ACTUATED FOLDABLE BUILDING SYSTEM MODULE

Abstract

A foldable building system module (FBSM) comprising an integrated deployable modular building system. The foldable building system module comprises prefabricated panels connected by hinges which allow the panels to be unfolded from a flat pack geometry to an unfolded, erected or deployed geometry. An actuating mechanism can be integrated in one or more of the panels and, by applying load to one or more of the panels, allow for automated erection of the module. Two or more of the FBSM's can be connected in series to provide a building system.

Description

BACKGROUND

The present disclosure generally relates to the construction of modular deployable integrated building systems. More specifically, the disclosure relates to the construction of foldable building modules.

Building systems are created through the integration of multiple systems to create occupiable space which provide shelter from the natural elements and typically serve a specific purpose. These systems include but are not limited to structural, enclosure, mechanical, electrical and plumbing systems. Conventional building systems are typically constructed in a sequenced or layered fashion, during which each system is installed independently of the other. This approach requires on-site coordination between trades resulting in longer construction schedules when compared with modular prefabricated alternatives.

The structural system must resist applied gravitational loads as well as the lateral loads which are typically the results of wind or seismic loading. While resisting these loads, structural systems must satisfy all strength and serviceability performance requirements based on the governing design code defined by the authority having jurisdiction. Strength requirements relate to the mechanical properties of the structural system and ensure that, over the lifespan of the building, none of the structural elements experience overstress or structural failure. Service requirements relate mainly to the allowable movement of structural systems to ensure occupant comfort is maintained. The structural system is typically fabricated and erected using discrete structural elements which include but are not limited to slabs, beams, columns, walls, braces and foundations. These elements are usually fabricated and erected using concrete, steel, aluminum & timber.

Depending on the function of a given building system, the enclosure system creates a watertight seal between interior and exterior spaces, while providing thermal and acoustic insulation as well as natural lighting to the space. A typical enclosure system consists of aluminum mullions supporting transparent/translucent panels which can be fixed or operable.

Similar to the enclosure systems, the complexity of the mechanical, electrical and plumbing systems are all subject to the operational requirements of the building system. The mechanical system typically relates to temperature and air quality control and is often integrated with the electrical and plumbing systems. The electrical system includes any building components which inhibit the transference of electricity for power or signaling and the plumbing system includes those which manage water transport within the building.

The variety of ways to achieve a deployable building system includes but is not limited to; trailered systems, light-weight framing+tensile membrane systems and foldable systems. Trailered systems are those which typically have all building system components prefabricated on top of a mobile trailer allowing for the system to be easily transported to site and rapidly deployed. These systems usually lack modular capabilities and have size limitations based on an allowable maximum payload size controlled by the local transportation authority. Light-weight framing+tensile membrane systems are typically constructed using a rigid framing which provides structural integrity that is combined with a membrane enclosure for water tightness. These systems are available in a wide range of sizes and can be deployed in a variety of terrains using relatively unskilled labor and basic construction equipment. One drawback of these systems is the lack of integration with other basic enclosure, mechanical, electrical & plumbing system components resulting in a limited range of applications. Foldable deployable systems are a relatively new system typology which is not typically utilized in building systems. These systems are often deployable from a condensed flat packed geometry allowing for efficient transport to erection sites. Strategic hinges are installed between flat panels allowing the system to change geometry on site and create a habitable enclosure. Many current systems required heavy construction equipment to unfold the geometry from its packaged state to the final building system geometry. This requirement for heavy equipment for deployment limits potential deployment sites and increases the level of skill required during erection.

Modular systems are those which are erected using smaller components which connect in a repetitive fashion to create a larger overall system. Modular systems typically take advantage of repetitive geometric patterns which can be aggregated many times over to create a variety of resulting geometric forms.

SUMMARY

Disclosed herein are one or more inventions relating to a foldable building system module (FBSM), a building system employing a FBSM, and methods for fabricating a building structure using plural FBSMs. Building structures employing the FBSMs can be referred to as integrated deployable modular building systems (IDMBSs). In some embodiments, the methods of erecting such building structures can be referred to as automated erection methods (AEMs).

The disclosed FBSM can provide a fully integrated module which performs as a structural system as well as a building enclosure system, while allowing for rapid deployment across a range of site typographies. Deployment of a FBSM occurs when a linear actuator is activated to transform a set of panels from a folder geometry into an unfolded building geometry by utilizing strategic hinges. Composite fiber reinforced polymer panels (composite FRP panels) can be used to prefabricate FBSMs to satisfy the performance requirements from both a structural and enclosure system standpoint. FBSMs can be integrated with additional building system components to achieve a modular building structure system. Further, an actuator (mechanical or otherwise) can be integrated and prefabricated into each FSBM to speed up construction and eliminate the need for heavy construction equipment.

As used herein:

“Prefabricated” means built in advance and transportable to an installation site for installation at the installation site.
“Modular” means a system which has been subdivided into smaller parts that can be put together on site to create an overall structure or system.
“FRP” means fiber reinforced polymer
“FRP Panel” means a composite fiber reinforced polymer panel which is made up of an external fiber reinforced polymer skin and a structural foam core which act compositely together structurally.
“Composite” means when two dissimilar materials are combined such that they act together to resist applied loads.
“Actuator” means a device which applies a force or forces to a system or elements, causing movement of the system or element.
“Track” means a component which guides the movement of a structural system element along a specified path.
“Hinge” means a component which connects two panels while allowing relative rotational motion about a single axis.
“Platform” means a base or substructure of components of a structural system which provide connectivity between a Superstructure above the Platform and a Foundation below the Platform.
“Superstructure” means a structural system above the “Platform”
“Foundation” means any system elements which directly transfer loads to earth or the ground.
“Gable roof” means a roof with two symmetric roof slopes which meet at a single ridge and are supported on walls below.
“Grade” means ground surface slope or degree of inclination. A level grade is a ground surface with relatively no slope or inclination.

In an embodiment, there is disclosed a foldable building system module comprising:

• • prefabricated panels connected by hinges;
  • an integrated actuator mechanism; and
  • deployable struts,
  • wherein,
    • the integrated actuator mechanism is connected to at least two of the panels to apply force to strategic points of at least two panels and cause the foldable building system module to unfold from a folded flat pack geometry into a deployed building geometry, and
    • the panels include prefabricated strut connection points to which the struts can be connected during the unfolding process, to impart structural stabilizing forces to the foldable building system module.

