Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
ENCLOSURE COMPONENT PANEL SECTIONS
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] 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
[0002] 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.
[0003] 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.
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[0004] 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.
[0005] 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
[0006] The present inventions constitute advancements in the manufacturing
efficiency of
transportable structures. These inventions define a basic laminate panel
section that can be
utilized to construct foldable, transportable buildings of varying size, and
thereby simplify
their manufacturing.
[0007] In one aspect, the present inventions are directed to a folded building
structure
comprising a fixed space portion, which in turn comprises a rectangular first
floor portion
and a first wall structure. The first floor portion has a first longitudinal
edge and an
adjacent transverse edge, with the first floor portion comprising a first
plurality of laminate
panel sections, N in number, where N is equal to or greater than 2, and with
each of the first
plurality of laminate panel sections having a rectangular shape with a first
panel edge of
span S, and two opposed orthogonal edges adjacent the first panel edge. The
first plurality
of laminate panel sections are positioned adjacent each other with their
orthogonal edges
side-by-side, to provide N - 1 first pairs of adjacent panel sections with the
first longitudinal
edge having a length equal to N x S. The first wall structure adjoins the
first floor portion
and comprising a first further laminate panel section having a rectangular
shape and a
second panel edge of span S, with the second panel edge vertically positioned
so that the
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first wall structure has a height equal to S. There is also provided a second
floor portion
having a second longitudinal edge positioned against the first longitudinal
edge of the first
floor portion and pivotally connected thereto, to permit the second floor
portion to pivot
about a horizontal axis, relative to the first floor portion, from a second
floor portion folded
position to a second floor portion unfolded position.
[0008] In another aspect, the present inventions are directed to a folded
building
comprising a fixed space portion, which in turn comprises a rectangular first
roof portion
and a first wall structure. The first roof portion has a first longitudinal
edge and an adjacent
transverse edge, with the first roof portion comprising a first plurality of
laminate panel
sections N in number, where N is equal to or greater than 2. Each of the first
plurality of
laminate panel sections has a rectangular shape with a first panel edge of
span S, and two
opposed orthogonal edges adjacent the first panel edge. The first plurality of
laminate panel
sections are positioned side-by-side to provide N ¨ 1 first pairs of adjacent
panel sections
with the first longitudinal edge having a length equal to N x S. The first
wall structure
adjoins the first roof portion and comprises a first further laminate panel
section having a
rectangular shape and a second panel edge of span S, with the second panel
edge vertically
positioned so that the first wall structure has a height equal to S. There is
also provided a
second roof portion having a second longitudinal edge positioned against the
first
longitudinal edge, with the second roof portion pivotally connected to the
first roof portion
to permit the second roof portion to pivot, about a first horizontal axis
relative to the first
roof portion, from a second roof portion folded position to a second roof
portion unfolded
position.
[0009] In yet another aspect, the present inventions are directed to a folded
building
comprising a fixed space portion, which in turn comprises a rectangular first
floor portion, a
rectangular first roof portion and a first wall structure. The first floor
portion has a first
longitudinal edge and an adjacent transverse edge, with the first floor
portion comprising a
first plurality of laminate panel sections N in number, where N is equal to or
greater than 2.
Each of the first plurality of laminate panel sections has a rectangular shape
with a first
panel edge of span S, and two opposed orthogonal edges adjacent the first
panel span edge.
The first plurality of laminate panel sections are positioned adjacent each
other with their
orthogonal edges side-by-side, to provide N ¨ 1 first pairs of adjacent panel
sections with
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the first longitudinal edge having a length equal to N x S. The first roof
portion has a
second longitudinal edge and an adjacent transverse edge, with the first roof
portion
comprising a second plurality of laminate panel sections N in number. Each of
the second
plurality of laminate panel sections has a rectangular shape with a second
panel edge of
span S, and two opposed orthogonal edges adjacent the second panel edge. The
second
plurality of laminate panel sections are positioned adjacent each other with
their orthogonal
edges side-by-side, to provide N ¨ 1 second pairs of adjacent panel sections
with the second
longitudinal edge having a length equal to N x S. The first wall structure has
a top edge
adjoining the first roof portion and an opposed bottom edge adjoining the
first floor portion.
