures, the panel
section span S
between I-beam assembly 325 and either of the first and second transverse
floor edges 120,
118 is 9.5 feet, and the panel section span S between I-beam assembly 425
either of the first
and second transverse roof edges 408, 410 is 9.5 feet. Further, by selecting
foam panels 214
of different thickness, wall components 200 can also be manufactured utilizing
panel
sections of span S. Accordingly, each wall component 200 in the embodiment of
structure
150 shown in Figure 1 has a height H of 9.5 feet.
[00142] These same height/span relationships can also be utilized to make
structures 150
where two of its opposing wall components 200 are longer than the other two
opposing wall
components 200. For example, Figure 27 depicts a roof component 400
approximately 1.5
times longer in the longitudinal direction than in the transverse direction.
In this example,
roof portions 400a, 400b and 400c are each assembled from a series of three
laminate panel
sections, each such section having a panel section span of 9.5 feet in the
longitudinal
direction. The laminate panel sections of each of the three roof portions
400a, 400b and
400c are joined by two beam assemblies 425, rather than one as in the
embodiment shown
in Figure 1, to yield a roof component 400 approximately 29 feet long by 19
feet wide. The
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wall floor component 300 and wall components 200 are assembled from similarly-
dimensioned laminate panel sections to yield the desired rectangular structure
150. The
foregoing design relationship can be extended to a structure 150 of any length
in the
longitudinal direction simply by adding, in the case of roof component 400 as
an example,
one or more additional beam assemblies 425 and further series of laminate
panel sections.
[00143] Figure 2 shows a top schematic view of finished structure 150 shown in
Figure 1,
and includes a geometrical orthogonal grid for clarity of explaining the
preferred
dimensional relationships among its enclosure components 155. The basic length
used for
dimensioning is indicated as "E" in Figure 2; the orthogonal grid overlaid in
Figure 2 is 8E
long and 8E wide; notably, the entire structure 150, including perimeter
boards 310,
preferably is bounded by this 8E by 8E orthogonal grid.
[00144] Roof portions 400a, 400b and 400c each can be identically dimensioned
in the
transverse direction. Alternatively, referring to Figure 3, roof portion 400c
(which is
stacked upon roof portions 400a arid 400b when roof portions 400h, 400c are
fully folded)
can be dimensioned to be larger than either of roof portion 400a and roof
portion 400b in
the transverse direction for example, by ten to fifteen percent, or by at
least the aggregate
thickness of roof components 400a and 400b. This transverse direction
dimensional
increase is to reduce the chances of binding during the unfolding of roof
portions 400b,
400c. In addition, as described in U.S. Nonprovisional Patent Application No.
16/786,315,
entitled "Equipment and Methods for Erecting a Transportable Foldable Building
Structure," and filed on February 10, 2020, friction-reducing components can
be used to
facilitate unfolding roof component 400, such as by positioning a first wheel
caster at the
leading edge of roof portion 400c proximate to the corner of roof portion 400c
that is
supported by wall portion 200s-2 as roof portion 400c is deployed, and
positioning a second
similar wheel caster at the leading edge of roof portion 400c proximate to the
corner of roof
portion 400c that is supported by wall portion 200s-4 as roof portion 400c is
deployed. In
such a case, roof portion 400c can be dimensioned larger than either of roof
portions 400a
and 400b in the transverse direction by at least the aggregate thickness of
roof components
400a and 400b, less the length of the first or second wheel caster.
[00145] In Figure 2, the four wall components 200 are each approximately 8E
long, and
each of roof portions 400a and 400b is approximately 8E long and 2.5E wide.
Roof portion
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400c is approximately 8E long and 2.9E wide. In Figures 2 and 3, each of floor
components
300a and 300b is 8H long; whereas floor component 300a is just over 3E wide
and floor
component 300b is just under 5E wide.
[00146] The shipping module 100 shown edge-on in Figure 3 includes a fixed
space
portion 102 defined by roof component 400a, floor component 300a, wall
component 200R,
wall portion 200s-1 and wall portion 200s-3. As shown in Figure 2, second wall
portion
200s-2 is folded inward and positioned generally against fixed space portion
102, and fourth
wall portion 200s-4 is folded inward and positioned generally against second
wall portion
200s-2 (wall portions 200s-2 and 200s-4 are respectively identified in Figure
2 as portions
200s-2f and 200s-4f when so folded and positioned). The three roof components
400a,
400b and 400c are shown unfolded in Figure 1 and shown accordion folded
(stacked) in
Figure 3, with roof component 400b stacked on top of roof component 400a, and
roof
component 400c stacked on top of the roof component 400b. Wall component 200P,
shown
in Figures 2 and 3, is pivotally secured to floor portion 300b at the location
of axis 105, and
is vertically positioned against the outside of wall portions 200s-2 and 200s-
4. In turn, floor
portion 300b is vertically positioned proximate fixed space portion 102, with
wall
component 200P pending from floor portion 300b between floor portion 300b and
wall
portions 200s-2 and 200s-4.
[00147] Sizing the enclosure components 155 of structure 150 according to the
dimensional
relationships disclosed above yields a compact shipping module 100, as can be
seen from
the figures. Thus shipping module 100 depicted in Figure 3, when dimensioned
according
to the relationships disclosed herein using an "E" dimension (see Figure 2) of
approximately
28.625 inches (72.7 cm), and when its components are stacked and positioned as
shown in
Figure 3, has an overall length of approximately 19 feet (5.79 m), an overall
width of
approximately 8.5 feet (2.59 meters) and an overall height of approximately
12.7 feet (3.87
meters). These overall dimensions are less than a typical shipping container.
[00148] It is preferred that the fixed space portion 102 be in a relatively
finished state prior
to positioning (folding) together all of the other wall, roof and floor
portions as described
above. In the embodiment shown in Figures 1 and 2, wall components 200 are
fitted during
manufacture and prior to shipment with all necessary door and window
assemblies, with the
enclosure components 155 being pre-wired, and fixed space portion 102 is
fitted during
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manufacture with all mechanical and other functionality that structure 150
will require, such
as kitchens, bathrooms, closets and other interior partitions, storage areas,
corridors, etc.