In an embodiment, at least one panel is prefabricated from a composite fiber reinforced polymer material.

In an embodiment, at least one panel is prefabricated from timber comprising cross laminated timber, dowel laminated timber, nail laminated timber or dimensional lumber.

In an embodiment, at least one panel is prefabricated with (a) a rigid frame which performs all required structural requirements and (b) a nonstructural infill panel received within the rigid frame.

In an embodiment, the foldable building system module comprises five panels including a base panel, two wall panels and two roof panels, each wall panel having a first edge connected to the base panel, each roof panel having a first edge connected to a respective second edge of the wall panels, and each roof panel having a second edge connected to the second edge of the other roof panel.

In an embodiment, the folded flat pack geometry includes the base panel on the bottom of the pack, the wall panels on the base panel, and the roof panels on the wall panels.

In an embodiment, the deployed, or unfolded building geometry includes the base panel in a horizontal orientation, the two wall panels connected to respective transverse edges of the base panel and in a vertical orientation, and the roof panels forming a gable roof.

In an embodiment, each of the panels have a planar geometry.

In an embodiment, at least one of the panels has a corrugated geometry.

In an embodiment, at least one of the panels has a curved geometry.

In an embodiment, at least one panel has integrated transparent or translucent panels prefabricated into it.

In an embodiment, at least one panel is without penetrations.

In an embodiment, each panel includes a continuous integrated waterproofing gasket around a perimeter of the panel.

In an embodiment, the waterproofing gasket is connected to the panel by means of an adhesive bond, or by being embedded into an extruded track.

In an embodiment, the waterproofing gasket is connected to the modular panel by embedment into an extruded track made from fiber reinforced polymer or aluminum.

In an embodiment, the waterproofing gasket is installed in the field using wet silicone.

In an embodiment, the hinges are integral to the panels and fabricated from the same material as the modular.

In an embodiment, the hinges are separate components which are connected to the panels.

In an embodiment, the actuator mechanism is embedded in a base panel.

In an embodiment, the actuator mechanism performs in a linear fashion.

In an embodiment, the actuator mechanism uses a screw jack type mechanism to convert rotation torque to linear motion.

In an embodiment, the actuator mechanism uses a winch mechanism to convert rotation torque to linear motion.

In an embodiment, the actuator mechanism utilizes a hydraulic jack to achieve linear motion.

In an embodiment, the actuator mechanism utilizes a belt drive to achieve linear motion.

In an embodiment, the actuator mechanism utilizes a series of electromagnets to create a magnetic levitation or propulsion system to achieve linear motion.

In an embodiment, at least one panel including an integrated deployable strut prefabricated into the at least one panel.

In an embodiment, the deployable struts are separate from the panels and can be connected to the connection points during unfolding of the folding building system module.

In an embodiment, the deployable struts comprise timber, aluminum, steel, or fiber reinforced polymer.

In an embodiment, there is provided a modular building comprising

• • a foundation system;
  • a platform on the foundation system;
  • an end wall system; and
  • plural foldable building system modules on the platform, each foldable building system module according a foldable building system module as set forth above.

In an embodiment, there is provided a modular building comprising:

• • foundation system;
  • a platform on the foundation system;
  • plural foldable building system modules on the platform, each foldable building system module as set forth above;
  • a plumbing circuit; and
  • an electrical circuit.

In an embodiment, the foundation system includes leveling mechanisms to level the platform.

In an embodiment, the foundation system includes ground screws to transfer structural forces from the modular building to earth.

In an embodiment, the foundation system includes cast-in-place or precast concrete footings to transfer structural forces from the modular building to earth.

In an embodiment, the foundation system includes one or more counterweights or ballasts to transfer structural forces from the modular building to earth.

In an embodiment, the platform includes beam elements and bearing elements.

In an embodiment, the beam elements comprise primary beam elements which connect directly to the foundation system and provide primary support of the foldable building system modules.

In an embodiment, the beam elements include secondary beam elements which space apart the primary linear elements.

In an embodiment, the bearing elements are located to spread heavy mechanical loads.

In an embodiment, there is provided a method of erecting a modular building comprising:

• • unfolding foldable building system modules next to each other in a series arrangement, each foldable building system module as set forth above; and
  • connecting the foldable building system modules together to form a single building structure.

In an embodiment, the foldable building system modules are placed directly on primary beam elements.

In an embodiment, adjacent foldable building system modules are connected to one another at discrete points.

In an embodiment, adjacent foldable building system modules are connected continuously along shared edges.

In an embodiment, the method also comprises extending a tension element through all adjacent foldable building system models and tightening the tension element to achieve a post tensioned effect resulting in diaphragm action across the adjacent foldable building system modules.

In an embodiment, end panels are erected at opposite longitudinal ends of the building structure.

In an embodiment, the end panels are either structural or non-structural in nature and achieve a watertight seal at the longitudinal ends of the building structure.

In an embodiment, an FBSM comprises

five composite FRP panels, including a base panel, two wall panels, and two roof panels, wherein:

• • the five composite FRP panels are connected by hinges,
  • deployable struts are used as locking mechanisms at hinge locations to stabilize the FBSM structure against lateral loads,
  • integrated waterproofing gaskets are provided on each panel to achieve a water tight seal at hinge locations between two FRP panels,
  • the FRP panels are flat packed for transportation to site, preferably connected via the hinges, and
  • a linear actuator is integrated in the base panel to translate the flat pack geometry into a final building system geometry.
    A hinge can either be made from FRP and are fabricated as part of the composite FRP panel, or made as a separate component which is connected to two FRP panels by way of fasteners. In the latter configuration, the hinge components can be made from steel, aluminum, or FRP.

In an embodiment, the deployable strut material is s steel, aluminum or timber.

In an embodiment, the deployable struts are brace-like elements which have a sloped configuration in the deployed state.

In an embodiment, the integrated waterproofing gasket is connected to the FRP panel by means of an adhesive bond, or by being embedded into an extruded track made from materials which include but are not limited to FRP and aluminum.

In an embodiment, a linear actuator is embedded in the base panel and applies force to a work point connected to the bottom of a wall panel.

In an embodiment, the linear actuator applies force to either one wall panel or both wall panels.

In an embodiment, the force of the linear actuator is achieved either by a screw jack mechanism, a winch mechanism, a hydraulic mechanism, a belt drive mechanism or an electromagnetic mechanism.