There is also provided a second roof portion having a third longitudinal edge
positioned
against the second longitudinal edge, with the second roof portion pivotally
connected to the
first roof portion to permit the second roof portion to pivot, about a first
horizontal axis
relative to the first roof portion, from a second roof portion folded position
to a second roof
portion 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.
[0015] Figure 6 is a schematic perspective view depicting the exterior edge
reinforcement
for a wall component in accordance with the present inventions.
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[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 8A is a perspective view of a foldable I-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 I-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 I-beam for a roof
component in
accordance with the present inventions, in the beam unfolded position, and
Figure 15B is a
side view of a foldable 1-beam for a roof component in accordance with the
present
inventions, in the beam folded position.
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[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 25T)
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.
[0036] Figure 27A is a perspective view of a rectangular roof component
containing two
foldable I-beam assemblies in accordance with the present inventions, and
Figure 27B is a
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perspective view of a rectangular roof component containing N ¨ 1 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 (the direction aligning with the height "H" 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.
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B. Enclosure Component Exterior Edge Reinforcement
[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 be joined by hinge structures 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 he 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 an end of I-beam 326a to an end of the corresponding 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 I-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,1-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 an end of I-beam 426a to an end of the corresponding
I-beam
426b, and a hinge assembly 429C joins the other end of I-beam 426h to an end
of the
corresponding 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
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section 432, a pin interlock section 434, a free interlock section 438 and a
locking pin barrel
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
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vertically oriented and co-linear with the centerline of lock pin holes 447 of
pin interlock
leaves 436.
[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 42911 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
42911 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 43011. 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 43011 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
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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.
[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
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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
lower faces of pin 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,
I-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 1-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 I-beams 426a and 426b, causes those I-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 1-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
(+0.5 ), 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
"r shape in
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profile, for receiving an end of one of 1-beams 426a and 426h. It is preferred
that the I-
beams 426a, 426b be secured to the reverse faces 419 by welding their flanges
to hinge
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
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of each of its two hinge assembly portions 430B is adapted to he secured to a
respective end
of the two I-beams 426a and 426b adjacent to each other, and referring to
hinge assembly
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 1-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 400b
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 I-beams 426a and 426b, while
I-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 4261, 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
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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
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 42611 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
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same thickness and are spaced apart a distance equal to the thickness of a
hinge leaf 453, so
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
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portions 450B to the reinforcing board 437 adjacent second interior edge 412b.
As to the
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
1-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, 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 250 (described further below) 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 250 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 250 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 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 250 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. Each panel section 250 has a rectangular shape and a
panel span of
length "S". 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, the panel span S between I-beam assembly 325 and either of
the first and
second transverse floor edges 120. 118 can be 9.5 feet (see Figure 13B, in
which span S can
be seen between I-beam assembly 325 and first transverse floor edge 120; see
also Figure
2). Likewise, the panel span S between I-beam assembly 425 either of the first
and second
transverse roof edges 408, 410 can be 9.5 feet (see Figure 24B; see also
Figure 1). Wall
components 200 can also be manufactured utilizing panel sections 250 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; either with the same thickness as floor
components 300 and/or
roof components 400, or with a different thickness, as follows from utilizing
foam panels
214 having a different thickness from the thickness of the foam panels 214
used to fabricate
floor components 300 and/or roof components 400.
[00142] These same height/span relationships can also be utilized to make
structures 150
with different footprints (i.e., longer in the longitudinal direction than
depicted in Figure 1),
as where two of its opposing wall components 200 are longer than the other two
opposing
wall components 200. For example, Figure 27A depicts a roof component 400
approximately 1.5 times longer in the longitudinal direction than in the
transverse direction.
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In this example, roof portions 400a, 400b and 400c are each assembled from a
series of
three laminate panel sections 250 having the same geometry and dimensions,
denominated
panel sections 250-1, 250-2 and 250-3 respectively in Figure 27A. As indicated
above, each
panel section 250 has a rectangular shape and is defined by a panel edge 251,
an opposed
panel edge 252, an orthogonal edge 253 and an opposed orthogonal edge 254, as
shown for
an exemplary panel section 250-1 in Figure 27A, with orthogonal edges 253, 254
adjacent
panel edges 251, 252 to form the rectangular shape. Panel edges 251 and 252
each has a
panel span of length "S".