Carrying out the foregoing steps prior to shipment permits the builder, in
effect, to erect a
largely finished structure simply by "unfolding" (deploying) the positioned
components of
shipping module 100.
[00149] Each of the wall, floor and roof components 200, 300 and 400, and/or
the portions
thereof, can be sheathed in protective film 177 during fabrication and prior
to forming the
shipping module 100. Alternatively or in addition, the entire shipping module
100 can be
sheathed in a protective film. Such protective films can remain in place until
after the
shipping module 100 is at the construction site, and then removed as required
to facilitate
enclosure component deployment and finishing.
Shipping Module Transport
[00150] The shipping module is shipped to the building site by appropriate
transport
means. One such transport means is disclosed in U.S. Patent No. 11,007,921,
issued May
18, 2021; the contents of which are incorporated by reference as if fully set
forth herein,
particularly as found at column 3, line 26 to column 6, line 25 and in Figures
1A-2D
thereof. As an alternative transport means, shipping module 100 can be shipped
to the
building site by means of a conventional truck trailer or a low bed trailer
(also referred to as
a lowboy trailer), and in the case of over-the-water shipments, by ship.
Structure Deployment and Finishing
[00151] At the building site, shipping module 100 is positioned over its
desired location,
such as over a prepared foundation; for example, a poured concrete slab, a
poured concrete
or cinder block foundation, sleeper beams or concrete posts or columns. This
can be
accomplished by using a crane, either to lift shipping module 100 from its
transport and
move it to the desired location, or by positioning the transport means over
the desired
location, lifting shipping module 100, then moving the transport means from
the desired
location, and then lowering shipping module 100 to a rest state at the desired
location.
Particularly suitable equipment and techniques for facilitating the
positioning of a shipping
module 100 at the desired location are disclosed in U.S. Nonprovisional Patent
Application
No. 16/786,315, entitled "Equipment and Methods for Erecting a Transportable
Foldable
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Building Structure," and filed on February 10, 2020. The contents of that U.S.
Nonprovisional Patent Application No. 16/786,315, entitled "Equipment and
Methods for
Erecting a Transportable Foldable Building Structure," and filed on February
10, 2020, are
incorporated by reference as if fully set forth herein, particularly including
the equipment
and techniques described for example at paragraphs 00126-00128 and in
connection with
Figures 11A and 11B thereof.
[00152] Following positioning of shipping module 100 at the building site, the
appropriate
portions of wall, floor and roof components 200, 300 and 400 are "unfolded"
(i.e.,
deployed) to yield structure 150. Unfolding occurs in the following sequence:
(1) floor
portion 300b is pivotally rotated about horizontal axis 305 (shown in Figures
3 and 4) to an
unfolded position, (2) wall component 200P is pivotally rotated about
horizontal axis 105
(shown in Figure 3 behind perimeter board 312) to an unfolded position, (3)
wall portions
200s-2 and 200s-4 are pivotally rotated about vertical axes 192 and 194 (shown
in Figure 2)
respectively to unfolded positions, and (4) roof portions 400b and 400c are
pivotally rotated
about horizontal axes 405a and 405b (shown in Figures 3 and 4) respectively to
unfolded
positions. When accordion folded as a stack, it can be appreciated that the
protective layer
218 of roof portion 400a is distal from the protective layer of roof portion
400b, whereas the
protective layer 218 of roof portion 400b is in contact with, or proximate to,
the protective
layer of roof portion 400c. Thus in unfolding roof portions 400b and 400c, it
is regarded
herein that the protective layer 218 of the second component portion rotates
toward the
protective layer 218 of the first component portion 400a, whereas the
protective layer 218 of
the third component portion 400c rotates away from the protective layer 218 of
the second
component portion 400b.
[00153] A mobile crane can be used to assist in the deployment of certain of
the enclosure
components 155, specifically roof portions 400b and 400c, floor portion 300b,
as well as the
wall component 200P pivotally secured to floor portion 300b. Alternatively,
particularly
suitable equipment and techniques for facilitating the deployment of enclosure
components
155 are disclosed in U.S. Nonprovisional Patent Application No. 16/786,315,
entitled
"Equipment and Methods for Erecting a Transportable Foldable Building
Structure," and
filed on February 10, 2020. The contents of that U.S. Nonprovisional Patent
Application
No. 16/786,315, entitled "Equipment and Methods for Erecting a Transportable
Foldable
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Building Structure," and filed on February 10, 2020, are incorporated by
reference as if
fully set forth herein, particularly including the equipment and techniques
described for
example at paragraphs 00132-00145 and depicted in Figures 12A-14B thereof.
[00154] After unfolding, the enclosure components 155 are secured together to
finish the
structure 150 that is shown in Figure 1. If any temporary hinge structures
have been
utilized, then these temporary hinge structures can be removed if desired and
the enclosure
components 155 can be secured together. During or after unfolding and securing
of the
enclosure components 155, any remaining finishing operations are performed,
such as
addition of roofing material, and making hook-ups to electrical, fresh water
and sewer lines
to complete structure 150, as relevant here.
[00155] This disclosure should be understood to include (as illustrative and
not limiting)
the subject matter set forth in the following numbered clauses:
Clause 1. A hinge assembly
rotatable between an open first position and a closed
second position comprising:
(a) a first hinge portion and a second hinge portion, each such hinge portion
comprising:
(i) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(iii) a locking pin barrel extending from the obverse face and positioned to a
first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel; and
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(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
with each other, the free interlock leaves positioned to a second side of the
base plate vertical
centerline at a position so that, when the hinge assembly is in the second
position, the free
interlock leaves of each of the first and second hinge portions interleave
with the locking pin
leaves of the other of the first and second hinge portions;
(b) the hinge leaves of the first hinge portion interleaved with the hinge
leaves of the
second hinge portion, with a hinge pin positioned in the hinge leaf apertures
of the
interleaved hinge leaves of the first and second hinge portions to pivotally
join the first hinge
portion and the second hinge portion and permit the second hinge portion to
rotate relative to
the first hinge portion from the first position to the second position; and
(c) a first locking pin adapted to be inserted into the bore defined in the
locking pin
barrel of the first hinge portion and received in (i) the locking pin
apertures of the first hinge
portion and (ii) the interlock apertures of the second hinge portion, when the
hinge assembly
is in the second position.