In an embodiment, the FBSM has two primary geometric states: a folded geometry and an unfolded geometry, wherein,

• • in the folded geometry, all five panels are relatively flat with the base panel on the bottom, the two wall panels above the base panel and the two roof panels above the wall panels, and
  • in the unfolded geometry, the base panel is the lowest panel and in a horizontal configuration, the two wall panels are connected to the transverse edges of the base panel via hinges and are in the vertical orientation, and the roof panels are in an inclined orientation, being connected to the top edges of the wall panels and to each other at the peak of the gable roof.

In an embodiment, penetrations in the FRP panels are provided and transparent or translucent panels are integrated in the FRP panels, allowing natural light to pass through the panel.

In an embodiment, FBSMs are integrated with a platform and foundation system, structural and enclosure end wall components, exterior stairs and ramps, mechanical/electrical equipment and a raised floor system, wherein:

• • The platform system guides the placement of and provides connection locations for the FBSMs.
  • The foundation system supports the platform system and superstructure system above. This system transfers all axial, shear and moment reactions from the structural system to ground.
  • The end wall components are fabricated using composite FRP material and serve to support the roof ridge, resist external lateral forces, close out the ends of the build systems to achieve a fully enclosed space and provide means of ingress and egress.
  • The exterior stairs and ramps are components which accommodate any difference in elevation between interior space and the exterior grade.
  • The mechanical equipment provides temperature and air quality control for the interior space.
  • The raised floor system provides a finished floor surface while creating a plenum space below the finished floor which is utilized for mechanical, electrical or plumbing components.

In an embodiment, the foundation system is selected from the group consisting of ground screws, cast-in-place or precast concrete footings and counterweight or ballast components. For each of these options, a leveling component can be included in the connection detail between the foundation and the platform to allow for a level structure on sites with varying topography.

In an embodiment, the platform system comprises a series of linear and bearing elements, wherein,

• • the primary elements run perpendicular to the FBSM and the secondary elements run parallel to the FBSM.
  • the primary elements are connected to the foundation elements via the leveling component described above.
  • the primary elements function as a track to guide the placement of the FBSMs and allow for linear movement of the FBSMs in the direction parallel to the primary elements.
  • the secondary elements act as spacers for the primary elements to ensure the platform layout is consistent with the FBSM geometry.
  • bearing blocks are provided over discrete areas as required to allow for support of excessive loads from Mechanical equipment.

In an embodiment, the erection of an integrated deployable modular building system (IDMBS) using FBSMs is performed over several steps, the steps comprising

• • Step 1—Layout foundation locations
  • Step 2—Install Foundation Components
  • Step 3—Install Primary platform elements
  • Step 4—Install secondary platform elements
  • Step 5—Install bearing block elements
  • Step 6—Place AFM on platform
  • Step 7—Erect the roof panels of the AFM using the linear actuator
  • Step 8—Install upper strut component to lock roof hinge
  • Step 9—Erect the first wall panel of the AFM using the linear actuator
  • Step 10—Install the lower strut at the base of wall 1
  • Step 11—Erect the second wall panel of the AFM using the linear actuator
  • Step 12—Install the middle strut at the top of wall 1
  • Step 13—Install the lower and middle struts of wall 2
  • Step 14—Adjust location of AFM using platform track system as required
  • Step 15—Connect adjacent AFM's if they are present
  • Step 16—Repeat steps 6-15 for additional FBSM based building geometry
  • Step 17—Install the end wall components
  • Step 18—Connect the end wall components to the FBSMs
  • Step 19—Install the mechanical, electrical and plumbing systems
  • Step 20—Install the raised floor system

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a single foldable building system module in its unfolded state consistent with the principles disclosed herein.

FIG. 2 is an exploded perspective view of the foldable building module illustrated in FIG. 1.

FIG. 3a is a plan view or view looking from above at the foldable building system module of FIG. 1.

FIGS. 3b and 3c are longitudinal and transverse (respectively) sections of the foldable building system module of FIG. 1 which illustrate in two dimensions the geometric relationship between each of a base panel 10, wall panels 11, and roof panels 12. Refer to FIG. 3a for section cut references for FIGS. 3b and 3c.

FIG. 4 is a sectional view of the folded geometry of a foldable building system module of FIG. 1.

FIGS. 5a-5d are perspective diagrams showing the applied force provided by the linear actuator 40 to transform the foldable building system module from a folded geometry to an unfolded geometry.

FIG. 6a is an exploded perspective view of the base panel of a foldable building system module.

FIG. 6b is an exploded perspective view of a left wall panel 11a.

FIG. 6c is an exploded perspective view of a roof panel 12.

FIG. 7a is an exploded perspective view of an exemplary integrated hinge.

FIG. 7b is an exploded view of an exemplary nonintegrated hinge

FIGS. 8a and 8b are sectional views of two illustrative tie configurations.

FIG. 9 is a perspective connection detail illustrating how a strut connection plate 23 can be connected to a roof panel 12.

FIG. 10a-10e are diagrammatic cross sections showing a variety of linear actuating mechanisms and their components that could be used to deploy a foldable building system module.

FIG. 11 is a two-dimensional section detail cut at a skylight in a roof panel 12.

FIG. 12 is a perspective view of an integrated deployable modular building system constructed using foldable building system modules.

FIG. 13 is an exploded perspective view of the integrated deployable modular building system of FIG. 12 showing the interconnection of each of the primary systems.

FIG. 14a-14d are a series of plan views of the integrated deployable modular building system taken at various elevations.

FIGS. 15a & 15b are elevations of the integrated deployable modular building system looking at the longitudinal and transverse side of the structure, respectively.

FIG. 16 is an interior section of the integrated deployable modular building system (refer to FIG. 14d for section cut locations).

FIG. 17 is a step by step erection diagram of an integrated deployable modular building system

FIG. 18 is a perspective view of the foundation system 100, the platform system 110 and a single foldable building system module 120.

FIG. 19 is section detail illustrating an exemplary connection between the foldable building system module 120 and a primary beam element 111 as well as how the foundation element 101 supports these primary beam elements.

FIG. 20a-20c are three potential foundation elements that can be utilized to transfer forces from the overall structural system to the ground.

FIG. 21a-21c are perspective views which illustrate potential strategies to connect adjacent foldable building system modules 120.

