Enclosure Component Panel Sections

Abstract

A folded building structure comprising a fixed space portion including a rectangular floor or roof portion and a wall structure. The floor or roof portion has a longitudinal edge and comprises plural laminate panel sections, N in number, where N is equal to or greater than 2, and with each of the plural 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 plural laminate panel sections are positioned adjacent each other with their orthogonal edges side-by-side, to provide N−1 pairs of adjacent panel sections with the longitudinal edge having a length equal to N×S. The wall structure adjoins the floor or roof portion and comprising a 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 wall structure has a height equal to S.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part application of PCT Patent Application No. PCT/US21/59440, filed Nov. 16, 2021, which claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021; and a continuation-in-part application of U.S. Nonprovisional application Ser. No. 17/527,520, filed Nov. 16, 2021, which is a continuation application of No. PCT/US21/59440, filed Nov. 16, 2021 and which claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021; and a continuation application of PCT/US21/61343, filed Dec. 1, 2021, which is a continuation-in-part application of PCT/US21/59440, filed Nov. 16, 2021, and a continuation-in-part application of U.S. Nonprovisional application Ser. No. 17/527,520, filed Nov. 16, 2021, and which claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021; and this application also claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021 and U.S. Provisional Application No. 63/188,101 filed May 13, 2021.

BACKGROUND OF THE INVENTION

Field of the Invention

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

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.

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.

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.

Significant advancements in the construction of dwellings and commercial space are described in U.S. Pat. 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

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.

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×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 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.

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×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.

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 the first longitudinal edge having a length equal to N×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×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.

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

FIG. 1 is a perspective view of finished structures prepared in accordance with the present inventions.

FIG. 2 is a top schematic view of a finished structure prepared in accordance with the present inventions.

FIG. 3 is an end view of a shipping module from which is formed the finished structure respectively shown in FIG. 1.

FIGS. 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.

FIG. 6 is a schematic perspective view depicting the exterior edge reinforcement for a wall component in accordance with the present inventions.

FIG. 7 is an exploded cross-sectional view of a multi-layered, laminate construction for use in the enclosure components of the present inventions.

FIG. 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 FIG. 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.

FIG. 9 is a perspective view showing the obverse face of one embodiment of a hinge assembly portion in accordance with the present inventions.

FIG. 10 is a front view of the embodiment of the hinge assembly portion shown in FIG. 9.

FIG. 11 is a side view of the embodiment of the hinge assembly portion shown in FIG. 9.

FIG. 12 is a perspective view showing the reverse face of the embodiment of the hinge assembly portion shown in FIG. 9.

FIG. 13A is a cutaway perspective view showing the embodiment of the hinge assembly portion shown in FIG. 9 incorporated into the structure of a floor component in accordance with the present inventions, FIG. 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, FIG. 13C is a perspective view of a locking pin, and FIGS. 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 FIGS. 9-12.

FIG. 14A is a perspective view of a floor end hinge in accordance with the present inventions, and FIG. 14B is a front view of a floor end hinge in accordance with the present inventions.

FIG. 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 FIG. 15B is a side view of a foldable I-beam for a roof component in accordance with the present inventions, in the beam folded position.

FIG. 16 is a perspective view showing the obverse face of another embodiment of a hinge assembly portion in accordance with the present inventions.

FIG. 17 is a front view of the embodiment of the hinge assembly portion shown in FIG. 16.

FIG. 18 is a side view of the embodiment of the hinge assembly portion shown in FIG. 16.

FIG. 19 is a perspective view showing the reverse face of the embodiment of the hinge assembly portion shown in FIG. 16.

FIG. 20 is a perspective view showing the obverse face of a further embodiment of a hinge assembly portion in accordance with the present inventions.

FIG. 21 is a front view of the embodiment of the hinge assembly portion shown in FIG. 20.

FIG. 22 is a side view of the embodiment of the hinge assembly portion shown in FIG. 20.

FIG. 23 is a perspective view showing the reverse face of the embodiment of the hinge assembly portion shown in FIG. 20.

FIG. 24A is a cutaway perspective view showing the embodiment of the hinge assembly portion shown in FIG. 16 incorporated into the structure of a roof component in accordance with the present inventions, and FIG. 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.

FIGS. 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 FIG. 25D is a perspective view of another embodiment of a roof end hinge in accordance with the present inventions.