Clause 2. The hinge assembly of clause 1, further comprising a second locking
pin
adapted to be inserted into the bore defined in the locking pin barrel of the
second hinge
portion and received in (i) the locking pin apertures of the second hinge
portion and (ii) the
interlock apertures of the first hinge portion, when the hinge assembly is in
the second
position.
Clause 3. The hinge assembly of either clause 1 or 2, wherein the hinge
section
vertical centerline of each of the first and second hinge portions is
positioned so that the base
plate vertical centerline of the first and second hinge portions are in an
overlying relationship
when the hinge assembly is in the second position.
Clause 4. The hinge assembly of any one of clause 1, 2 or 3, wherein each of
the
plurality of spaced-apart hinge leaves of each of the first and second hinge
portions has a
thickness the same as the other of the plurality of spaced-apart hinge leaves,
and the hinge
leaves are spaced-apart a distance equal to the thickness.
Clause 5. The hinge assembly of clause 4, wherein the hinge section vertical
centerline of each of the first and second hinge portions is positioned so
that the base plate
vertical centerline of the first and second hinge portions is offset from the
hinge section
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vertical centerline an offset distance equal to one-half the thickness of any
of the plurality of
spaced-apart hinge leaves.
Clause 6. The hinge assembly of any one of clause 1, 2, 3, 4 or 5 wherein at
least a
portion of the first locking pin is tapered.
Clause 7. The hinge assembly of any one of clause 1, 2, 3, 4, 5 or 6, wherein
the first
locking pin is cylindrical in cross-section.
Clause 8. The hinge assembly of any one of clause 1, 2, 3, 4, 5, 6 or 7,
wherein a
portion of the first locking pin, adapted to be received in (i) the locking
pin apertures of the
first hinge portion and (ii) the interlock apertures of the second hinge
portion, when the hinge
assembly is in the second position, is tapered.
Clause 9. The hinge assembly of any one of clauses 1-8, wherein the locking
pin
apertures of each of the first and second hinge portions are smaller with
increasing distance
from the hinge aperture centerline.
Clause 10. The hinge assembly of any one of clauses 1-9, wherein the interlock
apertures of each of the first and second hinge portions are smaller with
increasing distance
from the hinge aperture centerline.
Clause 11. The hinge assembly of any one of clauses 1-10, wherein each locking
pin
leaf of each of the first and second hinge portions has an upper face and a
lower face which
are curved about the hinge aperture centerline.
Clause 12. The hinge assembly of any one of clauses 1-11, wherein each free
interlock leaf of each of the first and second hinge portions has an upper
face and a lower
face which are curved about the hinge aperture centerline.
Clause 13. The hinge assembly of any one of clauses 1-12, wherein of each of
the
first and second hinge portions further comprises a stop projection extending
from a free
interlock leaf at a point distal from its base.
Clause 14. The hinge assembly of any one of clauses 1-13, wherein the reverse
face
of the first hinge portion is adapted to be secured to an end of a first beam
by one or more
positioning tabs extending away from the reverse face of the first hinge
portion, which one or
more positioning tabs are positioned to conform to the profile of the end of
the first beam,
and wherein the reverse face of the second hinge portion is adapted to be
secured to an end of
a second beam by one or more positioning tabs extending away from the reverse
face of the
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second hinge portion, which one or more positioning tabs are positioned to
conform to the
profile of the end of the second beam.
Clause 15. The hinge assembly of clause 14, wherein the one or more
positioning
tabs of the first hinge portion comprise plural positioning tabs forming a
guide frame having
an '1" shape in profile, and the one or more positioning tabs of the second
hinge portion
comprise plural positioning tabs forming a guide frame having an "I" shape in
profile.
Clause 16. The hinge assembly of clause 15, wherein at least one of the plural
positioning tabs of the first hinge assembly is provided with a serpentine cut-
out, and at least
one of the plural positioning tabs of the second hinge assembly is provided
with a serpentine
cut-out.
Clause 17. The hinge assembly of any one of clauses 1-16, wherein the hinge
leaves
extend from the obverse face so that the hinge aperture centerline is
positioned above the
upper edge.
Clause 18. The hinge assembly of any one of clauses 1-16, wherein the hinge
leaves
extend from the obverse face proximate the upper edge and a sufficient
distance from the
lower edge so that the hinge assembly can rotate through one hundred eighty
degrees from
the first position to the second position.
Clause 19. A folding beam assembly rotatable from a folded position to an
unfolded
position comprising:
(a) a first beam having a first end;
(b) a second beam having a second end and an opposed third end;
(c) a first hinge portion secured to the first end and a second hinge portion
secured to
the second end, each such hinge portion comprising:
(i) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
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(i i i) a locking pin barrel extending from the obverse face and positioned to
a first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel; and
(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
with each other, the free interlock leaves positioned to a second side of the
base plate vertical
centerline at a position so that, when the second beam is in an unfolded
position relative to
the first beam, the free interlock leaves of each of the first and second
hinge portions
interleave with the locking pin leaves of the other of the first and second
hinge portions;
(d) the hinge leaves of the first hinge portion interleaved with the hinge
leaves of the
second hinge portion, with a hinge pin positioned in the hinge leaf apertures
of the
interleaved hinge leaves of the first and second hinge portions to pivotally
join the first hinge
portion and the second hinge portion and permit the second beam to rotate
relative to the first
beam from the folded position to the unfolded position; and
(e) a first locking pin adapted to be inserted into the bore defined in the
locking pin
barrel of the first hinge portion and received in (i) the locking pin
apertures of the first hinge
portion and (ii) the interlock apertures of the second hinge portion, when the
second beam is
in the unfolded position relative to the first beam.