FIG. 22a-22e are perspective views of connection details between adjacent foldable building system modules.

FIG. 23 is a diagrammatic section of a heating ventilation and cooling (HVAC) system of an integrated deployable modular building system.

FIG. 24 is a diagrammatic section of an electrical system of an integrated deployable modular building system.

FIGS. 25a-25c are three-dimensional images of a single panel and illustrate alternative build ups that can be used to create the panels of an foldable building system module.

FIGS. 26a-26d are conceptual elevations of alternative panel and hinge geometries for a foldable building system module.

DETAILED DESCRIPTION

Reference will now be made in detail to one or more implementations of a foldable building system module consistent with the principles disclosed herein as illustrated in the accompanying drawings. Through integration with additional systems, the foldable building system module may provide the structural system as well as an enclosure envelope for a building system or other structure. The foldable nature of the modules allows for panels to unfolded from a flat pack geometry used for transportation into a building geometry which exhibits floors, walls and a roof. The modular nature of the foldable building system module allows flexibility such that a building system utilizing the foldable building system module may be expanded in size using two or more modules preferably connected as illustrated in the accompanying drawings and description. The prefabricated integrated nature of the modules allows them to be erected using relatively simple construction techniques and equipment during deployment.

Exemplary embodiments of the foldable building system module of this disclosure and systems employing the same are illustrated in the accompanying drawings and description. However, the foldable building system module may be implemented such that any combination of the primary component configurations (panel, hinge, actuator & enclosure) presented herein may be utilized at any point during the lifespan of a structural system to achieve a structural and/or enclosure system or other systems as disclosed herein. A foldable building system module consistent with principles disclosed herein enables the rapid deployment of on a variety of potential sites using relatively simple construction equipment. Additional benefits of the proposed disclosure include but are not limited to: an FBSM is lightweight and stackable making for easy packaging and transport, and easy reusability allowing for deployment on many different sites over the lifespan of the product; and plural FBSMs provide expandability of building system size through the addition of new foldable building system modules.

FIG. 1 is a perspective view of a single foldable building system module in its unfolded, deployed, or erected state consistent with the principles disclosed herein. As seen in FIG. 1, the foldable building system module includes a base panel 10, two wall panels 11 (11 collectively, 11a or 11b individually, as needed) and two roof panels 12 (12 collectively, 12a or 12b individually, as needed), all connected by five hinges 30 (30 collectively, 30a, 30b, 30c, 30d, or 30e individually, as needed). The hinges 30 allow the module to unfold from its packaged geometry to its final geometry on site. Structural struts and ties (20, 21 and 22) are connected to two or more panels to act as stabilizing elements to lock the hinge motion in the deployed state and provide stabilizing forces to the global structure. In this illustrative example, an integrated linear actuator component 40 is embedded into the base panel and applies a linear force to transform the module from its folded geometry to its unfolded or deployed state. Additionally, one or more continuous waterproofing strips 50 are present on the edge of base, wall and roof panels (10, 11 and 12 respectively). Penetrations with transparent or translucent infill panels 60 may be prefabricated into the panel to allow natural light and airflow into the building system.

FIG. 2 is an exploded perspective view of the foldable building system module described in FIG. 1. This FIG. 2 shows how five planar panels are oriented in the unfolded or deployed configuration and how each of these panels relates to one another. As shown, the base panel 10 is in a horizontal orientation relative to ground or earth. The wall panels 11 are in a vertical orientation relative to ground or earth with the bottom or first edge of each wall panel connecting to the respective transverse edges at opposite ends of the base panel 10 by means of hinges 30a and 30b. The roof panels 12 are in an inclined orientation and have their lower or first edge connecting to the corresponding second edge of a respective wall panel by means of hinges 30c and 30d with their upper or second edge connecting to each other by means of a hinge 30e and forming a gable ridge.

FIG. 3a is a plan view or view looking from above at the foldable building system module. In this illustrative example, penetrations 60 have been provided in roof panels 12 near the peak of the roof. The size and location of these penetrations may vary depending on building performance requirements.

FIGS. 3b and 3c are longitudinal and transverse (respectively) sections of the foldable building system module which illustrate in two dimensions the geometric relationship between each of the base panel 10, wall panels 11 and roof panels 12. Refer to FIG. 3a for section cut references for FIGS. 3b and 3c. Since the view is in two dimensions, it should be understood that preferably, the opposition side is a mirror image of the side shown, and this description refers to components on both sides.

As shown in FIG. 3b, in this illustrative example, lower struts 20 are connected to both the base panel 10 and the wall panel 11 at the hinge joint between these panels on both sides of the module. Similarly, struts 21 are connected to both the wall panel 11 and the roof panel 12 on both sides of the module and serve to lock the hinge joint between these panels. Lastly a single pair of tie elements preferably are connected to both roof panels to lock the top most hinge of the module located at the peak of the roof or the gable ridge. As can be appreciated, in addition to locking the hinge locations, these struts and ties also provide structural stabilization to resist both gravity and lateral applied loads.

FIG. 4 is a sectional view of the folded geometry of a foldable building system module. As shown in this illustrative example, in the folded or transport geometry, the base panel 10 is below the wall panels 11a and 11b which are below the roof panels 12a and 12b, all of which are in an approximate horizontal orientation during packaging and transport. In this section, the right hinge 30a is a “fixed” hinge location meaning that its location relative to the base panel 10 does not change while it allows rotation between the base panel 10 and the right wall panel 11a. The left hinge 30b is a “translational” hinge, meaning that this hinge assembly is allowed to translate along the longitudinal axis of the base panel 10 while allowing rotation between the base panel 10 and left wall panel 11b. It is at the translation hinge 30b that forces are applied by the linear actuator 40.

FIGS. 5a-5d are perspective diagrams showing the applied force provided by the linear actuator 40 to transform the foldable building system module from a folded geometry to an unfolded geometry. FIG. 5a is an illustrative example of the folded geometry in three dimensions or 3D which shows the relative locations of the fixed hinge 30a and the translational hinge 30b. FIG. 5b illustrates the linear force applied by the linear actuator 40 to the translational hinge 30b during which the translational and fixed hinges 30a and 30b are pulled relatively together to erect the roof panels 12. As noted above, the hinge 30a is fixed at one transverse edge of the base 10, and thus, in reality, only the hinge 30b translates.

