UNIVERSAL PANEL

Abstract

An enclosure component for a building structure is provided and includes a first structural panel arranged in a side-by-side relationship with a first edge of a first extension spline, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel. The component includes a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel. The component includes a first structural panel arranged in a side-by-side relationship with a first edge of a second extension spline, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/388,366, which was filed on Jul. 12, 2022. The entire content of the foregoing provisional application is incorporated herein by reference.

BACKGROUND

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, in an effort to reduce costs. In this regard, a significant advancement is embodied in the Boxabl® foldable transportable dwelling unit, which consists of a number of enclosure components (four wall components, a floor component and a roof component), and portions thereof, which are dimensioned, positioned and folded together to form a compact shipping module 15, as shown in FIG. 1A. The enclosure components and enclosure component portions are dimensioned so that the shipping module 15 is within applicable highway dimensional restrictions. As a result, shipping module 15 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize load permits. Thus, the basic components of structure 150 can be manufactured in a factory, positioned and joined together to form the shipping module 15, and the modules 15 can then be transported to the desired site for the structure, where they can be readily deployed (unfolded) to yield a relatively finished structure 150, which is shown in FIG. 1B.

The use of factory manufacturing also has the potential to reduce manufacturing costs. For example, manufacturing improvements can advantageously reduce both assembly time and labor costs. Relatedly, traditional home construction utilizes a great number of parts of different types. To capitalize on the efficiency of factory manufacturing, it is therefore desirable to reduce the variety of parts needed for dwelling assembly.

SUMMARY OF THE INVENTION

The present invention constitutes an advancement in enclosure component design that reduces the number of core elements needed to manufacture the floor, roof and wall components of a dwelling unit.

In one aspect, the present invention is directed to an enclosure component for a building structure, where the enclosure component comprises a first structural layer, a core layer and a second structural layer. The first structural layer has a first face, an opposed second face and comprises a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline arranged in a side-by-side relationship with a second structural panel of magnesium oxide. The core layer has a first face, an opposed second face and comprises a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, with a second edge of the foam spline opposed to the first edge of the foam spline arranged in a side-by-side relationship with a second foam panel, and with the first face of the core layer bonded to the second face of the first structural layer. A first lap joint spline of magnesium oxide is positioned between the first extension spline of the first structural layer and the first face of the core layer, and joins the first and second structural panels of the first structural layer. The second structural layer has a first face, an opposed second face and comprises a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, and with the second face of the core layer bonded to the first face of the second structural layer. A second lap joint spline of magnesium oxide is positioned between the second extension spline of the second structural layer and the second face of the core layer, and joins the first and second structural panels of the second structural layer.

In accordance with embodiments of the present disclosure, an exemplary enclosure component for a building structure is provided. The enclosure component has a length, a width and a thickness. The enclosure component includes a first structural layer having a first face, an opposed second face and including a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide. The enclosure component includes a core layer having a first face, an opposed second face and including a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer. The enclosure component includes a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer. The enclosure component includes a second structural layer having a first face, an opposed second face and including a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer. The enclosure component includes a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.

The second extension spline can be proximate to the foam spline in a superposed relationship. The first extension spline can be distal from the foam spline. A surface of the first foam panel coinciding with the first face of the core layer can include a recess to receive the first extension spline. A portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline can define a recess to receive a first edge of the second lap joint spline, and a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline can define a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.

The enclosure component can include a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer. The enclosure component can include a channel formed within the foam spline proximate to a second surface of the rigid beam. The channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.

The foam spline can include a series of keys along the first edge of the foam spline and along the second edge of the foam spline. The first foam panel can include slots at first and second abutting edges. The second foam panel can include slots at first and second abutting edges. The series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.

The foam spline can include a rigid beam disposed therein and extending a length of the foam spline. The foam spline can include a channel disposed adjacent to the rigid beam and extending the length of the foam spline.

