Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVED FOLDING ROOF COMPONENT
CROSS-REFERENCES TO RELATED APPLICATIONS
[001] This application is a continuation-in-part application of U.S.
Nonprovisional
Application No. 17/527,520, filed November 16, 2021, which is a continuation
application
of PCT Patent Application No. PCT/US2021/059440, filed November 16, 2021, and
which
claims the benefit of U.S. Provisional Application No. 63/136,268, filed
January 12, 2021
and U.S. Provisional Application No. 63/188,101, filed May 13, 2021; this
application is
also a continuation-in-part application of U.S. Nonprovisional Application No.
17/504,883,
filed October 19, 2021, which claims the benefit of U.S. Provisional
Application No.
63/136.268, filed January 12, 2021, U.S. Provisional Application No.
63/181,447, filed
April 29, 2021, and U.S. Provisional Application No. 63/196,400, filed June 3,
2021; and
this application additionally claims the benefit of U.S. Provisional
Application No.
63/196.400, filed June 3. 2021, U.S. Provisional Application No. 63/188,101,
filed May 13,
2021, and U.S. Provisional Application No. 63/136,268, filed January 12, 2021.
BACKGROUND OF THE INVENTION
Field of the Invention
[002] 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
[003] 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.
[004] 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
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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.
[005] 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 arc 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.
[006] Significant advancements in the construction of dwellings and commercial
space
have been made by the current inventors, as exemplified by their patent
documents,
including 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
[007] The present inventions constitute advancements in the deployment of roof
portions of
folded building structures to reduce the risk of certain of the roof portions
being "pinned"
against other portions of the building structures during the steps of
unfolding.
[008] In one aspect, the present inventions are directed to a folded building
structure
comprising a fixed space portion defined by (i) a first floor portion, (ii) a
rectangular planar
first roof portion having a thickness, a longitudinal length, a first
transverse width and an
interior surface, and (iii) a planar first fixed wall portion of a first wall
component, which
first fixed wall portion has a first fixed portion top edge and adjoins a
first transverse edge
of the first floor portion and a first transverse edge of the first roof
portion. There is
provided a rectangular planar second roof portion having a thickness, a
longitudinal length,
a second transverse width and an interior surface, with the second roof
portion horizontally
stacked in a second roof portion folded position on the first roof portion and
pivotally
connected along a horizontal longitudinal first axis to the first roof portion
to permit the
second roof portion to pivot, about the first axis relative to the first roof
portion, from the
second roof portion folded position to a second roof portion unfolded position
at which the
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first and second roof portions are coplanar; and also a rectangular planar
third roof portion
having a thickness, a longitudinal length, a longitudinally-oriented leading
edge, a third
transverse width and an interior surface, with the third transverse width
being greater than
the first transverse width and being greater than the second transverse width,
and with the
third roof portion horizontally stacked in a third roof portion folded
position on the second
roof portion and pivotally connected along a horizontal longitudinal second
axis to the
second roof portion to permit the third roof portion to pivot, about the
second axis relative
to the second roof portion, from the third roof portion folded position to a
third roof portion
unfolded position at which the third roof portion is coplanar with the second
roof portion in
the second roof portion unfolded position. The first wall component
additionally includes a
planar first pivoting wall portion with a first pivoting portion top edge
having a first
pivoting portion top edge length, with the first pivoting wall portion (i)
disposed in a first
pivoting portion folded position proximate the fixed space portion and (ii)
pivotally
connected along a vertical third axis to the first fixed wall portion of the
first wall
component to permit the first pivoting wall portion to pivot, about the third
axis relative to
the first fixed wall portion, from the first pivoting portion folded position
to a first pivoting
portion unfolded position, coplanar with the first fixed wall portion, in
which the first
pivoting portion top edge is positioned under the interior surfaces of the
second and third
roof portions when the second and third roof portions are in their unfolded
positions.
[009] In another aspect, the present inventions are directed to a folded
building structure
comprising a planar first roof portion having a thickness, a first
longitudinal edge, a first
transverse roof edge having a width, an opposed second transverse roof edge
having a
width, and an interior surface, with the first transverse roof edge adjoining
the first
longitudinal edge at a first end and the opposed second transverse roof edge
adjoining the
first longitudinal edge at a second end. In addition, a planar second roof
portion having a
thickness, a third transverse roof edge having a width, an opposed fourth
transverse roof
edge having a width, and an interior surface, is horizontally stacked in a
second roof portion
folded position on the first roof portion and pivotally connected along a
horizontal
longitudinal first axis to the first roof portion to permit the second roof
portion to pivot,
about the first axis relative to the first roof portion, from the second roof
portion folded
position to a second roof portion unfolded position at which the first and
second roof
portions are coplanar. There is additionally provided a planar third roof
portion having a
thickness, a longitudinally-oriented leading edge, a fifth transverse roof
edge having a
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width, an opposed sixth transverse roof edge having a width, and a planar
interior surface,
which is horizontally stacked in a third roof portion folded position on the
second roof
portion and pivotally connected along a horizontal longitudinal second axis to
the second
roof portion to permit the third roof portion to pivot, about the second axis
relative to the
second roof portion, from the third roof portion folded position to a third
roof portion
unfolded position coplanar with the second roof portion in the second roof
portion unfolded
position. There is also provided a first wall having a first vertical edge and
a first transverse
top edge that adjoins the first vertical edge, the first transverse top edge
having a top edge
length at least equal to the sum of the widths of the first, third and fifth
transverse roof
edges, with the first roof portion joined to the first transverse top edge
proximate to the first
transverse roof edge with the first end proximate to the first vertical edge;
and a second wall
having a second vertical edge and a second transverse top edge that adjoins
the second
vertical edge, the second transverse top edge having a top edge length at
least equal to the
sum of the widths of the second, fourth and sixth transverse roof edges, the
first roof portion
joined to the second transverse top edge proximate to the second transverse
roof edge with
the second end proximate to the second vertical edge. The width of the fifth
transverse roof
edge is greater than the width of the first transverse roof edge and greater
than the width of
the third transverse roof edge, and the width of the sixth transverse roof
edge is greater than
the width of the second transverse roof edge and greater than the width of the
fourth
transverse roof edge.