It can be appreciated that as the hinges 30a and 30b are pulled together, this causes the roof panels 12 to be pushed together. The forces on the roof panels 12 in turn cause the panels 12 to act on the hinge 30e causing them to pivot about the hinge 30e and form a gable roof. At the end of this stage a pair of upper ties 22 are installed to stabilize the roof panels 12 through the rest of the erection process as well as in the final structural system. The next primary stage of erection is illustrated in FIG. 5c during which the force applied by the linear actuator 40 is reversed to then push the translational and fixed hinges 30a and 30b relatively apart from one another to bring the wall panels 11 to their vertical positions. Again, given that hinge 30a is fixed, it is hinge 30b that translates along base 10. During this stage, there is an intermediate locking step. Once the wall panel 11a is in the vertical orientation, the lower struts 20a located at the corner defined by the wall 11a and the base 10 are installed. Following this intermediate step, the linear actuator 40 continues to push the hinges 30a and 30b relatively apart from one another until the other wall panel 11b is erected, i.e., is in its vertical position. During this stage of the erection process, pivoting action occurs at hinges 30c and 30d until wall panel 11b is vertical. After both wall panels 11a and 11b are in a vertical orientation, the remaining struts 20b and 21 are installed.

FIG. 6a is an exploded perspective view of the base panel of a foldable building system module. In this illustrative example, the base panel 10 is fabricated using a composite fiber reinforced panel which has a fiber reinforced polymer shell with a structural insulation core. Strut connection plates 23 can be prefabricated into the base panel allowing for easy strut connections during the erection process. In this exemplary diagram, a screw jack is shown as the linear actuating mechanism that is integrated into the base panel and will be described in detail here. Alternative actuating mechanisms may be utilized to achieve the same resulting motion and are described in connection with later figures.

Preferably three longitudinally extending tracks are embedded in the base panel 10. A middle actuator track 40d houses a threaded rod 40c and at each end of the actuator track are bearing blocks 40f. These bearing blocks allow the threaded rod to spin freely while transferring force between the base panel and a thrust block 40a. As the threaded rod 40c is rotated, this rotational torque is translated into linear motion through the threaded thrust block 40a. The thrust block is rigidly connected to the translational hinge 30b such that the two move together. Two guide tracks 40e which are parallel to and on opposite sides of the actuator track 40d provide additional lateral stability to the translational hinge 30b. Guide blocks 40a run inside the guide tracks 40e and also are rigidly connected to the translational hinge 30b. Again, the fixed hinge 30a is rigidly connected to the base panel 10 and is used to connect the left wall panel 11a to the base panel 10. A continuous waterproofing gasket 51 is provided to ensure a watertight seal is achieved between adjacent foldable building system modules as well as at hinge locations.

FIG. 6b is an exploded perspective view of a left wall panel 11b. Similar to the base panel, in this illustrative example the wall panels 11a and 11b are fabricated using a composite fiber reinforced panel which has a fiber reinforced polymer shell with a structural insulation core. They include strut connection plates 23 at strategic locations and a continuous waterproofing gasket 51.

FIG. 6c is an exploded perspective view of a roof panel 12. Similar to the base panel, in this illustrative example the roof panels 12 are fabricated using a composite fiber reinforced panel which has a fiber reinforced polymer shell with a structural insulation core. They include strut connection plates 23 at strategic locations and a continuous waterproofing gasket 51, as well as a flexible shingle 52 at the roof ridge.

In each of the FIGS. 6a, 6b and 6c, hinge pins 31 are provided which connect adjacent panels at hinge locations.

FIG. 7a is an exploded perspective view of an exemplary integrated hinge. In this configuration hinge collars 32a and 32b are prefabricated into the wall panel 11a and roof panel 12. A common pin 31 is installed through these collars which ties the two panels together while allowing rotation. As can be appreciated, this type of integrated hinge may be achieved with a variety of collar geometries which shall be considered as part of this embodiment. In this example, the wall panel has the one collar 32a centrally located on the edge of the panel and the roof panel has two collars 32b which flank the collar 32a when secured together by pin 31. It can be appreciated that the arrangements of the collars can be reversed. Further a given hinge can have more than three collars in any arrangement, for example, like a traditional door hinge or a piano hinge.

FIG. 7b is an exploded view of an exemplary non-integrated hinge. In this hinge configuration both the wall panel 11a and the roof panel 12 have simplified geometries and are connected together using a separate hinge component 33 which allows rotation between the two panels relative to each other. This hinge component 33 is connected to each panel via structural fasteners 33a. It can be appreciated that this hinge component 33 can also be connected to the panels using some for epoxy bonding or an alternative fastener configuration.

FIGS. 8a and 8b are sectional views of two illustrative tie configurations for the upper tie 22. In FIG. 8a the upper tie 22 is installed in a horizontal configuration, however it can be appreciated that the upper tie function can be performed by a pair of diagonal ties 22a as shown in FIG. 8b.

FIG. 9 is a perspective connection detail illustrating how a strut connection plate 23 is connected to a typical roof panel 12. In this example, the roof panel is notched at an outer side of an underside edge to allow the connector plate 23 to be recessed, allowing for a flush connection between adjacent foldable building system modules. Of course, such notches can be provided at all the connection points of all of the struts. Connection hardware 23a is used to structurally connect the connector plate 23 to the roof panel 12. A strut connection pin 23b is used to structurally connect the strut 21 and the strut connection plate 23. This FIG. 9 also shows how the double lines of waterproofing gaskets 51 run past the connector plate 23 to ensure a continuous watertight seal. It can be appreciated that similar detailing is utilized at other strut and tie connection locations.

As previously discussed in FIG. 6a, alternative linear actuators to the screw jack mechanism may be used to achieve the folding motion of the foldable building system module. FIG. 10a-10e are diagrammatic cross sections showing a variety of linear actuating mechanisms and their components that could be used. FIG. 10a shows a screw jack mechanism which includes a thrust block 40a which travels along the threaded rod 40c inside an actuator track 40d. The threaded rod is supported at each end by bearing blocks 40f which allow for smooth rotation of the threaded rod 40c in tension. FIG. 10b illustrates a winch actuator which utilizes a winch 41a, a drive cable 41b, a sliding track 41c and a cable connector 41d which transfer force from the actuator to the wall panel being moved. FIG. 10c illustrates a belt driven actuator system which includes a belt drive motor 42a, a drive belt 42b, a sliding track 42c and a belt driven thrust block 42d. FIG. 10d shows a magnetic levitation actuator system which uses levitation, guidance and propulsion electromagnetic coils 43a embedded in an actuator track 43b which impose electromagnetic forces on a permanent magnet 43c. FIG. 10e shows a hydraulic piston actuator system which has a hydraulic jack 44a embedded in an actuator track 44b both of which are anchored to the base panel 10.