The first lap joint spline can be positioned under the first extension spline. The first lap joint spline can define a width dimensioned greater than a width of the first extension spline. The first lap joint spline can underlie the first extension spline and at least a portion of each of the first structural panel and the second structural panel. The first face of the core layer can include a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.

The first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer. A position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer. Seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset. Seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.

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. 1A is a perspective view of a folded building structure (a shipping module), and

FIG. 1B is a perspective view of an unfolded building structure.

FIG. 2 is a top schematic view of the structure shown in FIG. 1B.

FIG. 3 is an end view of a shipping module as shown in FIG. 1A, from which is formed the structure shown in FIG. 1B.

FIG. 4 is an exploded perspective view of the panel of the present invention.

FIG. 5 is an exploded side view of the panel of the present invention.

FIG. 6 is a side view of the panel of the present invention showing certain details of the foam spline and lap joint spline of the present invention.

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. 1-3. When fully unfolded, as exemplified by FIG. 1B, 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. 1A, 1B and 2, the perimeter of structure 150 is defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge 116 and second transverse edge 110. For convenience, a direction parallel to first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction, a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction; and a direction parallel to the vertical direction in FIG. 1B 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 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 single universal panel 165, which is characterized by a series of repeating elements to form an enclosure component 155 of an arbitrary size, as desired.

The panel 165 utilizes a multi-layered, laminate design generally shown in FIG. 4. The elements of panel 165 comprise a core layer 160, a first structural layer 170 and a second structural layer 180.

As shown in FIGS. 4 and 5, core layer 160 comprises one or a series of repeating core units 161_i, i in number, where i=1, 2, . . . m. A core unit 161 comprises a planar foam panel 163 adjoining a foam spline 164, and each core unit 161 is the same as the other core units 161; i.e., core unit 161₁, core unit 161₂ . . . core unit 161_m are the same. In the case where i≥2, m number of core units are arranged in a side-by-side, contacting relationship to form a core layer 160 of arbitrary length; i.e., foam panel 163₁, foam spline 164₁, foam panel 163₂, foam spline 164₂, . . . foam panel 164_m, foam spline 164_m. Thus the general relationship where i≥2 is a core unit 161_k positioned adjacent to a core unit 161_k+1, where 0<k≤m. The mating of foam panels 163 with foam splines 164 can be facilitated by providing a series of keys 166a along the edge of foam spline 164, shown generally in FIG. 4, which are received in corresponding slots 166b located along the abutting edge of foam panel 163. Foam panels 163 can be made for example of expanded polystyrene (EPS) or polyurethane foam.

Each foam spline 164 has an elongate cuboid shape characterized by a foam spline length (“X” direction in FIG. 4) greater than the foam spline width (“Y” direction in FIG. 4) or the foam spline thickness (“Z” direction in FIG. 4), as shown in FIG. 4. Foam splines 164 can be made of the same material as foam panels 163, such as expanded polystyrene (EPS) or polyurethane foam. There is provided within each foam spline 164 a rigid beam 167, shown end-on in FIG. 6, which has an elongate cuboid shape of six surfaces characterized by a beam length (the dimension in the “X” direction, into/out of the drawing shown in FIG. 6) greater than the beam width or the beam thickness, and in the embodiment shown the beam width is greater than the beam thickness. A first surface of beam 167 whose area is defined by the length and width of beam 167 is coplanar with a first surface of foam spline 164. A second surface of beam 167, which is opposed to the first surface of beam 167 and is distal from the first surface of foam spline 164 (referenced above), is proximate to a channel 169, shown end-on in FIG. 6. Channel 169 is formed in the interior of foam spline 164 and runs the length of foam spline 164. Each beam 167 can be made for example of laminated veneer lumber.