Clause 20. The folding beam assembly of clause 19, further comprising a second
locking pin adapted to be inserted into the bore defined in the locking pin
barrel of the second
hinge portion and received in (i) the locking pin apertures of the second
hinge portion and (ii)
the interlock apertures of the first hinge portion, when the second beam is in
the unfolded
position relative to the first beam.
Clause 21. The folding beam assembly of either clause 19 or 20, wherein the
hinge
section vertical centerline of each of the first and second hinge portions is
positioned so that
the base plate vertical centerline of the first and second hinge portions are
in an overlying
relationship when the hinge assembly is in the unfolded position.
Clause 22. The folding beam assembly of any one of clause 19, 20 or 21,
wherein
each of the plurality of spaced-apart hinge leaves of each of the first and
second hinge
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portions has a thickness the same as the other of the plurality of spaced-
apart hinge leaves,
and the hinge leaves are spaced-apart a distance equal to the thickness.
Clause 23. The folding beam assembly of clause 22, wherein the hinge section
vertical centerline of each of the first and second hinge portions is
positioned so that the base
plate vertical centerline of the first and second hinge portions is offset
from the hinge section
vertical centerline an offset distance equal to one-half the thickness of any
of the plurality of
spaced-apart hinge leaves.
Clause 24. The folding beam assembly of any one of clause 19, 20, 21, 22 or
23,
wherein each locking pin leaf of each of the first and second hinge portions
has an upper face
and a lower face which are curved about the hinge aperture centerline.
Clause 25. The folding beam assembly of any one of clause 19, 20, 21, 22, 23
or 24,
wherein each free interlock leaf of each of the first and second hinge
portions has an upper
face and a lower face which are curved about the hinge aperture centerline.
Clause 26. The folding beam assembly of any one of clauses 19-25, wherein the
first
end of the first beam is received in one or more positioning tabs extending
away from the
reverse face of the first hinge portion, which one or more positioning tabs
are positioned to
conform to a profile of the first end of the first beam, and wherein the
second end of the
second beam is received in one or more positioning tabs extending away from
the reverse
face of the second hinge portion, which one or more positioning tabs are
positioned to
conform to a profile of the second end of the second beam.
Clause 27. The folding beam assembly of clause 26, wherein the one or more
positioning tabs of the first hinge portion comprise plural positioning tabs
forming a guide
frame having an "I" shape in profile, and the one or more positioning tabs of
the second hinge
portion comprise plural positioning tabs forming a guide frame having an "I"
shape in profile.
Clause 28. The folding beam assembly of clause 27, wherein at least one of the
plural
positioning tabs of the first hinge assembly is provided with a serpentine cut-
out, and at least
one of the plural positioning tabs of the second hinge assembly is provided
with a serpentine
cut-out.
Clause 29. The folding beam assembly of clause 28, wherein the first hinge
portion is
secured to the first beam by a weld line along at least part of the serpentine
cut-out thereof,
and the second beam assembly portion is secured to the second beam by a weld
line along at
least part of the serpentine cut-out thereof.
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Clause 30. The folding beam assembly of any one of clauses 19-29, wherein the
first
beam and the second beam are co-linear when the folding beam assembly is in
the unfolded
position.
Clause 31. The folding beam assembly of any one of clauses 19-29, wherein the
first
beam and the second beam are not co-linear when the folding beam assembly is
in the
unfolded position.
Clause 32. The folding beam assembly of clause 31, wherein the obverse face of
each
of the first and second hinge portions is canted a positive angle about the
hinge aperture
centerline relative to the reverse face thereof.
Clause 33. The folding beam assembly of clause 31, wherein the obverse face of
each
of the first and second hinge portion is not coplanar with the respective
reverse face thereof.
Clause 34. The folding beam assembly of any one of clauses 19-33, further
comprising:
(f) a third beam having a fourth end;
(g) a third hinge portion secured to the third end and a fourth hinge portion
secured to
the fourth end, each such hinge portion comprising:
(i) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(iii) a locking pin barrel extending from the obverse face and positioned to a
first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel; and
(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
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with each other, the free interlock leaves positioned to a second side of the
base plate vertical
centerline at a position so that, when the third beam is in an unfolded
position relative to the
second beam, the free interlock leaves of each of the third and fourth hinge
portions
interleave with the locking pin leaves of the other of the third and fourth
hinge portions;
(h) the hinge leaves of the third hinge portion interleaved with the hinge
leaves of the
fourth hinge portion, with a hinge pin positioned in the hinge leaf apertures
of the interleaved
hinge leaves of the third and fourth hinge portions to pivotally join the
third hinge portion and
the fourth hinge portion and permit the third beam to rotate relative to the
second beam; and
(i) a third locking pin adapted to be inserted into the bore defined in the
locking pin
barrel of the third hinge portion and received in (i) the locking pin
apertures of the third hinge
portion and (ii) the interlock apertures of the fourth hinge portion, when the
third beam is in
the unfolded position relative to the second beam.
Clause 35. The folding beam assembly of clause 34, further comprising a fourth
locking pin adapted to be inserted into the bore defined in the locking pin
barrel of the fourth
hinge portion and received in (i) the locking pin apertures of the fourth
hinge portion and (ii)
the interlock apertures of the third hinge portion, when the third beam is in
the unfolded
position relative to the second beam.
Clause 36. The folding beam assembly of either of clause 34 or 35, wherein the
second beam and the third beam are co-linear when the folding beam assembly is
in the
unfolded position.
Clause 37. The folding beam assembly of either of clause 34 or 35, wherein the
second beam and the third beam are not co-linear when the folding beam
assembly is in the
unfolded position.
Clause 38. The folding beam assembly of any one of clause 34, 35 or 37,
wherein the
obverse face of each of the third and fourth hinge portions is not coplanar
with the respective
reverse face thereof.
Clause 39. The folding beam assembly of any one of clauses 34-38, wherein the
hinge aperture centerline of each of the first, second, third and fourth hinge
portions is closer
to the upper edge of the base plate thereof than to the lower edge thereof.
Clause 40. The folding beam assembly of clause 39, wherein the first and
second
hinge portions are secured to the first and second ends in a first
orientation, and the third and
fourth hinge portions are secured to the third and fourth ends in a second
orientation, where
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the first orientation is opposite to the second orientation so that the beam
assembly folds in an
accordion pattern.