FIG. 11 is a two-dimension section detail cut at a skylight in the roof panel 12. In this detail, a prefabricated skylight panel 61 is inserted into a roof panel 12 penetration. A continuous waterproofing gasket 51 is provided to ensure a watertight seal is achieved and silicone or epoxy is applied to the perimeter of the skylight panel 61 to connect it to the roof panel 12.

FIG. 12 is a perspective image of a deployable modular building system constructed using a foldable building system module such as described herein. By combining a series of foldable building system modules 120 with other critical building systems, a complete building system is achieved which can be used for a variety of programs. In this FIG. 12, five foldable building system modules 120 are connected in series. The building system modules 120 are erected on a platform system 110 which is supported on a foundation system 100 that transfers loads directly to the earth. At each end of the series of foldable modules are entry modules 130 and end wall modules 140 which close out the building system and allow for ingress and egress as well as allow for natural light to enter the space. Ramp and stair systems 180 are provided at least one end of the building system to accommodate any change in elevation between the exterior grade and the interior finished floor.

FIG. 13 is an exploded perspective view of the deployable modular building system showing the interconnection of each of the primary systems. In addition to the system illustrated and described in FIG. 12, FIG. 13 includes: the heating ventilation and cooling (HVAC) system 150 which is embedded in the end wall panels 140, the electrical system 160, the raised floor system 170, the exterior stair and ramp system 180 and the lighting system 190.

FIG. 14a is a plan view of the foundation and platform system 100 and 110 respectively. Grid lines have been provided in this and other plans at the interface between adjacent foldable building system modules for reference. Discrete foundation elements 101 are provided at each grid line. These foundation elements are primarily located along grid lines A, B & C where grid lines A & C align with the foldable building system module walls, and grid line B aligns with the foldable building system modules gable ridge. Additional foundation elements 101a are provided below the end walls at grid lines 1 & 6 as required based on building system behavior.

The platform system is composed of primary beam elements 111 which align with grid lines A, B & C. Foldable building system modules connect directly to these primary beam elements 111. Details of one such connection are discussed below in connection with FIG. 19. Secondary beam elements 112 are provided which run perpendicular to the primary beam elements 111 at each of the numbered grid lines. These secondary beam elements 112 act as spacer elements to guide the placement of the primary beam elements. As can be appreciated, lesser or more grids of both primary or secondary beam elements can be provided based on structural and construction requirements. In addition to these beam elements, bearing pads 113 are also included in the platform system to support heavy concentrated loads from heavy equipment. The size and location of these bearing pads 113 will depend on the loading requirements of a particular building design. In this exemplary description, the bearing pads 113 are provided below the closet which houses the HVAC equipment (refer to FIG. 14b).

FIG. 14b is a plan view of the foldable building system modules 120 connected in series showing the base panels 10 of each foldable building system module. FIG. 14b illustrates the locations of the four entry modules 130 as well as the end wall modules 140 along grid lines 1 & 6. As can be seen in this plan, the HVAC systems 150 are located at one end of the building system and are embedded in a closet which is integrated with the end wall module 140. Similarly, the electrical system 160 is also embedded in the end wall module 140.

FIG. 14c is a plan view showing the area over which the raised floor system 170 is applied. As can be seen, in this illustrative example the raised floor extends over the entire interior area of the building system except for within the end wall modules 140. Additionally, this FIG. 14c plan illustrates the exterior stair and ramp system components which are: the stair 181, the ramp 182 and the porch 183 which make up the elevation difference between the exterior grade and raised floor system 170.

FIG. 14d is a roof plan of the deployable modular building system similar to FIG. 14b plan. This roof plan shows how five foldable building system modules are connected in series to create the building system roof and walls. In this illustrative example, the two modules at each end of the series are without roof penetrations due to conflict with the end wall modules. As can be appreciated, panel penetrations may vary between modules while still achieving a repetitive modular building system.

FIG. 15a is an elevation of the deployable modular building system looking at the longitudinal side of the structure. Similarly, FIG. 15b is an elevation of the deployable modular building system looking at the transverse side of the structure (refer to FIG. 14d for section cut locations).

FIG. 16 is an interior section of the deployable modular building system (refer to FIG. 14d for section cut locations). In this illustrative example, the raised floor system 170 is shown above the foldable building system modules base panel 10. The lower strut 20 is concealed below the raised floor system 170. The interior lighting fixtures 190 are hung from the upper tie's 22 connector plates 23, however it can be appreciated that interior lighting fixtures 190 can be hung from a number of different points in the system.

FIG. 17 is a step by step erection diagram of a deployable modular building system that has been described above. Below is a list of the steps shown in this FIG. 17 as well as the primary components/systems which are installed during each step. A brief description has been provided for each step outline the primary tasks which are to be completed which are consistent with the embodiment described herein.

• • Step 1—Install Foundation Components 100: Grounds screws are screwed into the ground at coordinated locations which will receive the primary beam elements 111 of the platform system.
  • Step 2—Install Platform system 110: Primary beam elements 111 are connected to the foundation elements 101 while using the secondary beam elements 112 to position the primary beams, after which bearing pad elements 113 are installed.
  • Step 3—Set foldable building module 120 on to platform system: Flat packed foldable building system module 120 is placed onto the primary beam elements close to their final location.
  • Step 4—Erect foldable building system module 120 (refer to prior figures and descriptions for erection steps): Shift the foldable building system module 120 along the primary beam elements 111 as required to lock in the foldable module at the correct location and make connection between adjacent foldable modules 120.
  • Step 5—Repeat steps 3 and 4 until the desired number of foldable building system modules are installed and erected: as described in step 4, the primary beam elements 111 of the platform system act as support and for the foldable building system module 120 but also provide a track to move the foldable modules 120 in a direction parallel to the primary beam element 111.
  • Step 6—Install end wall module: Connect the end wall modules 140 via structural connectors to the end most foldable building system module 120.
  • Step 7—Install entry module: Connect the entry modules 130 to the end most foldable building system module 120.
  • Step 8—Install exterior ramp and stairs: as required install the exterior access stairs 181, ramp 182 and porch 183 to one or both ends of the modular building system.