Referring particularly to FIG. 5, the first structural layer 170 comprises first structural units 1711, i in number, where i=1, 2, . . . m. A first structural unit 171 comprises a planar first structural panel 211 adjacent a planar first extension spline 212 that is coplanar with the first structural panel 211. In the case where i≥2, m number of first structural units 171 are arranged in a side-by-side, contacting relationship (first structural panel 211₁, first extension spline 212₁, first structural panel 211₂, first extension spline 212₂, . . . first structural panel 211_m, first extension spline 212_m) to form a first structural layer 170 of arbitrary length. Thus, the general relationship where i≥2 is a first structural unit 171_k positioned adjacent to a first structural unit 171_k+1, with first structural panel 211_k+1 of first structural unit 171_k+1 positioned adjacent to first extension spline 212_k of first structural unit 171_k, where 0<k≤m. An elongate planar first lap joint spline 213, in this case 213_k, is positioned under first extension spline 212_k. First lap joint spline 213_k has a width greater than the width of first extension spline 212_k so as to underlie a narrow portion of each of first structural panel 211_k+1 and first structural panel 211_k. A rectangular recess 168_k+1 is cut into foam panel 163_k+1 to receive first lap joint spline 213_k and allow the portions first structural panels 211_k, 211_k+1 overlapping foam panel 163_k+1 to lie flat against foam panel 163_k+1, as shown in FIG. 6. First structural panels 211, first extension splines 212 and first lap joint splines 213 can each be made of an inorganic composition of relatively high strength, such as magnesium oxide (MgO).

Continuing to particularly refer to FIG. 5, the second structural layer 180 comprises second structural units 181_i, i in number, where i=1, 2, . . . m. A second structural unit 181 comprises a planar second structural panel 216 adjacent a planar second extension spline 217 that is coplanar with the second structural panel 216. In the case where i≥2, m number of second structural units 181 are arranged in a side-by-side, contacting relationship (second structural panel 216₁, second extension spline 217₁, second structural panel 216₂, second extension spline 217₂, . . . second structural panel 216_m, second extension spline 217_m) to form a second structural layer 180 of arbitrary length. Thus, the general relationship where i≥2 is a second structural unit 181_k positioned adjacent to a second structural unit 181_k+1, with second structural panel 216_k+1 of second structural unit 181_k+1 positioned adjacent to second extension spline 217_k of second structural unit 181_k, where 0<k≤m.

As can be seen in FIG. 6, each foam spline 164 is oriented so that the first surface of beam 167, which is coplanar with the first surface of foam spline 164, is adjacent to second structural layer 180.

As shown in FIG. 5, an elongate planar second lap joint spline 218, in this case 218_k, is positioned under second extension spline 217_k. Second lap joint spline 218_k has a width greater than the width of second extension spline 217_k so as to overlap a narrow portion of each of second structural panel 216_k+1 and second structural panel 216_k. A rectangular recess edge 162_k is cut into the edge of foam panel 163_k to receive a first edge region of second lap joint spline 218_k, a rectangular recess edge 162_k+1 is cut into the edge of foam panel 163_k+1 to receive a second edge region of second lap joint spline 218_k and the thickness of foam spline 164_k is less than the thickness of foam panels 163_k, 163_k+1 by an amount equal to the thickness of second lap joint spline 218_k. to allow the portions of second structural panels 216_k, 216_k+1 respectively positioned over foam panels 163_k, 163_k+1 to lie flat against foam panels 163_k, 163_k+1, as shown in FIG. 6. Second structural panels 216 and second extension splines 217 can each be for example a cement board composition, and second lap joint splines 218 can each be made for example of magnesium oxide (MgO).

As is evident from the foregoing, and as can be seen in for example FIGS. 5 and 6, the kth first extension spline 212 does not overlie the corresponding kth second extension spline 218, but rather is offset a select distance so that the seams between and in each of the first structural units 171 do not match the corresponding seams between and in each of the second structural units 181 across the thickness (measured parallel to the z-axis) of panel 165. The core layer 160, first structural layer 170 and second structural layer 180 of each panel 165 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive. Likewise, the portion of each first lap joint spline 213 underlying the narrow portion of the abutting first structural panel 211 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive, and the portion of each second lap joint spline 218 overlapping the narrow portion of the second structural panel 216 are bonded together using for example a suitable adhesive, preferably a polyurethane-based construction adhesive.