[0010] In yet another aspect, the present inventions are directed to a folded
building
structure comprising a planar first roof portion having a thickness, a first
longitudinal edge,
a first transverse roof edge having a width, an opposed second transverse roof
edge having a
width, and an interior surface, with the first transverse roof edge adjoining
the first
longitudinal edge at a first end and the opposed second transverse roof edge
adjoining the
first longitudinal edge at a second end. In addition, a planar second roof
portion having a
thickness, a third transverse roof edge having a width, an opposed fourth
transverse roof
edge having a width, and an interior surface, is horizontally stacked in a
second roof portion
folded position on the first roof portion and pivotally connected along a
horizontal
longitudinal first axis to the first roof portion to permit the second roof
portion to pivot,
about the first axis relative to the first roof portion, from the second roof
portion folded
position to a second roof portion unfolded position at which the first and
second roof
portions are coplanar. There is additionally a planar third roof portion
having a thickness, a
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longitudinally-oriented leading edge, a fifth transverse roof edge having a
width, an
opposed sixth transverse roof edge having a width, and an interior surface,
which is
horizontally stacked in a third roof portion folded position on the second
roof portion and
pivotally connected along a horizontal longitudinal second axis to the second
roof portion to
permit the third roof portion to pivot, about the second axis relative to the
second roof
portion, from the third roof portion folded position to a third roof portion
unfolded position
coplanar with the second roof portion in the second roof portion unfolded
position. There is
also provided a first wall having a first vertical edge and a first transverse
top edge that
adjoins the first vertical edge, the first transverse top edge having a top
edge length at least
equal to the sum of the widths of the first, third and fifth transverse roof
edges, with the first
roof portion joined to the first transverse top edge proximate to the first
transverse roof edge
with the first end proximate to the first vertical edge; and a second wall
having a second
vertical edge and a second transverse top edge that adjoins the second
vertical edge, the
second transverse top edge having a top edge length at least equal to the sum
of the widths
of the second, fourth and sixth transverse roof edges, the first roof portion
joined to the first
transverse top edge proximate to the second transverse roof edge with the
second end
proximate to the second vertical edge. A first wheel caster having a first
caster length is
secured proximate to the leading edge of the third roof portion at a location
such that the
first wheel caster comes into rolling contact with the first transverse top
edge for a least a
portion of the top edge length thereof when the third roof portion is moved
between the
third roof portion folded position and the third roof portion unfolded
position; and the sum
of the width of the fifth transverse roof edge and the first caster length is
greater than the
width of the first transverse roof edge and greater than the width of the
third transverse roof
edge.
[0011] These and other aspects of the present inventions arc described in the
drawings
annexed hereto, and in the description of the preferred embodiments and claims
set forth
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 is a perspective view of a finished structure prepared in
accordance with
the present inventions.
[0013] Figure 2 is a schematic top view of a finished structure prepared in
accordance with
the present inventions.
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[0014] Figure 3 is a schematic end view of a shipping module from which is
formed the
finished structure shown in Figure 1.
[0015] 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.
[0016] Figure 6 is a schematic perspective view depicting the exterior edge
reinforcement
for a wall component in accordance with the present inventions.
[0017] Figure 7 is an exploded cross-sectional view of a multi-layered,
laminate
construction for use in the enclosure components of the present inventions.
[0018] Figures 8A. 8B and 8C are schematic side views showing an unfolding
sequence of
three roof portions having the same dimension in the transverse direction.
[0019] Figure 9 is a schematic side view of the unfolding at a particular
point in the
unfolding sequence of three roof portions, with one differently dimensioned in
the
transverse direction, in accordance with the present inventions.