FIG. 18 is a perspective view of the foundation system 100, the platform system 110 and a single foldable building system module 120. In this illustrative FIG. 18, the primary beam elements 111 act as tracks to allow linear sliding motion of the foldable building system module 120.

FIG. 19 is section detail illustrating an exemplary connection between the foldable building system module 120 and the primary beam element 111 as well as how the foundation element 101 supports these primary beam elements. As shown in the FIG. 19, a leveling component 102 is installed between the ground screw 101a and primary beam element 111. Connection hardware 102a is used to connect the foundation ground screw 101a and the primary beam element 111. In this example, the primary beam element 111 is an upturned channel section which provides the track which receives a sled rail component 10a. This sled rail 10a is prefabricated with the foldable building module and structurally connected to the underside of the base panel 10. In this example, a thru bolt with nuts and washers 111a is used to connect the primary beam element 111a to the sled rail component 10a As can be appreciated, the track section of the primary beam element 111 and the sled rail 10a can come in a variety of sectional profiles, as long as a nesting action occurs between these two components to allow for controlled linear motion of the panel atop the platform system 110.

FIG. 20a-20c are three potential foundation elements that can be utilized to transfer forces from the overall structural system to the ground. These components are responsible for transferring three primary base reactions to the ground: Compression (downward forces), Tension (upward forces) and Shear (lateral forces). FIG. 20a shows a ground screw type foundation 101a. This type of foundation is screwed into the earth by hand or using mechanical equipment to engage enough of the earth to resolve the primary base reactions. A variation of this foundation may also be utilized which has an auger type geometry. FIG. 20b illustrates an alternative foundation type which is a concrete pier 101b. This option is achieved using either cast-in-place or precast concrete components. In this system, a series of concrete blocks or piers is embedded in the ground with sufficient bearing area to resolve the primary base reactions. FIG. 20c is a third alternative foundation option which is achieved using strip bearing elements 101c and counterweights 101d. In this system, strip bearing elements 101c and counterweights 101d sit directly on the grade with sufficient bearing area to ensure the allowable soil bearing pressure is not exceeded. The counterweights 101d must possess sufficient weight to ensure no global uplift occurs during lateral loading cases.

FIG. 21a-21c are perspective views which illustrate potential strategies to connect adjacent foldable building system modules 120. FIG. 21a illustrated the preferred embodiment in which adjacent panels are connected at discrete points 25. Alternatively, FIG. 21b illustrates a system in which continuous connection 26 between adjacent panels is made to distribute structural forces across the entire joint. Another alternative is provided by FIG. 21c in which tensioning elements 27 are connected across all panels (these may be embedded in the panels or external) and tensioned once all panels are installed to achieve a global clamping force. The purpose of all three of the options is to achieve a continuous structural system from a series of independent foldable building system modules.

FIG. 22a-22c are perspective views of connection details between adjacent foldable building system modules. For reference, all of these details have been drawn at the interface between two roof panels 12. FIG. 22a illustrates an example of a discrete dowel type connector between two adjacent modules. In this detail, a dowel connector plate 24a is connected to one of the panels and acts as the male portion of the connection while a corresponding recess and dowel bearing plate (female portion) 24b is connected to the adjacent panel. When the two panels are brought together, the dowel connector plate 24a is inserted into the dowel bearing plate 24b creating a shear transfer mechanism allowing compressive and shear forces to transfer between panels. FIG. 22b illustrates a similar type of connection which is a continuous tongue and groove connection detail. As seen in this detail, a continuous tongue insert 26a is connected to one panela and a corresponding groove insert 26b is connected to the adjacent panel. Like the detail described in FIG. 22a, when the panels are brought together and the continuous tongue is inserted into the groove, a compressive and shear force transfer mechanism is created between the two panels. As can be appreciated, both details 22a and 22b can be achieved without the female insert with direct bearing occurring on the foldable module surface. FIG. 22c is a 3D view illustrating how a post tensioning cable 27b can be run through prefabricated sleeves 27a. This cable 27b can run through all adjacent panels and can be tensioned from an end bearing point to act to pull adjacent panels together.

FIG. 22d illustrates a clamping connection detail. In this illustrative example, these locations correspond to the strut connection plates 23. An additional hole is provided in the strut connection 23 to allow for a clamping bolt 23c to be installed once adjacent panels have been erected next to one another. An alternative discrete clamping connection detail is provided in the perspective view shown in FIG. 22e. In this illustration, an embedded latch 25a is connected to two adjacent panels. When the panels are brought together and this latch is engaged a clamping force is applied at these locations.

FIG. 23 is a diagrammatic section of the heating ventilation and cooling (HVAC) system of the modular building system. As previously described, the HVAC unit 151 is housed within the end wall module 140. Air is brought into the system through a series of exterior louvers 152 on the exterior face of the building system. This air is pushed through HVAC ducts 153 and forced into the space through a perforated supply panel 154. After circulating through the space, the air enters through floor return grills 155 which are integrated into the raised floor system 170. The return air then travels below the raised floor system 170 and is exhausted out of the system through an exhaust vent 156.

Similar to FIG. 23, FIG. 24 is a diagrammatic section of the electrical system. The electrical system is fed by an external power source 161 which includes but is not limited to; existing municipal power supply, diesel generator, hydrogen fuel cells or solar power array. This power passes through a step-down transformer 162, generator connection cabinet 163 and a panel board 164 as required. Following this the power is transferred through electrical conduit to local receptacles or outlets 165.

FIGS. 25a-25c are three-dimensional images of a single panel and illustrate alternative build ups that can be used to create the panels of an foldable building system module. FIG. 25a shows a composite FRP option in which an external fiber reinforced polymer shell 13a acts compositely with the internal structural foam core 13b. FIG. 25b shows an alternative configuration in which a perimeter rigid frame 14a is used to provide the structural capacity of the panel and a lightweight infill panel 14b is prefabricated within the frame. FIG. 25c is another alternative configuration in which timber planks 15 are used to build up a larger timber panel. For each of these figures a section has been provided below to help illustrate the concept.