FIG. 26 is a perspective view of an enclosure component fabrication facility in accordance with the present inventions.

FIG. 27A is a perspective view of a rectangular roof component containing two foldable I-beam assemblies in accordance with the present inventions, and FIG. 27B is a perspective view of a rectangular roof component containing N−1 foldable I-beam assemblies in accordance with the present inventions.

FIGS. 28A and 28B respectively depict perspective and side views of an I-beam cover in accordance with the present inventions, and FIG. 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 THE PREFERRED EMBODIMENTS

An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1 through 5. When fully unfolded, as exemplified by FIG. 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 FIGS. 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 FIG. 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.

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 FIG. 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

The enclosure components 155 of the present invention include a number of shared design features that are described below.

A. Laminate Structure Design

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 FIG. 7 and described further below.

In particular, first structural layer 210 is provided in the embodiment of enclosure component 155 that is depicted in FIG. 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.

Referring again to FIG. 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

In the embodiment of the enclosure component 155 depicted in FIG. 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.

In the embodiment of the enclosure component 155 depicted in FIG. 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.

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 Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on Feb. 10, 2020 and now issued as U.S. Pat. No. 11,118,344. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on Feb. 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 FIGS. 4A-4D thereof.

B. Enclosure Component Exterior Edge Reinforcement

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

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.

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

An enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect the foam panel material of foam panel layer 213 which that would otherwise be exposed at the interior edges of enclosure components 155. Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

E. Enclosure Component Load Transfer

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).

For this purpose, multi-layered, laminate designs as shown in FIG. 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

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.

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 Oct. 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 Oct. 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 and depicted in FIGS. 9-20 thereof, and also including the exemplary placements for such sealing systems described in paragraphs 0168-0174 and depicted in FIGS. 8A-8B thereof.

Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following.

Wall Component (200)

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

Wall component 200 has a generally rectangular perimeter. As shown in FIG. 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.

As indicated above, wall components 200 of the present inventions can utilize a multi-layered, laminate design. In the embodiment depicted in FIGS. 1 through 6, wall component 200 utilizes the multi-layered, laminate design shown in FIG. 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.

The perimeter of each wall component 200 is generally provided with exterior edge reinforcement. As exemplified by wall component 200 shown in FIG. 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 FIGS. 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

Referring to FIG. 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 FIG. 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 FIGS. 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.

Referring again to FIG. 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.

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, FIG. 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 FIG. 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 (2005-2f and 200s-4f), they facilitate forming a compact shipping module. When wall portion 200s-2 is in its unfolded position (2005-2u), 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 (2005-4u), it forms with wall portion 200s-3 a wall component 200 proximate second transverse edge 110.

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 be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.

C. Unpartitioned Wall Components

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 FIG. 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 FIG. 2.

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)

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

Floor component 300 has a generally rectangular perimeter. FIGS. 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.

The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 2, 4 and 5, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

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 FIG. 7. In the embodiment shown in FIGS. 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 FIGS. 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.

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 FIGS. 4 and 5, a first footing beam 320 (visible edge-on in FIG. 4) is positioned at the first longitudinal floor edge 117 of floor component 300, a second footing beam 320 (visible edge-on in FIG. 5) is positioned at the second transverse floor edge 118 of floor component 300, a third footing beam 320 (visible edge-on in FIG. 5) is positioned at the first transverse floor edge 120 of floor component 300, and a fourth footing beam 320 (visible edge-on in FIG. 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 FIGS. 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

The floor component 300 is partitioned into floor portion 300a and floor portion 300b. FIG. 2 shows flow portions 300a and 300b in plan view, and FIG. 4 shows floor portions 300a and 300b in section view, edge-on.

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 FIG. 4. As interior edge reinforcement, a reinforcing board 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 FIGS. 1 through 6, the interior edge reinforcement provided by reinforcing boards 307 is laminated strand lumber board 7.125″ deep and 1.5″ thick.

Referring to structure 150 shown in FIGS. 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 FIG. 3, and a fully unfolded position, shown in FIGS. 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

FIG. 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 I-beams 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 FIG. 8B and unfolded to a beam unfolded position shown in FIG. 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.

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 FIGS. 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 300b. FIGS. 13D and 13E are section views, sectioned in the transverse and longitudinal directions respectively.