Clause 4L The folding beam assembly of any one of clauses 34-40, wherein the
hinge aperture centerlines of the first and second hinge portions are
positioned a hinge pivot
distance from the lower edges of the first and second hinge portions
sufficient so that the
second component portion can rotate relative to the first component portion at
least one
hundred eighty degrees from a folded position to an unfolded position.
Clause 42. The folding beam assembly of clause 41, wherein the hinge aperture
centerlines of the third and fourth hinge portions are positioned a hinge
pivot distance from
the lower edges of the third and fourth hinge portions sufficient so that the
third component
portion can rotate relative to the second component portion at least one
hundred eighty
degrees from a folded position to an unfolded position.
Clause 43. The folding beam assembly of clause 40, wherein the obverse face of
each
of the first and second hinge portions is canted a positive angle about the
hinge aperture
centerline relative to the reverse face thereof.
Clause 44. The folding beam assembly of clause 43, wherein the obverse face of
each
of the third and fourth hinge portions is canted a negative angle about the
hinge aperture
centerline relative to the reverse face thereof.
Clause 45. A foldable enclosure component having a folded position and an
unfolded
position comprising:
(a) a planar first component portion having a planar laminate construction and
a first
edge, and a first beam reinforcing the planar laminate construction with a
first end positioned
proximate to the first edge;
(b) a planar second component portion having a planar laminate construction
and an
elongate second edge, and a second beam reinforcing the planar laminate
construction with a
second end positioned proximate to the second edge, with the first edge of the
first
component portion positioned proximate to the second edge of the second
component
portion;
(c) the planar laminate construction of each of the first and second component
portions comprising: (i) a planar foam panel layer having a first face and an
opposed second
face, (ii) a planar first metal layer bonded to the first face of the planar
foam panel layer, and
(iii) a planar second metal layer bonded to the second face of the planar foam
panel layer; and
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(d) a first hinge assembly comprising a first hinge portion and a second hinge
portion,
the first hinge portion secured to the first end of the first beam and the
second hinge portion
secured to the second end of the second beam, the first hinge portion
pivotally joined to the
second hinge portion to permit the second component portion to rotate relative
to the first
component portion from a folded position to an unfolded position.
Clause 46. The foldable enclosure component of clause 45, wherein each of the
first
hinge portion and the second hinge portion comprises:
(I) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(iii) a locking pin barrel extending from the obverse face and positioned to a
first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel; and
(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
with each other, the free interlock leaves positioned to a second side of the
base plate vertical
centerline at a position so that, when the second component portion is in the
unfolded
position relative to the first component portion, the free interlock leaves of
each of the first
and second hinge portions interleave with the locking pin leaves of the other
of the first and
second hinge portions, wherein:
(e) the hinge leaves of the first hinge portion interleave with the hinge
leaves of the
second hinge portion, with a hinge pin positioned in the hinge leaf apertures
of the
interleaved hinge leaves of the first and second hinge portions to pivotally
join the first hinge
portion and the second hinge portion and permit the second component portion
to rotate
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relative to the first component portion; and the foldable enclosure component
additionally
comprises:
(f) a first locking pin adapted to be inserted into the bore defined in the
locking pin
barrel of the first hinge portion and received in (i) the locking pin
apertures of the first hinge
portion and (ii) the interlock apertures of the second hinge portion, when the
second
component portion is in the unfolded position relative to the first component
portion.
Clause 47. The foldable enclosure component of clause 46, further comprising a
second locking pin adapted to be inserted into the bore defined in the locking
pin barrel of the
second hinge portion and received in (i) the locking pin apertures of the
second hinge portion
and (ii) the interlock apertures of the first hinge portion, when the second
component portion
is in the unfolded position relative to the first component portion.
Clause 48. The foldable enclosure component of either of clause 46 or 47,
wherein
each of the plurality of spaced-apart hinge leaves of each of the first and
second hinge
portions has a thickness the same as the other of the plurality of spaced-
apart hinge leaves,
and the hinge leaves are spaced-apart a distance equal to the thickness.
Clause 49. The foldable enclosure component of clause 48, wherein the hinge
section
vertical centerline of each of the first and second hinge portions is
positioned so that the base
plate vertical centerline of the first and second hinge portions is offset
from the hinge section
vertical centerline an offset distance equal to one-half the thickness of any
of the plurality of
spaced-apart hinge leaves.
Clause 50. The foldable enclosure component of any one of clause 46, 47, 48 or
49,
wherein each locking pin leaf of each of the first and second hinge portions
has an upper face
and a lower face which are curved about the hinge aperture centerline.
Clause 51. The foldable enclosure component of any one of clause 46, 47, 48,
49 or
50, wherein each free interlock leaf of each of the first and second hinge
portions has an
upper face and a lower face which are curved about the hinge aperture
centerline.
Clause 52. The foldable enclosure component of any one of clauses 46-51,
wherein
the first end of the first beam is received in one or more positioning tabs
extending away
from the reverse face of the first hinge portion, which one or more
positioning tabs are
positioned to conform to a profile of the first end of the first beam, and
wherein the second
end of the second beam is received in one or more positioning tabs extending
away from the
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reverse face of the second hinge portion, which one or more positioning tabs
are positioned to
conform to a profile of the second end of the second beam.
Clause 53. The foldable enclosure component of clause 52, wherein each of the
first
and second beams has an "I" shape in profile, and the one or more positioning
tabs of the first
hinge portion comprise plural positioning tabs forming a guide frame having an
"I" shape in
profile, and the one or more positioning tabs of the second hinge portion
comprise plural
positioning tabs forming a guide frame having an "I" shape in profile.
Clause 54. The foldable enclosure component of clause 53, wherein at least one
of
the plural positioning tabs of the first hinge portions is provided with a
serpentine cut-out,
and at least one of the plural positioning tabs of the second hinge portions
is provided with a
serpentine cut-out.