[0020] Figure 10 is a schematic side view of the unfolding at a particular
point in the
unfolding sequence of three roof portions, wherein one is provided with wheel
casters, in
accordance with the present inventions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] An embodiment of the foldable, transportable structure 150 in which the
inventions
disclosed herein can be implemented is depicted in Figures 1 through 5. When
fully
unfolded, as exemplified by Figure 1, structure 150 has a rectangular shape
made of three
types of generally planar and rectangular enclosure components 155, the three
types of
enclosure components 155 consisting of a wall component 200, a floor component
300, and
a roof component 400. As shown in Figures 1 and 2, the perimeter of structure
150 is
defined by first longitudinal edge 106, first transverse edge 108, second
longitudinal edge
116 and second transverse edge 110. For convenience, a direction parallel to
first
longitudinal edge 106 and second longitudinal edge 116 may be referred to as
the
"longitudinal" direction, a direction parallel to first transverse edge 108
and second
transverse edge 110 may be referred to as the "transverse" direction, and a
direction parallel
to the vertical direction in Figure 1 may be referred to as the -vertical"
direction. Structure
150 as shown has one floor component 300, one roof component 400 and four wall
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components 200; although it should be understood that the present inventions
are applicable
to structures having other configurations as well.
[0022] 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,
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
[0023] The enclosure components 155 of the present invention include a number
of shared
design features that are described below.
A. Laminate Structure Design
[0024] 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.
[0025] 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.
[0026] 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 than' 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
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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
[0027] 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
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.
[0028] 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.
[0029] 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," having the same inventors as
this
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disclosure, 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," having the
same
inventors as this disclosure 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 ut 0034-57 and depicted in Figures 4A-4D thereof.
B. Enclosure Component Exterior Edge Reinforcement
[0030] 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
[0031] 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.
[0032] 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
[0033] 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
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foam panel layer 213 which that would otherwise be exposed at the interior
edges of
enclosure components 155. Interior edge reinforcement can be fabricated from
one or more
of laminated strand lumber board, wooden board, C-channel extruded aluminum or
steel, or
the like, and is generally secured to the interior edges of enclosure
component 155 with
fasteners, such as screw or nail fasteners, and/or adhesive.
E. Enclosure Component Load Transfer
[0034] 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).
[0035] 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 embodiments of such structural members, which also incorporate
hinge
structures, are described in in U.S. Nonprovisional Patent Application No.
17/527,520
entitled "Folding Beam Systems", filed November 16, 2021 and having the same
inventors
as this disclosure. The contents of that U.S. Nonprovisional Patent
Application No.
17/527.520 entitled "Folding Beam Systems", filed November 16, 2021 and having
the
same inventors as this disclosure, is incorporated by reference as if fully
set forth herein,
particularly the description of the hinged vertical load transfer components
set forth for
example in 9[[ 0074-0089 and 0104-0126 and in Figures 8A-13E and 15A-24A
thereof, as
well as the description of the associated end hinge assemblies set forth for
example in 191
0090-0093 and 0127-0132 and in Figures 14A-14B, 24B and 25A-25D thereof.
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F. Enclosure Component Sealing Systems
[0036] 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.
[0037] 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 this disclosure, are incorporated by reference as if fully set
forth herein,
particularly including the sealing systems described for example at In 0080-
0167 and
depicted in Figures 9-20 thereof, and also including the exemplary placements
for such
sealing systems described inn 0168-0174 and depicted in Figures 8A-8B thereof.
[0038] Further design details of wall component 200, floor component 300, and
roof
component 400 are provided in the sections following.
Wall Component (200)
[0039] 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
[0040] 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
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other dimensions, such as where two opposing wall components 200 are longer
than the
other two opposing wall components 200.
[0041] 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: the 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.
[0042] 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
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 hoard
5.625" deep
and 1.5" thick.
B. Partitioned Wall Components
[0043] 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
configuration. 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
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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.
[0044] 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.
[0045] 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 fourth wall portion 200s-4 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.
[0046] 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
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hinge structures. Suitable hinge structures can be fabricated for example of
ferrous or non-
ferrous metal, plastic or leather material.
C. Unpartitioned Wall Components
[0047] 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
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.
[0048] 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
peimanent 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)
[0049] 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
[0050] Floor component 300 has a generally rectangular perimeter. Figures 4
and 5 depict
edge-on views of 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
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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.
[0051] 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).
[0052] 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
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.
[0053] 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
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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
[0054] 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.
[0055] 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 board 307 is positioned in floor portion 300a
adjacent interior
edge 301a, and a reinforcing board 307 is positioned in floor portion 300b
adjacent interior
edge 301b. In the embodiment shown in Figures 1 through 5, the interior edge
reinforcement provided by reinforcing boards 307 is laminated strand lumber
board 7.125"
deep and 1.5" thick.
[0056] 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
200R. 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.
Roof Component (400)
[0057] 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
[0058] 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
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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.
[0059] 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.
[0060] 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.
[0061] 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
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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 he fabricated from laminated strand lumber hoard 7.125"
deep and
1.5" thick.
B. Roof Partitioning
[0062] 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.
[0063] Each of the roof portions 400a, 400b 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.
[0064] In the shipping module 100 shown in Figure 3, roof portions 400a, 400b
and 400c
preferably are accordion folded (stacked), with roof component 400b stacked on
top of roof
component 400a, and roof component 400c stacked on top of the roof component
400b.
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. Thus to
realize the accordion folded configuration shown in Figure 3 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 (1800) of
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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 stacked flat against roof portion 400a, and the fully
unfolded position
shown in Figure 4. 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 stacked
flat against roof
portion 400b (when roof portion 400b is positioned to lie flat against roof
portion 400a), and
the fully unfolded position shown in Figure 4.