Hinge assembly portion 330A, shown in FIG. 9, in principal part includes a hinge base plate 331 having a generally planar, rectangular or, as shown in FIGS. 9, 10 and 12, a square configuration, with an obverse face 318 and a reverse face 319 (visible in FIG. 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.

Hinge section 332 shown in FIG. 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.

Pin interlock section 334 shown in FIG. 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.

Free interlock section 338 shown in FIG. 9 has two free interlock leaves 339. Each free interlock leaf 339 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 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).

Locking pin barrel 340 shown in FIG. 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.

As can be seen in FIG. 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 FIG. 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 FIG. 8B, to a second, hinge closed position, where I-beam 325 is in the beam unfolded position shown in FIG. 8A.

As shown in FIG. 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 FIG. 13E. Correspondingly in the hinge closed position (the beam unfolded position), the free interlock leaves 339 of the free 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 FIG. 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.

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 FIGS. 13D and 13E.

Locking pin 349, which is shown in FIG. 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 FIG. 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 FIGS. 13C-13E, to permit securing locking pin 349 in place.

To facilitate the rotation of hinge assembly 329A so that beam assembly 325 can smoothly move into the beam unfolded position shown in FIG. 8A, it is preferred that the upper and lower faces of leaves 336, 339 not be planar, but rather curved. Referring to FIG. 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.

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 FIG. 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.

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 oriented upwardly, so that I-beam 326b shown in FIG. 8A can fold up relative to I-beam 326a, as shown in FIG. 8B. In particular, as shown in FIG. 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 I-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.

FIG. 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 FIG. 13A (and also visible in FIG. 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 FIG. 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).

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 FIG. 13B.

Floor end hinge assembly 345A. Floor end hinge assembly 345A comprises two identical floor end hinge portions 350A. Referring to FIGS. 14A and 14B, floor end hinge 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.

As can be seen in FIG. 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 FIG. 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 FIG. 8B, to a second, hinge closed position, corresponding to where I-beam 325 is in the unfolded position shown in FIG. 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.

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.

Referring to the floor end hinge assembly 345A shown in FIG. 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 hinge assembly 345A shown in FIG. 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.

Optionally, an I-beam cover 505, shown in FIGS. 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 FIG. 28C, two I-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)

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

Roof component 400 has a generally rectangular perimeter. FIGS. 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.

The length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1, 4 and 5, the length and width of roof component 400 approximates the length and width of floor component 300.

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 FIG. 7. In the embodiment shown in FIGS. 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 FIGS. 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.

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 FIGS. 4 and 5, a first shoulder beam 435 (visible edge-on in FIG. 4) is positioned at the first longitudinal roof edge 406 of roof component 400, a second shoulder beam 435 (visible edge-on in FIG. 5) is positioned at the first transverse roof edge 408 of roof component 400, a third shoulder beam 435 (visible edge-on in FIG. 5) is positioned at the second transverse roof edge 410 of roof component 400, and a fourth shoulder beam 435 (visible edge-on in FIG. 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.

B. Roof Partitioning

The roof component 400 of structure 150 is partitioned into roof portions 400a, 400b and 400c. FIG. 1 shows roof portions 400a, 400b and 400c in perspective view, and FIG. 4 shows roof portions 400a, 400b and 400c in section view, edge-on.

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 FIG. 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 FIG. 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 FIGS. 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.

Referring to structure 150 shown in FIG. 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 FIG. 4, between the roof fully folded position shown in FIG. 3, where roof portion 400b lies flat against roof portion 400a, and the fully unfolded position shown in FIG. 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 FIG. 4, between the folded position shown in FIG. 3, where roof portion 400c lies 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 FIG. 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

FIGS. 15A and 15B shows a beam assembly 425 that can be placed within roof component 400 to provide reinforcement in the direction along the beam and assist in transferring vertical loads borne by floor component 300 to its edges. Beam assembly 425 includes three I-beams 426a, 426b and 426c. I-beam 426a is positioned approximately in the middle of roof portion 400a, I-beam 426b is positioned approximately in the middle of floor portion 400b, I-beam 426c is positioned approximately in the middle of floor portion 400c, and each of I-beams 426a, 426b and 426c is oriented in the transverse direction. A hinge assembly 429B joins 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 426b 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 FIG. 15B, and unfolded to a beam unfolded position, shown in FIG. 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.

Hinge assemblies 429B and 429C are described further below.

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 FIGS. 13D and 13E in reference to the two hinge assembly portions 330A forming hinge assembly 329A.