Clause 55. The foldable enclosure component of clause 54, wherein the first
hinge
portion is secured to the first beam by a weld line along at least part of the
serpentine cut-out
thereof, and the second beam assembly portion is secured to the second beam by
a weld line
along at least part of the serpentine cut-out thereof.
Clause 56. The foldable enclosure component of any one of clauses 45-55,
wherein
the first beam and the second beam are co-linear when the folding beam
assembly is in the
unfolded position.
Clause 57. The foldable enclosure component of any one of clauses 45-55,
wherein
the first beam and the second beam are not co-linear when the folding beam
assembly is in
the unfolded position.
Clause 58. The foldable enclosure component of clause 46, wherein the obverse
face
of each of the first and second hinge portions is canted a positive angle
about the hinge
aperture centerline relative to the reverse face thereof.
Clause 59. The foldable enclosure component of clause 46, wherein the obverse
face
of each of the first and second hinge portion is not coplanar with the
respective reverse face
thereof.
Clause 60. The foldable enclosure component of any one of clauses 45-59,
wherein
the first hinge assembly is adapted to permit the foldable enclosure component
to rotate the
second component portion relative to the first component portion from a folded
position to an
unfolded position at least ninety degrees from the folded position.
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Clause 61. The foldable enclosure component of any one of clauses 45-60,
wherein
the first hinge assembly is adapted to permit the foldable enclosure component
to rotate the
second component portion relative to the first component portion from a folded
position to an
unfolded position at least one hundred eighty degrees from the folded
position.
Clause 62. The foldable enclosure component of any one of clauses 45-61,
further
comprising:
(g) a second hinge assembly having a third hinge portion and a fourth hinge
portion,
wherein the third and fourth hinge portions each comprises:
(i) a base plate with an obverse face, a reverse face, a first vertical edge,
an opposed
second vertical edge and a base plate vertical centerline; and
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(h) a hinge pin positioned in the hinge leave apertures of the third hinge
portion and
the fourth hinge portion to pivotally join the third hinge portion and the
fourth hinge portion;
and
(i) the third hinge portion secured to the first component portion adjacent
the first
edge thereof at a location distal from the first hinge assembly, and the
fourth hinge portion
secured to the second component portion adjacent the second edge thereof at a
location distal
from the first hinge assembly.
Clause 63. The foldable enclosure component of clause 62, further comprising a
planar first shield having a thickness and extending from the obverse face of
the third hinge
portion adjacent the first vertical edge thereof, and a planar second shield
having a thickness
and extending from the obverse face of the fourth hinge portion adjacent the
first vertical
edge thereof.
Clause 64. The foldable enclosure component of clause 63, further comprising a
planar third shield extending from the obverse face of the third hinge portion
proximate to the
second vertical edge thereof inset an inset distance at equal to or greater
than the thickness of
the second shield, and a planar fourth shield extending from the obverse face
of the fourth
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hinge portion proximate to the second vertical edge thereof inset an inset
distance equal to or
greater than the thickness of the first shield.
Clause 65. The foldable enclosure component of clause 53, wherein the first
beam
comprises a pair of elongate opposed flanges, and the foldable enclosure
component further
comprises a pair of elongate insulating members, each of the pair of
insulating members
defining a channel in which is positioned a respective one of the pair of
opposed flanges.
Clause 66. The foldable enclosure component of clause 65, wherein each of the
pair
of elongate insulating members is polyvinyl chloride.
Clause 67. A foldable enclosure component having a folded position and an
unfolded
position comprising:
(a) a planar first component portion having a planar laminate construction and
a first
edge;
(b) a planar second component portion having a planar laminate construction, a
second edge and an opposed third edge, with the first edge of the first
component portion
positioned proximate to the second edge of the second component portion;
(c) the planar laminate construction of each of the first and second component
portions comprising: (i) a planar foam panel layer having a first face and an
opposed second
face, (ii) a planar first metal layer having a first face and an opposed
second face bonded to
the first face of the planar foam panel layer, (iii) a planar second metal
layer having a first
face bonded to the second face of the planar foam panel layer and an opposed
second face;
and (iv) a protective layer having an inorganic composition, a first face
bonded to the second
face of the second metal layer, and an opposed second face;
(d) a first hinge assembly comprising a first hinge portion and a second hinge
portion
joining the planar first component portion and the planar second component
portion along
their respective first and second edges, the first hinge assembly adapted to
permit the second
component portion to rotate relative to the first component portion from a
folded position to
an unfolded position, with the protective layers of the first and second
component portions
positioned adjacent to each other when the second component portion is in the
unfolded
position.
Clause 68. The foldable enclosure component of clause 67, wherein the first
component portion includes a first beam reinforcing the laminate construction
of the first
component portion, with a first end proximate to the first edge, and a second
beam
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reinforcing the laminate construction of the second component portion, with a
second end
proximate to the second edge and an opposed third end proximate to the third
edge.
Clause 69. The foldable enclosure component of clause 68, wherein the first
hinge
portion and the second hinge portion each comprises:
(i) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(iii) a locking pin barrel extending from the obverse face and positioned to a
first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel;
(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
with each other, the free interlock leaves positioned to a second side of the
base plate vertical
centerline at a position so that, when the second component portion is in the
unfolded
position relative to the first component portion, the free interlock leaves of
each of the first
and second hinge portions interleave with the locking pin leaves of the other
of the first and
second hinge portions; wherein
(e) the hinge leaves of the first hinge portion interleave with the hinge
leaves of the
second hinge portion, with a hinge pin positioned in the hinge leaf apertures
of the
interleaved hinge leaves of the first and second hinge portions to pivotally
join the first hinge
portion and the second hinge portion and permit the second component portion
to rotate
relative to the first component portion; and the foldable enclosure component
further
comprises:
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(f) a first locking pin adapted to he inserted into the bore defined in the
locking pin
barrel of the first hinge portion and received in (i) the locking pin
apertures of the first hinge
portion and (ii) the interlock apertures of the second hinge portion, when the
second
component portion is in the unfolded position relative to the first component
portion.