C. Roof Portion Dimensioning
[0065] Roof portions 400b, 400c each can be identically dimensioned in the
transverse
direction. When so dimensioned however, there is a risk that roof portion 400c
will be
impeded from deploying during the unfolding process. In particular, as roof
portions 400b,
400c are unfolded from the folded stacked position (shown in Figure 3) through
the inclined
orientation (shown in Figure 8A), the weight of roof portion 400c will cause
roof portion
400c to remain resting against roof portion 400b, up to the vertical
orientation (shown in
Figure 8B), particularly if the unfolding force is being applied to roof
portion 400b.
Therefore, at approximately the vertical position shown in Figure 8B, further
unfolding
preferably is undertaken by applying a horizontal force 431 to roof portion
400c in the
transverse direction shown in Figure 8B, typically applied proximate to
leading edge 421 of
roof portion 400c, coupled with applying a retarding horizontal force 432 to
roof portion
400b in the transverse direction shown in Figure 8B, typically at horizontal
axis 405b or to
roof portion 400b below horizontal axis 405b. These horizontal forces cause
roof portion
400c to rotate away and separate from roof portion 400b, and thereby permit
unfolding to
continue. Otherwise, as unfolding proceeds there is a risk that the weight of
roof portion
400c acting downwardly will "pin" the upper portion 422 of leading edge 42
lagainst the top
edges 221 of transversely-oriented wall components 200 (namely, against the
segment of
top edge 221 of wall portion 200s-2 shown in Figure 8C, and against the
corresponding
opposing segment of top edge 221 of wall portion 200s-4), as shown in Figure
8C, with the
potential to impede unfolding and even cause damage to either or both of roof
portion 400c
and transversely-oriented wall components 200.
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[0066] To reduce the foregoing risk, roof portion 400c can be appropriately
dimensioned so
that the width of roof portion 400c in the transverse direction is greater
than the width in the
transverse direction of either of roof portion 400a and roof portion 400b. An
example of
this is shown in Figure 9. As can be seen in that figure, by increasing the
transverse width
W2 of roof portion 400c an appropriate amount, the leading edge 421 of roof
portion 400c
will come into contact with the top edges 221 of transverse] y-oriented wall
components 200
before roof portions 400b, 400c are vertically-oriented. In that circumstance,
further efforts
to rotate the roof portions 400b, 400c about horizontal axis 405a tend to
beneficially act to
separate roof portions 400b and 400c and reduce the risk of the leading edge
421 of roof
portion 400c being pinned against the top edges 221 of transversely-oriented
wall
components 200.
[0067] In the case where roof portions 400a and 400b have the same transverse
width WI,
the transverse width W2 of roof portion 400c can be greater than the
transverse width Wi for
example, by ten to fifteen percent, depending upon the thicknesses of roof
components
400b, 400c. Alternatively, the transverse width W-) of roof portion 400c can
be greater than
the transverse width Wi of roof portions 400a and 400b by an amount sufficient
such that
the leading edge 421 of roof portion 400c, and particularly lower portion 423
thereof, comes
into contact with the top edges 221 of transversely-oriented wall components
200 when roof
portions 400b and 400c are acutely oriented during unfolding relative to roof
portion 400a;
i.e., before roof portions 400b, 400c are vertically-oriented during
unfolding. As a further
alternative, the transverse width W2 of roof portion 400c can be greater than
the transverse
width Wi of each of roof portions 400a and 400b by an amount equal to or
greater than the
aggregate thickness (Ti + T2 in Figure 9) of roof components 400a and 400b.
[0068] In addition, friction-reducing components can be used to facilitate
unfolding roof
component 400, such as by positioning a first wheel caster 499 at the leading
edge 421 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, as shown in Figure 10, and
positioning a
similar second wheel caster 499 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. Each of the wheel casters 499 comprises a wheel rotatably mounted in
a frame so
as to trace a linear track when displaced. Such wheel casters 499 permit the
leading edge
421 of roof portion 400c in effect, to roll along the top edges 221 of
transversely-oriented
wall components 200 and thus facilitate unfolding. Where such wheel casters
are utilized.
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the transverse width W2 of roof portion 400c can be dimensioned larger than
either of roof
portions 400a and 400b in the transverse direction in accordance with the
foregoing design
alternatives, less the length -L", shown in Figure 10, of the first or second
wheel caster 499.
Further information on wheel casters 499 is found in U.S. Nonprovisional
Patent
Application No. 16/786,315, entitled "Equipment and Methods for Erecting a
Transportable
Foldable Building Structure," having the same inventors as this disclosure and
filed on
February 10, 2020, the contents of which are incorporated by reference as if
fully set forth
herein, particularly the description of the wheel casters 499 and their
placements found for
example in 911 0133 and Figures 13D, 13E and 14B thereof.
Enclosure Component Manufacture
[0069] For enclosure components 155 utilizing the multi-layered, laminate
design 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.
[0070] 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 9[9100187-
00205 and 00212 and in Figures 8, 9A-9C, 23A-23J and 24A-24B thereof.
[0071] A facility suitable for the manufacture of enclosure components 155, 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 inventions described herein and filed on October 19, 2021,
are incorporated
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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 19100178-00186 and 00206-00222,
and in
Figures 22, 23A-23J and 24A-24B.