[00143] For each roof portion 400a, 400b and 400c shown in Figure 27A, the
three panel
sections 250-1, 250-2 and 250-3 are positioned adjacent each other with their
orthogonal
edges side-by-side, to provide a pair 255 of adjacent orthogonal edges 253,
254 between
panel section 250-1 and 250-2, and a pair 255 of adjacent orthogonal edges
253, 254
between panel section 250-2 and 250-3; thus there are two pairs of adjacent
orthogonal
edges for the three panel sections 250-1, 250-2 and 250-3 of roof portion
400c. Likewise,
there are two pairs of adjacent orthogonal edges 253, 254 for the three panel
sections 250-1,
250-2 and 250-3 of roof portion 400b, and there are two pairs of adjacent
orthogonal edges
253, 254 for the three panel sections 250-1, 250-2 and 250-3 of roof portion
400a (the latter
two pairs being omitted from Figure 27A for simplicity). A first beam assembly
425 is
positioned between the pair 255 of orthogonal edges 253, 254 of the panel
sections 250-1
and 250-2 forming each of roof portions 400a, 400b and 400c, and a second beam
assembly
425 is positioned between the pair 255 of orthogonal edges 253, 254 of the
panel sections
250-2 and 250-3 forming each of roof portions 400a, 400b and 400c. As made
evident by
the disclosure above, the proximate ends of the corresponding beams 426a and
426b of each
of the first and second beam assemblies 425 are joined by a hinge assembly
429B, and the
proximate ends of the corresponding beams 426b and 426c of each of the first
and second
beam assemblies 425 are joined by a hinge assembly 429C.
[00144] Each panel section 250 in Figure 27A can have a panel span S of 9.5
feet in the
longitudinal direction, consistent with bed width 49 shown in Figure 26.
Accordingly, each
of the three roof portions 400a, 400b and 400c are approximately 3S long, or
approximately
29 feet, in the longitudinal direction, and correspondingly the first
longitudinal roof edge
406 and second longitudinal roof edge 416 of roof component 400 each has a
length of
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approximately 29 feet. In comparison, the corresponding dimensions of roof
portions 400a,
400b and 400c in the transverse direction are not limited by bed width 49, and
can be varied
as desired.
[00145] 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 laminate panel
sections.
Thus as shown in Figure 27B, there is provided a roof component 400 with roof
portions
400a, 400b and 400c, in which each roof portion contains N panel sections 250,
denominated 250-1, 250-2, . . . , 250-N. Each of the N panel sections 250 has
a panel span
of length S. As a result, the longitudinal edges of each roof portion 400a,
400b and 400c
have a length equal to N x S, and correspondingly the first longitudinal roof
edge 406 and
second longitudinal roof edge 416 of roof component 400 each has a length of N
x S. As is
evident, there also will be N ¨ 1 pairs 255 of adjacent orthogonal edges in
each of roof
portions 400a, 400b and 400c, with a transversely oriented beam 425 positioned
between
each of the N-1 pairs 255.
[00146] The floor component 300 for the structure 150 utilizing the roof
component 400
shown in Figure 27B can also be fabricated from laminate panel sections 250
having a panel
span of length S, and thus, in the case of a structure 150 having a cuboid
shape, the
longitudinal edges of each floor portion 300a and 300b have a length equal to
N x S, and
correspondingly the first longitudinal floor edge 117 and the second
longitudinal floor edge
119 of floor component 300 each has a length of N x S. Likewise, each wall
structure (in
this disclosure, a "wall structure" includes any wall component 200 and any
wall portion of
a wall component 200) is fabricated from laminate panel sections 250 having a
panel span
of length S, with each panel edge of span S vertically oriented so that each
wall structure
has a height equal to S.
[00147] 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 SE by SE orthogonal grid.
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[00148] Roof portions 400a, 400b and 400c each can he identically dimensioned
in the
transverse direction. Alternatively, referring to Figure 3, roof portion 400c
(which is
stacked upon roof portions 400a and 400b when roof portions 400b, 400c are
fully folded)
can be dimensioned to be larger than either of roof portion 400a and roof
portion 40011 in
the transverse direction for example, by ten to fifteen percent, or by at
least the aggregate
thickness of roof components 400a and 400h. 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.
[00149] 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
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 30011 is just under 5E wide.
[00150] 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
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Figure 3, with roof component 400h 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 30011 and
wall
portions 200s-2 and 200s-4.
[00151] 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.
[00152] 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
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.
[00153] 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_
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Shipping Module Transport
[00154] 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
[00155] 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
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.