Clause 70. The foldable enclosure component of clause 69, further comprising a
second locking pin adapted to be inserted into the bore defined in the locking
pin barrel of the
second hinge portion and received in (i) the locking pin apertures of the
second hinge portion
and (ii) the interlock apertures of the first hinge portion, when the second
component portion
is in the unfolded position relative to the first component portion.
Clause 71. The foldable enclosure component of either of clause 69 or 70,
wherein
each of the plurality of spaced-apart hinge leaves of each of the first and
second hinge
portions has a thickness the same as the other of the plurality of spaced-
apart hinge leaves,
and the hinge leaves are spaced-apart a distance equal to the thickness.
Clause 72. The foldable enclosure component of clause 71, wherein the hinge
section
vertical centerline of each of the first and second hinge portions is
positioned so that the base
plate vertical centerline of the first and second hinge portions is offset
from the hinge section
vertical centerline an offset distance equal to one-half the thickness of any
of the plurality of
spaced-apart hinge leaves.
Clause 73. The foldable enclosure component of any one of clause 69, 70, 71 or
72,
wherein each locking pin leaf of each of the first and second hinge portions
has an upper face
and a lower face which are curved about the hinge aperture centerline.
Clause 74. The foldable enclosure component of any of clause 69, 70, 71, 72 or
73,
wherein each free interlock leaf of each of the first and second hinge
portions has an upper
face and a lower face which are curved about the hinge aperture centerline.
Clause 75. The foldable enclosure component of any one of clause 69, 70, 71,
72, 73
or 74, wherein the first end of the first beam is received in one or more
positioning tabs
extending away from the reverse face of the first hinge portion, which one or
more
positioning tabs are positioned to conform to a profile of the first end of
the first beam, and
wherein the second end of the second beam is received in one or more
positioning tabs
extending away from the reverse face of the second hinge portion, which one or
more
positioning tabs are positioned to conform to a profile of the second end of
the second beam.
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Clause 76. The foldable enclosure component of clause 70, wherein the first
and
second beams each has an "I" shape in profile, the one or more positioning
tabs of the first
hinge portion comprise plural positioning tabs forming a guide frame having an
"I" shape in
profile, and the one or more positioning tabs of the second hinge portion
comprise plural
positioning tabs forming a guide frame having an "I" shape in profile.
Clause 77. The foldable enclosure component of any one of clauses 67-76,
wherein
the protective layer of the second component portion rotates away from the
protective layer
of the first component portion when rotating the second component portion
relative to the
first component portion from a folded position to an unfolded position.
Clause 78. The foldable enclosure component of any one of clause 67-76,
wherein
the protective layer of the second component portion rotates toward the
protective layer of the
first component portion when rotating the second component portion relative to
the first
component portion from a folded position to an unfolded position.
Clause 79. The foldable enclosure component of any one of clauses 67-76,
further
comprising:
(e) a planar third component portion having a planar laminate construction and
a
fourth edge positioned proximate to the third edge of the second component
portion, the
planar laminate construction of the third component portion comprising (i) a
planar foam
panel layer having a first face and an opposed second face, (ii) a planar
first metal layer
bonded to the first face of the planar foam panel layer, and (iii) a planar
second metal layer
having a first face bonded to the second face of the planar foam panel layer
and an opposed
second face; and (iv) a protective layer having an inorganic composition, a
first face bonded
to the second face of the second metal layer and an opposed second face, with
the protective
layers of the second and third component portions positioned adjacent each
other when the
second and third component portions are in their unfolded positions; and
(f) a second hinge assembly joining the planar second component portion and
the
planar third component portion along their respective third edge and fourth
edge and adapted
to permit the third component portion to rotate relative to the second
component portion from
a folded position to an unfolded position.
Clause 80. The foldable enclosure component of clause 79, wherein the
protective
layer of the first component portion rotates toward the protective layer of
the first component
portion when rotating the second component portion relative to the first
component portion
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from a folded position to an unfolded position, and the protective layer of
the third
component portion rotates away from the protective layer of the second
component portion
when rotating the third component portion relative to the second component
portion from a
folded position to an unfolded position.
Clause 81. The foldable enclosure component of either of clause 79 or 80,
wherein
the third component portion includes a third beam reinforcing the laminate
construction of
the third component portion, with a fourth end proximate to the fourth edge,
and a second
hinge assembly joining the planar second component portion and the planar
third component
portion along their respective third edge and fourth edge adapted to permit
the third
component portion to be rotated relative to the second component portion from
a folded
position to an unfolded position.
Clause 82. The foldable enclosure component of clause 81, wherein the second
hinge
assembly comprises a third hinge portion secured to the third end of the
second beam and a
fourth hinge portion secured to the fourth end of the third beam, and each of
the third hinge
portion and the fourth hinge portion comprises:
(i) a base plate with an obverse face, a reverse face, an upper edge, an
opposed lower
edge and a base plate vertical centerline;
(ii) a hinge section with a hinge section vertical centerline, the hinge
section
extending from the obverse face and comprising a plurality of spaced-apart
hinge leaves
symmetrically positioned about the hinge section vertical centerline, with the
hinge section
vertical centerline being offset from the base plate vertical centerline, each
of the plurality of
hinge leaves defining a hinge leaf aperture, and with the hinge leaf apertures
positioned in
horizontal alignment with each other along a hinge aperture centerline;
(iii) a locking pin barrel extending from the obverse face and positioned to a
first side
of the base plate vertical centerline, the locking pin barrel defining a bore;
(iv) a plurality of locking pin leaves extending from the obverse face and
positioned
to the first side of the base plate vertical centerline, each locking pin leaf
defining a locking
pin aperture, the locking pin apertures positioned in vertical alignment with
each other, and
with the bore of the locking pin barrel; and
(v) a plurality of free interlock leaves extending from the obverse face, each
free
interlock leaf defining an interlock aperture, with the interlock apertures in
vertical alignment
with each other, the free interlock leaves positioned to a second side of the
base plate vertical
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centerline at a position so that, when the third component portion is in the
unfolded position
relative to the second component portion, the free interlock leaves of each of
the first and
second hinge portions interleave with the locking pin leaves of the other of
the first and
second hinge portions; wherein:
(g) the hinge leaves of the third hinge portion interleave with the hinge
leaves of the
fourth hinge portion, with a hinge pin positioned in the hinge leave apertures
of the
interleaved hinge leaves of the third and fourth hinge portions to pivotally
join the third hinge
portion and the fourth hinge portion and permit the third component portion to
rotate relative
to the second component portion; and the foldable enclosure component further
comprises:
(h) a third locking pin adapted to be inserted into the bore defined in the
locking pin
barrel of the third hinge portion and received in (i) the locking pin
apertures of the third hinge
portion and (ii) the interlock apertures of the second hinge portion, when the
third component
portion is in the unfolded position relative to the second component portion.