Enclosure Component Relationships and Assembly for Transport
[0072] It is preferred that there be a specific dimensional relationship among
enclosure
components 155.
[0073] 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, preferably is bounded by
this 8E by 8E
orthogonal grid.
[0074] 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 300b is just under 5E wide.
[0075] 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, fourth wall
portion 200s-4 is
folded inward and positioned generally against fixed space portion 102, and
second wall
portion 200s-2 is folded inward and positioned generally against second wall
portion 200s-4
(wall portions 200s-2 and 200s-4 are respectively identified in Figure 2 as
portions 200s-2f
and 200s-4f when so folded and positioned). The three roof components 400a,
400b and
400c are shown unfolded in Figure 1 and shown accordion folded (stacked) in
Figure 3.
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 300h
between
floor portion 300b and wall portions 200s-2 and 200s-4.
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[0076] 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.
[0077] 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,
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.
[0078] Each of the wall, floor and roof components 200, 300 and 400, and/or
the portions
thereof, can he sheathed in a protective film during fabrication and prior to
forming the
shipping module 100. Alternatively or in addition, the entire shipping module
100 can be
sheathed in a protective film. Such protective films can remain in place until
after the
shipping module 100 is at the construction site, and then removed as required
to facilitate
enclosure component deployment and finishing.
Shipping Module Transport
[0079] 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
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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
[0080] 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 means
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,- having the same inventors as this disclosure 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," having
the same inventors as this disclosure 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 atn 00126 ¨ 00128 and in connection with Figures 11A and
11B
thereof.
[0081] 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
(indicated in Figure 3) to an unfolded position, (3) wall portions 200s-2 and
200s-4 are
pivotally rotated about vertical axes 192 and 194 (shown in Figure 2)
respectively to
unfolded positions, and (4) roof portions 400b and 400c are pivotally rotated
about
horizontal axes 405a and 405b (shown in Figures 3 and 4) respectively to
unfolded
positions. When accordion folded as a stack, it can be appreciated that the
protective layer
218 of roof portion 400a is distal from the protective layer of roof portion
400b, whereas the
protective layer 218 of roof portion 400b is in contact with, or proximate to,
the protective
layer of roof portion 400c. Thus in unfolding roof portions 400b and 400c, it
is regarded
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herein that the protective layer 218 of the second component portion rotates
toward the
protective layer 218 of the first component portion 400a, whereas the
protective layer 218
of the third component portion 400c rotates away from the protective layer 218
of the
second component portion 400b.
[0082] A mobile crane can be used to assist in the deployment of certain of
the enclosure
components 155, specifically roof portions 400b and 400c, floor portion 300b,
as well as the
wall component 200P pivotally secured to floor portion 300b. Alternatively,
particularly
suitable equipment and techniques for facilitating the deployment of enclosure
components
155 are disclosed in U.S. Nonprovisional Patent Application No. 16/786,315,
entitled
"Equipment and Methods for Erecting a Transportable Foldable Building
Structure," having
the same inventors as this disclosure 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," having the same
inventors as this
disclosure 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 191
00132-00145 and depicted in Figures 12A-14B thereof.
[0083] 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.
[0084] This disclosure should be understood to include (as illustrative and
not limiting) the
subject matter set forth in the following numbered clauses:
Clause 1. A folded building structure comprising:
a fixed space portion defined by (i) a first floor portion, (ii) a rectangular
planar first
roof portion having a thickness, a longitudinal length, a first transverse
width and an interior
surface, and (iii) a planar first fixed wall portion of a first wall
component, the first fixed wall
portion (x) having a first fixed portion top edge, and (y) adjoining a first
transverse edge of
the first floor portion and a first transverse edge of the first roof portion;
a rectangular planar second roof portion having a thickness, a longitudinal
length, a
second transverse width and a planar interior surface, the second roof portion
horizontally
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stacked in a second roof portion folded position on the first roof portion and
pivotally
connected along a horizontal longitudinal first axis to the first roof portion
to permit the
second roof portion to pivot, about the first axis relative to the first roof
portion, from the
second roof portion folded position to a second roof portion unfolded position
at which the
first and second roof portions are coplanar;
a rectangular planar third roof portion having a thickness, a longitudinal
length, a
longitudinally-oriented leading edge, a third transverse width and an interior
surface, the third
transverse width being greater than the first transverse width and being
greater than the
second transverse width, the third roof portion horizontally stacked in a
third roof portion
folded position on the second roof portion and pivotally connected along a
horizontal
longitudinal second axis to the second roof portion to permit the third roof
portion to pivot,
about the second axis relative to the second roof portion, from the third roof
portion folded
position to a third roof portion unfolded position coplanar with the second
roof portion in the
second roof portion unfolded position;
the first wall component additionally including a planar first pivoting wall
portion
with a first pivoting portion top edge having a first pivoting portion top
edge length, the first
pivoting wall portion (i) disposed in a first pivoting portion folded position
proximate the
fixed space portion and (ii) pivotally connected along a vertical third axis
to the first fixed
wall portion of the first wall component to permit the first pivoting wall
portion to pivot,
about the third axis relative to the first fixed wall portion, from the first
pivoting portion
folded position to a first pivoting portion unfolded position, coplanar with
the first fixed wall
portion, in which the first pivoting portion top edge is positioned under the
interior surfaces
of the second and third roof portions when the second and third roof portions
are in their
unfolded positions.