[00156] 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
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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 he 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 400h 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 400h.
[00157] A mobile crane can be used to assist in the deployment of certain of
the enclosure
components 155, specifically roof portions 400h and 400c, floor portion 300h.
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
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.
[00158] 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.
[00159] This disclosure should be understood to include (as illustrative and
not limiting)
the subject matter set forth in the following numbered clauses:
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Clause 1. A folded building structure comprising:
(a) a fixed space portion comprising:
(i) a rectangular first floor portion having a first longitudinal edge and an
adjacent transverse
edge, the first floor portion comprising a first plurality of laminate panel
sections, N in
number, where N is equal to or greater than 2, each of the first plurality of
laminate panel
sections having a rectangular shape with a first panel edge of span S, and two
opposed
orthogonal edges adjacent the first panel edge, the first plurality of
laminate panel sections
positioned adjacent each other with their orthogonal edges side-by-side, to
provide N - 1 first
pairs of adjacent panel sections with the first longitudinal edge having a
length equal to N x
S; and
(ii) a first wall structure adjoining the first floor portion and comprising a
first further
laminate panel section having a rectangular shape and a second panel edge of
span S, the
second panel edge vertically positioned so that the first wall structure has a
height equal to S;
and
(b) a second floor portion having a second longitudinal edge positioned
against the first
longitudinal edge of the first floor portion and pivotally connected thereto,
to permit the
second floor portion to pivot about a horizontal axis, relative to the first
floor portion, from a
second floor portion folded position to a second floor portion unfolded
position.
Clause 2. The folded building structure as in clause 1, wherein the second
floor portion
comprises a second plurality of laminate panel sections, N in number, each of
the second
plurality of laminate panel sections having a rectangular shape with a third
panel edge of span
S, and two opposed orthogonal edges adjacent the third panel edge, the second
plurality of
panel sections positioned side-by-side, with their orthogonal edges parallel
to each other, to
provide N - 1 second pairs of adjacent panel sections with the second
longitudinal edge
having a length equal to N x S.
Clause 3. The folded building structure as in either of clause 1 or clause 2,
wherein each of
the first plurality of laminate panel sections 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,
and (iii) a planar
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second metal layer having a first face bonded to the second face of the planar
foam panel
layer and an opposed second face.
Clause 4. The folded building structure as in clause 3, further comprising a
protective layer
having an inorganic composition, the protective layer having a first face
bonded to the second
face of the second metal layer, and an opposed second face.
Clause 5. The folded building structure as in clause 2, wherein each of the
second plurality
of laminate panel sections 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, 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.
Clause 6. The folded building structure as in clause 5, further comprising a
protective layer
having an inorganic composition, the protective layer having a first face
bonded to the second
face of the second metal layer, and an opposed second face.
Clause 7. The folded building structure as in clause 2, further comprising a
transversely
oriented beam positioned between each adjacent pair of the first pairs of
adjacent panel
sections.
Clause 8. The folded building structure as in clause 7, further comprising a
transversely
oriented beam positioned between each adjacent pair of the second pairs of
adjacent panel
sections.
Clause 9. The folded building structure as in clause 8, wherein an end of each
beam
positioned between the first pairs of adjacent panel sections is pivotally
connected with a
lockable hinge assembly to an end of a corresponding beam positioned between
one of the
second pairs of adjacent panel sections.
Clause 10. A folded building comprising:
(a) a fixed space portion comprising:
(i) a rectangular first roof portion having a first longitudinal edge and an
adjacent transverse
edge, the first roof portion comprising a first plurality of laminate panel
sections N in
number, where N is equal to or greater than 2, each of the first plurality of
laminate panel
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sections having a rectangular shape with a first panel edge of span S, and two
opposed
orthogonal edges adjacent the first panel edge, the first plurality of
laminate panel sections
positioned side-by-side to provide N ¨ 1 first pairs of adjacent panel
sections with the first
longitudinal edge having a length equal to N x S; and
(ii) a first wall structure adjoining the first roof portion and comprising a
first further laminate
panel section having a rectangular shape and a second panel edge of span S,
the second panel
edge vertically positioned so that the first wall structure has a height equal
to S; and
(b) a second roof portion having a second longitudinal edge positioned against
the first
longitudinal edge and an opposed third longitudinal edge, the second roof
portion pivotally
connected to the first roof portion to permit the second roof portion to
pivot, about a first
horizontal axis relative to the first roof portion, from a second roof portion
folded position to
a second roof portion unfolded position.