Hinge assembly portion 430B is shown in FIG. 16. The design of hinge assembly portion 430B is similar to hinge assembly portion 330A discussed above. Accordingly, referring to FIG. 16, hinge assembly portion 430B includes a hinge base plate 431 having an obverse face 418 and a reverse face 419 (visible in FIG. 19). A hinge 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.

Hinge section 432 shown in FIG. 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.

Pin interlock section 434 shown in FIG. 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.

Free interlock section 438 shown in FIG. 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).

Locking pin barrel 440 shown in FIG. 16 extends away in a perpendicular direction from base plate 431 defines a locking pin bore 441. The centerline of bore 441 is vertically oriented and co-linear with the centerline of lock pin holes 447 of pin interlock leaves 436.

As can be seen in FIG. 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 FIG. 17, leftward an offset distance 444, which is one-half the thickness of a hinge leaf 433. This permits utilizing two hinge assembly portions 430B with identical designs in a partnering relationship to form the hinge assembly 429B and the desired pivoting junction. Hinge assembly 429B is assembled by interleaving the hinge leaves 433 of two hinge assembly portions 430B and inserting a hinge pin 464 (shown in FIG. 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 FIG. 18, extend above hinge base plate 431 so that hinge pin holes 427 are positioned a vertical distance 411, the B hinge pin pivot distance, from the lower edge of hinge assembly portion 430B. B hinge pin pivot distance 411 is sufficient to permit hinge assembly 429B to pivot one hundred and eighty degrees (180°) from a first, hinge open position, where I-beam 425 is in the beam folded position shown in FIG. 15B, to a second, hinge closed position, where I-beam 425 is in the beam unfolded position shown in FIG. 15A.

As shown in FIG. 17, the free interlock leaves 439 of free interlock section 438 are offset in the vertical direction from the position of the pin interlock leaves 436 of the pin interlock section 434 by an offset distance 446, which is equal to the thickness of a free interlock leaf 439 (which is equal to the thickness of a pin interlock leaf 436). In the hinge closed position (the beam unfolded position), the free interlock leaves 439 of the free interlock section 438 of a first of the two hinge assembly portions 430B will interleave with the pin interlock leaves 436 of the pin interlock section 434 of the second of the two hinge assembly portions 430B. Correspondingly in the hinge closed position (the beam unfolded position), the free interlock leaves 439 of the free interlock section 438 of the second of the two hinge assembly portions 430B will interleave with the pin interlock leaves 436 of the pin interlock section 434 of the first of the two hinge assembly portions 430B. The centerline of lock pin holes 447 of the free interlock leaves 439 of each hinge assembly portion 430B is positioned so that, when a hinge assembly 429B is in the hinge closed position (the beam unfolded position), that lock pin hole centerline will be co-linear with the centerline of the lock pin holes 447 in the pin interlock section 434 of the other hinge assembly portion 430B of the hinge assembly 429B.

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 FIG. 13C) into the locking pin bore 441 provided in the locking pin barrel 440 of each of its two hinge assembly portions 430B.

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 FIG. 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 FIGS. 13C-13E), to permit securing locking pin 349 in place.

To facilitate the rotation of hinge assembly 429B so that beam assembly 425 can smoothly move into the fully unfolded position shown in FIG. 15A, it is preferred that the upper and lower faces of leaves 436, 439 not be planar, but rather curved. Referring to FIG. 18, there is shown interlock leaves 436 in profile. As compared to planar surfaces 448, which originate at hinge base plate 431 and extend out in an orientation normal to the plane of hinge base plate 431, the upper and lower faces of free interlock leaves 439 can be seen to be curved, about a point proximate to hinge pin hole 427. Similarly, the upper and 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.

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 I-beams 426a and 426b not be co-linear. In particular, in the beam unfolded position it is preferred that hinge assembly 429B, when joined to 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 I-beam 426a or 426b, obverse face 418 is canted a select positive angle (i.e., angularly rotated clockwise about hinge pin hole 427 in FIG. 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.

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 FIG. 15A can fold up relative to I-beam 426a to the beam folded position shown in FIG. 15B. In particular, as shown in FIG. 19 reverse face 419 is provided with four positioning tabs 421 extending away from reverse face 419 in a perpendicular direction. Each positioning tab 421 has two flat sections 417 oriented perpendicular to each other and joined by a rounded section 415. The positioning tabs 421 secured to reverse face 419 form a guide frame, having an “I” shape in profile, for receiving an end of one of I-beams 426a and 426b. It is preferred that the I-beams 426a, 426b be secured to the reverse faces 419 by welding their flanges to hinge 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.