Clause 2. The folded building structure of clause 1, wherein the fixed space
portion is
further defined by (iv) a planar second fixed wall portion of a second wall
component in an
opposing relationship with the first wall portion, the second fixed wall
portion adjoining a
second transverse edge of the first floor portion, which is opposed to the
first transverse edge
of the first floor portion, and adjoining a second transverse edge of the
first roof portion,
which is opposed to the first transverse edge of the first roof portion, with
the second wall
component additionally including a planar second pivoting wall portion with a
second
pivoting portion top edge having a second pivoting portion top edge length,
the second
pivoting wall portion (i) disposed in a second pivoting portion folded
position proximate the
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fixed space portion, and (ii) pivotally connected along a vertical fourth axis
to the second
fixed wall portion, to permit the second pivoting wall portion to pivot, about
the fourth axis
relative to the second fixed wall portion of the second wall component, from
the second
pivoting portion folded position to a second pivoting portion unfolded
position in which the
second pivoting portion top edge is positioned under the interior surfaces of
the second and
third roof portions when the second and third roof portions are in their
unfolded positions.
Clause 3. The folded building structure of either of clause 1 or clause 2,
wherein the
fixed space portion is further defined by (v) a third wall component having
(i) a longitudinal
top edge that is positioned under the interior surface of the first roof
portion proximate the
longitudinal edge of the first roof portion, (ii) a vertical edge that adjoins
the first fixed wall
portion proximate a vertical edge thereof, and (iii) a longitudinal bottom
edge that adjoins the
first floor portion proximate a longitudinal edge thereof.
Clause 4. The folded building structure of any one of clause 1, 2 or 3,
wherein the
first and second transverse widths are equal.
Clause 5. The folded building structure of any one of clause 1, 2, 3 or 4,
wherein the
third transverse width is greater than the second transverse width by at least
the sum of the
thicknesses of the first roof portion and the second roof portion.
Clause 6. The folded building structure of any one of clause 1, 2, 3, 4 or 5,
wherein
the third transverse width is greater than the second transverse width by an
amount such that
when the first pivoting wall portion is in the first pivoting portion unfolded
position and the
second and third roof portions are unfolded from the second and third roof
portion folded
positions and remain in mutual contact when so unfolded, the second and third
roof portions
are acutely oriented relative to the first fixed portion top edge when the
leading edge of the
third roof portion comes into contact with the first pivoting portion top
edge.
Clause 7. The folded building structure of any one of clause 1, 2, 3, 4 or 5,
further
comprising a first wheel caster secured proximate the leading edge of the
third roof portion at
a location such that the first wheel caster comes into rolling contact with
the first pivoting
portion top edge for a least a portion of the first pivoting portion top edge
length when the
first pivoting wall portion is in the first pivoting portion unfolded position
and the third roof
portion is moved between the third roof portion folded position and the third
roof portion
unfolded position.
Clause 8. The folded building structure of clause 2, further comprising a
second
wheel caster secured proximate the leading edge of the third roof portion at a
location such
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that the second wheel caster comes into rolling contact with the second
pivoting portion top
edge for a least a portion of the second pivoting portion top edge length when
the third roof
portion is moved between the third roof portion folded position and the third
roof portion
unfolded position.
Clause 9. The folded building structure of any one of clause 1, 2, 3 or 4,
wherein the
third transverse width is greater than the first trail sverse width by an
amount in the range of
from ten to fifteen percent of the first transverse width, and is greater than
the second
transverse width by an amount in the range of from ten to fifteen percent of
the second
transverse width.
Clause 10. A folded building structure comprising:
a planar first roof portion having a thickness, a first longitudinal edge, a
first
transverse roof edge having a width, an opposed second transverse roof edge
having a width,
and an interior surface, the first transverse roof edge adjoining the first
longitudinal edge at a
first end and the opposed second transverse roof edge adjoining the first
longitudinal edge at
a second end;
a planar second roof portion having a thickness, a third transverse roof edge
having a
width, an opposed fourth transverse roof edge having a width, and an interior
surface, the
second roof portion horizontally stacked in a second roof portion folded
position on the first
roof portion and pivotally connected along a horizontal longitudinal first
axis to the first roof
portion to permit the second roof portion to pivot, about the first axis
relative to the first roof
portion, from the second roof portion folded position to a second roof portion
unfolded
position at which the first and second roof portions are coplanar;
a planar third roof portion having a thickness, a longitudinally-oriented
leading edge,
a fifth transverse roof edge having a width, an opposed sixth transverse roof
edge having a
width, and an interior surface, the third roof portion horizontally stacked in
a third roof
portion folded position on the second roof portion and pivotally connected
along a horizontal
longitudinal second axis to the second roof portion to permit the third roof
portion to pivot,
about the second axis relative to the second roof portion, from the third roof
portion folded
position to a third roof portion unfolded position coplanar with the second
roof portion in the
second roof portion unfolded position; and
a first wall having a first vertical edge and a first transverse top edge that
adjoins the
first vertical edge, the first transverse top edge having a top edge length at
least equal to the
sum of the widths of the first, third and fifth transverse roof edges, the
first roof portion
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joined to the first transverse top edge proximate to the first transverse roof
edge with the first
end proximate to the first vertical edge;
a second wall having a second vertical edge and a second transverse top edge
that
adjoins the second vertical edge, the second transverse top edge having a top
edge length at
least equal to the sum of the widths of the second, fourth and sixth
transverse roof edges, the
first roof portion joined to second first transverse top edge proximate to the
second transverse
roof edge with the second end proximate to the second vertical edge; and
wherein the width of the fifth transverse roof edge is greater than the width
of the first
transverse roof edge and greater than the width of the third transverse roof
edge, and the
width of the sixth transverse roof edge is greater than the width of the
second transverse roof
edge and greater than the width of the fourth transverse roof edge.