FIGS. 26a-26d are conceptual elevations of alternative panel and hinge geometries which are also considered potential forms for the system described above. It should be noted that each of these geometries represent the unfolded geometry of the module. As can be seen in these figures, the number and relative orientation of panels 01 can vary as well as the number and location of the hinges 02. by slightly modifying the actuator location and point of application of the actuator forces. As can be appreciated, each of these forms can be unfolded from a flat pack geometry into the geometry shown in these FIGS. 26a-26d.

The forgoing description of an implementation of the disclosure has been present for the purpose of illustration and description. It is not exhaustive and does not limit the disclosure to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing the disclosure. Accordingly, while various embodiments of the present disclosure may have been described, it will be apparent to those of skill in the art that many more embodiments and implementations are possible that are within the scope of this disclosure. Accordingly, the present disclosure is not to be restricted except in light of the attached claims and their equivalents

Claims

1. A foldable building system module comprising:

prefabricated panels connected by hinges;

an integrated actuator mechanism; and

deployable struts,

wherein, the integrated actuator mechanism is connected to at least two of the panels to apply force to strategic points on the at least two panels and cause the foldable building system module to unfold from a folded flat pack geometry into a deployed building geometry, and the panels include prefabricated strut connection points to which the struts can be connected during the unfolding process, to impart structural stabilizing forces to the foldable building system module.

2. The foldable building system module of claim 1, wherein at least one panel is prefabricated from a composite fiber reinforced polymer material.

3. The foldable building system module of claim 1, wherein at least one panel is prefabricated from timber comprising cross laminated timber, dowel laminated timber, or nail laminated timber.

4. The foldable building system module of claim 1, wherein at least one panel is prefabricated with (a) a rigid frame which performs all required structural requirements and (b) a nonstructural infill panel received within the rigid frame.

5. The foldable building system module of claim 1, comprising five panels including abase panel, two wall panels and two roof panels, each wall panel having a first edge connected to the base panel, each roof panel having a first edge connected to a respective second edge of the wall panels, and each roof panel having a second edge connected to the second edge of the other roof panel.

6. The foldable building system module of claim 5, wherein the folded flat pack geometry includes the base panel on a bottom of the pack,the wall panels about on the base panel, and the roof panels on the wall panels.

7. The foldable building system module of claim 5, wherein the deployed building geometry includes the base panel in a horizontal orientation, the two wall panels connected to respective transverse edges of the base panel and in a vertical orientation, and the roof panels forming a gable roof.

8. The foldable building system module of claim 1, wherein each of the panels has a planar geometry.

9. The foldable building system module of claim 1, wherein at least one of the panels has a corrugated geometry.

10. The foldable building system module of claim 1, wherein at least one of the panels has a curved geometry.

11. The foldable building system module of claim 1, wherein at least one panel has integrated transparent or translucent panels prefabricated into it.

12. The foldable building system module of claim 1, wherein at least one of the panels is without penetrations.

13. The foldable building system module of claim 1, wherein each panel includes a continuous integrated waterproofing gasket around a perimeter of the panel.

14. The foldable building system module of claim 13, wherein the waterproofing gasket is connected to the panel by means of an adhesive bond, or by being embedded into an extruded track.

15. The foldable building system module of claim 13, wherein the waterproofing gasket is connected to the modular panel by embedment into an extruded track made from fiber reinforced polymer or aluminum.

16. The foldable building system module of claim 1, wherein the hinges are integral to the panels and fabricated from the same material as the modular.

17. The foldable building system module of claim 1, wherein the hinges are separate components which are connected to the panels.

18. The foldable building system module of claim 1, wherein the actuator mechanism is embedded in a base panel.

19. The foldable building system module of claim 1, wherein the actuator mechanism performs in a linear fashion.

20. The foldable building system module of claim 1, wherein the actuator mechanism uses a screw jack type mechanism to convert rotation torque to linear motion.

21. The foldable building system module of claim 1, wherein the actuator mechanism uses a winch mechanism to convert rotation torque to linear motion.

22. The foldable building system module of claim 1, wherein the actuator mechanism utilizes a hydraulic jack to achieve linear motion.

23. The foldable building system module of claim 1, wherein an integrated deployable strut is prefabricated into at least one panel.

24. The foldable building system module of claim 1, wherein the deployable struts are separate from the panels and can be connected to the connection points during unfolding of the folding building system module.

25. The foldable building system module of claim 1, wherein the deployable struts comprise timber, aluminum, steel, or fiber reinforced polymer.

26. A modular building comprising: plural foldable building system modules on the platform, each foldable building system module according to claim 1;

a foundation system;

a platform on the foundation system;

an end wall system;

a plumbing circuit; and

an electrical circuit.

27. The modular building of claim 26, wherein the foundation system includes leveling mechanisms to level the platform.

28. The modular building of claim 26, wherein the foundation system includes ground screws to transfer structural forces from the modular building to earth.

29. The modular building of claim 26, wherein the foundation system includes cast-in-place or precast concrete footings to transfer structural forces from the modular building to earth.

30. The modular building of claim 26, wherein the foundation system includes one or more counterweights or ballasts to transfer structural forces from the modular building to earth.

31. The modular building of claim 26, wherein the platform includes beam elements and bearing elements.

32. The modular building of claim 31, wherein the beam elements comprise primary beam elements which connect directly to the foundation system and provide primary support of the foldable building system modules.

33. The modular building of claim 31, wherein the beam elements include secondary beam elements which space a part the primary linear elements.

34. The modular building of claim 32, wherein the bearing elements are located to spread heavy mechanical loads.

35. A method of erecting a modular building comprising:

unfolding foldable building system modules next to each other in a series arrangement, each foldable building system module according to claim 1; and

connecting the foldable building system modules together to form a single building structure.

36. The method of claim 35, wherein the foldable building system modules are placed directly on the primary beam elements.

37. The method of claim 36, wherein adjacent foldable building system modules are connected to one another at discrete points.

38. The method of claim 36, wherein adjacent foldable building system modules are connected continuously along shared edges.

39. The method of claim 36, comprising extending a tension element through all adjacent foldable building system models and tightening the tension element to achieve a post tensioned effect resulting in diaphragm action across the adjacent foldable building system modules.

40. The method of claim 36, wherein end panels are erected at opposite longitudinal ends of the building structure.

41. The method of claim 41, wherein the end panels are either structural or non-structural in nature and achieve a watertight seal at the longitudinal ends of the building structure.

42. The method of claim 36, wherein at least one of the end panels includes a door opening.