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 FIGS. 13D and 13E in reference to the two hinge assembly portions 330A forming hinge assembly 329A.

Hinge assembly portion 430C is shown in FIGS. 20-23. The design of hinge assembly portion 430C is the same as hinge assembly portion 430B, discussed above, with three exceptions.

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 FIGS. 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.

The second exception is shown in FIG. 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 FIG. 15B, to a second, closed position, where I-beam 425 is in the beam unfolded position shown in FIG. 15A, without crimping or interfering with such protective layer 218 (shown in FIG. 22) as may be positioned on second structural layer 215.

The third exception relates to the fact that hinge assemblies 429B and 429C are mounted in opposite orientations. Referring to hinge assembly 429B, the reverse face 419 of each of its two hinge assembly portions 430B is adapted to be secured to a respective end of the two I-beams 426a and 426b adjacent to each other, and referring to hinge assembly 429C the reverse face 419 of each of the two hinge assembly portions 430C is adapted to be secured to a respective end of the two I-beams 426b and 426c adjacent to each other. As was discussed above, the hinge assembly portions 430B that join I-beam 426a and I-beam 426b are secured to those I-beams 426a, 426b with their hinge sections 332 oriented upwardly, so that I-beam 426b shown in FIG. 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 FIG. 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 FIG. 15B. With these orientations, the three roof components 400a, 400b and 400c can be accordion folded (stacked), as shown in FIG. 3, with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b.

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 426b and 426c, causes those I-beams to assume a small upwardly arched configuration. This can be realized for example by designing hinge assembly portion 430C so that when hinge assembly portion 430C is secured to an end of an I-beam 426b or 426c, obverse face 418 is canted in the opposite direction as preferably found in hinge assembly 430B; in other words, it is preferred that obverse face 418 of hinge assembly portion 430C be canted a select negative angle (i.e., angularly rotated counterclockwise about hinge pin hole 427 in FIG. 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.

FIG. 24A, a cutaway view of a section of roof component 400 in the roof component unfolded position, depicts the mounting of hinge assembly 429B within the floor component 400, specifically between floor portion 400a and floor portion 400b. Bolt plate 414 joins the reinforcing board 437 positioned in roof portion 400b adjacent second interior edge 412b to the hinge assembly portion 430B secured to I-beam 426b. A similar bolt plate 414 is located on the portion of I-beam 426b not visible in FIG. 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.

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 FIG. 24B, and the locations of first and second roof end hinge assemblies 445C are indicated in FIG. 24B. The designs of roof end hinge assemblies 445B and 445C are described below.

Roof End Hinge assembly 445B. Roof end hinge assembly 445B comprises two identical roof end hinge portions 450B. Referring to FIG. 25A, roof end hinge portion 450B in principal part includes a hinge base plate 451 on which is secured a hinge section 452. Hinge section 452 has five hinge leaves 453 in the depicted embodiment, each of which extends in a perpendicular direction away from hinge base plate 451 and defines a hinge pin hole 454 in the region distal from hinge base plate 453. The centerline of each hinge pin hole 454 is horizontally oriented and aligned with the centerline of the hinge pin holes 454 in the other hinge leaves 453 of hinge section 452. Hinge leaves 453 each has the same thickness and are spaced apart a distance equal to the thickness of a hinge leaf 453, so as to permit interleaving the corresponding hinge leaves 453 of the partnering hinge assembly portion 450B.

As depicted in FIG. 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 FIG. 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 (180°) from a first, hinge open position, corresponding to where I-beam 425 of roof portion 400b is in the beam folded position shown in FIG. 15B, to a second, hinge closed position, corresponding to where I-beam 425 is in the beam unfolded position shown in FIG. 15A.

Roof end hinge portion 450B additionally includes two opposed block-out shields 455a and 455b, which are shown in FIG. 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.

The roof end hinge assemblies 445B shown in FIG. 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 FIG. 24B is secured in place by joining one of its hinge assembly portions 450B to the reinforcing board 437 adjacent edge 412a, and by joining the other of its hinge assembly portions 450B to the reinforcing board 437 adjacent second interior edge 412b. As to the roof end hinge assembly 445B shown in FIG. 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.