Clause 11. The folded building structure as in clause 10, wherein the second
roof portion
comprises a second plurality of laminate panel sections N in number, each of
the second
plurality of laminate panel sections having a rectangular shape with a third
panel edge of span
S, and two opposed orthogonal edges adjacent the third panel edge, the second
plurality of
panel sections positioned adjacent each other with their orthogonal edges side-
by-side, to
provide N - 1 second pairs of adjacent panel sections and the second and third
longitudinal
edges each having a length equal to N x S.
Clause 12. The folded building structure as in either of clause 10 or clause
11, wherein each
of the first plurality of laminate panel sections 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, 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.
Clause 13. The folded building structure as in clause 12, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 14. The folded building structure as in clause 11, wherein each of the
second plurality
of laminate panel sections comprises (i) a planar foam panel layer having a
first face and an
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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, 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.
Clause 15. The folded building structure as in clause 14, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 16. The folded building structure as in clause 10 or clause 11, further
comprising a
third roof portion having a fourth longitudinal edge positioned against the
third longitudinal
edge, the third roof portion pivotally connected to the second roof portion to
permit the third
roof portion to pivot, about a second horizontal axis relative to the second
roof portion, from
a third roof portion folded position to a third roof portion unfolded
position.
Clause 17. The folded building structure as in clause 16, wherein the third
roof portion
comprises a third plurality of laminate panel sections, N in number, each of
the third plurality
of laminate panel sections having a rectangular shape with a fourth panel edge
of span S, and
two opposed orthogonal edges adjacent the fourth panel edge, the third
plurality of panel
sections positioned adjacent each other with their orthogonal edges side-by-
side, to provide
N - 1 third pairs of adjacent panel sections with the fourth longitudinal edge
having a length
equal to N x S.
Clause 18. The folded building structure as in clause 17, wherein each of the
third plurality
of laminate panel sections 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, 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.
Clause 19. The folded building structure as in clause 12, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
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Clause 20. The folded building structure as in clause 11, further compri sing
a transversely
oriented beam positioned between each adjacent pair of the first pairs of
adjacent panel
sections.
Clause 21. The folded building structure as in clause 20, further comprising a
transversely
oriented beam positioned between each adjacent pair of the second pairs of
adjacent panel
sections.
Clause 22. The folded building structure as in clause 21, wherein an end of
each beam
positioned between the first pairs of adjacent panel sections is pivotally
connected with a
lockable hinge assembly to an end of a corresponding beam positioned between
one of the
second pairs of adjacent panel sections.
Clause 23. The folded building structure as in clause 17, further comprising a
transversely
oriented beam positioned between each adjacent pair of the third pairs of
adjacent panel
sections.
Clause 24. The folded building structure as in clause 23, wherein an end of
each beam
positioned between the first pairs of adjacent panel sections is pivotally
connected with a
lockable hinge assembly to an end of a corresponding beam positioned between
one of the
second pairs of adjacent panel sections.
Clause 25. A folded building comprising:
(a) a fixed space portion comprising:
(i) a rectangular first floor portion having a first longitudinal edge and an
adjacent transverse
edge, the first floor portion comprising a first plurality of laminate panel
sections N in
number, where N is equal to or greater than 2, each of the first plurality of
laminate panel
sections having a rectangular shape with a first panel edge of span S, and two
opposed
orthogonal edges adjacent the first panel span edge, the first plurality of
laminate panel
sections positioned adjacent each other with their orthogonal edges side-by-
side, to provide N
¨ 1 first pairs of adjacent panel sections with the first longitudinal edge
having a length equal
to N x S;
(ii) a rectangular first roof portion having a second longitudinal edge and an
adjacent
transverse edge, the first roof portion comprising a second plurality of
laminate panel sections
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N in number, each of the second plurality of laminate panel sections having a
rectangular
shape with a second panel edge of span S, and two opposed orthogonal edges
adjacent the
second panel edge, the second plurality of laminate panel sections positioned
adjacent each
other with their orthogonal edges side-by-side, to provide N ¨ 1 second pairs
of adjacent
panel sections with the second longitudinal edge having a length equal to N x
S, and
(iii) a first wall structure having a top edge adjoining the first roof
portion and an opposed
bottom edge adjoining the first floor portion; and
(b) a second roof portion having a third longitudinal edge positioned against
the second
longitudinal edge, the second roof portion pivotally connected to the first
roof portion to
permit the second roof portion to pivot, about a first horizontal axis
relative to the first roof
portion, from a second roof portion folded position to a second roof portion
unfolded
position.