Clause 83. The foldable enclosure component of clause 82, further comprising a
fourth locking pin adapted to be inserted into the bore defined in the locking
pin barrel of the
fourth hinge portion and received in (i) the locking pin apertures of the
fourth hinge portion
and (ii) the interlock apertures of the third hinge portion, when the third
component portion is
in the unfolded position relative to the second component portion.
Clause 84. The foldable enclosure component of either of clause 82 or 83,
wherein
each of the plurality of spaced-apart hinge leaves of each of the third and
fourth hinge
portions has a thickness the same as the other of the plurality of spaced-
apart hinge leaves,
and the hinge leaves are spaced-apart a distance equal to the thickness.
Clause 85. The foldable enclosure component of clause 84, wherein the hinge
section
vertical centerline of each of the third and fourth hinge portions is
positioned so that the base
plate vertical centerline of the third and fourth hinge portions is offset
from the hinge section
vertical centerline an offset distance equal to one-half the thickness of any
of the plurality of
spaced-apart hinge leaves.
Clause 86. The foldable enclosure component of any one of clause 82, 83, 84 or
85,
wherein each locking pin leaf of each of the third and fourth hinge portions
has an upper face
and a lower face which are curved about the hinge aperture centerline.
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Clause 87. The foldable enclosure component of any one of clause 82, 83, 84,
85 or
86, wherein each free interlock leaf of each of the third and fourth hinge
portions has an
upper face and a lower face which are curved about the hinge aperture
centerline.
Clause 88. The foldable enclosure component of any one of clause 82, 83, 84,
85 or
86, wherein the third end of the second beam is received in one or more
positioning tabs
extending away from the reverse face of the third hinge portion, which one or
more
positioning tabs are positioned to conform to a profile of the third end of
the second beam,
and wherein the fourth end of the third beam is received in one or more
positioning tabs
extending away from the reverse face of the fourth hinge portion, which one or
more
positioning tabs are positioned to conform to a profile of the fourth end of
the third beam.
Clause 89. The foldable enclosure component of clause 88, wherein the third
beam
has an "1" shape in profile and the one or more positioning tabs of the third
hinge portion
comprise plural positioning tabs forming a guide frame having an "I- shape in
profile, and the
one or more positioning tabs of the fourth hinge portion comprise plural
positioning tabs
forming a guide frame having an "I" shape in profile.
Clause 90. The foldable enclosure component of any one of clauses 80-89,
wherein
the hinge aperture centerline of each of the first, second, third and fourth
hinge portions is
closer to the upper edge of the base plate thereof than to the lower edge
thereof.
Clause 91. The foldable enclosure component of clause 90, wherein the first
and
second hinge portions are respectively oriented so that the hinge aperture
centerlines of the
first and second hinge portions are closer to the first metal layer of the
first and second
component portions than to the protective layer of the first and second
component portions,
and the hinge aperture centerlines of the third and fourth hinge portions are
closer to the
protective layer of the first and second component portions than to the first
metal layer of the
first and second component portions.
Clause 92. The foldable enclosure component of clause 91, wherein the hinge
aperture centerlines of the first and second hinge portions are positioned a
hinge pivot
distance from the lower edges of the first and second hinge portions
sufficient so that the
second component portion can rotate relative to the first component portion at
least one
hundred eighty degrees from a folded position to an unfolded position.
Clause 93. The foldable enclosure component of clause 92, wherein the hinge
aperture centerlines of the third and fourth hinge portions are positioned a
hinge pivot
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distance from the lower edges of the third and fourth hinge portions
sufficient so that the third
component portion can rotate relative to the second component portion at least
one hundred
eighty degrees from a folded position to an unfolded position.
Clause 94. The foldable enclosure component of clause 90, wherein the hinge
aperture centerlines of the first and second hinge portions extend beyond the
first face of the
first metal layer of each of the first and second component portions.
Clause 95. The foldable enclosure component of any one of clauses 82-94,
wherein
the hinge aperture centerlines of the third and fourth hinge portions extend
beyond the second
face of the protective layer of each of the second and third component
portions.
Clause 96. The foldable enclosure component of any one of clauses 82-95,
wherein
the locking pin leaf of the plurality of locking pin leaves which is proximate
the lower edge
of each of the third and fourth hinge portions is extended toward the second
side thereof to
provide a platform tab.
Clause 97. The foldable enclosure component of any one of clauses 67-96,
wherein
the first hinge assembly is adapted to permit the foldable enclosure component
to rotate the
second component portion relative to the first component portion from a folded
position to an
unfolded position at least ninety degrees from the folded position.
Clause 98. The foldable enclosure component of any one of clauses 67-97,
wherein
the first hinge assembly is adapted to permit the foldable enclosure component
to rotate the
second component portion relative to the first component portion from a folded
position to an
unfolded position at least one hundred eighty degrees from the folded
position.
Clause 99. The foldable enclosure component of clause 76, wherein the first
beam
comprises a pair of elongate opposed flanges proximate to the protective
layer, and the
foldable enclosure component further comprises a pair of elongate insulating
members, each
of the pair of insulating members defining a channel in which is positioned a
respective one
of the pair of opposed flanges.
Clause 100. The foldable enclosure component of clause 99, wherein each of the
pair
of elongate insulating members is polyvinyl chloride.
Clause 101. The foldable enclosure component of clause 67-100, wherein the
inorganic composition of every protective layer comprises magnesium oxide.
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