Roof End Hinge assembly 445C. Roof end hinge assembly 445C comprises two identical roof end hinge portions 450C, one of which is shown in FIG. 25D. The principal elements and geometry of roof end hinge portion 450C are the same as roof end hinge portion 450B, except that hinge leaves 453 of roof end hinge portion 445C extend above hinge base plate 451 so that hinge pin holes 454 are positioned a vertical distance 462, the C roof end hinge pivot distance, from the lower edge of hinge assembly portion 450C. C roof end hinge pivot distance 462 is sufficient to permit hinge assembly 445C to pivot one hundred and eighty degrees (180°) from a first, hinge open position, corresponding to where I-beam 425 of roof portion 400b is in the beam folded position shown in FIG. 15B, to a second, hinge closed position, corresponding to where I-beam 425 is in the beam unfolded position shown in FIG. 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.

The roof end hinge assemblies 445C shown in FIG. 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 FIG. 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 FIG. 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.

Optionally, an I-beam cover 505, as shown in FIGS. 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

For enclosure components 155 having the construction disclosed herein in reference to FIG. 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.

Particular edge structure designs for metal sheets 206 and 217 are described in U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021. The contents of U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 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 FIGS. 8, 9A-9C, 23A-23J and 24A-24B thereof.

FIG. 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 FIG. 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.

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 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.

The facility 10 depicted in FIG. 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 FIG. 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 FIG. 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.

Additional information concerning the facility 10 shown in FIG. 26, as well as exemplary manufacturing steps, are also described in U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventions described herein and filed on Oct. 19, 2021. The contents of U.S. Nonprovisional patent application Ser. No. 17/504,883 entitled “Sheet/Panel Design for Enclosure Component Manufacture,” having the same inventors as the inventors described herein and filed on Oct. 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 FIGS. 22, 23A-23J and 24A-24B.

Enclosure Component Relationships and Assembly for Transport

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 the height “H” of wall components 200 be the same as the span “Se” 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 “S_r” 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=S_f=S_r. Accordingly, S_f and S_r are referred to herein simply as “S”, the panel span.

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 FIG. 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 FIG. 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 FIG. 13B, in which span S can be seen between I-beam assembly 325 and first transverse floor edge 120; see also FIG. 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 FIG. 24B; see also FIG. 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 FIG. 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.

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 FIG. 1), as where two of its opposing wall components 200 are longer than the other two opposing wall components 200. For example, FIG. 27A depicts a roof component 400 approximately 1.5 times longer in the longitudinal direction than in the transverse direction. In this example, roof portions 400a, 400b and 400c are each assembled from a series of three laminate panel sections 250 having the same geometry and dimensions, denominated panel sections 250-1, 250-2 and 250-3 respectively in FIG. 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 FIG. 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”.

For each roof portion 400a, 400b and 400c shown in FIG. 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 FIG. 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.

Each panel section 250 in FIG. 27A can have a panel span S of 9.5 feet in the longitudinal direction, consistent with bed width 49 shown in FIG. 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 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.

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 FIG. 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×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×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.

The floor component 300 for the structure 150 utilizing the roof component 400 shown in FIG. 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×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×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.

FIG. 2 shows a top schematic view of finished structure 150 shown in FIG. 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 FIG. 2; the orthogonal grid overlaid in FIG. 2 is 8E long and 8E wide; notably, the entire structure 150, including perimeter boards 310, preferably is bounded by this 8E by 8E orthogonal grid.

Roof portions 400a, 400b and 400c each can be identically dimensioned in the transverse direction. Alternatively, referring to FIG. 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 400b in the transverse direction for example, by ten to fifteen percent, or by at least the aggregate thickness of roof components 400a and 400b. This transverse direction dimensional increase is to reduce the chances of binding during the unfolding of roof portions 400b, 400c. In addition, as described in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 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.

In FIG. 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 FIGS. 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.

The shipping module 100 shown edge-on in FIG. 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 FIG. 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 FIG. 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 FIG. 1 and shown accordion folded (stacked) in FIG. 3, with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b. Wall component 200P, shown in FIGS. 2 and 3, is pivotally secured to floor portion 300b at the location of axis 105, and is vertically positioned against the outside of wall portions 200s-2 and 200s-4. In turn, floor portion 300b is vertically positioned proximate fixed space portion 102, with wall component 200P pending from floor portion 300b between floor portion 300b and wall portions 200s-2 and 200s-4.