Clause 11. The folded building structure of clause 10, further comprising a
third wall
having a longitudinal top edge adjoining: (i) the interior surface of the
first roof portion
proximate the longitudinal edge of the first roof portion, (ii) the first wall
proximate the first
vertical edge, and (iii) the second wall proximate to the second vertical
edge.
Clause 12. The folded building structure of either of clause 10 or clause 11,
wherein
the widths of the first and third transverse roof edges are equal to each
other, and the widths
of the second and fourth transverse roof edges are equal to each other.
Clause 13. The folded building structure of any one of clause 10, 11 or 12,
wherein
the width of the fifth transverse roof edge is greater than the width of the
third transverse roof
edge by at least the sum of the thicknesses of the first roof portion and the
second roof
portion, and the width of the sixth transverse roof edge is greater than the
width of the fourth
transverse roof edge by at least the sum of the thicknesses of the first roof
portion and the
second roof portion.
Clause 14. The folded building structure of any one of clause 10, 11, 12 or
13,
wherein the width of the fifth transverse roof edge is greater than the width
of the third
transverse roof edge by an amount such that when the second and third roof
portions are
unfolded from the second and third roof portion folded positions and remain in
mutual
contact when so unfolded, the second and third roof portions are acutely
oriented relative to
the first transverse top edge and the second transverse top edge when the
leading edge of the
third portion comes into contact therewith.
Clause 15. The folded building structure of any one of clause 10, 11, 12 or
13, further
comprising a first wheel caster secured proximate the leading edge of the
third roof portion at
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a location such that the first wheel caster comes into rolling contact with
the first transverse
top edge for a least a portion of the top edge length thereof when the third
roof portion is
moved between the third roof portion folded position and the third roof
portion unfolded
position.
Clause 16. The folded building structure of clause 15, further comprising a
second
wheel caster secured proximate the leading edge of the third roof portion at a
location such
that the second wheel caster comes into rolling contact with the second
transverse top edge
for a least a portion of the top edge length thereof when the third roof
portion is moved
between the third roof portion folded position and the third roof portion
unfolded position.
Clause 17. The folded building structure of any one of clause 10, 11 or 12,
wherein
the width of the fifth transverse roof edge is greater than the width of the
first transverse roof
edge and greater than the width of the third transverse roof edge by an amount
in the range of
from ten to fifteen percent of the width of the first transverse roof edge,
and the width of the
sixth transverse roof edge is greater than the width of the second transverse
roof edge and
greater than the width of the fourth transverse roof edge by an amount in the
range of from
ten to fifteen percent of the width of the second transverse roof edge.
Clause 18. A folded building structure comprising:
a planar first roof portion having a thickness, a first longitudinal edge, a
first
transverse roof edge having a width, an opposed second transverse roof edge
having a width,
and an interior surface, the first transverse roof edge adjoining the first
longitudinal edge at a
first end and the opposed second transverse roof edge adjoining the first
longitudinal edge at
a second end;
a planar second roof portion having a thickness, a third transverse roof edge
having a
width, an opposed fourth transverse roof edge having a width, and an interior
surface, the
second roof portion horizontally stacked in a second roof portion folded
position on the first
roof portion and pivotally connected along a horizontal longitudinal first
axis to the first roof
portion to permit the second roof portion to pivot, about the first axis
relative to the first roof
portion, from the second roof portion folded position to a second roof portion
unfolded
position at which the first and second roof portions are coplanar;
a planar third roof portion having a thickness, a longitudinally-oriented
leading edge,
a fifth transverse roof edge having a width, an opposed sixth transverse roof
edge having a
width, and an interior surface, the third roof portion horizontally stacked in
a third roof
portion folded position on the second roof portion and pivotally connected
along a horizontal
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longitudinal second axis to the second roof portion to permit the third roof
portion to pivot,
about the second axis relative to the second roof portion, from the third roof
portion folded
position to a third roof portion unfolded position coplanar with the second
roof portion in the
second roof portion unfolded position; and
a first wall having a first vertical edge and a first transverse top edge that
adjoins the
first vertical edge, the first transverse top edge having a top edge length at
least equal to the
sum of the widths of the first, third and fifth transverse roof edges, the
first roof portion
joined to the first transverse top edge proximate to the first transverse roof
edge with the first
end proximate to the first vertical edge;
a second wall having a second vertical edge and a second transverse top edge
that
adjoins the second vertical edge, the second transverse top edge having a top
edge length at
least equal to the sum of the widths of the second, fourth and sixth
transverse roof edges, the
first roof portion joined to the second transverse top edge proximate to the
second transverse
roof edge with the second end proximate to the second vertical edge;
a first wheel caster having a first caster length secured proximate to the
leading edge
of the third roof portion at a location such that the first wheel caster comes
into rolling
contact with the first transverse top edge for a least a portion of the top
edge length thereof
when the third roof portion is moved between the third roof portion folded
position and the
third roof portion unfolded position; and
wherein the sum of the width of the fifth transverse roof edge and the first
caster
length is greater than the width of the third transverse edge by an amount
such that when the
second and third roof portions are unfolded from the second and third roof
portion folded
positions and remain in mutual contact when so unfolded, the second and third
roof portions
are acutely oriented relative to the first transverse top edge when the first
caster comes into
contact therewith.