Clause 26. The folded building structure as in clause 25, wherein the second
roof portion
comprises a third plurality of laminate panel sections N in number, each of
the third plurality
of laminate panel sections having a rectangular shape with a third panel edge
of span S, and
two opposed orthogonal edges adjacent the third panel edge, the third
plurality of panel
sections positioned adjacent each other with their orthogonal edges side-by-
side, to provide
N - 1 third pairs of adjacent panel sections with the third longitudinal edge
having a length
equal to N x S.
Clause 27. The folded building structure as in clause 26, wherein each of the
third plurality
of laminate panel sections 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, 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.
Clause 28. The folded building structure as in clause 27, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 29. The folding building structure as in one of clause 25, 26, 27 or
28, further
comprising a second floor portion having a fourth longitudinal edge and an
opposed fifth
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longitudinal edge, the fourth longitudinal edge positioned against the first
longitudinal edge
of the first floor portion and pivotally connected thereto, to permit the
second floor portion to
pivot about a second horizontal axis, relative to the first floor portion,
from a second floor
portion folded position to a second floor portion unfolded position.
Clause 30. The folded building structure as in clause 29, wherein the second
floor portion
comprises a fourth plurality of laminate panel sections N in number, each of
the fourth
plurality of laminate panel sections having a rectangular shape with a fourth
panel edge of
span S, and two opposed orthogonal edges adjacent the fourth panel edge, the
fourth plurality
of panel sections positioned adjacent each other with their orthogonal edges
side-by-side, to
provide N - 1 fourth pairs of adjacent panel sections with the fourth
longitudinal edge having
a length equal to N x S.
Clause 31. The folded building structure as in clause 30, wherein each of the
fourth plurality
of laminate panel sections 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, 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.
Clause 32. The folded building structure as in clause 31, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 33. The folded building structure as in clause 25, wherein the first
wall structure
comprises a first further laminate panel section having a rectangular shape
with a fifth panel
edge of span S adjoining the top and bottom edges, the fifth panel edge
vertically positioned
so that the first wall structure has a height equal to S.
Clause 34. The folded building structure as in any one of clause 29, 30, 31 or
32, further
comprising a second wall structure pivotally connected to the second floor
portion proximate
to the fifth longitudinal edge to permit the second wall structure to pivot,
about a third
horizontal axis relative to the second floor portion, from a second wall
structure folded
position to a second wall structure unfolded position.
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Clause 35. The folded building structure as in clause 34, wherein the second
wall structure
comprises a second further laminate panel section having a rectangular shape
with a sixth
panel edge of span S, the sixth panel edge vertically positioned so that the
second wall
structure has a height equal to S.
Clause 36. The folded building structure as in clause 31, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 37. The folded building structure as in clause 26, further comprising a
transversely
oriented beam positioned between each adjacent pair of the third pairs of
adjacent panel
sections.
Clause 38. The folded building structure as in clause 37, wherein an end of
each beam
positioned between the second pairs of adjacent panel sections is pivotally
connected with a
lockable hinge assembly to an end of a corresponding beam positioned between
one of the
third pairs of adjacent panel sections
Clause 39. The folded building structure as in clause 30, further comprising a
transversely
oriented beam positioned between each adjacent pair of the fourth pairs of
adjacent panel
sections.
Clause 40. The folded building structure as in clause 39, wherein an end of
each beam
positioned between the first pairs of adjacent panel sections is pivotally
connected with a
lockable hinge assembly to an end of a corresponding beam positioned between
one of the
fourth pairs of adjacent panel sections.
Clause 41. The folded building structure as in clause 33, wherein the first
further laminate
panel section 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, 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.
Clause 42. The folded building structure as in clause 35, wherein the second
further laminate
panel section 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
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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.
Clause 43. The folded building structure as in clause 41, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
Clause 44. The folded building structure as in clause 42, further comprising a
protective
layer having an inorganic composition, the protective layer having a first
face bonded to the
second face of the second metal layer, and an opposed second face.
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