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 FIG. 3, when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2) of approximately 28.625 inches (72.7 cm), and when its components are stacked and positioned as shown in FIG. 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.

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 FIGS. 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.

Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film 177 during fabrication and prior to forming the shipping module 100. Alternatively or in addition, the entire shipping module 100 can be sheathed in a protective film. Such protective films can remain in place until after the shipping module 100 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.

Shipping Module Transport

The shipping module is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Pat. 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 FIGS. 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

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 Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 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 FIGS. 11A and 11B thereof.

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 FIGS. 3 and 4) to an unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105 (shown in FIG. 3 behind perimeter board 312) to an unfolded position, (3) wall portions 200s-2 and 200s-4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2) respectively to unfolded positions, and (4) roof portions 400b and 400c are pivotally rotated about horizontal axes 405a and 405b (shown in FIGS. 3 and 4) respectively to unfolded positions. When accordion folded as a stack, it can be appreciated that the protective layer 218 of roof portion 400a is distal from the protective layer of roof portion 400b, whereas the protective layer 218 of roof portion 400b is in contact with, or proximate to, the protective layer of roof portion 400c. Thus in unfolding roof portions 400b and 400c, it is regarded herein that the protective layer 218 of the second component portion rotates toward the protective layer 218 of the first component portion 400a, whereas the protective layer 218 of the third component portion 400c rotates away from the protective layer 218 of the second component portion 400b.

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 Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 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 FIGS. 12A-14B thereof.

After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 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.

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) 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×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×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 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 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×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×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 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×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.
Clause 20. The folded building structure as in clause 11, further comprising 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×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 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×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×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 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×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.
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 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.

Claims

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×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.

2. The folded building structure as in claim 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 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×S.

3. The folded building structure as in claim 1, 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.

4. The folded building structure as in claim 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.

5. The folded building structure as in claim 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.

6. The folded building structure as in claim 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.

7. The folded building structure as in claim 2, further comprising a transversely oriented beam positioned between each adjacent pair of the first pairs of adjacent panel sections.

8. The folded building structure as in claim 7, further comprising a transversely oriented beam positioned between each adjacent pair of the second pairs of adjacent panel sections.

9. The folded building structure as in claim 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.

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 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×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.

11. The folded building structure as in claim 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×S.

12. The folded building structure as in claim 10, 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.

13. The folded building structure as in claim 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.

14. The folded building structure as in claim 11, 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.

15. The folded building structure as in claim 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.

16. The folded building structure as in claim 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.

17. The folded building structure as in claim 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×S.

18. The folded building structure as in claim 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.

19. The folded building structure as in claim 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.

20. The folded building structure as in claim 11, further comprising a transversely oriented beam positioned between each adjacent pair of the first pairs of adjacent panel sections.

21. The folded building structure as in claim 20, further comprising a transversely oriented beam positioned between each adjacent pair of the second pairs of adjacent panel sections.

22. The folded building structure as in claim 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.

23. The folded building structure as in claim 17, further comprising a transversely oriented beam positioned between each adjacent pair of the third pairs of adjacent panel sections.

24. The folded building structure as in claim 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.

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×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 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×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.

26. The folded building structure as in claim 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×S.

27. The folded building structure as in claim 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.

28. The folded building structure as in claim 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.

29. The folding building structure as in claim 25, further comprising a second floor portion having a fourth longitudinal edge and an opposed fifth 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.

30. The folded building structure as in claim 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×S.

31. The folded building structure as in claim 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.

32. The folded building structure as in claim 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.

33. The folded building structure as in claim 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.

34. The folded building structure as in claim 25, 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.

35. The folded building structure as in claim 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.

36. The folded building structure as in claim 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.

37. The folded building structure as in claim 26, further comprising a transversely oriented beam positioned between each adjacent pair of the third pairs of adjacent panel sections.

38. The folded building structure as in claim 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

39. The folded building structure as in claim 30, further comprising a transversely oriented beam positioned between each adjacent pair of the fourth pairs of adjacent panel sections.

40. The folded building structure as in claim 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.

41. The folded building structure as in claim 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.

42. The folded building structure as in claim 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 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.

43. The folded building structure as in claim 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.

44. The folded building structure as in claim 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.