Clause 19. The folded building structure of clause 18, wherein the widths of
the first
and third transverse roof edges are equal to each other, and the widths of the
second and
fourth transverse roof edges are equal to each other.
Clause 20. The folded building structure of either of clause 18 or clause 19,
wherein
the sum of the width of the fifth transverse roof edge and the first caster
length is greater than
the width of the third transverse roof edge by at least the sum of the
thicknesses of the first
roof portion and the second roof portion.
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Clause 21. The folded building structure of any one of clause 18, 19 or 20,
further
comprising a second wheel caster having a second caster length secured
proximate the
leading edge of the third roof portion at a location such that the second
wheel caster comes
into rolling contact with the second transverse top edge for a least a portion
of the top edge
length thereof when the third roof portion is moved between the third roof
portion folded
position and the third roof portion unfolded position; and
wherein the sum of the width of the sixth transverse roof edge and the second
caster
length is greater than the width of the fourth transverse roof edge by an
amount such that
when the second and third roof portions are unfolded from the second and third
roof portion
folded positions and remain in mutual contact when so unfolded, the second and
third roof
portions are acutely oriented relative to the second transverse top edge when
the second
caster comes into contact therewith.
Clause 22. The folded building structure of clause 21, wherein the sum of the
width
of the sixth transverse roof edge and the second caster length is greater than
the width of the
fourth transverse roof edge by at least the sum of the thicknesses of the
first roof portion and
the second roof portion.
Clause 23. The folded building structure of clause 21, wherein the sum of the
width
of the fifth transverse roof edge and the first caster length is greater than
the width of the first
transverse roof edge and greater than the width of the third transverse roof
edge by an amount
in the range of from ten to fifteen percent of the width of the first
transverse roof edge, and
the sum of the width of the sixth transverse roof edge and the second caster
length is greater
than the width of the second transverse roof edge and greater than the width
of the fourth
transverse roof edge by an amount in the range of from ten to fifteen percent
of the width of
the second transverse roof edge.
Clause 24. The folded building structure of any one of clause 5, 13, 20 or 22,
wherein
each of the first, second and third roof portions comprises across its
thickness:
a first structural layer having a first face and an opposing second face;
a foam panel layer having a first face and an opposing second face, the first
face of
the foam panel layer being bonded to the opposing second face of the first
structural layer;
a second structural layer having a first face and an opposing second face, the
first face
of the second structural layer being bonded to the opposing second face of the
foam panel
layer.
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Clause 25. The folded building structure of clause 24, wherein the first
structural
layer has a metallic composition.
Clause 26. The folded building structure of either of clause 24 or clause 25,
wherein
the second structural layer has a metallic composition.
Clause 27. The folded building structure of any one of clause 24, 25 or 26,
further
comprising a protective layer having a first face, an opposing second face,
and an inorganic
composition, the first face of the protective layer being bonded to the
opposing second face of
the second structural layer and the opposing second face of the protective
layer constituting
the interior surface of the roof portion.
Clause 28. The folded building structure of any one of clauses 1-27, wherein
the first
roof portion, the second roof portion in the second roof portion folded
position, and the third
roof portion in the third roof portion folded position have an accordion
folded configuration.
Clause 29. The folded building structure of claim 10, wherein the width of the
fifth
transverse roof edge is greater than the width of the first transverse roof
edge and greater than
the width of the third transverse roof edge by an amount in the range of from
ten to fifteen
percent of the width of the third transverse roof edge, and the width of the
sixth transverse
roof edge is greater than the width of the second transverse roof edge and
greater than the
width of the fourth transverse roof edge by an amount in the range of from ten
to fifteen
percent of the width of the fourth transverse roof edge.
Clause 30. The folded building structure of claim 21, wherein the sum of the
width of
the fifth transverse roof edge and the first caster length is greater than the
width of the first
transverse roof edge and greater than the width of the third transverse roof
edge by an amount
in the range of from ten to fifteen percent of the width of the third
transverse roof edge, and
the sum of the width of the sixth transverse roof edge and the second caster
length is greater
than the width of the second transverse roof edge and greater than the width
of the fourth
transverse roof edge by an amount in the range of from ten to fifteen percent
of the width of
the fourth transverse roof edge.
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