It is preferred that each first structural panel 211 be four feet (1.22 m) wide by eight feet (2.44 m) long, and that each second structural panel 216 be four feet (1.22 m) wide by eight feet (2.44 m) long. It is further preferred that each first extension spline 212 be nine inches (0.23 m) wide by eight feet (2.44 m) long, and that each second extension spline 217 be nine inches (0.23 m) wide by eight feet (2.44 m) long. With these dimensions, each first structural unit 171, core unit 161 and second structural unit 181 will have a width of 57 inches (1.45 m).

Another embodiment of a laminate design that can be used to fabricate enclosure components 155 is described in U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021. The contents of that U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶0027-0032 and depicted in FIG. 7.

Yet other embodiments of multi-layered, laminate designs that can be used to fabricate the enclosure components 155 of the present invention, are described in U.S. Non-Provisional 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. Non-Provisional 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 ¶¶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 foam panel material 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 15. 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 15.

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 foam panel material 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.

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

Wall Component (200)

Typically, 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. 1B, 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.

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.

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 fourth wall portion 200s-4 by a distance approximately equal to the thickness of wall component 200. Furthermore, wall portion 200s-1 and wall portion 200s-3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300a in the transverse direction. Dimensioning the lengths of wall portions 200s-1, 200s-2, 200s-3 and 200s-4 in this manner permits wall portions 200s-2 and 200s-4 to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard, 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 (200s-2f and 200s-4f), they facilitate forming a compact shipping module. When wall portion 200s-2 is in its unfolded position (200s-2u), it forms with wall portion 200s-1 a wall component 200 proximate first transverse edge 108, and when wall portion 200s-4 is in its unfolded position (200s-4u), it forms with wall portion 200s-3 a wall component 200 proximate second transverse edge 110.

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 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 15. 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.

Floor Component (300)

Typically, 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. 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. 1B and 2, 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.

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. Each of the floor portions 300a and 300b is a planar generally rectangular structure, with floor portion 300a adjoining floor portion 300b.

Referring to structure 150 shown in FIG. 2, floor portion 300a is fixed in position relative to first wall portion 200s-1, third wall portion 200s-3 and wall component 200R. Floor portion 300a is joined with hinge structures to floor portion 300b, so as to permit floor portion 300b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305, generally located as indicated in FIG. 3, 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 the fully unfolded position shown in FIG. 2, where floor portion 300b is horizontally oriented and co-planar with floor portion 300a.

Roof Component (400)

Typically, 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. FIG. 1B depicts roof component 400. The length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIG. 1B, 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.

B. Roof Partitioning

The roof component 400 of structure 150 is partitioned into roof portions 400a, 400b and 400c, shown in FIGS. 1A and 3 when folded, and in FIG. 1B when unfolded. 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.

In the shipping module 15 shown in FIG. 3, roof portions 400a, 400b and 400c preferably are accordion folded (stacked), with roof component 400b stacked on top of roof component 400a, and roof component 400c stacked on top of the roof component 400b. As can be appreciated from FIG. 3, roof portion 400a is fixed in position relative to first wall portion 200s-1, third wall portion 200s-3 and wall component 200R. Thus to realize the accordion folded configuration shown in FIG. 3 roof portion 400a is joined to roof portion 400b with hinge structures that 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 (see FIG. 3) between the roof fully folded position shown in FIGS. 1A and 3, where roof portion 400b lies stacked flat against roof portion 400a, and the fully unfolded position shown in FIG. 1B. In turn, roof portion 400b is joined to roof portion 400c with hinge structures that 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 (see FIG. 3) between the folded position shown in FIGS. 1A and 3, where roof portion 400c lies stacked flat against roof portion 400b (when roof portion 400b is positioned to lie flat against roof portion 400a), and the fully unfolded position shown in FIG. 1B.

Fixed Space Portion Build-Out and Finishing

Referring to FIG. 2, structure 150 includes a fixed space portion 102 defined by roof component 400a (shown in FIG. 3), floor component 300a, wall component 200R, wall portion 200s-1 and wall portion 200s-3. (Fixed space portion 102 is also shown edge-on in the shipping module 15 depicted in FIG. 3). It is preferred that the fixed space portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module 15. Also, in the embodiment shown in FIGS. 1A, 1B 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 for electrical needs.

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 15.

Enclosure Component Relationships and Assembly for Transport

It is preferred that there be a specific dimensional relationship among enclosure components 155.

FIG. 2 shows a top schematic view of structure 150 shown in FIGS. 1A and 1B, 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 4E long and 4E wide; notably, the entire structure 150 preferably is bounded by this 4E by 4E 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 can be dimensioned to be larger than either of roof portion 400a and roof portion 400b in the transverse direction to reduce the chances of binding during the unfolding of roof portions 400b, 400c. Further specifics on dimensioning roof portion 400c in the foregoing manner are described in U.S. Non-Provisional application Ser. No. 17/569,962, entitled “Improved Folding Roof Component,” filed on Jan. 6, 2022. In addition, as described in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” filed on Feb. 10, 2020 and now U.S. Pat. No. 11,220,816, as well as in U.S. Non-Provisional application Ser. No. 17/569,962 mentioned above, 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 by 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 FIG. 2, the four wall components 200 are each approximately 4E long, and each of roof portions 400a and 400b is approximately 4E long and 1.25E wide. Roof portion 400c is approximately 4E long and 1.45E wide. In FIGS. 2 and 3, each of floor components 300a and 300b is 4E long; whereas floor component 300a is just over 1.5E wide and floor component 300b is just under 2.5E wide.

As shown in FIG. 2, fourth wall portion 200s-4 is folded inward and positioned generally against fixed space portion 102, and second wall portion 200s-2 is folded inward and positioned generally against fourth wall portion 200s-4 (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. 1B and shown 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 15, as can be seen from the figures. Thus shipping module 15 depicted in FIG. 3, when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2) of 57 inches (144.8 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.

Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film during fabrication and prior to forming the shipping module 15. Alternatively or in addition, the entire shipping module 15 can be sheathed in a protective film. Such protective films can remain in place until after the shipping module 15 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.

Shipping Module Transport

The shipping module 15 is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018, are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2D thereof. As an alternative transport means, shipping module 15 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 15 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 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15, then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 15 at the desired location are disclosed in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, now U.S. Pat. No. 11,220,816. The contents of that U.S. Non-Provisional 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 ¶¶126-128 and in connection with FIGS. 11A and 11B thereof.

Following positioning of shipping module 15 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 FIG. 3) to an unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105 (the general location of which is shown in FIG. 3) 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 FIG. 3) respectively to unfolded positions.

After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1A. 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.

The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims.

Claims

1. An enclosure component for a building structure, the enclosure component having a length, a width and a thickness, comprising:

a first structural layer having a first face, an opposed second face and comprising a first structural panel of magnesium oxide arranged in a side-by-side relationship with a first edge of a first extension spline of magnesium oxide, and with a second edge of the first extension spline opposed to the first edge of the first extension spline in a side-by-side relationship with a second structural panel of magnesium oxide;

a core layer having a first face, an opposed second face and comprising a first foam panel arranged in a side-by-side relationship with a first edge of a foam spline, and with a second edge of the foam spline opposed to the first edge of the foam spline in a side-by-side relationship with a second foam panel, with the first face of the core layer bonded to the second face of the first structural layer;

a first lap joint spline of magnesium oxide, positioned between the first extension spline of the first structural layer and the first face of the core layer, and joining the first and second structural panels of the first structural layer;

a second structural layer having a first face, an opposed second face and comprising a first structural panel of cement board arranged in a side-by-side relationship with a first edge of a second extension spline of cement board, and with a second edge of the second extension spline opposed to the first edge in a side-by-side relationship with a second structural panel of cement board, with the second face of the core layer bonded to the first face of the second structural layer;

a second lap joint spline of magnesium oxide, positioned between the second extension spline of the second structural layer and the second face of the core layer, and joining the first and second structural panels of the second structural layer.

2. The enclosure component of claim 1, wherein the second extension spline is proximate to the foam spline in a superposed relationship.

3. The enclosure component of claim 2, wherein the first extension spline is distal from the foam spline.

4. The enclosure component of claim 3, wherein a surface of the first foam panel coinciding with the first face of the core layer includes a recess to receive the first extension spline.

5. The enclosure component of claim 4, wherein a portion of the first foam panel adjacent to the second face of the core layer and proximate to the first edge of the foam spline defines a recess to receive a first edge of the second lap joint spline, and a portion of the second foam panel adjacent to the second face of the core layer and proximate to the second edge of the foam spline defines a second recess to receive a second edge of the second lap joint spline opposed to the first edge of the second lap joint spline.

6. The enclosure component of claim 1, further comprising a rigid beam within the foam spline, the rigid beam having a first surface that is coplanar with the second face of the core layer.

7. The enclosure component of claim 6, comprising a channel formed within the foam spline proximate to a second surface of the rigid beam, wherein the channel is opposed to the first surface of the rigid beam and distal from the second face of the core layer.

8. The enclosure component of claim 1, wherein the foam spline comprises a series of keys along the first edge of the foam spline and along the second edge of the foam spline.

9. The enclosure component of claim 8, wherein the first foam panel comprises slots at first and second abutting edges, and wherein the second foam panel comprises slots at first and second abutting edges.

10. The enclosure component of claim 9, wherein the series of keys along the first edge of the foam spline are configured to be received by the slots at the first abutting edge of the first foam panel, and wherein the series of keys along the second edge of the foam spline are configured to be received by the slots at the second abutting edge of the second foam panel, to mate the first foam panel and the second foam panel to opposing sides of the foam spline.

11. The enclosure component of claim 1, wherein the foam spline comprises a rigid beam disposed therein and extending a length of the foam spline.

12. The enclosure component of claim 11, wherein the foam spline comprises a channel disposed adjacent to the rigid beam and extending the length of the foam spline.

13. The enclosure component of claim 1, wherein the first lap joint spline is positioned under the first extension spline.

14. The enclosure component of claim 1, wherein the first lap joint spline defines a width dimensioned greater than a width of the first extension spline.

15. The enclosure component of claim 1, wherein the first lap joint spline underlies the first extension spline and at least a portion of each of the first structural panel and the second structural panel.

16. The enclosure component of claim 1, wherein the first face of the core layer comprises a recess formed therein, the recess dimensioned equally to a thickness of the first lap joint spline to receive the first lap joint spline such that the second face of the first structural layer lies flat against the first face of the core layer.

17. The enclosure component of claim 1, wherein the first structural layer is disposed against the first face of the core layer and the second structural layer is disposed against the second face of the core layer.

18. The enclosure component of claim 17, wherein a position of the first lap joint spline at the first face of the core layer is offset a distance along the core layer from a position of the second lap joint spline at the second face of the core layer.

19. The enclosure component of claim 17, wherein seams of the first lap joint spline with the first structural layer do not match to corresponding seams of the second lap joint spline with the second structural layer across a thickness of the core layer due to the offset.

20. The enclosure component of claim 17, wherein seams of the first structural layer do not match to corresponding seams of the second structural layer across a thickness of the core layer.